specifications - murray irrigation · contours where possible and by the use of trapezoidal rather...

SPECIFICATIONS of 48

Date of Issue: Wednesday, February 19, 2014

Last saved by Ramesh Shrestha

SPECIFICATIONS

MURRAY IRRIGATION LIMITED ABN 23 067 197 933

443 CHARLOTTE STREET

(P O BOX 528)

DENILIQUIN NSW 2710

2014

Date of Issue: Wednesday, February 19, 2014 of 48

Specification.doc

SECTION 1 - EARTHWORKS

1.01 STANDARDS & CODES The following relevant Australian Standards will apply for soils testing and construction: AS 1152 Test Sieves AS 1289 Methods of Testing Soils for Engineering Purposes AS 2187 Explosives - Storage, Transport and Use AS 2188 Explosives - Relocatable magazines for Storage A Testing Authority with current appropriate NATA registration shall be engaged by the Contractor to carry out all testing. Test results are to be made available to the Superintendent promptly.

1.02 PROTECTION OF WORKS AND DOWNSTREAM WATERWAYS It shall be the Contractor’s responsibility to comply with all requirements and directions of Murray Irrigation Limited, the Environment Protection Authority and associated water pollution and erosion control measures specified or necessary, and to allow for all such works in his tender price. Obligations under licensing requirements shall pass on to the Contractor who shall also be liable for any associated penalties due to non-compliance. The sediment and erosion control measures will be provided, operated and managed, maintained and repaired or replaced by the Contractor as necessary up to final completion of the Contract. It is the responsibility of the Contractor to protect formations from erosion and deposition, during construction. Grade earthworks and sub-grades to drain without pounding. Stockpiles are to be located to minimise effects on site and adjacent areas. The Contractor, at his own cost, shall plan and carry out the whole of the works to minimise the effects of runoff on the site and on downstream waterways. Where flows are to be carried by temporary earth channels, stabilise the channel with jute mesh as detailed and spray surface of mesh with bitumen emulsion. The jute mesh is to be securely fitted in place to the satisfaction of the Superintendent. Avoid unnecessary ground disturbance and provide as necessary for the proper control of stormwater runoff at every stage. Where practicable, limit movement and parking of vehicles and plant to areas where ground cover has been removed for construction purposes. It shall be the responsibility of the Contractor to design, construct, operate and maintain temporary erosion control measures in accordance with Murray Irrigation Limited guidelines and remove them when no longer required.


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The design of temporary earth drains should minimise water velocities by following contours where possible and by the use of trapezoidal rather than vee cross sections. If necessary or directed, construct straw bale weirs, silt fences or other structures in temporary drains to retard flows. Locate stockpiles clear of natural drainage lines and provide temporary drainage as necessary. For the purpose of retaining mobilised coarse solids and preventing their entrainment to waters or the stormwater drainage system during the construction phase, sediment barriers comprising geo-fabric silt-fence, straw bales or similar material, shall be constructed and placed so as to be effective to intercepting sediment as far as practicable in operation. An effective barrier shall be placed along the contour below obvious sediment sources such as fill batters and stockpiles. All areas to be disturbed including areas subject to earthmoving activities or storage of vegetation or soil stockpiles, shall drain to a sediment retention pond facility. All areas of the site not subject to erosion, contamination or disturbance shall have provision for all run-off to be diverted without causing scouring or erosion. Impervious bunds shall be constructed around all fuel or oil storage areas and the bund volume shall be large enough to contain 110 percent of the volume held in the largest tank. Structures designed to intercept sediment shall be de-silted as often as necessary to ensure continued effective operation, but shall not in any case be allowed to lose more than 30% of effective design storage volume. The contents of the sediment retention pond shall be treated with gypsum or similar approved flocculating agent and be pumped out within 36 hours of the end of any rainfall event. The Contractor shall provide the Superintendent by facsimile transmission, with 24 hours prior notice of any intention to discharge from any sediment retention pond. The Contractor shall treat and discharge the contents of a sediment retention pond in a manner which ensures optimum treatment efficiency but any discharge shall not in any case, contain greater than 30 milligrams / litre of non-filtrable residues, unless the approval holder can substantiate that this level was not practicable to be achieved in the circumstances. These circumstances shall include a natural rain event which cause the design capacity of the pond to be exceeded. Sediment retention ponds are to be maintained whenever possible at a low water level in readiness for containment and treatment for discharge from further rainfall runoff. The Contractor shall ensure that when discharge occurs from any sediment retention pond, or other control measures, no erosion of the spillway, channels or banks of the receiving water occurs. Runoff from vehicle, construction plant or mobile plant maintenance and cleaning areas, shall be contained, collected and disposed of in such a manner as to prevent entry into any waters including the water pollution control pond. Absorption into the ground shall be prevented, unless the contaminated ground is removed on the same day.


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Fuelling of vehicles and construction plant must be carried out with an operator or driver being in attendance and in a manner which prevents spillage’s occurring. Litter shall be removed from the site on at least a weekly basis for proper disposal and trade waste containers shall be provided on-site and serviced weekly. Concrete wastes or washing’s from concrete mixers shall not be deposited in any location where the wastes or washing’s may flow or be washed into water.

1.03 CLEARING AND GRUBBING

GENERAL All trees, debris and obstructions on the drain alignment shall be removed and stockpiled clear of the work area. Any material cleared by the Contractor that is not required by the landowner shall be removed by the Contractor. The Contractor shall promptly repair at his cost, any fencing damaged by him whilst carrying out this section of the work. During clearing and other earthworks the greatest care shall be taken to avoid interference with any benchmark, survey or level peg or supplementary reference mark.

(a) Definitions Applying to Clearing and Grubbing Limits of clearing shall be the boundaries of areas affected by earthworks, together with the boundaries of any other areas designated to be cleared. Areas outside of these boundaries shall be reinstated to the Superintendent’s satisfaction at the contractor’s expense. All disturbed areas are to be revegetated.

(b) Extent of Clearing and Grubbing Clearing and grubbing shall be carried out in advance of any earthwork operations, and shall include the removal of all foreign material and vegetation, except trees and plants required to be preserved, from within the limits of necessary clearing. All vegetable growth such as trees, logs, stumps, roots, scrub and brush, and all other foreign material including concrete, masonry, boulders and rubbish, shall be cleared from the natural surface. No clearing shall commence until the Superintendent has indicated which trees are to be preserved. Unless otherwise specifically indicated by the Superintendent, all trees shall be assumed to be preserved. Protect trees marked to be retained. All trees indicated for removal shall be removed from site and due allowance for this is to be incorporated in the tendered rate. If separate schedule rates are provided for tree clearing the cost of this work will not be included in other clearing items. For the purpose of this specification, trees are defined as having a circumference of in excess of 150mm. Irrespective of size, existing fallen trees shall be classified as part of the general item for Clearing and Grubbing.


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1.04 EXCAVATION

1.04.1 GENERAL The Contractor shall commence at the downstream end of the work and progress in an upstream direction. The Superintendent may direct that no further lengths of drain be opened up until the downstream section (including structures) are completed. Allowance is to be made for excavation in all classes of material as found. It is the Contractor’s responsibility to ensure that he has sufficient material to complete the earthworks. The quantities shown on the plans are intended to represent the quantities required to complete the works and include allowances for compaction where required, but no guarantee is given as to the correctness of such quantities. The excavation volumes in the quantity schedules are solid volumes based on existing natural surface levels. The Contractor’s attention is drawn to regulations in respect of the Mines Act 1958 and shall allow for compliance within his tender. The waterway of the drain shall be excavated to the alignment, levels, grades and dimensions as shown on the Drawings. The tolerances shall be those shown in Section 1.05.5 “Tolerances”. If the Contractor over-excavates anywhere, greater than the tolerances specified in Section 1.05.6, he shall, if required by the Superintendent, re-fill the over excavation, at his own cost and to the lines indicated on the drawings with approved compacted material to the requirements of this specification under the heading - “Controlled Fill”.

1.04.2 USE OF EXPLOSIVES Blasting shall not be permitted without prior written approval from the Superintendent. The Contractor shall keep and provide the Superintendent with accurate records of each blast showing blasting pattern, explosives used firing delays and date and time of detonation, and shall comply in all respects with the appropriate Australian Standards and Authority requirements.

