part 3 - scope of · web viewmonitoring the health and safety on the construction works on a...

Agribusiness Development Agency Volume 3Cappeny Estates - Ballito Part 3 – Scope of Work

PART 3 - SCOPE OF WORK

3-18


C3 - SCOPE OF WORK

CONTENTS

Item Description Page

1. DESCRIPTION OF THE WORKS 3-201.1 Employer’s Objectives 3-201.2 Overview of the Works 3-201.3 Extent of the Works 3-201.4 Coordination with other Contractors 3-201.5 Construction Programme 3-201.6 Location of the Works 3-201.7 Temporary Works 3-20

2. ENGINEERING 3-212.1 Design Services and Activity Matrix 3-212.2 Employer’s Design 3-212.3 Design Brief 3-212.4 Drawings 3-21

3. PROCUREMENT 3-223.1 Procurement Policy 3-223.2 Subcontracting 3-22

4. CONSTRUCTION 3-224.1 Works Specifications 3-234.2 Construction Equipment 3-234.3 Existing Services 3-244.4 Site Establishment 3-254.5 Site Usage 3-254.6 Permits and Way Leaves 3-254.7 Connection to Existing Services 3-254.8 Water for Construction Purposes 3-254.9 Construction using Community Based sub-contractors 3-25

5. MANAGEMENT 3-255.1 Management of the Works 3-255.2 Health and Safety 3-26

6. ANNEXURES

Annexure A - Variations to Standardized Specifications and Additional Clauses 3-28

Annexure B - Particular Specifications 3-42Annexure C - Drawings 3-83Annexure D - Standard Forms to be used during the currency

of the Contract 3-84

3-19


1. DESCRIPTION OF THE WORKS

1.1 Employer’s Objectives

The Agribusiness Development Agency’s overall objective is to provide effective and efficient agricultural support to Kwazulu-Natal farmers and to link the farmers with the commodity sectors and potential markets, while introducing improved farming techniques and planning and to promote value chain within the industry.

1.2 Overview of the Works

Expansion of the post-harvest strawberry processing facility at Cappeny Estates, located in Ballito, KwaZulu-Natal.

1.3 Extent of the Works

The project scope is to supply and install the following works at Cappeny Estates in Ballito, KwaZulu-Natal.

1) Earthworks (Provisional)2) Processing Facility Building Works and related facilities3) Sewer and Water reticulation and bulk supply4) Waste management facility5) Electrical facilities with standby generator.6) Gravel access roads and re-graveling 7) Associated civil, mechanical and electrical works.

1.3.2 Work Stated Provisionally

None.

1.4 Coordination with other Contractors

1.4.1 General

Other contractors are envisaged working in the same area of other projects.

1.5 Construction Programme

1.5.1 Construction Phases

The contractor to program the works to finish within the allocated time for completion.

1.6 Location of the Works

a) The post-harvest strawberry processing facility at Cappeny Estates, located in Ballito, KwaZulu-Natal.

1.7 Temporary Works

See 2.1 below.

3-20


2. ENGINEERING

2.1 Design Services and Activity Matrix

The Contractor is not responsible for the design of the permanent works except where otherwise stated in the Bill of Quantities.

The Contractor shall be responsible for the design and safety of all temporary formwork, support work required in the construction.

2.2 Employer’s Design

The Employer’s design of the Works is complete.

The Employer retains the right to issue whatever additional drawings during the progress of the works as may be required.

2.3 Design Brief

The Employer’s preference with respect to the works components are as shown on the drawings.

2.4 Drawings

2.4.1 Drawings Prepared by the Employer

The drawings prepared by the Employer comprise of the following:

1) General

The Contractor will be supplied with three full-scale prints of each construction drawing free-of-charge. Further copies will be charged for at commercial rates.

Only figured dimensions shall be used and drawings shall not be scaled unless so instructed by the Engineer. The Engineer will supply any figured dimensions which may have been omitted from the drawings.

2) Drawings included in the Annexures to the Scope of Work

Refer to Annexure C of the tender.

3) Drawings issued separately (after award of contract)

Remaining details for the works

3-21


3. PROCUREMENT

3.1 Procurement Policy

Procurement policy of Agribusiness Development Agency applies to this contract.

3.2 Subcontracting

The Contractor may use specialist subcontractors for parts of the work. Such specialist subcontractor shall be proposed to the Engineer for his approval. Should the sub-contractor not be acceptable to the Engineer, the Contractor will have to propose an alternative subcontractor that is acceptable to the Engineer.

4. CONSTRUCTION

4.1 Works Specifications

4.1.1 Applicable SABS Standardised Specifications

The applicable standardised specifications for this Contract shall be the following:

SABS 1200A - General SABS 1200L - Medium Pressure PipelinesSABS 1200D - EarthworksSABS 1200G - Concrete StructuralSABS 1200H - Structural Steelwork SABS 1200 HB - Cladding and sheetingSABS ISO 1461 - Hot-dip galvanised coatings on fabricated iron and steel articlesSABS 1273 - Fasteners for sheet roof and wall coverings

Note:

Each of the SABS Standards above contains an Appendix A which lists further specifications not bound into this document. These additional specifications shall also apply, inter alia, to this Contract.

* Not issued with this document, but available at the Contractors expense from the:

SABS International Organization for StandardizationPrivate Bag X191 http://www.iso.orgPRETORIA0001

4.1.2 Variations to Standardised Specifications and Additional Clauses

The following variations to standardised and additional clauses are applicable to this Contract and are contained in the Annexure A to the Scope of Works.

PSAA - General (Small Works)PSL - Medium Pressure PipelinePSG - Concrete

3-22


4.1.3 Particular Specifications

The following Particular Specifications are applicable to this Contract and are contained in the Annexure B to the Scope of Works.

PB - Building WorksPSC - ConcretePSS - Structural SteelPSEL - Emergency Diesel Generator SetPSE - Electrical Technical SpecificationPSW - Waste ManagementPF - FencingPOHSA - Health and Safety Specifications

4.2 Construction Equipment

The contractor’s equipment for construction shall be adequate for the purpose required, of modern design and in good condition to carry out the works expeditiously. Should the Engineer be of the opinion that the equipment in use is in any way unsuitable for carrying out the works in a manner or at a rate commensurate with the requirements of the contract, he shall have the right to call on the Contractor at any time during the progress of the works to provide such additional or improved equipment as may be necessary to meet these requirements.

The Employer makes no provision in this contract for financial assistance to the Contractor for the acquisition of plant, machinery and equipment.

4.3 Existing Services

4.3.1 Care of Existing Services

The Contractor shall, before starting any excavations, carefully search and probe the terrain for any existing services or indications of the presence of such services. The cost thereof is to be included in the Preliminary and General payment items.

In addition, if the proposed new construction works crosses underneath overhead power lines belonging to Eskom as well as underground pipelines and communication cables belonging to Telkom, the Contractor shall have to comply with all the requirements laid down by the relevant authorities when working in the vicinity thereof. The Contractor shall be responsible for checking the locations of all such services with representative of the relevant authorities to ensure that no damage is caused by construction operations.

Work executed within the road reserve of provincial or local roads shall be carried out strictly in accordance with the requirements laid down by the relevant provincial or local authorities. These include the use of traffic signs, flagmen and other requirements as applicable.

4.3.2 Connection to Existing Services

Prior to connection of new services to existing services, the Contractor shall ensure that the constructed services are clean and free of foreign matter and shall subsequently request the Engineer, in writing, to inspect such Works. Only upon written approval of the Engineer, may connections to existing services be made.

4.3.3 Contractor to Notify Relevant Authority and the Engineer of Damaged Service

In the event of any service being damaged or accidentally disconnected for any reason, the Contractor shall immediately contact the relevant authority for instructions and shall report the

3-23


occurrence to the Engineer in writing. The report shall include the reasons for the occurrence of the incident. When instructed, the damage is to be repaired as soon as possible to the approval of the Engineer and Authority. The Contractor will be held responsible for paying all costs incurred by the Service owner or himself as result of each incident where the relevant service was clearly identified beforehand.

4.4 Site Establishment

4.4.1 Services and Facilities provided by the Employer

a) Water

The Contractor shall be responsible for making his own arrangements to provide the water that he may require for his site and construction purposes.

b) Electricity/Power Supply

The Contractor shall be responsible for making his own arrangements to provide electric power and other services that he may require for construction purposes.

The cost of making such arrangements, for meeting the conditions imposed and for the metered consumption shall be paid by the Contractor, and his tender will be held to include for all such requirements throughout the duration of the Contract.

4.4.2 Facilities Provided by the Contractor

The Contractor will be required to make his own arrangements for the provision of a suitable construction camp, offices and workshops at a designated location on the site. He shall be responsible for all negotiations with the relevant authorities and he shall comply with all requirements imposed by those authorities. Suitable sites available at the project will be pointed out during the site inspection.

The facility shall be properly fenced around the perimeter. Temporary buildings and fencing are to be neat and presentable and the surrounding areas must at all times be kept in a neat, clean and orderly condition. The costs associated with the provision of these items shall be borne by the Contractor. The Contractor will be required to remove all facilities and restore the site to its original condition on completion of Works.

4.4.3 Other Facilities and Services

a) Latrine and Ablution Facilities

It will be required of the Contractor to provide temporary toilets and ablution facilities for his staff for the duration of the contract, to generally acceptable standards and the conditions as stipulated in the Environmental Management Plan.

b) Housing of Contractor’s Staff

The Contractor shall make his own arrangements for the housing of his supervisory staff.

c) Security

The Contractor will be responsible for providing adequate security for the Works and for the site establishment. All costs associated with the provision of watchmen shall be borne by the Contractor and deemed to be included in his tendered rates.

3-24


4.5 Site Usage

The Employer expects the contractor, his staff or agents to maintain good public relations with landowners, other contractors and members of the public at all time.

The Employer will arrange the contractor’s access to the site.

4.6 Permits and Way Leaves

Not applicable.

4.7 Connection to Existing ServicesPrior to connection of new services to existing services, the Contractor shall ensure that the constructed services are clean and free of foreign matter and shall subsequently request the Engineer, in writing to inspect such work. Only upon written approval of the Engineer, may connections to existing services be made.

4.8 Water for Construction Purposes

The Contractor shall be responsible to provide water for construction purposes.

4.9 Construction using Community Based sub-contractors

The Contractor shall provide management support, supervisors, materials and transport to get the materials to site. He shall then employ community based sub-contractors each with their own foreman to construct any general works required to specification.

5. MANAGEMENT

5.1 Management of the Works

5.1.1 Planning and Programming

The Contractor shall supply within the period stated in the Contract Data a suitable and realistic construction programme, cash flow diagram, and critical path diagram for the consideration of the Engineer. This programme shall show the proposed scheduling and methods of execution of the Works and the resources to be allocated to each item or phase of the work. Quantities proposed for execution during each week and the anticipated cash flow based upon these quantities should be shown, due allowance being made for price escalations and retention monies.

The programme shall make provision for the accommodation of other contractors’ requirements. It will be required from the contractor to liaise regularly and closely with other contractors to ensure continuous co-ordination and execution of the scheduled work.

5.1.2 Recording of Weather

The Contractor shall provide and install a rain gauge on site and shall record rainfall data in the site diary on a daily basis. A site diary will be issued to the Contractor.

3-25


5.1.3 Workmanship and Supervision

The onus is on the Contractor to produce work which will conform in quality and in accuracy of the detail to the requirements hereinafter specified.

5.1.4 Commissioning of the Works

As per the programme.

5.1.5 As-built information

As-built information to be compiled by the Contractor on hard copy plans to the satisfaction of the Engineer.

5.2 Health and Safety

5.2.1 Health and Safety Requirements

The Occupational Health and Safety Act, Act 85 of 1993 shall apply to this contract. The Contractor shall comply with the Particular Specification for Occupational Health and Safety.

5.2.2 Protection of the Public

As the contract entails working on a operational plant, special attention must be paid to the following aspects:

1) No blasting will be allowed unless prior written approval from the Engineer and local authorities is obtained.

2) Safety of the public is of prime importance and the utmost care must be taken to ensure that the correct signs, barriers and warning devices are in place.

3) Movement of construction equipment must be controlled on site at all times.

6. ANNEXURES TO THE SCOPE OF WORKS

Annexure A - Variations to Standarised Specifications and Additional Clauses

PSA - General (Small Works)PSG - ConcretePSL - Medium Pressure Pipeline

Annexure B - Particular Specifications

PB - Building WorkPSC - ConcretePSS - Structural SteelPSEL - Emergency Diesel Generator SetPSE - Electrical Technical SpecificationPSW - Waste ManagementPF - FencingPOHSA- Health and Safety Specifications

3-26


Annexure C - Standard Forms to be used during the currency of the ContractDay work ReturnsCertificate SummarySummary of ScheduleSchedule DescriptionRequisition for final checking of work

3-27


ANNEXURE A

VARIATIONS TO STANDARDISED SPECIFICATIONS AND ADDITIONAL CLAUSES

Page

PSA - General (Small Works) 3-29PSG - Concrete 3-31PSL - Medium Pressure Pipelines 3-34

3-28


PSA - GENERAL (SMALL WORKS)

PSA1 SPECIFICATION DRAWINGS (Clause 2.7)

Specification Drawings are included in this document as annexures to the Project and Particular Specifications. Where such Specification Drawings depict items and standard structures according to lay-outs and details differing from those shown in the Standardised Specifications, the lay-outs and details shown to the Project and Particular Specifications shall prevail.

PSA2 QUALITY (Clause 3.1)

All material used in the Works shall, where such mark has been awarded for a specific type of material, bear the SABS mark.

PSA3 TESTING (Clause 7)

PSA3.1 All test results obtained by the Contractor in the course of his process control of the Works shall be submitted to the Engineer or his Representative prior to requesting inspection of the relevant portions of the Works. Any request for inspection shall be submitted on the prescribed forms appended as to these Specifications.

PSA3.2 The Contractor shall make suitable arrangements for process control prior to commencement with the Works. Should he intend using site personnel for this purpose he shall ensure that suitably trained and competent personnel take charge of the necessary test work and that the necessary equipment is at their disposal prior to commencement of the Works. Failure to comply with these requirements shall be just cause for the Engineer to order suspension of the works without additional remuneration in terms of clause 42 of the Conditions of Contract or for him to recommend determination to the Employer in terms of Clause 58 thereof.

PSA4 INSTRUCTIONS BY THE ENGINEER

Site instructions by the Engineer, addressed to the Contractor at his office on the site, will be numbered consecutively and will be deemed to have been received by the Contractor's Representative unless a break in the sequence of numbers is brought to the notice of the Engineer in writing immediately.