1.04.3 DISPOSAL OF SURPLUS SPOIL Unless otherwise specified, surplus material from excavations shall be disposed of by side-casting or stockpile construction in locations as indicated or as otherwise directed. If required, separate stockpiles shall be maintained for surplus materials suitable for use as topsoil acceptable to the Superintendent.

1.04.4 SETTING OUT Re-establishment and Control survey and set-out will be undertaken by the Superintendent. The Superintendent will establish the drain centreline and mark the centreline at chainages as indicated on the drawings, prior to the commencement of work on the sections concerned. The Contractor shall inform the Superintendent of his intention to commence any particular portion of the work not less than seven (7) working days prior to commencement, so that setting out may proceed ahead of construction.


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Unless otherwise specified, the Contractor shall perform all setting out to enable the construction of the works to the levels and dimensions shown on the drawings. Levels shall be set out from the benchmarks indicated by the Superintendent. During clearing the greatest care shall be taken to avoid interference with any benchmark, survey or level peg or supplementary reference mark. Before any pegs are affected by earthwork operations the Contractor shall transfer such pegs to side positions clear of operations and shall note the extent of the movement, in distance and level. The superintendent shall be given a list in writing showing the positions and levels of such transfer pegs. The Contractor shall give at least two days notice of his intention to move pegs. Interference with benchmarks or reference or recovery pegs shall not be allowed under any circumstances. Any survey or reference marks damaged as a result of action by the Contractor will be replaced by the Superintendent at the expense of the Contractor. The Contractor shall furnish all materials, labour and equipment that may be required by the Contractor in setting out any part of the works beyond the establishment or control survey established by the Superintendent.

1.05 SIDECASTING TO BANKS, FILLING AND DISPOSAL OF

SURPLUS MATERIAL

1.05.1 GENERAL Excavation shall be disposed of to neatly trimmed banks to both sides of the drain. the minimum bank width at the crest shall be one metre and be uniformly graded in a longitudinal direction to the lines and elevations detailed on the drawings. Where individual landowners require, excavated material in excess of that required for the banks shall be stockpiled or placed at locations away from the drain. The Superintendent shall negotiate with the landowner and advise the Contractor. Any additional costs associated with such works will be borne by the Landowners. The Contractor shall be responsible for arranging and providing water supply necessary to achieve the required moisture content and compaction of all fill and/or banks. Place and compact banks/filling/side-cast to conform to lines, grades, levels and dimensions indicated on the drawings. Grade all stripped surfaces to prevent accumulation of water. For areas to be topsoiled after profiling the topsoil and any loamier materials in the top 150mm below topsoil layer are to be used. All surfaces which are to have fill or banks placed above are to be stripped of topsoil to a minimum depth of 200mm and scarified to 150mm below the stripped surface prior to placement of fill. Proof rolling of soft areas of the stripped surface is to occur where directed by the Superintendent. Any soft areas or unsuitable material are to be removed at the direction of the Superintendent and replaced with select fill and compacted to 95% Standard Compaction as defined by AS 1289 5.1.1 – 1993. For fill to be placed against slopes steeper than 1 in 4, bench and roughen the slope prior to fill placement.


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For the sections constructed on-grade and in cutting where clay soils form the sub-grade; after the vegetation stripping and performing the bulk earthworks, the exposed sub-grade shall be scarified to a depth of 150mm below stripping level and re-compacted to 95% Standard Compaction. Locally where granular soils and extremely weathered rock form the sub-grade, the compaction is to be increased to 98% Standard Compaction. The wet state of some soil is likely to preclude their use as sub-grade and fill materials. Allowance is to be made for air drying of these soils by scarifying and tyning in the Tender. Alternatively, drying of the soils by lime treatment at the Contractor’s cost may be considered, subject to the written confirmation of the Superintendent to the Contractor’s proposal. The installation of temporary surface drainage along the limits of the works, to intercept and divert surface water flows and near-surface seepages away from the works area, is to be allowed for in the tendered price. Subsurface drains for pavements shall be not less than 1.0m below the adjacent final pavement surface level.

1.05.2 CONTROLLED FILLING Where Filling is designated by the Contract as Controlled Filling it shall comply with the additional requirements contained within this section of the Specification. For Controlled Filling the Contractor shall keep comprehensive records of the exact location, depth, type and extent of that fill. Where the depth of Controlled Filling exceeds 400mm, the Contractor shall arrange at his own cost for overview and testing by a recognised Geotechnical Engineering Consultant with appropriate qualifications and experience. Frequency of Field Density Tests shall be carried out as set out in Table 1.A unless specified otherwise elsewhere. One laboratory compaction test is to be taken with every field density test. Generally the sample used for the laboratory compaction should be the material obtained from or immediately adjacent to the relevant field density test. Particular care will be required if the sample breaks down under compaction. In addition where the depth of controlled Filling exceeds 400mm the Contractor shall submit a comprehensive report prepared by the Geotechnical Engineering Consultant. The report shall deal with all relevant aspects of the Controlled Filling and include a covering letter, the test result forms, a location drawing and other elements as set out in Table 1.B. The report shall include on the first page a certification by the Geotechnical Engineering Consultant that the Controlled Filling is in compliance with the requirements of the Specification.


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TABLE 1.A GUIDELINES TO FREQUENCY OF FIELD TESTING

Type of Fill Field Density Tests (See Note 1) Large Scale Operation Not less than (a) (b) or (c) (a) 1 test per 500m

3

distributed (eg. Continuous levees, whichever requires the most reasonably evenly throughout Large Industrial Lots tests: full depth and area, or Road Embankments) (b) 1 test per layer or 200mm thickness per material type, or (c) 3 tests per visit Small Scale Operations Not less than (a) (b) or (c) (a) 1 test per 200m

3

distributed (eg. small embankments) whichever requires the more reasonably evenly throughout tests: full depth and area (b) 1 test per layer or 200mm thickness (see Note 2), or (c) 1 test per lot Concentrated Operation Not less than (a) (b) or (c) (a) 1 test per 100m

3

distributed (eg. gullies and farm whichever requires the most reasonably evenly throughout dams) tests: full depth and area, or (b) 1 test per layer or 200mm thickness, or (c) 3 tests per visit Confined operations 1 test per 2 layers per 50m

2

(eg. backfill for structures)(Note 2) Road pavements 2-3 tests/100m length of pavement layer Trenches 1 test per 2 layers per 40

linear m

Note: 1. Tests in visually doubtful areas, and re-tests of failed areas are additional to the testing recommended below.

2. Implies hand operated or small equipment.


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TABLE 1.B ELEMENTS OF EARTHWORKS REPORTING 1.0 Stripping. 1.1 Statement of basis for selection stripping depth (eg. proof rolling). 1.2 Statement that stripped surface was viewed for substantial compliance with (1.1). 1.3 Plan showing stripped levels. 2.0 Filling. 2.1 Statement regarding fill compliance with Specification. 2.2 Statement of minimum density ratios required by Specification. 2.3 Statement on frequency of site attendance. 2.4 General statement on frequency of testing. 2.5 Results of Testing (see Table 2.C). 2.6 Plan with density test locations plotted. 2.7 Statement on who selected test locations and basis for selection. 2.8 Statement on retesting of failed areas. 2.9 Plan showing final filled levels and extent of filling. 2.10 Statement on general compliance with Specification.

TABLE 1.C ITEMS TO BE PROVIDED ON DENSITY TEST

1.0 Result Sheets 1.1 Test Number 1.2 Test Date 1.3 Location and Reduced level of Test (if in Commission, or available). 1.4 Test Procedures for Field Density and Compaction. 1.5 Field Dry Density and Moisture Content. 1.6 Maximum Dry Density and Optimum Moisture Content. 1.7 Test number of relevant Compaction Test. 1.8 Dry Density Ratio (or Density Index). 1.9 Field Moisture Content minimum Optimum Moisture Content.


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1.10 Description of Soil in Sample. 1.11 Proportion of Oversize (and rock correction if applicable). 1.12 Specification Requirement (if known). Note : If test is a Repeat at earlier Test Location (if known). Table 1.C lists items which should be provided on the density test result forms. The documents are to be provided to the Superintendent in an acceptable form as a requirement for Practical Completion. Progressive details of Controlled Filling tests and reports are to be kept on site in an acceptable compiled format, and shall be made available for periodic inspection by the Superintendent. Each test shall be positively located by coordinates and Relative Level by the Surveyor.

1.05.3 FILL MATERIALS Materials used for filling will be obtained from cuttings unless otherwise directed, specified or approved. The Contractor shall manage and sort the materials to ensure that the most suitable materials are used for specific components of the works and in particular that the most granular and least plastic materials are used for embankments, non-dispersive cohesive clays are used in waterways, and any loam material used for dispersive cohesive clays are used in waterways, and any loam material used for general fill below grassed areas. Material in the top 150mm below sub-grade shall be free of particles larger than 75mm, for material in top 600mm below sub-grade particles shall be less than 150mm, and that rock greater than 600mm nominal size is not used in embankments. Filling over and around structures, pipes, culverts etc shall be undertaken in a manner which avoids unbalanced loading or movement. For compaction in confined spaces and adjacent to structures, unless otherwise specified the following shall apply: Gap Between Structure and Undisturbed Ground < 900mm Fine crushed rock > 900mm but less than 2.0 metres Crushed rock sub-base or suitable natural

gravel free of clay Select materials Material within 450mm of weepholes shall be coarse filter medium unless otherwise detailed.

1.05.4 WINNING OF MATERIALS The Contractor shall obtain written approval to develop borrow pits or borrow areas prior to removal of such material and shall provide adequate information to the Superintendent to assess his proposals including location, extent, depth, reinstatement and restoration.


Specification.doc

The Superintendent may approve the winning of material on site by uniform widening of cuttings, uniform flattening of cut batters or uniform grading of select areas.

Borrow from external sources will not normally be permitted where suitable material is available on site. Contractor shall obtain all necessary permits before commencement.

1.05.5 TOLERANCES Finished surfaces shall conform to the tolerances in level and shape as indicated below:

Drain Bed Elevation Design Bed Elevation: Plus 20mm, Minus 50mm Drain Bank Elevation Plus - no limit, Minus zero Cross Section Design cross sectional area-plus 10% minus 5% Drain Surface Finish Smooth and free of clods of Diameter greater than 75mm Cut sub-grade/drain in earth Straightness: 20mm maximum departure from 3m

straightedge both ways Cut sub-grade in rock Level: plus 25mm, Minus 50mm Straightness: Unspecified Fill sub-grade Level: Plus 25mm Straightness: 20mm maximum departure from 3m straightedge both ways Unpaved areas in cut or fill Level +- 50mm The compaction requirements specified are minimum requirements. When density tests are carried out on a section of the work, the number of results falling below the specified value shall not exceed the limits set out below:

Number of Tests Max. Results Max. Results Max. Results

below 0-2% below 1-2% below more than 2% 0-3 Nil Nil Nil 4-5 1 1 1 6-10 2 1 Nil 10 20% 10% Nil

Relative density test and the establishment of a reference density shall be carried out in accordance with AS 1289 5.1.1. If a section of the work is rejected on the basis of inspection or test results, further comparative effort shall be applied to the section until the specified standard is achieved.


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1.05.6 FILL FOUNDATIONS AFFECTED BY MOISTURE When an area to receive fill is unable to support construction equipment or it is not possible to compact overlying materials only because of high soil moisture content, then one or more of the following alternative actions may be taken: (i) allow the material to dry to a moisture content which will allow compaction and

the placement of fill material;

(ii) scarify the area to a depth of 150mm and work as necessary to accelerate

drying.

Re-compact as specified when moisture content approximates optimum;

(iii) excavate the soft material and place and compact fill material of suitable standard

The approach to be adopted shall be at the Contractor’s discretion and expense. No extensions of time will be granted in respect of any delay due to wet sub-grade unless it is demonstrated to the satisfaction of the superintendent that the sub-grade moisture content is due to other than the Contractor’s work practices.

1.06 NATURAL SURFACE PROFILES The Contractor is to provide not less than seven days written notification to the Superintendent if he intends to check the surface profiles shown on the drawings for accuracy. If the Contractor finds differences between the existing ground surface levels and those shown on the Drawings, he shall provide written notice and full detailing of the discrepancies to the Superintendent immediately. The Contractor shall avoid disturbance of the areas of discrepancy so that the Superintendent can investigate and resolve the discrepancy. The Contractor shall check the surface profiles sufficiently in advance to allow a reasonable time frame for investigation and resolution by the Superintendent without delaying the Contractor’s program of works. Failure of the Contractor to comply with any of the requirements of this Clause will be grounds for disallowance of any related claim by the Contractor.


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SECTION 2 - BURIED / UNDERGROUND ELEMENTS

2.01 GENERAL Work covered by this section of the specification includes construction of all underground pipes, conduits, cables and ducts.

2.02 STANDARDS The following Australian Standards for manufacture, supply, construction and testing will apply as appropriate, and shall be read in conjunction with relevant references ; AS 4130 Polyethylene Pipe for Pressure Applications AS 1254 Unplasticised PVC (uPVC) Pipes and Fittings for Storm of

Surface Water Applications

AS 1260 PVC Pipes and Fittings for drain, waste and vent applications AS 1289 Methods of Testing Soils for Engineering Purposes AS /NZS 4671 Steel Reinforcing Materials AS 3972 Portland Cement AS 4058 Precast Concrete Pipes ( Pressure and non – pressure) AS 4131 Polyethylene Pipe Compounds AS/NZS 1477 Unplasticised PVC Pipes and Fittings for Pressure Applications

AS 1554 Structural Steel Welding Code AS 1597 Precast Reinforced Concrete Box Culverts AS 1646 Rubber Joint Rings for Water Supply, Sewerage and Drainage

Purposes AS/NZS 4534 Hot Dipped Galvanised Coating on Ferrous Articles AS 2032 Code of Practice for Installation of uPVC Pipe Systems AS 2053 Non-Metallic Conduits and Fittings AS 2439 Perforated Plastics Drainage and Effluent Pipe and Fittings AS/NZS 2566.1 Plastic Pipelaying Design AS 2638 Cast iron Sluice valves for Waterworks Purposes AS 2701 Methods of Sampling and Testing Mortar for Masonry

Constructions AS 3600 Concrete Structures


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AS 3680 Polyethylene Sleeving for Ductile Iron Pipelines AS 3725 Loads on Buried Concrete Pipes HARDIE - IPLEX - (1990) Hobas Pipelines Manual

2.03 EXCAVATION Clear and grub trench alignment to trench width at the ground surface plus one metre each side. Strip and stockpile topsoil. Excavate trenches to dimensions and grades specified but allowing for depth of bedding material, timbering or battering for compliance with the mines Act 1958 and for widening and deepening at structures and fittings as necessary. Locate and expose existing services and compaction points within the trench confines before commencing trench excavation. Minimise the length of trench left open at any time. Support and protect all trees, landscape, structures, pavements, pipes etc in or adjacent to the trench. If a trench is over excavated or caves in due to inadequate support or failure to manage surface or ground water, the Superintendent may require the use of a higher standard of bedding or pipe strength or both without additional payment. Water entering the trench shall be controlled or sealed off to minimise damage to the trench, foundations and pipe installation. Costs of removal of water shall be deemed to be included in the Contractor’s tender price. Material in foundations which is damaged or rendered unsuitable by default or inappropriate action by the Contractor shall be removed and replaced with 15MPa concrete at the Contractor’s cost.

Provide for diversion and control of stormwater during construction. Where trenches cannot be drained by gravity, dewater by pumping.

2.04 BACKFILLING

Notify Superintendent when service laid for inspection prior to backfilling. Backfill trench promptly. Fill jointing holes in bedding with compacted bedding material fill over pipes with selected backfill to specified depths, compaction to not less than 85% modified maximum dry density. Height of select fill over water, sewer, stormwater and conduits shall normally be 300mm.