PSA5 PAYMENT (Clause 8.2)

Monthly progress payment certificates shall be submitted to the Engineer's Representative on site sufficiently early to allow for reconciliation of all quantities, rates, extensions and additions in the certificate. It will be assumed that the contractor has made adequate provision in the prices tendered for manufacture/supply, delivery, assembly, installation and commissioning of all necessary aids required to execute the contract. The certificates shall be according to the standard format included in the annexures to these specifications.

Upon approval by the Engineer's Representative the certificate should be submitted in typed form to the Engineer before or on the 20th of each month, together with the required number of copies, for certification.

3-29


Where dayworks have been instructed by the Engineer, the Contractor shall submit the returns to the Engineer for signature and approval within twenty-four (24) hours of the end of the working day on which the work was executed. Daywork returns shall be submitted on forms included in the annexures to the Specifications.

PSA6 SUMS STATED PROVISIONALLY (Clause 8.5)

PSA6.1 A Provisional Sum has been included in the Schedules for contingencies. No percentage mark-up will be applicable to any payments made in this regard other than those included in prices for variations determined in terms of clause 39 of the Conditions of Contract.

PSA6.2 Daywork items have been included in the Schedule of Quantities with all the items being provisionally measured.

A further provisional amount has been included in Schedule 1 for materials to be used during the execution of dayworks.

In addition to the abovementioned amount, provision is made in Schedule 1 for a mark-up on the materials to be used during the execution of dayworks. Payment made shall be regarded as full compensation for overheads, charges and profit on the materials to be used when executing dayworks.

PSA6.3 Other minor amounts as listed in the Schedule of Quantities.

3-30


PSG - CONCRETE

PSG1 CEMENT (Clause 3.2.1)

All Cement to be used shall conform with SANS 50197-1. The cement composition used shall be subject to the Engineer's approval.

PSG2 STORAGE OF CEMENT (Clause 3.2.3)

A first-in-first out circulation shall be followed to ensure that no cement for (i) reinforced concrete shall be older than 3 months from the date of manufacture and (ii) mass concrete shall be older than 6 months from the date of manufacture.

PSG3 ADMIXTURES (Clause 3.5.1)

Admixtures will only be permitted on concrete water retaining structures with the written approval of the Engineer.

PSG4 CONCRETE FINISHES (Clause 4.5.2)

Concrete against which earth will be backfilled will be finished rough. All exposed concrete surfaces shall be finished smooth to degree of accuracy II.

PSG4.1 Rubbed surface finish

Where a rubbed surface finish is specified or scheduled the surface shall first be treated as a smooth finish as specified in SABS 1200G 5.2.1 b).

After sufficient time has elapsed to allow the mortar to set the surface shall be saturated by water. Rubbing shall then be carried out with a medium coarse carborundum stone and a small amount of mortar until all form marks, projections and irregularities are removed and a uniform surface obtained.

Leaving the paste produced by the rubbing in place, rubbing shall be continued with a fine carborundum stone and water. Rubbing shall be continued until the entire surface is of a smooth even texture and uniform colour. After the final rubbing the surface shall be washed down to remove surplus paste and powder.

PSG4.2 Cement screeding (Subclause 5.5.10.2)

Cement screeding shall consist of three parts of sand to one part cement. The final level shall be finished to definite slopes (where required, i.e. roofs, gullies, etc.) and in no case shall the thickness be less than 20mm.

3-31


PSG4.3 Unformed surface finishes (Subclause 5.5.10.2)

PSG4.3.1 Wood-floated finish

Where wood floating is specified or scheduled, the surface shall first be given a finish as specified in Subclause 5.5.10.1 of SABS 1200G and, after the concrete has hardened sufficiently, it shall be floated to a uniform surface free of trowel marks. The screeded surface shall be wood-floated, either by hand or machine, only sufficiently to produce a uniform surface free from screed marks.

PSG4.3.2 Steel-floated finish

Where steel floating is specified or scheduled, the surface shall be treated as specified in PSG3.3.1 except that, when the moisture film has disappeared and the concrete has hardened sufficiently to prevent laitance from being worked to the surface, the screeded surface shall be steel-trowelled under firm pressure to produce a dense, smooth, uniform surface free from trowel marks.

PSG4.3.3 Power-floated finish

Where power floating is specified or scheduled, the surface shall be treated as specified in PSG4.3.1 except that the screeded surface shall be power-floated to produce a high quality dense, smooth, uniform surface free from trowel marks.

PSG5 CONCRETE STRENGTH (New clause)

The Contractor shall have the mix designed by an approved laboratory to give a high density, low permeability concrete.

No concrete shall be placed until the Contractor's concrete mix design has been approved by the Engineer.

PSG6 HOLES, CHASES AND FIXING BLOCKS (Clause 5.3)

Substitute the contents of the clause with:a) General

Holes, recesses and boxed-out openings shall be allowed in concrete structures, as specified, for the subsequent installation of mechanical equipment and/or pipework.

b) Preparation of openings for the installation of equipmentBefore commencing the positioning in holes of any pipes/specials the Contractor shall:i) Remove all shuttering and boxing remaining in the holes;ii) Make any alterations required to the position and shape of the holes;iii) Thoroughly clean the sides of the holes so as to obtain a satisfactory bond

surface for the new concrete; andiv) Free all surfaces of the pipes/specials of all coatings, and thoroughly scrape

and clean the pipes/specials.v) Apply a wet-to-dry concrete adhesive (similar to Epidermix 344 from ABE)

immediately before grouting.

c) Grouting of voidsThe concrete ingredients shall be mixed and placed as dry as possible to obtain a dense, waterproof concrete. Where a watertight seal is required, the concrete shall be carefully worked around the puddle flange, if any, and the pipe barrel or body of the

3-32


special, and shall be vibrated in layers so as to obviate any falling away from pipe/special surface of the concrete already placed. The whole shall, when set, form a dense, homogeneous, and waterproof mass. A spare vibrator with an independent power source shall be kept in readiness to ensure continuity of placing in the event of the breakdown of the duty vibrator.

Smooth formwork that has been suitably strengthened for use with a vibrator shall be provided for facing the concrete around each pipe/special.

PSG7 PIPES AND CONDUITS EMBEDDED IN CONCRETE (Clause 5.4)

Except with the written approval of the Engineer, no pipes other than those shown on the drawings shall be embedded in concrete, and the approval of the Engineer for the position of all services to be embedded shall be obtained before concreting commences. The clear space between pipes of any kind embedded in reinforced concrete and the clear space between such pipes and reinforcement shall not at any point be less than:

i) 40mm orii) 5mm plus the maximum size of coarse aggregate, whichever is the greater.

PSG8 WATERTIGHT CONCRETE (Clause 5.5.11)

PSG8.1 Scope

Refer to the Particular Specification dealing with Concrete for Water Retaining Structures.

PSG8.2 Concrete Roofslabs

All reinforced concrete roofs to be constructed, shall, subsequent to complete removal of formwork supports to the underside of roof slabs, be screeded to a definite fall. The minimum thickness of the screed, cast as second stage concrete, shall be 20mm.

One coat heavy duty Bituseal paint (supplied by African Bitumen Emulsions), or similar approved, shall be applied to the top surface of all concrete roofs at an application rate of 0,7 litre/sq.m.

PSG9 DEGREE OF ACCURACY (Clause 6.2)

The following degrees of accuracy shall be applicable:a) All exposed elements or components above foundations : Degree II

b) Elements above foundations which will be permanently covered by earthfill : Degree III

c) Foundations (excluding floor slabs) : Degree III

3-33


PSL - MEDIUM PRESSURE PIPELINES

PSL1 MATERIALS

PSL1.1 Grade of Steel (Clause 3.4)

All steel piping and fittings shall be electric welded low carbon Grade B, steel pipes in accordance with the requirements of SABS 719-1971 and BS 534-1966. Where non-standard specials have been detailed on the drawings, such dimensions shall be adhered to. All weld fabricated steel fittings shall be subject to dye penetrant testing as required by Clause 7.2.1 SABS1200L. In addition, radiographic examination (or similar approved) may be called for by the Engineer at his discretion.

Minimum Wall Thickness

The following shall be the minimum wall thicknesses:

i) For pipes of nominal outside diameter 400ND and smallerdiameter: 4,5mm

ii) For pipes of nominal outside diameter 450mm and up to 550mm nominal diameter: 6mm

iii) For pipes of nominal outside diameter 600mm and up to 1092mm nominal diameter: 8mm

iv) For pipes of nominal outside diameter 1118mm and up to 1245mmnominal diameter: 10mm

Flanges, bolts, nuts, etc

All flanged pipes and fittings (including Viking Johnson flanged adaptors) shall have flanges as specified and shall be supplied complete with all packings, seals, nuts, bolts and washers.) Gaskets for flanged joints shall be of compressed asbestos fibre to BS 2815 grade A, and full faced with a minimum thickness of 3mm. For pressures up to and including 1,6 MPa cloth-inserted rubber may be used.

Where new installations couple up with existing installations, the Contractor shall ascertain what the flange drillings are of all existing fittings prior to any placement or order, and shall confirm this information with the Engineer.

PSL1.2 PVC Pipes (Clause 3.7.1)

uPVC and mPVC pipes and fittings shall be fitted with spigot and socket rubber ring joints and shall comply with the relevant requirements of SABS 966 Part 1 and 2 respectively for all pipe sizes. BATCH RELEASE TESTING of PVC pressure pipes rated Class 9 and higher is mandatory and a report needs to be submitted to the Engineer for approval prior to despatch of pipes from the factory.

PSL1.3 HDPE Pipes (Clause 3.7.2)

Polyethylene pipes and fittings to comply with SANS ISO 4427 and the HDPE material used for the pipe manufacture to be PE80. Only pipes manufactured by a member of the South African Plastic Pipe Manufacturer’s Association may be supplied unless authorised by the Engineer.

PSL2 PIPE COUPLINGS (Additional to clause 3.7)

PSL2.1 PVC pipes shall be supplied with factory fitted “rubber ring type” couplings. PVC pipe

3-34


fittings shall be PVC or Spheroidal Graphite (SG) Iron, aluminium fittings are not allowed.

PSL2.2 Fittings for HDPE pipe

Fittings shall be of the compression type where tightening of the unit causes the thrust ring to push against the gasket, causing it to deform evenly towards the centerline of the fitting to, exerting pressure against the inserted pipe.

All fittings with a threaded female off take will be fitted with a reinforcing ring.

All fittings shall be pressure-rating PN16.

Saddles will be supplied with galvanized bolts and nuts.

The materials used in the manufacture of the fitting will comply with the following:

Body, nut and trust ring - Virgin polypropylene, UV stabilized

Clamp ring - Acetalic resin (POM)

Gaskets - Food safe rubber with Shore hardness 70

Reinforcing rings - Stainless steel

The fittings shall hold Acceptance Certificates from recognised quality control bodies in South Africa (JASWIC 594) and at least from two other countries in the European Union.

PSL3 VALVES (Clause 3.10)

PSL3.1 Gate Valves

All gate valves to comply with SABS 664, waterworks application, be clockwise closing, have a non-rising spindle and be plain thrust collared. Valves and flanges (if any) to be to the class specified.

Valves to be operated by either handwheel, cap top and tee-key or extended spindle and handwheel/tee-key. Operator to be specified.

Valves to be flanged or spigot ended as specified.

Note:"As specified" will mean as described in the schedule of rates. In the event of no description in the schedule of rates the following will prevail:

Valves to be at least Class 10 with a standard handwheel operator and valves to be flanged.

Valve trim shall be Type B: Gun metal trim to SABS664-1974 Clause 3.5.5.

Prior to commissioning, certification shall be handed to the Engineer of each valve having successfully passed hydraulic test to SABS664-1974 Clause 6.3.2.1 being 2,0 MPa for Class 10 valves and 3.2 MPa for Class 16 valves.

ii) Gate valves of 300mm diameter or smallerAll gate valves falling into this category to be fitted with resilient seal, rubber lined gates similar to "Elypso compression-sealing valves."

3-35


PSL3.2 Butterfly valves

All butterfly valves to be of the resilient sealing type and shall be supplied complete with geared operator and handwheel. All geared operators shall have horizontal spindles.

PSL3.3 Valve spindles

All extended valve spindles shall be supplied at both ends with cast iron tops for valve key operation. The spindle shall be fitted into the valve box with a bearing for easy operation. The lengths of extended spindles are to suit the dimensions of their installation positions, all spindles supported at 4m max. intervals.

PSL3.4 Threaded Fullway Gate Valves

The valves shall be of the dezinctified brass type with brass gate and body, non-rising spindle and BSP threaded socket ends. The valve shall conform to SABS 776/1965 Class 125. The valves shall be able to withstand a working pressure of 1 600kPa.

PSL3.5 Air Valves (for water)

The air vent valve shall be of the compact single chamber design with solid cylindrical HDPE control floats housed in a tubular stainless steel body with epoxy powder coated mild steel ends or stainless steel ends secured by means of stainless steel tie rods.

The valve shall have an integral anti-shock orifice mechanism which shall operate automatically to limit transient pressure rise or shock induced by closure to 1.5 times valve rated working pressure. The intake orifice area shall be equal to the nominal size of the valve i.e., a 150mm (6”) valve shall have a 150mm (6”) intake orifice.

Large orifice sealing shall be effected by the flat face of the control float seating against a nitrile rubber ‘O’ ring housed in a dovetail groove circumferentially surrounding the orifice.

Discharge of pressurised air shall be controlled by the seating and unseating of a small orifice nozzle on a natural rubber seal affixed into the control float. The nozzle shall have a flat seating land surrounding the orifice so that damage to the rubber seal is prevented.

The valve construction shall be proportioned with regard to material strength characteristics, so that deformation, leaking or damage of any kind does not occur by submission to twice the designed working pressure.

The valve design shall incorporate an over pressure safety feature that will fail without an explosive effect, such as is normally the case when highly compressed air is released suddenly. The feature shall consist of easily replaceable components such as gaskets, seals or the like.

Connection to the valve inlet shall be facilitated by a screwed BSP (ISO R7) or NPT male end (DN25 & DN50 only) or a flanged end conforming to PN10, 16, 25 or 40 ratings of BS4504 or SABS 1123 Standards or ANSI B16.1 Class 125 and Class 250 and ANSI B16.5 Class 300 Standards.

Flanged ends for DN80 and DN100 valves shall be supplied with the requisite number of stainless steel screwed studs inserted for alignment to the specified standard. Nuts and washers to be included.

A ¼” BSP/NPT Test/Bleed Cock to be provided if specified.

PSL3.6 Sewage Air Valves

3-36


The sewage air release and vacuum break valve shall consist of a compact tubular all stainless steel fabricated body, hollow direct acting float and solid large orifice float in HDPE – stainless steel nozzle and woven dirt inhibitor screen, EPDM rubber seals and seat.

The valve shall have an integral anti-shock orifice mechanism which shall operate automatically to limit transient pressure rise or shock induced by closure to 1.5 times valve rated working pressure. The intake orifice area shall be equal to the nominal size of the valve i.e., a 150mm (6”) valve shall have a 150mm (6”) intake orifice.