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Select material shall be crushed rock, natural gravels or suitable soils free from organic matter and other foreign or undesirable matter and may be won from on-site earthworks, approved borrow areas or imported. Trenches under roads shall be backfilled above the select fill level to sub-grade level with material complying with the following: (i) Sand (ii) Suitable material complying to:

Liquid limit <35% Plasticity Index <12% Linear Shrinkage <6% Wet Strength >50KN Wet/dry Strength <45% Max. particle size 7.5mm Material deeper than 600mm below sub-grade level compacted to 95% Standard Compaction and top 600mm compacted to 98% Standard Compaction. Support existing structures or pipes across the trench with a compacted granular material extending from trench floor to underline of structure or springing line of the pipe. Alternatively use minimum strength 10MPa concrete. No additional payment shall be made for such. Other trenches are to be backfilled with selected backfill free from stones greater than 75mm to the same density as adjacent undisturbed ground or where in rock to 95% Standard Compaction. Contractor to test adjacent ground at his own cost to ascertain compaction of the adjacent ground at various depths and locations. Dispose of surplus material to requirements of Section 1 – Earthworks

2.05 QUALITY CONTROL

2.05.1 WARRANTY

The Contractor shall be deemed to have obtained from the manufacturer, a warranty that the pipe system supplied under the Contract complies with the codes, standards and dimensional tolerances specified here-in and within the Manufacturer’s literature and will perform satisfactorily under the constructed conditions and to design intent. The Contractor shall also provide details to demonstrate quality assurance in production, and provide an acceptable quality assurance plan for manufacture of their pipe product. The Contractor shall provide to the Superintendent a written warranty from the Manufacturer that the pipes, joints and fittings supplied will comply with and perform to the Standards and criteria included in the Specification, and technical details provided.

2.05.2 IDENTIFICATION MARKING Each pipe and fitting is to be clearly and indelibly marked or stencilled with:


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* Date of Manufacture * Name of Manufacture * Class of Pipe * Centre Top (for concrete pipes) * Nominal Diameter * Length (if non-standard) * “Passed inspection” markings as appropriate * RSC value and profile (HDPE) Rubber rings are to be marked with: * Year of Manufacture * Manufacturer * Ring Size * Standard of Compliance * Class of ring Containers for separate rings shall similarly be labelled as listed below: * Manufacturers identification mark * Type of polymer * Number of standard compliance * Factory inspectors mark * Quantity of rings

2.05.3 SUPPLY The Contractor shall obtain a guarantee from the manufacturer that the pipes can be supplied to meet the Contractors program. Details of the Contractors program and the guarantee are to be delivered to the Superintendent.

2.06 CONCRETE PIPES, CULVERTS & STRUCTURES

2.06.1 MATERIALS (i) Pipe Reinforced concrete pipes shall comply with the requirements of AS 1342 - 1973. Pipes shall be of the class shown on the drawings. Generally, concrete pipes shall be Class 2 Reinforced Concrete Drainage Pipes to AS 4058 - 1992 with Rubber Ring Joints to AS 1646.


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Vitrified clay pipes shall comply with the requirements of AS 1741 - 1975. Unless otherwise specified, pipes up to 150mm diameter shall be Grade A. Pipes shall be of the class shown on the drawings. HDPE (High Density Polyethylene Pipes), where acceptable as an alternative to RCP, shall comply with AS 4131 - 1993 and AS 4130 - 1997. Rubber joint rings for use with reinforced concrete or vitrified clay pipes shall comply with the requirements of AS 1646 - 1984. (ii) Precast Reinforced Concrete Box Culverts Precast reinforced concrete box culverts shall comply with the requirements of AS 1597. (iii) Bedding material and Selected Backfill Bedding material and selected backfill shall comply with the requirements of detailed drawings, or the relevant codes or local authority requirements where not otherwise specified. (iv) Concrete Concrete, reinforcement and formwork for drainage structures shall comply with the requirements of this Technical Specification. Minimum concrete strength shall be 32MPa for all concrete structural work and 10MPa for all bedding and encasement work. (v) Cement Mortar Cement mortar shall comply with the requirements of AS 2701 - 1984.

2.06.2 PRECAST CONCRETE BOX DRAINS Precast concrete box drains shall be provided in the locations called for and to the details shown on the drawings. The box section shall be positioned true to line, the invert level of the section true to level and grade as shown on the Drawings and the sections closely butted together. A thin layer of mortar, on (1) part cement to three (3) parts sand, shall be used on the sections prior to placing the sections together. The maximum permissible tolerance shall not exceed 10mm above or below the true grade nor 20mm to wither side of the true alignment, for any two points 8m apart. moreover, no portion of the work shall depart more than 10mm from true level, as determined from the nearest convenient bench mark which shall be indicated by the Superintendent. Any culvert or culverts not laid within these tolerances shall be lifted and relayed so that the gradient and alignment are within the specified tolerances. Where these tolerances cannot be met due to defective manufacture of the units, such units shall be rejected. Such lifting and relaying or other approved corrective measures shall be at the cost of the Contractor if the defects occur or become apparent at any time before the expire of the maintenance period. In all cases care shall be taken with laying so that the interior of the box sections have a neat, smooth and uniform surface at the joints and the interior surfaces of the sections shall be cleaned of any excess mortar after jointing. The joints shall be


Specification.doc

protected from rapid drying by covering with wet bags for at least three (3) days after placing or alternatively by the application of an approved curing compound. Additional treatment of the joints shall be as specified on the drawings. Trenches at the sides of box drains shall be carefully packed and solidly rammed at the sides with sand or metal dust in uniform layers and shall be carried up to the top of the precast section all to the satisfaction of the Superintendent.

2.06.3 REINFORCED CONCRETE PIPE DRAINS Reinforced concrete pipe drains for drainage works shall be provided in the locations and to the details shown on the Drawings and/or as otherwise specified. (i) Pipe Bedding Bedding shall be as detailed on the detail drawings. (ii) Method of Laying Before pipes are laid all dirt and foreign material that may have entered the pipe shall be removed and the outside of spigots and inside of sockets thoroughly cleaned of foreign matter. The pipes shall be laid and jointed accurately to lines, gradients and levels shown on the plans. All pipes shall be laid in such a manner that pipe barrels have solid bearing throughout their length. The maximum permissible tolerance in any single length of pipe shall not exceed 10mm above or below true grade, nor 10mm to either side of the true alignment and the maximum departure from the grade shall not exceed 20mm between any two points 8 metres apart. Moreover, no portion of the work shall depart more than 10mm from true level, as determined from the nearest convenient bench mark which shall be indicated by the Superintendent. Any pipe or pipes not laid within these tolerances shall be lifted and relayed so that the gradient and alignment are within the tolerance specified. Such lifting and relaying or other approved corrective measures shall be at the cost of the contractor if the defects occur or become apparent at any time before the expire of the maintenance period. Unless otherwise approved, laying shall commence at the low points of the pipeline and proceed uphill. The space between abutting ends of pipes shall not exceed on-half (1/2) per cent of the diameter of the pipe. Where bandage joints or spigot and socket pipes are used, small recesses 150mm long shall be left under pipe joints to permit jointing, or in the case of spigot and socket pipes to allow the barrels to bear evenly on the foundation for their full length. Where two or more lines of pipe are to be laid side by side, the space between the lines of pipe shall be a width of 300mm unless otherwise specified or shown on the Drawings. All open ends of pipeline stubs shall be baulded and closed off before backfilling commences. No additional payment shall be made for this work.


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If required by the Superintendent the Contractor shall provide everything necessary to determine that no obstructions exist in the pipeline. Any obstruction shall be removed to the satisfaction of the Superintendent. (iii) Method of Jointing The method of jointing shall be as indicated on the drawings. Rubber ring joints for concrete pipes shall be formed by placing the rubber ring evenly over the spigot end of the pipe and rolling it into the socket, care being taken to ensure that the joint is free from dirt or other obstructions and that the rubber ring is place evenly in the joint. Rubber ring joints shall be fitted in the manner described by the manufacturer. Where precast collars or spigot and socket pipes are used, joints may be made with cement mortar or an approved bituminous filler. Where possible, the joint immediately adjacent to a pit and/or a headwall shall not be made until after the pit or headwall is constructed. In all cases care shall be taken that the interior of pipes are cleaned of any excess jointing material after jointing. Mortar joints shall be protected from the sun, and if necessary covered with earth or wet bags to prevent rapid drying of the mortar for at least three (3) days after placing or alternatively by the application of an approved curing compound. All holes provided in concrete pipes for lifting or handling purposes shall be plugged with concrete bungs supplied by the manufacturer and are to be rammed home. The Superintendent may require the contractor to install bungs using a bitumen paint. All holes shall be plugged to the satisfaction of the Superintendent prior to the backfilling of trenches. (iv) Type of Pipe Pipe shall be of the interlocking or spigot and socket joint type. The Principal reserves the right at any time to arrange for testing in accordance with the above mentioned Specification. (v) Mortar Unless otherwise shown on Drawings or specified, all mortar used shall be composed of one (1) part of cement to three (3) parts of sand. The sand shall be clean and free from any organic or foreign matter and, if necessary, shall be washed to conform with these requirements. Up to ten (10) per cent of lime shall be added if required by the Superintendent. The sand and cement shall be gauged by measurement, thoroughly mixed, first in a dry state and afterwards with clean fresh water until well incorporated. The mortar shall be mixed on approved clean sawn timber platforms close to where it is required. The mortar shall be used fresh; any which has become hard or partially set shall be immediately removed from the works. (iv) HDPE (Black Brute) Drainage Pipe The supply and installation of this pipe (where permitted or directed by the Superintendent), shall conform with the relevant Australian Standards. Additional guidance for the Contractor on installation shall be obtained from the Hardie-Iplex 1990 - Hobas Pipeline Manual and the manufactures recommended installation practices. Conformance with correct installation procedures will be by reference to the manufacturer’s recommendations where there is no relevant Australian Standard.


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2.06.4 DRAINAGE STRUCTURES (i) General Construct manholes, sumps, end walls and other structures as detailed on the relevant drawings. Bench bases as detailed and finish smoothly to minimise turbulence of flow. (ii) Formwork Formwork shall comply with the requirements of Section 10 of the Technical Specification. Both internal and external surfaces of walls shall normally be formed. However, where the depth of the structure and nature of the ground permit, the Superintendent may allow the casting of walls without external forms provided the ground is undisturbed, that it is trimmed to an even vertical surface and that wall thickness is increased by at least 50mm over that shown on the drawings. No additional payment will be allowed for this alternative procedure. External formwork shall be used for the top 300mm of manholes and the sumps in all cases. Formwork shall be used of both faces of end walls.

(iii) Backfilling Backfill around drainage structures as specified for the adjacent pipe trench. (iv) Alternative to Existing Structures Where existing structures are to be raised or lowered, break out sufficient of the walls to expose reinforcement and to allow at least 150mm of new concrete below the new cover or frame. Splice new reinforcement to old as necessary, form and place concrete as specified for new structures. (v) Galvanising of Mild Steel Fixtures Where shown on the drawing, mild steel fixtures including grates, frames, step irons, ladders, etc., shall be hot dip galvanised. Galvanising shall comply with the requirements of AS 1214 - 1983 or AS/NZS 4534 – 1998, as appropriate. Prepare and treat items to be galvanised so that the zinc coating adheres firmly and evenly over the entire surface. (vi) Sealed Sumps Sealed sumps, where shown on drawings, shall be constructed as for standard sumps but without an opening for surface water. (vii) Endwalls When backfilling adjacent to endwalls, provide a layer of permeable material adjacent to weepholes complying with the requirements for combined filter medium for subsoil drains. Where shown on the drawing construct a protective fence at each endwall as detailed on the relevant drawing. All fittings shall be galvanised as specified in Item (v) above. (viii) Stone Pitching Stone pitching shall be constructed as specified.


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2.07 SUBSOIL DRAINS

2.07.1 MATERIALS

(i) Pipes Unless otherwise detailed, pipes for subsoil drains shall be 100mm diameter complying with AS 2439 and of Class nominated below: Application Class Trench subject to heavy vehicular traffic loads 1000 Road not subjected to heavy traffic loads 400 Other 200 Slot widths shall be in the range 1.0 -1.5mm Pipes for subsoil drains shall preferably be corrugated black high-density polyethylene similar to A.C.I “Draincoil”. Unless otherwise specified, pipes shall be 10mm diameter. (ii) Filter Material Filter material shall be coarse sand or crushed stone complying with one of the gradings in Table 2.1. The use of filter materials not meeting these grading requirements will be approved subject to adequate permeability and to their use in conjunction with a suitable woven or knitted “sock” which completely surrounds the pipe and prevents the entry of filter material into the pipe. Where subsoil drains are laid in or adjacent to areas to be planted the pH of the filter material shall be in the range 6-7.

2.07.2 TRENCHES The standard width of trench shall be 300mm. Where invert levels are not specified the minimum depth to pipe invert shall be 1m. Unless otherwise detailed or directed, locate trenches for longitudinal drains so that the pipe centre line will be 150mm from edge of pavement or behind back of kerb as the case may be.

TABLE 2.1

Percentage Passing by Mass

AS Sieve Size (mm) Fine Filter Coarse Filter Combined Filter

26.5 100 100

19.0 90 - 100 95 - 100

9.5 100 65 - 85 80 - 95

4.25 90 - 100 - 65 - 80

2.36 70 - 90 - 45 - 65

1.18 - 15 - 30 25 - 45

0.60 - 0 - 2 12 - 20

0.30 7 - 16 - 3 - 8

0.15 0.4 - 0 - 2

0.075 0 - 2 - -


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2.07.3 BEDDING, LAYING AND JOINTING Bed and lay pipes as detailed on the standard drawings. Unless otherwise detailed or permitted, the minimum grade shall be 1%. Lay corrugated polyethylene pipes with one line of slots at the bottom. Filter media to be used under various conditions are described in Table 2.2 Place filter material in trench so as to avoid segregation. When placing two-zoned filters alongside pipes place a temporary shutter vertically in the trench to prevent mixing. Compact filter material in maximum layers of 300mm using a suitable mechanical plate vibrator. Joint pipes in accordance with manufacture’s instructions. The top 75mm of filter medium below pavement, topsoil or other specified finish shall be fine filter material. In planting beds extend fine filter to finished surface of topsoil

TABLE 2.2 Filter Type Type of Pipe Trench in Earth Trench in Rock Corrugated Polyethylene Fine Fine Perforated or Slotted A.C Combined to 2 zones Coarse

2.07.4 FINISHING

(i) High Ends The high end of drains not under road pavements shall be turned up and capped at the surface with a cast iron box with hinged lid set in a concrete surround 300mm square by 150mm deep. High ends under pavements shall be sealed with a suitable end cap.

(ii) Outlets Discharge drains to sumps, stormwater manholes, or pipes or to the surface as detailed or as directed. Where invert levels are not specified, the obvert of the subsoil drain shall not be lower than the highest obvert of other pipes at the point of connection. Where discharge is to the surface or an open drain, construct an endwall and fit a wire guard as detailed.

2.08 SETTING OUT (i) Level All levels shown on the drawings are based on the Australian Height Datum. Before commencement of work the Contractor shall request an official benchmark to be indicated to him near the site of the job. (ii) Pegging of Drainage Lines Setting out of drains in accordance with the drawings and specifications shall be the responsibility of the Contractor. The Contractor shall locate, for line and level, all structures as shown on the drawings.


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(iii) Re-establishment of Setout Pegs The Superintendent will re-establish, recover or transfer any setting out pegs which are disturbed in the course of construction at the Contractor’s expense. (iv) Protection of Benchmarks Under no circumstances shall any interference will any official benchmark be permitted. Before commencing work, all such benchmarks in the area covered by the contract shall be protected to the satisfaction of the Superintendent.

2.09 TESTING OF STRUCTURAL CONCRETE FOR DRAINAGE

STRUCTURES The Contractor shall be required to carry out at least one (1) concrete test, as specified in AS 3600 - 2001, per days pour for the purpose of determining the 28 day compressive strength of structural concrete used for drainage structures.

Unless otherwise provided for in the Bill of Quantities the cost of these tests shall be paid by the Contractor, who shall be deemed to have allowed in his Tender for all costs associated with such testing. Structural concrete shall include all formed and/or reinforced concrete.


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SECTION 3 - CONCRETE WORKS

3.01 SCOPE This section applies to all concrete structures and other concrete works as detailed and specified, and is to he read in conjunction with the requirement of other parts of the Specification.