Large orifice sealing shall be effected by the flat face of the control float seating against an EPDM rubber ‘O’ ring housed in a dovetail groove circumferentially surrounding the orifice.

Discharge of pressurised air shall be controlled by the seating and unseating of a small orifice nozzle on a natural rubber seal affixed into the control float. The nozzle shall have a flat seating land surrounding the orifice so that damage to the rubber seal is prevented.

The valve construction shall be proportioned with regard to material strength characteristics, so that deformation, leaking or damage of any kind does not occur by submission to twice the designed working pressure.

Connection to the valve inlet shall be facilitated by flanged ends conforming to PN10, 16, 25 ratings of SABS 1123 Standards. Flanged ends for DN80 and DN100 valves shall be supplied with the requisite number of stainless steel screwed studs inserted for alignment to the specified standard. Nuts and washers to be included.

PSL4 STEEL FLANGES (Clause 3.8.3)

PSL4.1 All flanges to be drilled to SABS 1123 (1000 kPa class drilling) unless otherwise specified on the drawings.

PSL4.2 Flange holes to be drilled to allow exact alignment vertically and horizontally as detailed on the drawings of all pipework and equipment.

PSL5 CORROSION PROTECTION (Clause 3.9)

PSL5.1 General

No separate payment will be made for work described in this sub-section.

The Contractor has to make available to the Engineer the necessary equipment for accurate measurement of paint thicknesses and pinholes.

Before painting or the application of anti-rust compounds all metal elements shall be cleaned of all rust, scale, grease and any substance deleterious to subsequent operations.

All steel surfaces shall then be treated in accordance with one of the following methods as specified.

PSL5.2 Galvanising

Where galvanising is specified it shall be carried out by the hot dip process to provide a 3-37


minimum mass of zinc coating of 105 micron (0.105mm) in accordance with SABS ISO 1461 (as amended). A certificate of compliance in accordance with ISO 10474 for all galvanizing is required. Cut ends and small damaged areas shall be repaired by the application of a zinc-rich epoxy (“ZINCFIX”).

Before applying the epoxy the affected areas shall be cleaned of all residues and washed with clean water. The area shall then be abraded with abrasive paper (roughness 80 grit) or alternatively cleaned by a stainless steel brush, from all dust and debris.

PSL5.3 Epoxy Tar

The epoxy tar to be used shall comply with the specifications of SABS 801 Type 2. It shall be applied in three coats, with either one or two coats being applied in the workshop. After installation any scratch or chip marks shall be touched up and the whole item covered with a further coat (or two coats) of epoxy tar to give a total final thickness of not less than 0,5mm.

PSL5.4 Epoxy Enamel

Epoxy resin paint shall be 'Copon EP 2300' or similar approved. The epoxy resin shall be evenly applied in the workshop by spraying to a final enamel thickness of not less than 250 micron (0.25 mm) over the whole surface to be coated/lined and there shall be no electrical insulation defects, excessive runs, sags, or other imperfections. Dry film thickness per layer shall be a minimum of 40 micrometers above the peaks of the blast profile as measured by an approved eddy current instrument. Successive coats, of either linings or coating, shall be in distinctly different colours. The pipe shall be so supported during coating as to prevent damage to the wet coating material and until the coating material has hardened adequately, shall remain suitably supported during curing and storing and during handling. After installation any chips or scratch marks shall be made good on site with brush applied epoxy paint.

Where specified, pipework and appurtenance which shall receive epoxy resin paint and be overcoated to the colours specified by the Engineer, shall, after curing of the full coating epoxy resin paint, be thoroughly degreased using an approved water emulsifiable degreaser as Plascon's "Aquasolv Degreaser gr. 1", followed by adequate water rinses. Surfaces shall subsequently receive thorough abrading with abrasive paper (220 - 350 grit) to achieve a matt surface, followed by the specified colour final coating of polyurethane recoatable enamel. The polyurethane recoatable enamel shall be applied in two coats, each coat to a minimum d.f.t. of 30 micron.

PSL5.5 Enamel Painting

All ungalvanised components of structural steelwork, fencing or any other components of steel or iron to be used in this contract for which no galvanising or other treatment has been specified, shall be painted in accordance with the following specifications.

a) Apply one prime coat of Red Lead paint to SABS 312 Type II Grade II and one coat of Zinc chromate primer to SABS 679 Type I.

b) Subsequently apply: Undercoat to SABS 681 Type I.

c) Subsequently apply: Final gloss enamel coat SABS 630 Grade I. (Colour as specified).

PSL5.6 Schedule of Corrosion Protection

3-38


For Steel Pipework Galvanising EpoxyEnamel

Poly-urethane

0 <= 150 ND Internal XExternal X

> 150 ND to 400ND

Internal XExternal X

Extra over on external surfaces of pipe-work above ground or pipe-work inside building

X

Pipe straps X

ValvesX

Extra over for pipes and fittings below ground

External Pipes below ground to be DENSO HT Petrolatum Tape wrapped (see PC 2.4)

PSL6 HANDLING AND RIGGING (Clause 4.1)

PSL6.1 Transportation

Pipes and valves shall be protected during transportation and handling against damages caused by impact, dropping, etc. Special care shall be taken during transportation to protect pipes. Rubber lined vertical posts shall be spaced on the sides of transporting vehicles to provide adequate support to the loaded pipes. All pipes shall be inspected for defects immediately before laying and faulty pipes or pipes which have suffered damage, which would affect their serviceability, shall not be used in the Works.

PSL6.2 Off-loading and storage

Pipes, which cannot be off-loaded by hand shall only be lifted by means of suitably approved broad band slings. The use of wire, chains, hooks, crowbars and similar items shall not be permitted and the pipes, fittings and specials shall not be handled in such a manner as could cause damage to occur.

Pipes, fittings and specials shall at no time be laid, stacked or rolled directly into the ground but shall be supported on suitable padded cradles or other approved material as recommended by the manufacturer near each end of the pipe, fittings or special.

For stacked uPVC pipes:

the supports shall be at least 75mm wide, spaced at an interval not exceeding 1.75m (ie. four supports/pipe length)

the pipes shall be cross-stacked with ends alternating to ensure barrel to barrel contact.

the pipe stack height must not exceed 1m. each completed pipe stack to be covered in 80% density green

shadecloth and secured against the wind. particular care shall be taken where pipes with integral couplings are

handled or stacked to prevent any pressure on the couplings.

All PVC-pipework as well as the rubber sealing rings in pipe couplings shall be protected from the elements to prevent deterioration of the pipework.

No concessions will be made in the above regard and failure on the Contractor's part to 3-39


comply shall be considered just cause for the Engineer to order such part of the works to be closed down.

PSL6.3 Inspection on delivery

The Engineer's Representative will be afforded the opportunity to thoroughly inspect all pipes, fittings and specials delivered to the site but his acceptance of same as being in good condition shall not relieve the Contractor of any of his obligations or responsibilities under this Contract.

Materials rejected by the Engineer shall be removed from the site and shall be replaced by other approved materials by the Contractor at his own expense.

PSL7 SETTING OUT (Clause 4.2)

Alignment of the pipes may be done either by means of infra-red sighting equipment or by sight rails. The following method should be followed if alignment is to be done by sight rails:

Prior to the preparation of the pipe bedding, the Contractor is to erect sight rails of 38mm x 150mm timber at intervals of a maximum of 60m or at points of change of pipe gradient, whichever may be the lesser. These shall be supported by wooden posts on each side firmly fixed on solid ground and the rails shall be accurately placed in position as regards alignment and invert level of the proposed trench. The centre line of the trench (i.e. pipeline) shall be denoted on each sight rail, both back and front by a single vertical line drawn thereon, and the rail on either side of the centre line painted in two contrasting colours. The Contractor shall also provide boning rods of an appropriate length marked in even decimetres for use in the fixing of the trench bottom to the correct line and level.

PSL8 LAYING AND JOINTING

PSL8.1 Approval of trenches and bedding

No pipe laying shall commence on any particular section until the Engineer has approved of the trenches and bedding. No pipes for which the jointing of pipe lengths is to be made in their final position shall be laid in trenches with freestanding water.

PSL8.2 Positioning pipes and fittings

The pipes shall be laid true to the lines, levels and grades shown on the drawings, or ordered by the Engineer, to within the specified tolerances.

PSL8.3 Jointing

All valves and fittings are to be checked beforehand to ensure their operational order prior to connection in the line.

The ends of laid pipes shall be suitably closed by means of approved caps, or as shown on the drawings, to prevent the ingress of soil of other matter. After the pipes have been laid, they shall be inspected and checked by the Engineer for grade, direction and line, to the specified tolerances.

PSL9 BACKFILL (New clause)

PSL9.1 Approval3-40


Following the inspection by the Engineer with respect to the grade, direction and line as well the successful testing of the pipeline the Contractor shall promptly refill trenches and excavations.

PSL9.2 Material and MethodMaterial used for backfill shall be either selected granular material, selected backfill material or mainfill as specified in SABS 1200 LB: Bedding (Pipes) with the backfill profile as described for the specific type of bedding.

The pipe must be supported underneath and on the side by placing prisms of the bedding material underneath the pipe. The backfill material shall then be punned around the pipe until a cover above the pipe of at least half the width of the trench is reached. Only then may mechanical compaction commence.

The selected material shall be brought up in 150mm layers, uniformly moistened to the optimum moisture content to attain the specified compaction. After reaching a cover of 300mm above the pipe, filling with the main fill may commence.

The degree of compaction shall in all cases be at least 90% of the modified AASHTO density.

PSL9.3 Finishing offThe backfill shall be mounded to a height of 100mm above ground level with gaps allowed at regular intervals for cross drainage. Sufficient topsoil shall be set-aside during vegetation to form not less than the upper 150mm layer of backfill material. Any surplus material shall then be levelled off adjacent to the pipeline.

PSL10 LEGEND AND NODAL DESCRIPTION

Descriptions of each pipeline node, giving details of the required fittings and the sequence of assembly, as well as legend explaining the codes used in the nodal descriptions are included on the nodal description drawings.

PSL11 TEST PRESSURE (Clause 7.3.1.2)

The maximum working pressure head for the purposes of clause 7.3.1.2 shall be taken as the class rating of the specified pipe (i.e. working pressure head for Class 9 pipe should be taken as 90m etc.).

PSL12 MEASUREMENT AND PAYMENT

PSL12.1 Principlesa) Measurement of the specials and valves shall be as per the appropriate items in

SABS 1200L i.e. Items 8.2.2 and 8.2.3.

Measurement of the pipes shall be as per item 8.2.1 in SABS 1200 L.

PSL12.2 PVC pressure pipes – Batch TestingThe cost for batch tests required in terms of PSL 1.2 should be included in the Contractor's rate for the supply of the pipes.

3-41


ANNEXURE B

PARTICULAR SPECIFICATIONS

Page

PB - Building Work 3-43PSC - Concrete 3-51PSS - Structural Steel 3-54PRE - Refrigeration Technical Specification 3-58PSEL - Emergency Diesel Generator Set 3-59PSE - Electrical Technical Specification 3-69PSW - Waste Management 3-71PF - Fencing 3-72POHSA - Health and Safety Specifications 3-76

3-42


PB – BUILDING WORK

PB1 SCOPE

This section of the Specifications deals specifically with all the building work associated with the Works.

Concrete work, steelwork, cladding, pipe laying, mechanical and electrical equipment, etc. forming part of or to be housed in a building erected in terms of this specification shall conform to the requirements of the relevant standardized or particular specifications referred to in the Project Specification.

PB2 INTERPRETATIONS

The relevant SABS 1200 Standardized Specifications such as Site Clearance, Earthworks, Earthworks (pipe trenches), Concrete (structural), Low pressure pipelines, Bedding (pipes), Sewers and Storm water drainage shall also apply to the work under this section.

PB3 MATERIALS

All materials used for the Building Work shall, where such mark has been awarded for a specific type of material, bear the SABS mark.

PB3.1 Brick and Plasterwork

Cement, sand and water shall conform to the requirements of SABS 1200 G – Concrete.

Unless otherwise described, cement mortar shall be composed of six parts by volume of sand to one part by volume of cement. The materials are to be mixed dry until the mixture is of a uniform colour and then clean water is to be added gradually through a fine rose and the mixture turned over until the ingredients are thoroughly incorporated.

Cement mortar must be mixed in small quantities and must be used within one hour of mixing, as the use of cement mortar that has commenced to set will not be permitted.

Plaster on concrete ceilings, beams, columns etc. shall be mixed one part cement to three parts sand.

Unless otherwise prescribed on the plans, bricks shall be of the best quality sound hard burnt pressed bricks or in the absence of clay bricks, concrete bricks; even in size and shape and equal to a sample submitted to and approved by the Engineer prior to commencement of work.

Clay bricks shall conform with the requirements of SABS 227 and concrete bricks to SABS 987.

Damp proof courses, unless otherwise described, shall be an asphaltic damp proof course with a base of fibre felt, and complying with the requirements of SABS 248 Horizontal Damp Proof Courses, and with a mass of 3,25 kg/m2 or a plastic damp proof course of 15 micron thickness as Type B, complying with the requirements of SABS 952.

3-43


PB3.2 Fascias, Barge Boards and Window sills

Nutec fascias and barge boards, where specified, shall be 10mm thick pressed sheets, 200mm wide free from cracks, twists, blemishes or other defects and complying with the requirements of SABS 685.

Internal Nutec sills shall be in single lengths cut between reveals, fitted with fixing lugs and solidly bedded in 3:1 cement mortar with a slight projection beyond the finished wall face below. Sills shall be pressed fibre cement of approved manufacture 152x15mm thick, set level.

PB3.3 Paintwork

PB3.3.1 PrimersPlastered surfaces must be cleaned down and have one coat alkali resisting primer of an approved brand applied in strict accordance with the manufacturer’s instructions, before any undercoats are applied.

Galvanised metal surfaces must be treated with one coat Metal Etch Primer complying with the requirements of SABS 723.

Steel surfaces must be treated with one coat Type Zinc Chromate Primer complying with the requirements of SABS 679.

Steel windows and doors and steel door frames, before being built in, must have all loose primer together with all rust spots, dirt, etc. removed and be treated with one coat red oxide or zinc chromate primer complying with the requirements of SABS 909.

Wood surfaces to receive paint finish must be cleaned down, all knots treated with knotting and be primed with Type I Wood Primer externally and Type III Wood Primer internally, both complying with the requirements of SABS 678.

PB3.3.2 Emulsion paint for interior use must be Grade I Emulsion Paint complying with the requirements of SABS 663. Emulsion paint for exterior use must be of the Synthetic Polymer Base Type complying with the requirements of SABS 634.