3.02 MATERIALS (i) Cement Except where otherwise nominated for a specific component of the works cement shall be Type C - Low Heat to AS 3972 except for grout for anchor bars and hand grouting where Type A cement shall be used. (ii) Admixtures Chemical admixtures will be used only where permitted by the Superintendent. Use of Fly Ash is not permitted. (iii) Aggregates Aggregates for concrete are to comply with as 2758. (iv) Reinforcement (a) General Steel reinforcing bars shall comply with AS/NZS 4671 and to the Grade stipulated on the drawings. Steel wire reinforcing fabric is to comply with AS/NZS 4671. Reinforcement shall comply with AS 3600 Clause 19.2 and shall be free from loose or thick rust, loose mill scale, grease, paint, oil, dirt, mortar or other unspecified coating. Reinforcement shall be stored supported above ground and protected from contaminants. Cover to reinforcement shall comply with AS 3600 Clause 4.10 or AS 3735 Clause 4.4 as applicable and splicing shall comply with AS 3600 Clause 13.2 unless otherwise specified. Reinforcement shall be readily identifiable as to grade, origin and its final location in the Works. The necessary tie wire, support chairs, spacers, supplementary reinforcement and the like shall be supplied for adequate fixing of the reinforcement. The Contractor shall furnish a certificate of compliance with the relevant standard AS/NZS 4671, or alternatively provide test certificates from a NATA registered testing authority The Superintendent shall be notified in writing prior to the welding of any reinforcement. Reinforcement shall not be welded within 75 mm of a section which has been affected by bending or re-bending.


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Reinforcement detailing for bridge works shall conform to the current edition of the Austroads Bridge Design Specification. (b) Protective Coated Reinforcement Galvanised reinforcement shall comply with AS/NZS 4534 - 1998. If damage occurs to the coating, either the damaged reinforcement shall be replaced, or repairs may be carried out to AS1650 Appendix F. “Starter Bars” to be exposed to the weather for extended periods, shall be coated with a cement wash. (c) Fixing Reinforcement The ends of wire ties shall be bent away from nearby faces of forms so that the ties do not project into the concrete cover. For bar reinforcement in the form of a mat, each bar shall be secured at alternate intersections, and at other points as required. Ligatures in beams shall be tied to the bars in each corner of each ligature. Other longitudinal bars shall be fixed to ligatures at not more than 1000mm intervals. Where spacing or cover of reinforcement does not comply with AS 3600 Clauses 8.1.7 and 4.10.2 respectively the Contractor shall notify the Superintendent prior to fixing of the steel. (d) Reinforcement Supports Damage to waterproofing membranes or vapour barriers shall be prevented by placing a metal or plastic plate under each support to prevent puncturing.

3.03 JOINTS

3.03.1 CONSTRUCTION JOINTS Construction joints shall be in accordance with AS 3600 Clause 19.4.1. The Contractor shall not amend or add a construction joint not shown on the Drawings, without prior approval of the Superintendent. Before fresh concrete is placed at a construction joint, the hardened concrete surface of the joint shall be dampened after it is roughened and cleaned so that all loose or soft material, free water, foreign matter and laitance is removed.

Surfaces of adjoining pours shall be butt joined and shall be approximately horizontal or vertical unless otherwise shown.

3.03.2 MOVEMENT JOINTS Movement joints, where specified, shall be one of the following types: Contraction joint: An unreinforced joint with a bond-breaking coating

separating the concrete joint surfaces. Expansion joint: An unreinforced joint with the joint surfaces separated by

a compressible filler.


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Control joint: A weakened plane contraction joint created by forming a

groove, extending at least one quarter of the depth of the section, either by means of a grooving tool, by sawing, or by inserting a pre-moulded strip. (Refer to “Industrial Floors and Pavement - Guide Specification”, Cement and Concrete Association of Australia, Technical Note TN55, for suggested times for sawing).

Isolation joint: A joint without keying, dowelling, or reinforcement, which

imposes no restraint on movement in any plane.

3.03.3 JOINTING MATERIALS Joint materials shall be used as recommended by the material manufacturers for the location and type of joint, compatible when used together, and non-staining to concrete in visible locations. Joint fillers shall be resin bonded cork to ASTM D1752 - 60T: Type 11 unless otherwise specified.

3.03.4 JOINT DOWELS Joint dowels shall generally be galvanised steel plain bars in expansion and contraction joints. A heavy coating of grease or a bitumen coat shall be applied to the free end and an expansion cap.

3.03.5 JOINT FILLING Joint surfaces shall be dry and clean before application, and primed as recommended by the joint material manufacturer. Joint Sealant shall be Thioflex 600 or equivalent unless otherwise specified, and shall be ready installed to the manufacturers’ recommendations.

3.03.6 WATERSTOPS Waterstops shall be installed such that they are surrounded by fully compacted concrete, and located so that: * reinforcement is’ not displaced from its correct position * the Contractor shall store the waterstops in such a way that the material does not deteriorate during storage. * adequate provision shall be made to support and protect the waterstops during the progress of the work. * the proper placing and compaction of the concrete is not inhibited; and Waterstops are subject to approval and shall be of extruded polyvinyl chloride complying with BS 2571, class 3, Compound Type G10. Waterstops shall be of sufficient stiffness so that they remain in their correct position during construction. Notwithstanding the above all waterstops shall have nailing strips of 5mm minimum thickness so located that the efficiency of the water stop is not impaired. Water stops shall be constructed so as to form a continuous water barrier. The number of joints in the stops shall be the minimum practicable. The Contractor shall protect the stops against perforation or damage during the progress of the work.


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The number of joints in PVC waterstops shall be of the minimum practicable and all joints and bends shall be made in accordance with the manufacturer’s recommendations as approved. The number of butt joints shall be kept to a minimum and all ‘Tee’ and ‘Flat X’ joints shall be factory produced. The equipment used for making field joints shall be furnished by the Contractor. All joints shall be made with a temperature controlled apparatus and shall be fusion-welded in such a manner as to ensure that: * the PVC is not damaged by heat, searing or by the application of cementing materials; * the splice has a tensile strength not less than 80% of that specified for the PVC;

* the splice is water tight and free of air bubbles; and * the ribs and central bulb, where applicable, match up exactly and are

continuous. * any other waterstops shall be fixed to manufacturer’s recommendations.

3.04 CURING AND PROTECTION

3.04.1 GENERAL The requirements for curing and protection shall be in accordance with AS3600 Clause 19.1.5 and the Specification.

3.04.2 CURING Fresh concrete shall be protected by maintaining the concrete at a reasonably constant temperature with minimum moisture loss by: (a) ponding or moist curing; (b) applying an impermeable membrane; (c) applying an absorptive cover kept continuously wet; (d) steam curing; (e) an approved curing compound; Where the Contractor proposes to use a liquid membrane curing compound, the Contractor shall submit the following information to the Superintendent prior to ordering concrete: * water retention performance details to AS 3799 Appendix B; * evidence an acceptable final surface colour will be provided; * evidence of compatibility with applied finishes; Curing compounds shall be to AS 3799.


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Curing shall commence immediately after finishing, and shall be applied continuously during which the air temperature in contact with the concrete is above 10

oC, totals

not less than the following: For durability exposure categories A1 and A2: 72 hours. For durability exposure categories B1, B2 and C: 168 hours For concrete placed during hot weather as defined by AS 3600 curing compounds are not acceptable. For visually important surfaces uniform curing methods shall be used on adjacent surfaces so as to produce uniform colour.

3.04.3 PROTECTION The Contractor shall allow adequate curing time before loading the concrete structure. The concrete shall be protected from damage due to load overstresses, heavy shocks and excessive vibrations, particularly during the curing period. Where the structure needs to sustain construction loads, the Contractor shall provide calculations to justify acceptable loading levels. Protect concrete surfaces from damage from any cause.

3.05 CONCRETE

3.05.1 GENERAL The Contractor shall use concrete supplied by a ready mix concrete supplier acceptable to the Principal and Superintendent, except where otherwise approved. The mix design shall be the responsibility of the Contractor, however, the Superintendent reserves the right to accept or reject the concrete mix. The Contractor shall provide full details of his proposed mix. Every effort shall be made to ensure concrete is of a uniform appearance and colour. Should the Contractor wish to change his ready mix concrete supplier he is to obtain the prior approval of the Superintendent, which will not be unreasonably withheld. Proof of competency of the new supplier and equivalent complying characteristics of the mix is to be furnished with the request. The Contractor shall submit details of the proposed method of conveying concrete to the Superintendent. Where pumping or pneumatic conveying equipment is proposed a stand by unit must be provided. For each truck of premixed concrete an identification certificate shall be supplied on delivery listing the information required by AS 1379 Clause 1.7.3. Water may be added to a mixed batch at any time prior to completion of discharge only if the requirements of Clause 4.2.3 of AS 1379 are satisfied.