PB3.3.3 High Gloss Enamel Paint Shall be used on all surfaces other than specified above. High Gloss enamel paint must be Grade I paint complying with the requirements of SABS 630 for decorative High Gloss Enamel Paints with a Non-Aqueous Solvent Base, for Interior and Exterior use.

Undercoats for paints, except Emulsion paints, must be Type I undercoat Paint complying with the requirements of SABS 681.

3-44


PB3.4 Doors, Windows and Glazing

PB3.4.1 DoorsUnless indicated otherwise on drawings, all doors and door frames shall be of solid hardwood. Frames shall be fitted with suitable tie bars and braces at bottom, and lugs for building in, three to each jamb of frames without fanlights and four to each jamb of frames with fanlights. All doors shall be provided with locks to the requirements of SABS 4 and each lock shall be provided with a duplicate key.

PB3.4.2 WindowsSteel windows must be of approved manufacture and design, constructed of rolled mild steel sections, properly mitred and welded at angles with welding cleaned off smooth on all faces and complying with the requirements of SABS 727. Window types and sizes shall be as specified on the drawings.

PB3.4.3 GlazingSheeting glass for glazing, unless otherwise specified, must be flat drawn clear glass of the thicknesses indicated below:

For panes not exceeding 0,65 m2 : 3mmFor panes exceeding 0,65 m2 and not exceeding 1,5 m2 : 4mm

PB3.5 Tiling

PB3.5.1 Adhesives and Grouts(a) Wall adhesive

A grey, cement-based thin bed, wall tile powder adhesive for fixing tiles to walls mixed with a bonding agent such as ‘Tylon – Bond It’.

(b) Floor adhesive A grey, cement-based thick bed, floor tile powder adhesive for fixing heavy tiles to floors or walls.

(c) Wall grout A cement-based, plasticized grouting compound for wall tile installation.

(d) Bonding agent A latex modified for use with adhesives and grouts to improve water resistance.

(e) Silicone sealant A silicone-based sealant of nearest approximate colour to tile, used to seal the corners of permanently wet areas and expansion joints (made at consistent interval positions) on large tiled surfaces.

PB3.5.2 TilesTiles shall be of first grade quality glazed ceramic tiles, white in colour, a maximum size of 160mm square, of a maximum thickness of 5mm, unless otherwise specified.

3-45


PB4 PLANT

Plant, equipment, tools, scaffolding, etc. utilised in building work shall be of suitable capacity, condition and design to ensure the satisfactory and timeous completion of the Works within the specified period and in terms of these specifications and good building practices.

Only registered artisans (e.g. plumbers, electricians, etc.) shall be employed on any work where this is compulsory building practice.

PB5 CONSTRUCTION

PB5.1 Brick and Plasterwork

PB5.1.1 Normal Brick WallsBrickwork must be built in stretcher bond. No false headers are to be used and none but whole bricks except where legitimately required to form a bond. The bricks are to be well wetted (saturated in hot weather) with water before being laid and the course of bricks last laid is to be well wetted before bedding fresh bricks upon it. All perpends and angles are to be kept plumb. The brickwork is to have the joints flushed up at every course solid throughout the whole width of the course, and each course is to be laid on a solid bed of mortar. Pointing is to be done as the work proceeds.

The joints of all walls to be plastered are to be raked out 15mm as the work proceeds to form a key for plaster or screed. All walls are to be built up in regular and horizontal courses and carried out so that no part built is more than 1,2m higher than any adjoining walls. Mortar beds generally are not to exceed 12mm thickness.

PB5.1.2 Face brick wallsIn all faced brickwork the bond must be set out on the first level course of brickwork, at floor level internally and two courses below ground level externally. The bond, if necessary, is to be broken in the centre of panels under windows or to piers between windows. All perpends must be kept true and all courses must be built to gauge rods. Facings must be carefully protected from damage, mortar droppings, paint splashes, etc. during the whole period of the Contract and, on completion, they must be thoroughly cleaned down and left perfect. The practice of oiling facings on completion will not be allowed.

PB5.1.3 Reinforced Brick LintolsBrick Lintels are to be built of normal, sound, well burnt, good quality building bricks, similar to the facings where exposed, properly bonded longitudinally and bedded and pointed in ce-ment mortar as described. Special care must be taken to ensure solid bedding, particularly where the reinforcement occurs.

The Lintels are to be reinforced with straight continuous mild steel rods of the size and number scheduled. The rods must each extend 300mm on each side of the opening and are to be evenly spaced across its thickness in the first horizontal joint above the soffit.

3-46


Brick Lintels in cavity walls must have all rods placed below the solid sections of the walls, excepting for those rods specifically scheduled to occur below the cavity.

Where two or more openings are less than 665mm apart, the lintel shall be continuous over all such openings and the dividing piers, plus 300mm bearing at each extreme end as before, shall have such height and reinforcement as scheduled for widest opening spanned.

Span in mm Min. Height of lintels above soffit course, in

brick courses

Reinforcement per half brick thickness of wall above for solid walls

No. of Rods Dia (mm)

600 2 1 6

900 3 2 6

1200 3 2 6

1500 4 3 6

1800 4 3 6

2400 6 3 6

In addition to any reinforcing specified in the table above one layer of brick reinforcing shall be placed at every alternate brick course above the lintol. The brick reinforcing thus placed shall extend at least 300mm on each side of the opening.

All brick lintels are to be supported by two 114 x 38 timber bearers (on edge) for a duration of 7 days. Extreme care shall be taken beforehand to ensure a level and straight support.

PB5.1.4 Damp proof coursesThe sheeting is to be cut into strips of the required width and laid on all foundation walls to the full thickness of the walls and without any longitudinal joints. At ends, angles and intersections the sheeting must be lapped 150mm and sealed.

Under all window sills exposed to the weather, the sheeting must be laid on the brickwork in the first joint immediately below the sill and turned up with an easy bend and tucked into window frame.

Over reinforced brick Lintels exposed to the weather, the sheeting must be laid to form damp proof course as detailed above for solid walls and cavity walls.

PB5.1.5 Reinforcing in Brick wallsReinforcing (brickforce) of an approved manufacture shall be placed on every fourth course in all brick walls and above doors and openings brickforce to be placed on every course. In halfbrick and cavity walls 80mm wide reinforcing mesh shall be used and 150mm wide mesh in the case of the one-brick walls.

PB5.1.6 PlasterworkAll chases must be cut and electrical conduiting and boxes fixed before any plastering is done. On no account will chasing be allowed in finished plaster work, and if such chasing is necessary, the entire wall surface must be hacked off and replastered.

Except where otherwise described, all external plaster is to be finished with a wooden float and all internal plaster is to be finished with steel trowel, all to perfectly true and even surfaces, free from tool marks and other defects on completion.

3-47


All finished surfaces are to be protected from injury. All joints in brickwork are to be well raked out, all surfaces, brickwork and concrete, to be plastered must be brushed down to remove all dirt and dust and be thoroughly wetted directly before plastering. Concrete surfaces must be roughened or hacked as necessary to give a proper key for plaster. The surfaces must then be slushed with coarse cement grout before plastering is commenced. The surfaces of all internal plaster must be steel trowelled to a smooth even and true finish. External plaster must be finished to a true and even surface with wood float. Plaster must be returned into reveals and soffit of openings and all angles and edges must be true and straight. All plaster surfaces must be free from blemish and any cracks, blisters, or other defects must be cut out and made good and the whole left perfect at completion. Plaster on walls must be not less than 12mm or more than 20mm in thickness, and plaster on concrete work must be not less than 10mm or more than 15mm in thickness, except where specifically otherwise described.

PB5.1.7 Slip jointsSlip joints shall be provided between brickwork and concrete slabs and beams by levelling up and steel trowelling smooth the bearing surfaces of brickwork with 3:1 mortar and covering the bearing surface before concrete is cast with 2 layers of 0.500mm (five hundred micron) black general purpose plastic sheeting membrane.

The ends and sides of beams and edges of concrete slabs shall be separated from the brickwork with 12mm polystyrene placed vertically against the brickwork before the concrete is cast.

PB5.1.8 Beam fillingUnless otherwise specified, beam filling shall be half brick thick, built in cement mortar, cut in between roof timbers and carried hard up to underside of roof covering and flushed up in mortar with a groove formed between covering and mortar. Care shall be taken to protect cladded surfaces from mortar, prior to beam filling.

PB5.1.9 Securing of RoofsRoof plates shall be fixed to walls with bands of 1,6mm thick galvanised hoop iron, 32mm wide, built six (6) courses deep into brickwork or embedded 300mm deep into concrete, at not exceeding 1,5 metre centres, and well lapped and spiked to plates and to roof trusses where adjacent, otherwise taken up to and lapped round the nearest purlin and well spiked thereto. A layer of brickforce shall be provided at each course above the building in of the hoop iron, to fix the roofs.

PB5.2 Rainwater Goods

All gutters, downpipes and flashings shall be 0,6mm thick galvanised sheet iron. Rates for sheet iron eaves gutter and rainwater pipes shall include for short lengths and for lapped, lintels and soldered joints. Eaves gutters are to be screwed or welded to fascia boards or roof timbers/beams with 38x3mm galvanised mild steel gutter brackets at approximately 900mm centres, or as otherwise described. Rainwater pipes are to be fixed with sheet iron ears to and including 25x76x150mm wrought and chamfered hardwood blocks, plugged to brickwork or concrete and oiled, or with 38x14 gauge galvanised hoop iron straps built into walls not more than 2 meter apart, bent around pipe and bolted at back.

Flashings shall be properly cut, lapped and shaped to render a waterproof finish. Flashings turned up against walls must be finished with cover flashings bent to shape, dressed over the underflashing and with top edge wedged into joint of brickwork and pointed or secured by other approved means.

Fascias and barge boards shall be secured with screws or bolts. Where joints occur in the length they are to be covered with two channels 40mm girth with web to suit thickness of plates formed from 0,5mm thick galvanised sheet iron cut to shape, bent as required and with the webs lintels together back to back. Tongues 15mm wide by 15mm long must be left

3-48


projecting at both ends of flanges and clamped down over edges of fascias or barge board when in position.

PB5.3 Paintwork

All surfaces not being painted, such as face brickwork, sills, floors and stained woodwork, must be covered up and protected against paint and distemper sports before any painting is commenced. All floors must be swept clean and walls dusted down before any paintwork is commenced and no sweeping or dusting must be done while painting is in progress.

All plastered wall; ceiling and similar surfaces must be perfectly dry and in a fit state to receive the finishings, before the work is put in hand.

All coats of paints, etc. must be thoroughly dry before subsequent coats are applied, and rubbed down where necessary.

All work must be finished to colours approved by the Engineer.

The tints of undercoats must approximate those of the finishing colour and in order to indicate the number of coats applied and to avoid misses when applying a succeeding coat a slight difference shall be made in the tint of each coat.

The Contractor must provide all necessary dust sheets, covers, etc., and shall exercise all necessary care to prevent marking the surfaces of joinery, walls, floors, glass, electrical fittings, etc., and must keep all parts of the works perfectly clean and free at all times from spotting, accumulation of rubbish, debris or dirt arising from the painting operations. Any surface disfigured or otherwise damaged must be completely renovated or replaced as necessary, by the Contractor at his own expense. The premises must be left clean and fit for occupation at the completion of the work.

PB5.4 Floor Finishes

Where a floated concrete floor finish is specified on the drawings, the requirements of SABS 1200G or GA, whichever is relevant, shall apply.

Granolithic finish to floors, treads and risers of steps, thresholds, landings etc., must be composed of two parts hard stone chippings; half part sand and one part cement, steel trowelled to a true and even surface. The granolithic must be laid before the concrete surface bed has matured, otherwise the surface of the concrete must be thoroughly cleaned with a wire brush and a coat of neat cement grout applied immediately before the granolithic is laid. The granolithic must be laid in panels not exceeding 6m2 in areas, and jointed to lines of panels and lined into smaller squares as directed with sunk V-joint. The joints between the panels should coincide with joints in the concrete surface bed, where these occur. No dusting on of colouring pigment will be allowed.

Terrazzo floor tiles shall be even in size and shape, free from cracks, chips, twists, blemished or other defects, uniform in colour and equal to samples to be submitted to and approved by the Engineer. Special care must be taken to preserve arises and faces during transit and handling.

Pointing, etc.: Terrazzo floor tiles are to be bedded and jointed solidly in cement mortar and unless otherwise described, flush pointed on all exposed faces with semi-dry cement mortar pressed in. On no account must liquid grout be poured in. Terrazzo floor tile work must be well protected to prevent all possibility of damage or discolouration and thoroughly cleaned on completion.

Vinyl floor tiles shall be fixed on to a screed of thickness at least 25mm. The screed shall have a wood floated finish and shall be smooth with no obstruction greater than 3mm

3-49


protruding and with the screeded surface level in such a way that no gap greater than 5mm would show underneath a 3m straight-edge or part thereof.

Vinyl tile adhesives shall carry the same product name as the vinyl tiles and the adhesives shall be applied as stipulated by the supplier.

The acceptable tolerance of the final tiled floor shall be similar to that specified for the screeded surface underlying the tiles.

PB6 TOLERANCES

Where tolerances are not specified in the clauses above those generally accepted as re-presenting good workmanship in the building trades shall apply.

PB7 TESTING

The Engineer reserves the right to order any tests, whether at place of manufacture or on site, necessary to evaluate the quality of the work and to ensure the finished building conforms to all the specified requirements.

PB8 MEASUREMENT AND PAYMENT

PB8.1 Schedule Items

PB8.1.1 BrickworkBrickwork, if measured as a separate item, shall be measured in square metre of the nett brick-walled area (with the wall width and type of brick-finish, indicated). No deductions will be made for small openings such as air bricks, etc. The tendered price per square metre of brickwork shall include also for the following:

a) Brick forcing (as specified in PB5.1.5)b) Reinforcing of Lintelsc) Miscellaneous items built into brickwork shown on the drawings such as air bricks.

PB8.1.2 Wall, ceiling, roof and floor finishesCement plaster on walls and ceilings, roof screeds, floor screeds, paint and any other finish described or specified, shall if measured as separate item be measured in square metre of the nett surface area. No deductions shall be made for small openings nor shall additions be made for small protrusions and reveals. No separate payment shall be made for the processes involved and material supplied for the complete painting of all fixtures and fittings, as specified herein and the costs thereof shall be included in the tendered price for the supply, manufacturing and erection of all such items to be erected.

PB8.1.3 Miscellaneous(f) Doors and windows shall be measured per unit of door or window complete with door

frame, lock keys, glazing, painting, etc., for each type and size of door or window or as a lump sum payment for all doors and windows included in the door and window schedule of the Works.

(g) Other items of building work, fixtures and fittings, shall be measured and paid for in the units of measurement listed in the Schedule of Quantities.