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3.05.2 PUMPED CONCRETE The Contractor shall submit to the Superintendent all certificates, documentation and details of the proposed mix and methods of placing prior to supply of any pumped concrete.

3.05.3 TESTING The Contractor shall undertake quality control testing and assessment of concrete and concrete materials as specified herein. Unless otherwise specified, testing shall be on a production and project assessment basis in accordance with AS 3600 Section 20, and AS 1379 Appendix B. The appropriate sampling and testing method specified in AS 1012 shall be used. Concrete shall be sampled on site prior to any site handling or treatment, as per AS 1379 Appendix B2.2. For each required test the Contractor shall maintain the records and reports of test results required by AS 1012, or similar information for tests not covered by AS1012. Two copies of each test report shall be submitted to the Superintendent. The Contractor shall take compliance tests as specified in AS 1379 Section 5 and Appendix B, and 2 copies of test certificates shall be supplied prior to changing the material characteristics, or mix constituents or their proportions of any concrete in the works. The Contractor shall sample and test for concrete slump to AS 1379 Clause 5.2. The Contractor shall sample and test for air entrainment to AS 1379 Clause 5.4

3.06 FORMWORK

3.06.1 GENERAL Formwork shall be designed and constructed by the Contractor to produce concrete members which will conform to the location, shapes, lines, levels and dimensions and to the qualities of surface finish required by the Contract.

3.06.2 STANDARDS Formwork shall conform to the requirements of AS 3610 and AS 3600.

3.06.3 OPENINGS IN FORMS Form openings or removable panels shall be provided in vertical or near vertical forms where necessary for cleaning and inspections.

3.06.4 CLEANING OF FORMS Forms shall be thoroughly cleaned and free water, dust, debris, rust and other stains shall be removed from the forms and formed space, prior to the application of the form release agent, and again prior to placing of concrete.

3.06.5 STRIPPING OF FORMWORK Formwork shall be stripped in accordance with AS 3600 Clause 19.6.2, where those requirements are more stringent than the relevant requirements of AS 3610, or in accordance with the requirements of the Contract Documentation.


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3.06.6 RELEASE AGENTS A release agent shall be applied to the interior surfaces of the formwork, except where the concrete is to receive and applied finish for which there is no compatible release agent. Release agents shall be chosen such that they are compatible with the form lining or facing, the plastic concrete and all its constituents and subsequent concrete surface treatments. No part of the reinforcement or construction joints shall be coated with the release agent.

3.06.7 CONCRETING AGAINST ROCK Subject to the approval of the Superintendent, concrete may be poured against rock faces, provided that the cover to the reinforcement on the rock face is increased by a minimum of 25mm. Before any concrete is poured against a rock face all leakage and percolation of water which could cause damage to the wet concrete shall be effectively sealed. Concrete shall not be poured against horizontal or inclined rubble, fill or earth surfaces in lieu of formwork, unless approved by the Superintendent.

3.06.8 PROVISION FOR MOVEMENT The formwork and falsework shall be designed to account for dimensional changes, deflections and/or cambers.

3.06.9 ERECTION OF FORMWORK ON FINISHED CONCRETE SURFACES Formwork shall not be erected on finished concrete surfaces until the surfaces have attained sufficient strength to support the formwork without damage, and not before three (3) days after placement of the concrete. Suitable protective materials shall be placed between formwork bases and the finished concrete surfaces.

3.06.10 DIMENSIONAL TOLERANCES Formwork and falsework shall be so designed and constructed that the concrete produced from the forms and construction joints and formwork lines where nominated in the project documentation, shall conform to the tolerances as indicated in AS 3610 Clause 3.4 and to AS 3600 Clause 19.5 or as otherwise permitted by the Contract.

3.06.11 FORMED SURFACE FINISH Finishes to formed surfaces shall be produced in accordance with the requirements and recommendations of AS 3610 and the project documentation. If the surface class is not specified, the class shall be the applicable one from the following list: Footing and other buried structures, rear surfaces of retaining walls, surfaces to be faced: Class 5 Bridge and other surfaces which will receive heavy applied finishes: Class 4 Concealed surfaces of walls, beams slab soffits, stairs, abutments, bridge decks etc: Class 3 Surfaces to receive a granule or plaster finish, and all exposed surfaces Class 2


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Surface not specified Class 2 For surfaces required to receive Class 2 finish, trial panels with joints not less than 1m square using the proposed formwork construction and representing the placing conditions for the in-situ surface shall be prepared for the approval of the Superintendent. The cost of the trial panel shall be deemed to be included in the rates for the concrete. For concrete surface classes 1,2 or 3 the formwork shall be set out to give regular arrangement of panels, joints, bolt holes and other visible elements of the formed surface. All corners and angles shall have 25mm chamfers and levels set at 45

o to

the surface face. Where colour control is specified, form linings shall not be inferior to those described as “suitable” in AS 3610 supplement 2, Table C5.4.1. If the Superintendent considers that the formed surface finish of the completed work does not comply with the Contract, an evaluation of the finish in accordance with AS 3610 Clause 5.6 may be requested. This evaluation shall be carded out by the Contractor in the presence of the Superintendent. Repairs to Class 1 surfaces shall not be permitted. Repair of defective formed surfaces of lesser class shall be performed in accordance with AS 3610 Clause 5.6.5. The method of repair, the materials and proposals for curing of repaired areas shall be submitted to the Superintendent prior to commencing repairs. Concrete spacer blocks, where they form part of the exposed surface of the concrete, shall be identical in colour and strength to the finished concrete.

3.06.12 FORM TIE BOLTS Tie bolts shall be positioned such that those left in the concrete do not project into the concrete cover. Tie bolts shall be removed without causing damage to the concrete surface. Where the concrete surface is to be later treated tie bolt cores shall be loosened but left in place until after the surface treatment is applied. Filling of tie bolt holes shall be with a material which matches the surface colour. Pilling shall be recessed 6mm below the concrete surface to give a neat appearance.

3.06.13 FORMWORK TEMPERATURE If it is likely that the ambient air temperature may fall to 5

oC or less during placement

of concrete, the forms shall be covered for at least 12 hours prior to concreting and the enclosed space shall be heated so that the temperature of the form faces is no below 5

oC at the time of concrete placement.

If it is likely that the ambient air temperature may rise to more than 32

oC during

placement of the concrete, the forms shall be adequately shaded or sprayed with water so as to prevent the temperature of the form faces rising above 35

oC.

3.07 PLACING

3.07.1 PLACING AND COMPACTION Placing and compaction shall be in accordance with AS 3600 Clause 19.1.3 and this Specification.


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In vertical elements, the free fall of concrete shall be limited to 1,500mm per 100mm element thickness, up to a maximum free fall of 3,000mm, subject to demonstration of satisfactory lack of segregation, by means such as enclosed chutes, access hatches in forms, and the like. As far as practicable chutes shall be kept vertical and full of concrete during placement with ends immersed in the place concrete. Concrete shall be deposited in layers not exceeding 600mm in thickness and compacted such that each succeeding layer is blended into the preceding one by the compaction process. Concrete affected by rain before it has set, including during mixing, transport or placing, shall be liable to rejection. The Contractor shall minimise shrinkage effects by pouring the sections of the work between construction joints in a sequence such that there will be suitable time delays between adjacent pours. The Contractor shall submit a proposed sequence and times for approval. The Contractor shall keep on site and make available for inspection a log book recording each placement of concrete including: * date; * the portion of work; * specified grade and source of concrete; * slump measurements; * volume placed.

3.07.2 COLD WEATHER PLACING The temperature of the freshly mixed concrete, unless otherwise specified shall be maintained within the limits shown in the following table:

Outdoor air temperature: Temperature of concrete:

Minimum: Less than 10oC Maximum: 35

oC

Under no circumstances shall calcium chloride, salts, chemicals or other material be used in the mix to lower the freezing point of the concrete. Frozen materials or materials containing ice shall not be allowed to enter the mixer, and forms, materials and equipment coming in contact with the concrete shall be free of frost and ice. In cold weather conditions Type HE Portland cement may be used, to enable the concrete to develop sufficient strength to permit formwork removal within the specified time, but not as a substitute for the heating of materials or for adequate protection of placed concrete against low temperatures. High alumina cement shall not be used. Concrete materials other than cement may be heated, but to a temperature not greater than the minimum necessary to ensure that the temperature of the placed concrete is within the limits specified in this clause. The temperature of water shall be not greater than 80

oC when it is placed in the mixer.