3-50


PSC – CONCRETE

PSC1 CEMENT (Clause 3.2.1)

All Cement to be used shall conform with SANS 50197-1. The cement composition used shall be subject to the Engineer's approval.

PSC2 STORAGE OF CEMENT (Clause 3.2.3)

A first-in-first out circulation shall be followed to ensure that no cement for (i) reinforced concrete shall be older than 3 months from the date of manufacture and (ii) mass concrete shall be older than 6 months from the date of manufacture.

PSC3 ADMIXTURES (Clause 3.5.1)

Admixtures will only be permitted on concrete water retaining structures with the written approval of the Engineer.

PSC4 CONCRETE FINISHES (Clause 4.5.2)

Concrete against which earth will be backfilled will be finished rough. All exposed concrete surfaces shall be finished smooth to degree of accuracy II.

PSC4.1 Rubbed surface finish

Where a rubbed surface finish is specified or scheduled the surface shall first be treated as a smooth finish as specified in SABS 1200G 5.2.1 b).

After sufficient time has elapsed to allow the mortar to set the surface shall be saturated by water. Rubbing shall then be carried out with a medium coarse carborundum stone and a small amount of mortar until all form marks, projections and irregularities are removed and a uniform surface obtained.

Leaving the paste produced by the rubbing in place, rubbing shall be continued with a fine carborundum stone and water. Rubbing shall be continued until the entire surface is of a smooth even texture and uniform colour. After the final rubbing the surface shall be washed down to remove surplus paste and powder.

PSC4.2 Cement screeding (Subclause 5.5.10.2)

Cement screeding shall consist of three parts of sand to one part cement. The final level shall be finished to definite slopes (where required, i.e. roofs, gullies, etc.) and in no case shall the thickness be less than 20mm.

3-51


PSC4.3 Unformed surface finishes (Subclause 5.5.10.2)

PSC4.3.1 Wood-floated finish

Where wood floating is specified or scheduled, the surface shall first be given a finish as specified in Subclause 5.5.10.1 of SABS 1200G and, after the concrete has hardened sufficiently, it shall be floated to a uniform surface free of trowel marks. The screeded surface shall be wood-floated, either by hand or machine, only sufficiently to produce a uniform surface free from screed marks.

PSC4.3.2 Steel-floated finish

Where steel floating is specified or scheduled, the surface shall be treated as specified in PSC3.3.1 except that, when the moisture film has disappeared and the concrete has hardened sufficiently to prevent laitance from being worked to the surface, the screeded surface shall be steel-trowelled under firm pressure to produce a dense, smooth, uniform surface free from trowel marks.

PSC4.3.3 Power-floated finish

Where power floating is specified or scheduled, the surface shall be treated as specified in PSC4.3.1 except that the screeded surface shall be power-floated to produce a high quality dense, smooth, uniform surface free from trowel marks.

PSC5 CONCRETE STRENGTH (New clause)

The Contractor shall have the mix designed by an approved laboratory to give a high density, low permeability concrete.

No concrete shall be placed until the Contractor's concrete mix design has been approved by the Engineer.

PSC6 HOLES, CHASES AND FIXING BLOCKS (Clause 5.3)

Substitute the contents of the clause with:

a) General

Holes, recesses and boxed-out openings shall be allowed in concrete structures, as specified, for the subsequent installation of mechanical equipment and/or pipework.

b) Preparation of openings for the installation of equipment

Before commencing the positioning in holes of any pipes/specials the Contractor shall:i) Remove all shuttering and boxing remaining in the holes;ii) Make any alterations required to the position and shape of the holes;iii) Thoroughly clean the sides of the holes so as to obtain a satisfactory bond

surface for the new concrete; andiv) Free all surfaces of the pipes/specials of all coatings, and thoroughly scrape

and clean the pipes/specials.v) Apply a wet-to-dry concrete adhesive (similar to Epidermix 344 from ABE)

immediately before grouting.

3-52


c) Grouting of voids

The concrete ingredients shall be mixed and placed as dry as possible to obtain a dense, waterproof concrete. Where a watertight seal is required, the concrete shall be carefully worked around the puddle flange, if any, and the pipe barrel or body of the special, and shall be vibrated in layers so as to obviate any falling away from pipe/special surface of the concrete already placed. The whole shall, when set, form a dense, homogeneous, and waterproof mass. A spare vibrator with an independent power source shall be kept in readiness to ensure continuity of placing in the event of the breakdown of the duty vibrator.

Smooth formwork that has been suitably strengthened for use with a vibrator shall be provided for facing the concrete around each pipe/special.

PSC7 PIPES AND CONDUITS EMBEDDED IN CONCRETE (Clause 5.4)

Except with the written approval of the Engineer, no pipes other than those shown on the drawings shall be embedded in concrete, and the approval of the Engineer for the position of all services to be embedded shall be obtained before concreting commences. The clear space between pipes of any kind embedded in reinforced concrete and the clear space between such pipes and reinforcement shall not at any point be less than:

j) 40mm orii) 5mm plus the maximum size of coarse aggregate, whichever is the greater.

PSC8 DEGREE OF ACCURACY (Clause 6.2)

The following degrees of accuracy shall be applicable:

a) All exposed elements or components above foundations : Degree II

b) Elements above foundations which will be permanently covered by earthfill : Degree III

c) Foundations (excluding floor slabs) : Degree III

3-53


PSS - STRUCTURAL STEELWORK

PSS1 GRADE OF STEEL (Clause 3.1.1)

All steel for structural steelwork to be to Grade 350W to SABS 1431.

All steel for handrails and ladders to be manufactured from Grade 43A (to BS 4360) or Grade 350W (to SABS 1431). Under no circumstances will the use of commercial grade steel be accepted.

PSS2 DRAWINGS AND SHOP DETAILS (Clause 5.1)

It should be noted that all the drawings dealing with structural steelwork and issued as part of the contract documents must be regarded as being general layout drawings. On these drawings issued by the Engineer the following information is given:

a) Sizes of structural members.b) Positioning of structural members relative to one another.c) Critical connection details.

These drawings shall not be regarded as being shop drawings and the responsibility of checking the actual on-site dimensions against those on the drawings, prior to the manufacturing or erection of steelwork shall remain with the Contractor.

PSS3 PROTECTIVE TREATMENT (Clause 5.3.9)

PHS3.1 Shop painting

i) Steelwork shall be sandblasted to S.A. 2.5 after fabrication to leave a smooth finish free of rust, scale, grease or any substance deleterious to the final protective coating.

ii) Within 4 hours after the completion of sandblasting, a SIGMA MC60 prime coat shall be applied to provide a dry film thickness of 75 micron.

iii) An intermediate coat of SIGMA CMM10 shall then be applied to a dry film thickness of 125 micron.

iv) One final finishing coat of SIGMADUR GLOSS shall be applied 24 hours after the application of the intermediate coat. The coat shall provide a dry film thickness of 35 micron. The colour of the final coat shall be match the existing members (Dark Green) unless otherwise specified.

vi) The total dry film thickness of the protected member shall be at least 235 microns.

PSS3.2 Painting after erection

i) After erection all areas where the primer coat has been damaged shall be wire brushed and touched up as specified in PSS3.1.

3-54


PSS3.3 Galvanising

Where galvanising is specified it shall be carried out by the hot dip process to provide a minimum mass of zinc coating of 105 micron (0.105mm) in accordance with SABS ISO 1461 (as amended). A certificate of compliance in accordance with ISO 10474 for all galvanizing is required. Cut ends and small damaged areas shall be repaired by the application of a zinc-rich epoxy (“ZINCFIX”).

Before applying the epoxy the affected areas shall be cleaned of all residues and washed with clean water. The area shall then be abraded with abrasive paper (roughness 80 grit) or alternatively cleaned by a stainless steel brush, from all dust and debris.

PSS3.4 Polyamide Cured Epoxy Resin

Where polyamide cured epoxy is specified the coating shall be applied through spraying in a workshop to a final thickness of at least 250 micron (0.25mm). The type to be used shall be "Copon EP2300", or similar approved.

Following installation the section shall be checked for any chips or scratch marks and shall be made good on site with brush applied epoxy paint.

PSS4 WELDING (Clause 5.3.4)

Delete this Clause in its entirety and add the following clauses:

Welding shall be done in accordance with the requirements of SABS 044 Part III Grade B, unless Grade A is specified.

Welding shall be Grade B welding.

The qualification of welders shall be in accordance with the relevant clauses of the above standards, and specifically SABS 044 Part III and IV. Welders qualified to SABS 044 Part 5 shall only be permitted with the Engineer's approval.

The Contractor shall provide evidence, acceptable to the Engineer, that welding procedures and welders have been tested in accordance with the requirements of SABS 044 Parts III and IV.

PSS5 SITE WELDING (New clause)

No welding shall be permitted on site without the express approval of the Engineer, with the exception of those details shown on the drawings as site welded.

PSS6 CUTTING (New clause)

No oxy-acetylene or other gas cutting and bending will be permitted on site without the Engineers approval.

The Engineer will have no hesitation in condemning any relevant component, member or unit should oxy-acetylene or other gas cutting and bending, processes be carried out by the Contractor without the Engineers approval.

3-55


PSS7 ERECTION PROCEDURE (New clause)

The setting-out of all holding-down bolts shall be accurately checked by the Contractor. Any discrepancies in excess of the permissible deviations of the positions of these bolts shall be reported immediately to the Engineer.

The Contractor shall not be permitted to make any relevant adjustment in the steelwork without the Engineers approval. (Refer to paragraph 2 of PSS6).

PSS8 HANDRAILS (SABS 1200HA - Subclause 5.2.10)

PSS8.1 Type

The handrails shall be manufactured by an approved firm specializing in such work and shall be of steel tubing of nominal thickness 2,6mm and of nominal outside diameter at least 34mm.

Normal stanchions shall be manufactured preformed in one piece and shall be of nominal outside diameter at least 42mm. Stanchions shall be fitted with double balls, accommodating knee and handrails. The bases of the stanchion shall be preformed to suit the situation in which they are to be installed and the stanchion spheres shall be performed to suit right angled or other angled intersections, all as given on the drawings.

Stanchions shall be spaced at intervals shown on the drawings, but in no case at intervals exceeding 2,0m. All joints shall be welded after the erection of handrails.

PSS8.2 Protective Treatment

Treatment of handrails shall be as specified in PSS3.1 and PSS3.2.

The colour of the final coat shall be golden yellow (SABS 1091 - B49).

PSS8.3 In-situ Measurement

The Contractor shall ensure, by making in-situ measurements before manufacture is started, that the handrails suit the situation in which they are to be installed.

PSS9 LADDERS AND WALKWAYS

PSS9.1 Type

Steel ladders shall be manufactured by an approved firm specializing in such work to the details on the applicable drawings.

PSS9.2 Protective Treatment

Treatment of ladders shall be as specified in PSS3.1 & PSS3.2. All walkways and walkway gratings shall be galvanised as specified in PSS3.3.

PSS9.3 In-situ Measurement

The Contractor shall ensure, by making in-situ measurements before manufacture is started, that the ladders/walkways suit the situation in which they are to be installed. Special attention shall be given to fixing details and the position at which it should be placed.

3-56


PSS10 MEASUREMENT AND PAYMENT (Clause 8)

PSS10.1 Structural Steelwork (New Clause)

The rate tendered shall include for all labour, material and equipment necessary to supply, fabricate, delivery to site, store and erect each assembly complete and is to include for all holding down bolts, washers, brackets, shims, fasteners and bearing plates which are necessary to fix the steelwork in place as specified and which shall not be separately measured.

The items shall be measured and paid for in the units of measurements listed in the Schedule of Quantities.

PSS10.2 Protective Coatings

Protective coatings shall be measured as a single item per kilogram of steel covered as specified in clause PSS3.

The rate tendered shall also be deemed to include for all surface treatment prior to painting.

PSS10.3 Handrails, Ladders and Floorplates or -Grating (Clause 8.3.2)

These items shall be measured as per the appropriate scheduled items included in SABS 1200HA - Clause 8.3.

3-57


PRE – REFRIGERATION TECHNICAL SPECIFICATION

PRE1 SCOPE

The contract covers the supply and installation of the refrigeration installations associated with the Processing Facility, all as specified herein and shown on the drawings.

In general the contract shall include the following:

a. Installation of refrigeration infrastructure for polystyrene/urethane (CHROMADEK finished) partitioned cold rooms and freezer rooms, with counter sunk floors for freezer rooms.

Thereafter, the balance of the work, as detailed herein, shall be the responsibility of the successful tenderer(s).

b. Basic refrigeration design and installation consisting of all electronic temperature control for all rooms.

c. Providing Compliance Certificates and “AS Built” drawings and detail.

PRE2 CONDENSER INSTALLATION

All Condensers and associated fittings shall be supplied by the contractor as shown in the Bills of Quantities.

Condensers to be weather proof cladded, pack type including all electrical mechanical safeties.

PRE3 PIPING

Piping to be placed on a rack system above insulated ceiling using chain supports from rafters.

PRE4 DOORS

Doors to be equipped with heat element around door frames.

PRE5 TESTING AND COMMISSIONING

The contractor shall provide a Certificate of Compliance, issued by an accredited person, registered with the South African Institute of Refrigeration and Air Conditioning (SAIRAC) or South African Refrigeration and Air Conditioning, Contractors Association (SARRACA) all as required by SANS 10147.

3-58


PSEL- EMERGENCY DIESEL GENERATOR SET

PSEL1 SCOPE

This specification covers the supply, delivery, complete installation and testing on site in full working order of the equipment detailed below.

Full particulars, performance curves and illustrations of the equipment offered must be submitted with the tender. Contractors may quote their standard equipment, complying as close as possible with the specification, but any deviations from the specifications must be fully detailed.

The schedules following this specification must be completed by the Contractor in all respects.

The Engineer reserves the right to accept any portion of any tender and does not bind itself to accept the lowest or any offer.

PSEL2 REQUIREMENTS

The set shall be manually started and shut-down. The changeover switch will be by others located in the electrical panel. The set shall be capable of delivering the specific output continuously under the site conditions, without overheating. The engine shall be capable of delivering 110% of the specified output for one hour in any period of 12 hours consecutive running, in accordance with BS 5514.

Full particulars, including detailed descriptions and illustrations, with engine performance and fuel consumption curves shall be submitted with the tender. The engine and alternator shall be mounted as a complete set on a common steel base which shall incorporate anti-vibration dampers. The set must be placed on a concrete floor of the power room. A drip tray, large enough to catch a drip from any part of the engine, must be fitted under the engine.

PSEL3 VOLTAGE AND OUTPUT

The output shall be rated to suit the specified, kVA, power factor and voltage ratings as shown on the specification schedule. The engine size shall not exceed the specified ratings by more than 25%.

PSEL4 ACCOMMODATION

Where a generator room is provided for the emergency equipment the Contractor shall indicate the proposed layout of all plant in the room. The Contractor shall confirm that the area provided will be sufficient to also accommodate the fuel tank and control panel.

Full requirements for louvers, ventilation fans, ducts and exhaust systems shall be submitted with the tenders. The equipment shall not be delivered to site until The Engineer has confirmed that the room is complete and ready.

No attenuation or louvers are required.

3-59


PSEL5 DIESEL ENGINE

The engine must be of the solid injection, compression ignition type, running at a speed not exceeding 1500 RPM. The engine must be amply rated for the required electrical output of the set, when running under the specified site conditions. Unless otherwise indicated, the starting period from either automatic or manual switching-on until the taking over by the generating set, in one step, of a load equal to the specified site electrical output shall not exceed 15 seconds. The engine shall be easily started from cold, without the use of any special ignition devices, under summer as well as winter conditions, against full load.

PSEL6 BATTERY

The set must be supplied with a fully charged low maintenance lead-acid type battery, complete with the necessary electrolyte. The battery will be of sufficient capacity to provide ample starting torque for the engine, which could require up to six consecutive starts.

A glass fibre battery box shall be provided to prevent acid etc. from spilling on the floor.

A complete set of distilled water bottles, funnel, hydrometer, etc. will be provided in a glass case fixed on to the plant room wall to maintain and test the battery.

PSEL7 COOLING

Air cooled or water cooled engines shall be acceptable to prevent excessive running temperatures. An engine-mounted radiator with blower-type fan shall be provided to maintain safe operation at 43°C ambient temperature. Total air flow restriction to and from the radiator shall not exceed 0,12 kPa. The Contractor shall provide duct work with flexible connecting section between radiator and discharge louvre frame.

An audible alarm and visual trip system shall be provided on the A.M.F. panel to indicate that excessive temperatures have been reached.

PSEL8 LUBRICATION

The main bearings and other important moving parts in the engine will be lubricated by a forced feed system. An audible alarm and visual trip system shall be provided on the A.M.F. panel to operate in the event of low oil pressure.

PSEL9 FUEL PUMP

The fuel injection equipment must be suitable for operation with all commercial brands of diesel fuel

PSEL10 FUEL TANK

The tank shall be mounted on a self-supporting floor standing steel frame and a minimum of 400mm A.F.F.L. The fuel tank shall be complete with mounting brackets, fuel gauge manual shut off valve on the fuel line, drain valve, pipes, filter and filling orifice and shall have sufficient capacity to run the engine on full load for eight hours. A 'low level' audible and visual alarm system will be fitted to the panel but it will not trip the engine. A switch which will activate on low fuel level will be available for remote monitoring purposes. A

3-60


water trap must be provided between the tank and the engine.

Fuel will be delivered in 220 litre drums and the Contractor will provide a suitable hand pump and all necessary oil resistant hose pipes to enable the transfer of fuel to be carried out on site with the minimum amount of skill.

All fuel pipes shall be tinted copper with appropriate bends to provide an expansion facility.

PSEL11 GOVERNOR

The speed of the engine shall be controlled accurately by a mechanical governor such that when full load is suddenly switched off the temporary increase in speed will not exceed 10% above 1500 RPM. The permanent speed variation shall not exceed 2%% of the nominal engine speed. Manual adjustment must be provided on the engine to adjust the normal speed setting.

PSEL12 FLYWHEEL

The flywheel must be large enough to prevent any visible flicker in the lights. The cyclic irregularity of the set must be within the limits specified in BS 5514.

PSEL13 SILENCER

A residential exhaust silencer (to 75 dB (A), muffler companion flanges, and flexible stainless steel, suitable for coastal conditions, bellows-type exhaust fitting properly sized shall be furnished and installed according to the manufacturer's recommendation. The exhaust outlet shall be fitted through the roof or external wall of the generator room and shall extend 0,5m above the room gutters and must be fitted with a weather flap.

The exhaust pipe must be flexibly connected to the engine to take up vibrations transmitted from the engine. The exhaust pipe and silencer must be lagged inside the generator room to reduce heat and noise transmission. The silencer shall be mounted so that its weight is not supported by the engine nor will exhaust system growth, due to thermal expansion, be imposed on the engine. Exhaust pipe size shall be sufficient to ensure that exhaust back pressure does not exceed the maximum limitations specified by the engine manufacturer.

The muffler and all indoor exhaust piping shall be lagged by the installing Contractor to maintain a surface temperature not to exceed 65.5°C. The insulation shall be installed so that it does not interfere with the functioning of the flexible exhaust fitting.

PSEL14 ALTERNATOR

Unless otherwise specified, the alternator shall be of the self excited brushless type enclosed in a ventilated drip-proof housing, and must be capable of supplying the specified kVA continuously with a temperature rise not exceeding the limits laid down in BS 5000 for rotor and stator windings having 'Class E' insulation.

The alternator windings will be suitably impregnated and tropicalized to withstand the specified climatic conditions. Contractor are to list the number of similar installations operating in similar climatic conditions.

3-61


PSEL15 REGULATION

Since alternator set could be installed in an area where maintenance staff are not readily available it is essential to offer regulating equipment which is simple and robust in construction. Complicated equipment requiring specialized knowledge will not be considered.

The alternator shall be self-regulated and the voltage regulation limits shall not exceed ± 5% of the nominal specified voltage, under all load conditions and at the specified power factor, while the engine speed variations between no load and full load shall not exceed 41/2%.

PSEL16 PERFORMANCE

The excitation system shall be designed to promote rapid voltage recovery following the sudden application of full load. The voltage shall recover to within 21/2% of the steady state within 300 milli-seconds following the application of full load and the transient voltage dip shall not exceed 15%.

PSEL17 COUPLING

The engine and alternator must be directly coupled with a high class quality flexible coupling which is designed to cope with the most severe torque changes, due to instantaneous load changes in the alternator from no load to full load.

PSEL18 COMPUTER POWER SUPPLY

The Contractor shall ensure that the output regulation of (+-) 5% and individual and total harmonic voltages not exceeding 1% and 3% respectively.

PSEL19 MAINS FAILURE PANEL The panel will incorporate all of the specified control and protection equipment required to operate and protect the alternator. The preferred AMF Panel is a Reid & Associate AMF 120 control unit – This will be manually operated.

The visual and audible alarms, battery charging unit and mains failure sensing relays will also be incorporated in the panel. All instruments are to be flush mounted.

Where solid state equipment is used for control circuits etc, these shall be of the printed circuit board design which can be easily unplugged and replaced with standard replacement cards in the event of failure, testing etc. Spares of these PCB cards etc must be available at all times from the supplier of the emergency equipment.

NOTE: REFER TO THE RELEVANT SECTIONS OF THE MOTOR CONTROL SPECIFICATION WHICH ARE APPLICABLE TO THE AMF PANEL

PSEL20 ALTERNATOR PROTECTION

The alternator shall be protected by a triple pole MCB or air circuit breaker with instantaneous short circuit trips and adjustable thermal overload protection of the correct characteristics which shall be provided on the front of the panel. The settings of this unit will ensure that the alternator is adequately protected against all short circuit conditions.

PSEL21 ALARM AND PROTECTION EQUIPMENT 3-62


Four alarm relays with re-set push buttons are required to give visible and audible alarm signals to protect the plant by shutting it down before any permanent damage result. The visual indication will remain uncancelled until the problem causing the trip has been returned to normal

The protection required will be:

TEMPERATURE HIGH LOW OIL PRESSURE OVER SPEED UNDERSPEED START FAILURE LOW WATER LEVEL In addition, one FUEL OIL LOW level alarm and indication as well one

BATTERY/CHARGER FAILURE alarm and indication as must be provided which does not trip the engine. The lights and associated push buttons will be engraved accordingly.

One common hooter is required with one cancel button, both mounted on the panel and supplied from the starting battery. Provision is to be made for remote alarm indication and remote cancellation.

PSEL22 OPERATION SELECTOR

A four position selector switch is to be provided on the AMF panel to select the mode of operation, which could be - 'Auto' , 'Manual', 'Test' and 'Off'.

The Auto function will not be utilised.

In the 'Test' position the engine shall be capable of being manually started and stopped without the alternator picking up any electrical load, to ensure that starting equipment, battery etc. are in operational condition. This routine will be repeated every week and a log book recording this fact must be provided in the plant room.

With the selector in the 'Manual' position, the set must pick up the electrical load when started but it must not be possible for this supply to be paralleled with the authorities supply. A change over relay/contactor is therefore to be provided in the main distribution board.

In the 'Off’ position the set shall be completely isolated and cannot be started manually or automatically. This setting will be used for maintenance of the machine only.

PSEL23 BATTERY CHARGING

The AMF panel is to include an automatic constant voltage trickle charging system to keep the battery at its optimum condition at all times. The system shall ensure that the batteries are not overcharged by being permanently connected to the charging system.

3-63


An ammeter and voltmeter suitably scaled to indicate the trickle charging supply will be flush mounted in the front panel. The voltmeter will operate by depressing a spring loaded push button and will not remain in the circuit continuously.

PSEL24 PANEL EQUIPMENT The following items of equipment will be fitted to the panel:

One flush mounted 96mm x 96mm PCI voltmeter scaled to the specified voltage to read all phase-neutral voltages.

One 7 way voltmeter selector switch to suit item above. One 96mm x 96mm frequency meter showing alternator frequency. One hour meter with cyclometer counter showing the actual running hours of the

engine. 3-2 amp HRC fuses for the voltmeter circuit, including spare fuses. 3-96mm x 96mm maximum demand indicating ammeters scaled to the specified

maximum load current, complete with current transformer, to indicate the current in each phase of the alternator.

One phase rotation indicator. One adjustable type triple pole MCB or air circuit breaker rated to protect the

alternator. One four position selector switch as specified. Two push buttons marked 'Start' and 'Stop' for test operation. One complete battery charger with instrumentation to be operated from

the mains supply. One start-delay timer. One stop-delay timer. Relays and reset push buttons for engine protection with spare lamps. One low fuel level relay device and spare lamps. One low water level relay device and spare lamps. One battery/charger relay device and spare lamps One 12 Volt DC. hooter/alarm with protection fuses etc and terminals for the

operation of a remote alarm. One push button for manual start operation. One set of terminals and all interconnecting wiring including earth connections. Any other equipment necessary for the correct and safe operation of the

installation.

PSEL25 EARTHING

The neutral of the system must be solidly earthed. The Contractor shall provide a 400 x 50 x 6mm thick copper bar fixed to the plant room wall on two insulators rated at 500V. The earth mat shall consist of 70mm2 bare stranded copper conductor and 4 or more 1500mm long x 16mm diameter earth spikes to achieve a maximum resistance of 10 OHMS. The earth mat shall be spaced 4 metres from the plant room. Two 70mm2

insulated copper conductors shall connect the diagonal ends of the earth mat and earth bar within the plant room.

3-64


PSEL26 WARNING NOTICES

A non-corrodible and non-deteriorating engraved warning notice will be wall mounted in a conspicuous position reading:

Danger: This engine will start without notice. Turn selector switch to ‘Off’' position before working on plant (Do not forget to reset)".

In addition all statutory notices required by the Occupational Health & Safety Act .

PSEL27 INSPECTION AND TESTING

Because of the number of Contracts and the need for the project to function as a coordinated whole, particular emphasis will be paid to testing. No test will be recognised unless it is documented in a previously agreed format. The test procedure shall ensure that every combination of switches and events is tested for correct functioning and each such combination is recorded in a test sheet and checked off.

No plant or equipment may be energised until testing IS complete and the results accepted by The Engineer.

The Contractor shall supply all test equipment and consumables and at least 3 radios shall be available at all times during site tests

The Contractor shall conduct tests at the following stages. The Engineer shall be advised of the tests one week in advance of the test dates.

a) At manufacturer's work before equipment is released to site. b) During installation where testing is necessary c) Before final connections are made d) After installation is complete

PSEL28 COMMISSIONING

Commissioning shall proceed in accordance with a previously agreed procedure which shall be documented and which shall form the basis of the commissioning report.

During commissioning the operating parameters of each piece of equipment and each device shall be established and recorded at no-load, average and full load conditions.

The final set of points of all adjustable devices shall be recorded.

The Contractor will be required to make appropriate arrangements, and supply the necessary instruments and apparatus, etc., for the testing of all plant and equipment, in the presence of The Engineer in order to demonstrate compliance with the requirements of the specification.

The Engineer may require valid calibration certificates to be submitted to cover any meters, gauges, or other instruments used in the tests and may, if considered necessary, arrange for the use of additional meters or other instruments in order to establish the

3-65


degree of accuracy of the tests.

The Contractor shall be responsible for performing all tests on completion and shall provide the services of an approved Commissioning Engineer and all necessary skilled and unskilled labour, as well as the required tools and test equipment. The Engineer shall approve the procedure for carrying out the tests on completion and shall witness all tests and shall approve any adjustments or modifications necessary to achieve satisfactory operation.

PSEL29 INSTRUCTION MANUALS

Two (2) copies of the operating and maintenance manuals shall be provided on delivery of the plant and equipment. These shall come in the form of plastic covered ring files with the following information indelibly printed on their covers.

OPERATING AND MAINTENANCE INSTRUCTIONS FOR THE GENERATOR SET AT.

SUPPLIED BY

Name : …………………………………………………………………

Address : …………………………………………………………………

Telephone : …………………………………………………………………

Fax number : …………………………………………………………………

Each, page, pamphlet, booklet, diagram drawing etc. shall be separately bound into the manuals in a clear plastic pocket. Each pocket shall be numbered and indexed.

The first page of each set of manuals shall be an index which shall include a list of the numbers and descriptions of all drawings and pamphlets included in the set and also a list of Engineer's drawings relating to the relevant sections of the Contract.

The instructions shall include the following:

A list of spares, tools and testing equipment supplied under the Contract. A list of spare parts and testing equipment which are not supplied under the

Contract but which may be required for future major overhaul and/or testing of electrical plant and equipment.

Suppliers' names, addresses, telephone numbers, fax numbers and costs must be listed for spares, tools and testing equipment

List of "Name Plate Data" giving full particulars of serial numbers and other descriptive data pertaining to the plant and equipment installed.

List of points requiring lubrication, stating for each point the type and grade of lubricant recommended and full details as to quantity, timing and renewing of lubrication. Before typing the manuals, the Contractor shall contact The

3-66


Engineer to obtain the name and brand of lubricants generally in use by The Engineer and, wherever possible, suitable grades of lubricant of that particular brand shall be nominated by the Contractor in the manuals.

Particulars of bearings, contacts and other moving parts with instructions relating to any special attention which may be required.

Precautions to be taken in starting, running and stopping the plant or equipment by remote or manual control.

Routine tests which the Contractor would suggest be carried out.

All information mentioned above shall be cross-referenced to the drawings.

Additionally the manuals shall provide the following information which shall also be cross-referenced to the drawings:

All technical and other information, in English, concerning the equipment.

Equipment layout drawings. Power single line diagrams. Schematic control diagrams.

Narrative description of the control circuit operation. Fault finding routines. Routine maintenance instructions, procedures and frequencies.

Equipment and component specification sheets. List of equipment and components including manufacturer, catalogue number

and suppliers address, fax and telephone numbers. Instrument data sheets Cable block diagram Cable schedules Termination schedules Issue a certificate of compliance for electrical installations signed off by a

currently registered Installation Electrician.

Copies of all computer generated drawings compatible with Autocad R 12 shall be submitted to the Engineer on a Compact Disk.

PSEL30 STANDBY GENERATOR

Under the sub-contract to the main contract, the contract shall allow for the supply, installation, testing and commissioning of a 100kVA (on site rating), manually started, diesel driven standby generator installation.

All the requirements in accordance with the Electrical standard Specification shall be provided.

a. The Environmental Management plan shall be the responsibility of the City Engineers, however, the sub-contractor shall ensure that all conditions are met and that the installation complies with the requirements form the Local Fire Chief. A hand-over certificate, in this regard, shall be obtained from the Fire Chief by the sub-contractor.

3-67


b. Factory Acceptance Test – the sub-contractor shall allow for a 2 hour test with the 1st hour utilized to built the load up in steps to a 100%, thereafter for the load to be maintained at 110% at capacity for 30 minutes and then stepping down the load to 50% of capacity over the next 30 minutes.

c. On completion of the testing, at hand-over, the sub-contractor shall ensure that the fuel tank is 100% full.

3-68


PSE - ELECTRICAL TECHNICAL SPECIFICATION

PSE1 SCOPE

The contract covers the supply and installation of the electrical installations associated with the Processing Facility, all as specified herein and shown on the drawings.

In general the contract shall include the following:

a. Verifying the existing meter point, at the existing Eskom Pole. Eskom to supply any Sectionaliser, transformer and cable connection down to the meter box if required, as part of the connection fee.

Thereafter, the balance of the work, as detailed herein, shall be the responsibility of the successful tender(s).

b. Basic electrical design and installation consisting of lighting and power connections to all the equipment.

c. Providing Compliance Certificates and “AS Built” drawings and detail.

PSE2 LIGHTING INSTALLATION

All light fittings shall be supplied by the contractor as shown in the Bills of Quantities.

A ceiling grid, consisting of P4000, galvanised steel, wiring channel equal to Capstrut or Strutahead will be installed.

The wiring channels shall be installed using accessories to suspend the channel off the steel purlins. Generally, the channels shall be at a level 1200 below the purlins. Conduiting for switch-drops shall be extended from the channel to positions for light switches, as shown on the drawings.

PSE3 CIRCUIT WIRING

Circuit wiring shall comply with SANS 10142, latest edition and shall generally conform to the following:

Light Circuit: 2 x 2,5 PVC + 2,5 PVC Green

Switch-Socket-Outlets: 2 x 2,5 PVC + 2,5 PVC Green

Conduiting for lighting (switch drops and jumpers) shall be 20mm diameter conduiting for switch-socket outlets (1-phase) shall be 25mm diameter.

3-69


PSE4 TESTING AND COMMISSIONING

The contractor shall provide a Certificate of Compliance, issued by an accredited person, on the forms as published by the Electrical Contracting Board of South Africa, all as required by SANS 10142. This will be done for each distribution board zone.

The engineer reserved the right to have any or all of the distribution boards re-tested in his presence.

3-70


PSW – WASTE MANAGEMENT SYSTEM

PSW1 SCOPE

This specification includes all work in connection with the erection and installation of a waste disposal system, including all equipment as specified. The positioning of the waste disposal systems and quantities shown in the Schedule of Quantities against each item under this section may be subject to variation and the Contractor shall ascertain, from the Engineer, the exact location of, and specification to which the waste disposal system shall be constructed, before placing any orders for material.

PSW2 CONSERVANCY TANK

The conservancy tanks are to be installed to handle and condition all effluent from the toilets and processing facility building. The conservancy tank shall be covered with a layer of soil 250mm deep. The conservancy tank shall be located at least 3m away from any of the buildings. The conservancy tanks shall have a combined capacity of no less than 12.0 m³. The inlet pipe shall have a nominal diameter of 110mm and shall have a gradient over the last 10 m of not steeper than 1:60.

3-71


PF - FENCING

PF1 SCOPE

This specification includes all work in connection with the erection of stock proof, fencing as shown on the drawings or as directed by the Engineer. It also includes any work necessary on the lifting and re-erecting of existing fences. The standard of fencing, the positioning of the gates and the quantities shown in the Schedule of Quantities against each item under this section, may be subject to variation and the Contractor shall ascertain, from the Engineer, the exact location of, and specification to which the fencing shall be constructed, before placing any orders for material. The minimum standards of fencing required are indicated on the drawings.

PF2 GENERAL

Prior to the commencement of the work and the placing of any orders the Engineer shall instruct the Contractor as to which type of fence must be erected.

PF3 MATERIALS

PF3.1 Stock proof Fencing

Straining posts and stays, standards, and droppers shall be as indicated on the drawings. All sections shall be to the dimensions indicated on the drawings. Timber sections shall be of creosote-impregnated hardwood. Steel sections for gates etc. shall be either galvanised or painted to the specifications indicated on the drawings.

All plain wire, barbed wire, wire netting, diamond mesh and binding wire shall be according to the diameters and specifications indicated on the drawings.

PF3.2 Wire Mesh Fencing

Wire mesh fencing material shall be prefabricated hinge joint fencing to the heights and wire spacing as indicated on the drawings. The wires making up the fence shall be the following:

Edge wires 3.06 mm diameter High tensile Breaking Force 7,10kNLine wire 2.24 mm diameter High tensile Breaking Force 4,14 kNStay wires 2.50 mm diameter Mild steel Breaking Force 2,00 kN

PF3.3 Gates

All gates shall be to the details indicated on the drawings and components shall either be galvanised or painted according to the specifications on the drawings.

PF3.4 Bolts

Bolts shall be galvanised steel bolts of the required length and diameter which shall not be less than 12mm. Eye bolts to gates of 16mm diameter. All the necessary bolts together with nuts and washers, shall be supplied with each post or gate.

PF4 CONSTRUCTION

PF4.1 Clearing and Grubbing of the Fence Site

3-72


All brush scrub and other obstructions, which may interfere with the proper construction of the fences for a distance of 0.5m each side of the fence centreline, shall be removed and surface irregularities shall be graded so that the fence will conform to the general contour of the ground.

PF4.2 Connections

Existing cross fences shall be connected to the new fences. Straining posts with stays for every direction of strain shall be placed at the junction with existing fences and the wires in both fences properly fastened to the posts.

PF4.3 Placing of Posts

All posts, struts and standards shall be firmly planted into the natural ground, be it soil, gravel or rock, to the depths detailed. Gate posts and struts shall be erected at all gates and straining posts and struts shall be erected at all ends and corners or bends in the line of the fence and at all junctions with other fences. Intermediate straining posts and struts, and standards shall be spaced at the intervals indicated on the drawings.

All posts (excepting struts), standards and droppers shall be placed in a vertical position except in unusual locations where, in the opinion of the Engineer, it will be more satisfactory to place such member perpendicular to the slope of the ground. All posts, struts, standards and droppers shall be set in holes dug to the specified depth even in rock where blasting might be necessary to obtain the required depth.

All gate posts shall be set in concrete and other members shall either be set in concrete or in well compacted backfill as indicated on the drawings. No concreting or backfilling shall be done until all members have been properly aligned. All posts and struts for security fencing shall be set in concrete as shown on the drawings. Steel members, not required to be set in concrete, may be driven into the ground provided such members are not buckled or otherwise damaged after being driven in, and provided further that correct alignment of the driven members is maintained.

PF4.4 Attaching Wire

After all posts, struts and standards have been set firmly and after all concrete has hardened for at least four days the fence wire shall be attached according to the details indicated on the drawings. All wire shall be attached to the sides of the posts and standards furthest from the object being fenced. Wire shall be carefully stretched and strung in true alignment and without sag. Wire shall be attached to each post and standard by one of the following methods:

a. by wire staples or where approved by the Engineer one of the following methods:b. by notching the member and securing the wire by means of binding wire or,c. by drilling holes through the member and strapping the wire with plain iron staples

passing completely through the member, ord. where iron members are used, by securing the wire by means of binding wire which

must pass through the hole in the standard

Droppers shall be placed parallel to the standards at the intervals detailed on the drawings. Droppers shall be fixed to each fence wire with binding wire in such a manner as to prevent any slipping.

PF4.5 Attaching Wire Mesh, Wire Netting or Diamond Mesh

Wire netting and diamond mesh covering shall be securely fixed to the fence according to the details on the drawings. Where U-nails (staples) are used to fix wire to posts each strand

3-73


of the single or multi-strand wire crossing the post horizontally shall be stapled to the post with the staple at an angle of 45 degrees.

Mesh fencing shall be strained using a special clamp bar as provided by the mesh fence manufacturer and two wire strainers, strictly in accordance with the prescriptions and erection guidelines of the mesh fence manufacturer.

PF4.6 Installing Gates

Gates shall be installed in the position indicated by the Engineer. The gates shall be erected so as to swing in a horizontal plane at right angles to gatepost clear of the ground in all positions.

PF5 FINISHING: TRIMMING AND PAINTING

Where timber posts have been used, the tops of the posts shall be trimmed after the fencing has been erected, such that the top of the completed fence has a pleasing profile. The cuts shall be liberally painted with creosote. All ungalvanised metal components of fencing shall be painted according to the specifications on the drawings. After the fencing has been erected, any chipped or damaged paint work shall be touched up according to the same paint specifications.

PF6 TOLERANCES

Fence: Maximum permissible deviation from horizontal alignment: ±25mm relative to a straight line measured at a level 100mm above natural ground level between corner posts.

Maximum permissible deviation from vertical alignment for corner posts: plus 25mm, minus zero off vertical. Positive notation applies to the sides of posts furthest from the object being fenced.

Gate Posts shall be constructed plumb to a tolerance of +3mm off vertical.

Intermediate posts and standards shall be constructed to a tolerance of +10mm minus zero off vertical. Positive notation applies to the sides of posts furthest from the object being fenced.

The rigidity of the planted posts will be tested and if inadequate in the Engineer’s opinion, then the posts will be replanted and to his satisfaction.

The quality of straining of the wire mesh will be checked by the Engineer and if found inadequate, will have to be restrained to his satisfaction.

PF7 REMOVAL OF FENCING

The fencing to be removed shall be according to the drawings or as directed by the Engineer. All surplus, waste or unsuitable material shall be handled, stored or disposed of as instructed by the Engineer.

PF8 MEASUREMENT AND PAYMENT

PF8.1 Stock proof Fencing

3-74


This fencing shall be measured in metres between the centres of gate and end posts along the general slope of the ground. Payment shall include full compensation for the supply, painting, excavation and erection of all standards, intermediate posts, droppers, plain wire, barbed wire, binding wire and all other components as specified on the drawings but shall specifically exclude corner, end, gate posts and their stays.

PF8.2 Straining Posts, Corners, Bends and Ends

Corners, bends and ends shall be measured by the number and shall include compensation for the supply, painting, excavation and erection of all posts and stays required at such ends, corners or bends and shall also include for any concreting where so specified.

PF8.3 Gates

Gates of various types shall be measured by the number. A double gate as required for security fencing shall be measured as one number double gate. Payment shall include full compensation for the supply, painting and erection of the gate and ancillary components, as well as for the supply, painting, excavation and erection of gate posts and struts and for the concreting of such posts and struts (where required).

PF8.4 Pedestrian Crossings

Pedestrian crossings shall be measured by the number. Payment shall include full compensation for the supply, excavation and erection of the structures well as for the concreting of such posts and struts (where required).

PF8.5 Removal of Fencing

The removal of fencing shall be measured in metres. Payment shall include full compensation for the removal, handling and storing or disposal of all standards, posts, stays, droppers, wires and gates.

PF8.6 Clearing and GrubbingThe clearing and grubbing of the Fence Site is described in PF4.1 shall be measured in meters.

PF8.7 Pay Items1. Stock proof Fencing : m2. Straining Posts, Corners, bends and ends (shall distinguish between

the different types of fencing) : no3. Gates (shall distinguish between the different types of

fencing and between the different types and widths of gates) : no4. Removal of fencing : m5. Clearing and grubbing : m

3-75


POHAS - HEALTH AND SAFETY SPECIFICATIONS

POHAS1 SCOPE

This specification details the health and safety requirements associated with the Works. This specification is drawn up in accordance with the requirements of the Construction Regulations.

POHAS2 INTERPRETATIONS

POHAS2.1 Legislation and Regulations

The following legislation apply:

Occupational Health and Safety Act, 1993 (hereinafter referred to as “the Act”).

Construction Regulations promulgated on 18 July 2003 (hereinafter referred to as “the Regulations”).

POHAS2.2 Definitions

(a) Construction work is defined as:

“The erecting, maintaining, altering, renovating, repairing, demolishing, dismantling or extending buildings, plants, infrastructure type projects or similar civil engineering structures, including earthworks and excavations”.

(b) The “Contractor” is defined as an employer who performs construction work and includes the principal contractor and his subcontractors.

(c) The “Employer” will be any person, institution or company for whom construction work is performed.

(d) The “Agent” means any person who acts as a representative for a Employer.

POHAS3 GENERAL

POHAS3.1 The Contractor will ensure that all work is executed in accordance with work procedures, which comply to accepted safety practices with the Act and the Regulations.

POHAS3.2 The Employer will appoint the Contractor in writing for execution of the Works. The Contractor shall accept its appointment under the terms and Conditions of Contract. The Contractor shall sign and agree to those terms and conditions and shall, before commencing work, notify the Department of Labour in writing of the intended construction work in terms of Regulation 3 of the Regulations.

POHAS3.3 Should the Contractor at any stage in execution of the Works -

(a) fail to implement or maintain his Health and Safety Plan;

3-76


(b) execute construction work which is not in accordance with his Health and Safety Plan; or

(c) act in any way which may pose a threat to the health and safety of persons,

the Employer, his Agent or the Engineer will, by written order, suspend the progress of the Works. The Contractor shall, during such suspension, properly protect the Works so far as is necessary.

POHAS3.4 The Contractor shall provide proof of his registration and good standing with the Compensation Fund or with a licensed compensation insurer prior to commencement with the Works.

POHAS 3.5 The Contractor shall inform the Engineer in writing of the name and address of the Contractor’s Construction Safety Officer (CSO) and of any subsequent changes in the name and address of the officer, together with the scope and limitations of the CSO’s authority to act for the Contractor. The Contractor’s CSO shall make available to the Employer an all-hours telephone number at which the CSO can be contacted at any time in the event of an emergency involving any of the Contractor’s employees, or other persons at the Works.

POHAS 3.6 The Contractor shall not engage in any construction work until confirmation has been received in writing on behalf of the Employer that the Health and Safety Plan is deemed suitable.

P0HAS4 GENERAL REQUIREMENTS

POHAS4.1 Health and Safety Plan

The Contractor shall provide and demonstrate to the Employer a suitable and sufficiently documented Health and Safety Plan, based on this Specification, the Act and the Regulations, which shall be applied from the date of commencement of and for the duration of execution of the Works.

(a) The Contractor’s Health and Safety Plan shall include the following principles:

i) A proper risk assessment of the construction work.

ii) Pro-active identification of potential hazards and unsafe working conditions.

iii) Informing and/or training of employees working in hazardous and risk areas.

iv) Provision of a safe working environment and safety equipment.

v) Ensure the safety of subcontractors through their safety plans.

vi) Monitoring the health and safety on the construction works on a regular basis.

vii) Use of competent construction safety officers.

(b) The Contractor’s Health and Safety Plan should cover the following detail:

i) Indication of competent supervision on site 3-77


ii) Appointed persons’ competencies (scaffold supervisors, first aiders, etc.)

iii) Duties and responsibilities of all appointed persons on the project.

iv) Indication of condition and availability of high-risk equipment, tools & equipment.

v) Monitoring mechanisms.

vi) Risk assessments of hazards identified.

vii) Arrangements for continuous risk assessments on the project.

viii) Medical and first aid arrangements.

ix) Emergency preparedness arrangements.

x) Accident/ incident reporting and investigation arrangements.

xi) Personal protective equipment arrangements.

xii) Site meeting arrangements.

xiii) Audit arrangements.

xiv) Selection, procurement & management of other contractors.

xv) Maintenance arrangements of machinery and equipment

xvi) Designer/Engineer interaction arrangements.

xvii)Workers welfare facilities.

xviii)_______Induction arrangements.

xix) Training arrangements.

xx) Performance review and improvements on the project.

xxi) Past health and safety performance statistics of the company.

POHAS4.2 Health and Safety File

(a) The Contractor shall ensure that a health and safety file, which shall include all documentation required in terms of the provisions of this specification, the Act and the Regulations, is opened and kept on site and made available to the Employer or inspector upon request.

(b) The Contractor’s health and safety file should inter alia cover the following detail:

viii) A copy of the health and safety plan.

ix) All inspection reports as indicated in POHAS4.4.

x) Accident and incident reports.

xi) Minutes of monthly health and safety meetings.

3-78


xii) Contact details of the CSO.

xiii) Inventory of safety and first aid equipment.

xiv) Method statements and procedures not included in the health and safety plan.

xv) Continuous risk assessments on the project.

xvi) Toxic and hazardous material data sheets.

(c) Upon completion of the Works, the Contractor shall hand over a consolidated Health and Safety File to the Employer.

POHAS4.3 Appointments

POHAS4.3.1 Construction Supervisor (CS)

The Contractor shall in writing appoint a full time competent employee as the construction supervisor, with the duty of supervising the construction work.

POHAS4.3.2 Construction Safety Officer (CSO)

Before commencing with the Works, the Contractor shall designate in writing a competent construction safety officer who shall be acceptable to the Agent, to represent and act for the Contractor in health and safety related matters.

POHAS4.3.3 Other Appointments

The Contractor shall in writing appoint competent suitable supervisors as identified in the Health and Safety Plan.

POHAS4.4 Monitoring Mechanisms

Inspections as required by the Act must be conducted and the records thereof kept in the health and safety file.

POHAS4.4.1 Weekly inspections of first aid boxes.

POHAS4.5 First Aid

POHAS4.5.1 Safety Notice Board

The Contractor shall provide a safety notice board where safety notices, site regulations concerning safe working practices and information on the location of the nearest first aid station, can be conspicuously displayed to its entire staff. The size of the notice board shall be at least 600mm x 800mm.

POHAS4.5.2 First Aid Equipment

The Contractor shall provide a stretcher for emergencies and a first aid box with the minimum contents as prescribed by the General Safety Regulations as published by means of Government Notices.

The first aid box shall be checked weekly by a responsible person, who shall be appointed by the Contractor and a record shall be kept of the contents. Any deficient

3-79


medical supplies shall be promptly replenished by the Contractor.

POHAS4.5.3 Hazard Notices

The Contractor shall display hazard notices in all areas where hazardous conditions prevail or may occur. Areas so demarcated shall be deemed to be “designated areas”.

POHAS4.5.4 Reporting of incidents and/or injuries

All incidents in respect of damage to Works, property or machinery or injury to persons shall be reported by the CSO or Site Representative to the Employer as soon as possible.

A mandatory incident report form, containing full details of the incident, shall be completed and submitted to the Employer within twenty four (24) hours of the occurrence of the incident.

The Employer shall have the right to make all or any enquiries as to the cause and result of any such incident. The Contractor shall provide the Employer with full facilities for carrying out such enquiries.

POHAS4.6 Good Housekeeping

The Contractor shall at all time carry out the works in a manner to avoid the risk of bodily harm to persons or risk of damage to any property. The Contractor shall take all precautions, which are necessary and adequate to eliminate any conditions, which contribute to the risk of injury to persons or damage to property. The Contractor shall continuously inspect all work, materials and equipment to discover and determine any such conditions and shall be solely responsible for the discovery, determination and elimination of such conditions.

The Contractor shall keep the construction site neat and tidy and shall dispose of all waste material in an orderly manner.

All materials and equipment on the construction site shall be stored neatly and safely.

POHAS4.7 Personal Protective Clothing

The Contractor shall provide the necessary personal protective clothing for his employees in hazardous areas, appropriate to the nature of the hazard.

POHAS4.7.1 Hard Hats

All employees of the Contractor shall wear hard hats in designated areas. The Contractor shall keep enough hard hats available, of a contrasting colour to that of his employees, for the use of visitors to the Works. Hard hats shall not be painted or otherwise defaced.

POHAS4.7.2 Eye & Ear Protection

Suitable eye and/or ear protection shall be worn in designated areas or when grinding, chipping, breaking, drilling, arc-welding, cutting with oxy-acetylene equipment or similar activities are taking place.

POHAS4.7.3 Footwear

All employees of the Contractor shall wear serviceable, laced-up safety footwear suitable for the intended purpose in designated areas.

3-80


POHAS4.7.4 Gloves

All employees of the Contractor shall wear suitable protective gloves in designated areas or when handling hot or hazardous materials or chemicals.

POHAS4.7.5 Clothing

All employees of the Contractor shall wear suitable protective clothing when working in proximity of machinery, power tools, hazardous materials or chemicals. Reflective vests shall be worn when working in or close to areas where traffic or movement of vehicles, earth moving equipment and poor visibility occur. Persons working over an accumulation of water e.g. reservoir, rivers, dams or harbours, where a danger exists of falling into the water, shall wear life belts.

POHAS4.8 Road Traffic and Transportation

POHAS4.8.1 The Contractor shall ensure that vehicles are maintained in a roadworthy condition.

POHAS4.8.2 The Contractor shall ensure that drivers of vehicles are in possession of an appropriate and valid driver’s license.

POHAS4.8.3 The Contractor shall not permit any driver to be in control of a vehicle on the works while under the influence of intoxicating liquor or narcotic drugs.

POHAS4.8.4 All vehicles of the Contractor shall display a name board bearing the Contractor’s name. Hired vehicles shall bear an identifying sticker.

POHAS4.9 Overhead Powerlines

Regulations of the electricity supply authority in connection with prohibition of operations in the vicinity of overhead power lines shall be complied with by the Contractor at all times.

POHAS4.10 Machinery, Tools and Equipment

The Contractor shall ensure that all machinery, tools and equipment are safe to use and maintained in a good condition. All tools and machinery driven by electrical, mechanical or other means shall be adequately guarded. All machinery, tools and equipment are to be regularly inspected and such registers are to be kept on site.

POHAS4.11 Welfare Facilities

POHAS4.11.1 The Contractor shall provide and maintain at or within reasonable access of the works, the following clean facilities:

(a) At least one (1) shower for every fifteen (15) workers of each sex.

(b) At least one (1) sanitary facility for every thirty (30) workers of each sex.

(c) Changing facilities for each sex, and

(d) Sheltered eating areas.

POHAS5 SPECIAL REQUIREMENTS

3-81


POHAS5.1 Commissioning Safety Precautions

The Contractor shall ensure that wherever repairs, adjustments or any other work are undertaken on any plant or machinery, the power supply is switched off, disconnected or the plant/machinery disengaged until the work or repairs have been completed.

POHAS5.2 Use and Storage of Toxic, Hazardous Chemical and Flammable Materials

(a) The Contractor shall take adequate safety precautions with the handling and storage of any toxic, hazardous chemicals and flammable materials.

(b) The Contractor shall provide suitable and adequate protective equipment when working in areas where toxic, hazardous chemicals and flammable materials are being used.

(c) The Contractor shall ensure that its employees have familiarized themselves with the toxic and hazardous material data sheets applicable as well as the location of fire fighting equipment, safety showers/baths and other washing facilities, prior to commencement of work.

POHAS5.3 Excavations

(a) Digging or excavation operations may not commence without the written authorization from the competent supervisor appointed by the Contractor in writing.

(b) Adequate precautions shall be taken by the Contractor to prevent slumping of excavations, as well as to prevent rocks and loose material falling onto workers.

(c) All excavations by the Contractor are to be clearly demarcated to prevent accidental access.

POHAS5.4 Indemnity of Employer and His Agents

(a) The annexure to this Contract Document contain a “Mandatory Form of Authority and Agreement in terms of Section 37(2) of the Occupational Health and Safety Act, No. 85 of 1993" which agreement shall be entered into and duly signed by both the Employer and Contractor prior to commencement with work.

A copy of the signed agreement shall be included in the Contractor’s Health and Safety Plan.

(b) Any acceptance, approval, check, certificate, consent, examination, inspection, instruction, notice, observation, proposal, request, test or similar act by either the Employer or any of his Agents (including absence of disapproval) shall not relieve the Contractor from any responsibility he has under the Contract, the Act and the Construction Regulations, including responsibility for errors, omissions, discrepancies and non-compliances.

3-82


ANNEXURE C

DRAWINGS

EVN Plan ref. Description

1683A.100.001 SITE LAYOUT PLAN 1683A.100.002 PLAN, WATER & SEWER LAYOUT PLAN1683A.300.001 TYPICAL ROAD SECTIONS1683A.800.001 TYPICAL ANCHOR BLOCK DETAILS, TRENCH & MANHOLE DETAIL

3-83


ANNEXURE D

STANDARD FORMS Page

Day work Returns 3-85Certificate Summary 3-86Summary of Schedule 3-87Schedule Description 3-88Requisition for final checking of work 3-89

3-84


DAYWORK RETURNS

CONTRACT: ______________________________________

DESCRIPTION OF DAYWORK: _____________________________________

DAYWORK RETURN FOR THIS DAY: ______________________________________

EMPLOYER: ______________________________________

CONSULTING ENGINEER: EVN AFRICA CONSULTING SERVICES (Pty) Ltd

CONTRACTOR: _____________________________________

PLANT/TRANSPORT

ITEM HOURS/km RATE AMOUNT

TOTAL FOR PLANT/TRANSPORTMATERIALS

DESCRIPTION QUANTITY UNIT RATE AMOUNT

SUB-TOTAL

ADD ...% ALLOWANCE

TOTAL FOR MATERIALSLABOUR

NO. OF WORKMEN

OCCUPATION HOURS RATE AMOUNT

SUB-TOTAL

ADD ...% ALLOWANCE

TOTAL FOR LABOUR

GRAND TOTAL FOR THIS DAYWORK RETURN

CONTRACTOR: ..................................... ENGINEER: .........................................

3-85


CERTIFICATE SUMMARY

EMPLOYER: SUBMISSION DATE:

CONSULTING ENGINEER: EVN AFRICA CONSULTING SERVICES (Pty) Ltd

CONTRACTOR:

ITEM AMOUNT

(a)

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(i)

(j)

(k)

(l)

(m)

CONTRACT PRICE: (Nett)

VAT Incl.

Total from Schedule

Materials on Site

Variation orders - subject to escalation

Sub-Total

Escalation on (d)

Variation orders - not subject to escalation

Sub-Total

Less: Retention on (a,c,e,f) (R max)

Less: Retention on (b) - ……%

Value of this Certificate

Less: Previously Certified (excluding VAT)

Sub-Total

VAT 14%

……………………………………………………..

……………………………………………………..

……………………………………………………..

……………………………………………………..

___________________________

……………………………………………………..

……………………………………………………..

___________________________

…………………………………………………….

___________________________

……………………………………………………..

……………………………………………………..

___________________________

…………………………………………………….

…………………………………………………….

AMOUNT NOW DUE R ………………………………………

3-86

SUMMARY OF SCHEDULE

CONTRACT: CONTRACT NO.: PAGE NO.:

EMPLOYER: CERTIFICATE NO:

CONSULTING ENGINEER: EVN AFRICA CONSULTING SERVICES (Pty) Ltd MONTH ENDING:

CONTRACTOR: SUBMISSION DATE:

SCHEDULENUMBER

DESCRIPTION PREVIOUS AMOUNT PRESENT AMOUNT

TOTAL

TOTAL CARRIED TO CERTIFICATE SUMMARY

3 -87

SCHEDULE: DESCRIPTION

CONTRACT: CONTRACT NO.: PAGE NO.:

EMPLOYER: CERTIFICATE NO.:

CONSULTING ENGINEER: EVN AFRICA CONSULTING SERVICES (PTY) LTD MONTH ENDING:

CONTRACTOR: SUBMISSION DATE:

ITEM NO. DESCRIPTION UNIT RATE VALUE TO DATER - C

PREVIOUS PRESENT TOTAL

TOTAL CARRIED FORWARD TO SUMMARY

3 -88

REQUISITION FOR FINAL CHECKING OF WORK

EVN AFRICA CONSULTING SERVICES (Pty) Ltd P O Box 13982CASCADES3202

PROJECT: ________________________________________________________ CONTRACTOR: ________________________________________________________ The Contractor has established that these controlled works have been constructed to the correct horizontal and vertical alignment and position and that such work has been carried out to the required standards and specifications as set out in the documents and drawings. CONTRACTOR’S SIGNATURE:_________________________ DATE: ___________________

Locality Component

and/or Chainage

Checks Carried Out (Specify

Alignment, Level etc.)

Design Level or Position

Constructed Level or Position

Deviation Relative Variation

ENGINEER’S REMARKS: ______________________________________________________________

3- 89

part 3 - scope of · web viewmonitoring the health and safety on the construction works on a...

Documents