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3.07.3 HOT WEATHER PLACING The provisions of this Clause shall apply to concreting when the surrounding shade outdoor temperature is greater than 30

oC.

Concrete shall not be mixed when the outdoor shade temperature on the site exceeds 38

oC.

The Contractor shall take precautions to prevent premature stiffening of the fresh mix and to reduce water absorption and evaporation losses. Mixing, transportation, placing and compaction of the concrete shall be carried out as rapidly as possible. Before and during placing of concrete the formwork and reinforcement shall be maintained at a temperature not greater than 35

oC by protection, cold water

spraying, or other effective means. The concrete shall be placed at a temperature not exceeding the following.

Concrete element: Temperature

Limit

Normal concrete in footings, hams, columns, walls and slabs: 35

oC

Concrete in large mass concrete sections: or Concrete of strength 50 MPa or greater, in sections exceeding 27

oC

600mm in thickness. Acceptable methods of maintaining the specified temperature of the concrete include: * using chilled mixing water; * spraying the coarse aggregate with cold water; * covering the container in which the concrete is transported to the forms; * cooling the concrete by liquid nitrogen injection prior to placing; * keeping aggregate shaded at batching plant; * a combination of these methods.

3.07.4 PLACING UNDER WATER If concrete is specified to be placed under water, it shall be placed by tremie as specified in AS 2159 Clause 4.5.7.

3.08 EMBEDMENTS, CORES AND FIXINGS

3.08.1 FIXINGS AND EMBEDDED ITEMS Fixing and embedded items shall comply with AS 3600 Section 14. Lifting bracing and fixing inserts for precast units shall be in accordance with AS 3850.1 Clause 4.3. If the locations of embedded items are not shown on the Drawings, or are shown diagrammatically, or if it is proposed to vary the locations shown, the Contractor shall


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submit shop drawings showing the proposed locations, clearances, cover and the like. In locating embedded items, the Contractor shall not cut or displace reinforcement, or cut hardened concrete, unless otherwise specified. Fixings and embedments shall be placed such that their maximum deviation from correct position is as follows: * Embedded items generally: Plus or minus 10mm. * Fixing, anchor bolts and the like: Plus or minus 3mm. * Fixing and embedded items in precast units: To AS 3610 Table 3.4.3, AS 3850.1 Clause 6.4, and AS 3850.2 Clause 3.7.7 as applicable. Where embedded pipes will contain liquid or vapour at a pressure of more than 10kPa, they shall be tested for leaks and the results of the test provided to the Superintendent prior to the pipe being embedded in the concrete.

3.08.2 PROTECTION OF FIXINGS All embedded and inserted ferrous fixings (other than stainless steel) shall be provided with a galvanised surface coating passivated by dipping in 0.2% sodium dichromate solution. The galvanised surface coating shall comply with the following : Threaded fastenings: To AS 1214 Structural sections: To AS/NZS 4535

3.08.3 INSERTED FIXINGS Fixing inserted by drilling (including masonry anchors and the like), or by explosive tools, shall only be used if specified or approved by the Superintendent. Use of such fixing shall be in strict accordance with the manufacturers’ recommendations.

3.09 INTEGRAL FINISHES

3.09.1 TOLERANCE CLASSES FOR FINISHES AS LAID Finishes as laid shall be defined by classes as follows, determined by a straight edge placed anywhere on the surface in any direction. Class A: Maximum deviation from a 3m straight edge: 3mm Class B: Maximum deviation from a 3m straight edge: 6mm Class C: Maximum deviation from a 600mm straight edge: 6mm

3.09.2 FINISHES AS LAID Classes of finish shall be as set out below where indicated. Machine Floated Finish: The screeded surface shall be finished with power

driven equipment to a uniform smooth texture, hand floated in locations inaccessible to the machine float.


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Steel Trowelled Finish: After screeding, the final finish shall be produced with steel hand trowels, free of trowel marks and uniform in texture and appearance.

Wood Float Finish: After screeding, the final finish shall be produced

with a wood float. Scored Finish: After screeding, the surface shall be given a coarse

scored texture in the direction shown on the Drawings, by drawing a scoring tool (broom, hessian belt, stiff brush, rake or the like) across the surface.

Unless shown otherwise on the Drawings, unformed surface shall receive the finishes specified below: Bridge deck surfaces to which asphaltic concrete surfacing is to be applied and all other upper surfaces not visible in the completed structure. Screeded Finish Footpaths, concrete pavements, median strips, mowing strips, stormwater inlet and outlet slabs. Wood Float Finish Kerbs, concrete edging strips, tops of wall and wall drains, parapets and all other upper surfaces visible in the completed structure. Steel Trowelled Finish


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SECTION 4 - INCIDENTAL WORKS

4.01 ROCKFILL BEACHING / RIP-RAP

4.01.1 MATERIALS Beaching Stone/Rip Rap shall consist of clean, sound, hard tough quarried rock or uniform quality with a crushing strength of not less than 25 MPA and free of defined cleavage planes. Rock is to have a Specific Gravity of not less than 2.5. The size of the stone shall conform as closely as practicable to the size distribution set out in Table 4.1:

TABLE 4.1 % Passing Screen Size

Beaching

Type

Nominal

Stone

Total

Thickness

of Layer

900

mm

600

mm

225

mm

150

mm

75

mm

37.5

mm

26.5

mm

Type 1 75mm 125mm 100 100 100 100 60-95 20-35 <10

Type 2 150mm 200mm 100 100 100 60-95 40-65 20-35 <10

Type 3 225mm 275mm 100 100 70-95 50-75 35-50 15-30 <10

Rip Rap As per drawings

100 50 15 Nil

Rock is to have shape factors as follows: Maximum 25% of rock with “length” dimension 2 times (twice) the “width” dimension. No rock is to have length greater than 2.5 times width.

4.01.2 PLACEMENT Rip-Rap is to be placed by hydraulic excavator or equivalent, with care taken to avoid damage to filter fabric/geotextile, pipes, culverts or structure. All Rock is to placed to avoid excessive segregation of size fractions. Larger rocks are to be at the surface interlocked with smaller rocks to give a clean surface profile. Filter Fabric/Geotextile is to be placed under all beaching in contact with parent material or fill. For Type 1 Beaching, the stones shall be dumped and then raked or spread into position. For Types 2 and 3 beaching, the stones shall be hand placed. Care shall be taken to avoid damage to geotextile material. For all types of beaching and rip-rap the finished surface shall conform to the design drain profile and shall present a uniform appearance with larger stones interlocked with graded smaller stones. Care shall be taken to ensure that the finished stone level is not above the design drain bed level.


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4.01.3 FILTER FABRIC

1. Filter Fabric Material Filter Fabric is to be laid under all rip-rap structures. Filter fabric/geotextile is to be BIDIM A14 or equivalent approved by the Superintendent. Alternative equivalent filter fabric shall be a non-woven geotextile manufactured from a continuous filament of either polyester or polypropylene. If a polypropylene filament is used the product shall be stabilised from ultraviolet degradation by the addition of from 1.5% to 2% by weight of carbon black. The continuous filament shall be mechanically bounded by needle punching. The fabric shall have the following properties: * mass not less than 0.21 kg/m2, * thickness not less than 1.9mm at 0.5kpa, * normal permeability not less than 3 x 10-3 m/s at 2 kpa, * bursting strength not less than 2.2 MPa, * continuous tearing strength not less than 90 N, * other physical, chemical and mechanical characteristics specified by the manufacturer. The Contractor shall at the time of tender nominate the filter fabric that he proposes to use and shall submit test certificates showing that it complies with this clause. The filter fabric shall be handled in such a manner as to avoid damage or contamination of the fabric. The fabric shall be stored out of direct sunlight on the site. The filter fabric shall be supplied as far as practicable in a roll of 5.3m width or in continuous pieces. Allowance shall be made for overlap of 0.5m at all joints. The Contractor shall provide to the Superintendent all relevant information regarding correct handling, site preparation and laying details and overlap to be adopted in conformity with the manufacturer’s recommendations. 2. Laying of Filter Fabric The underside ground contact surface shall be carefully prepared and graded free of protrusions more than 10mm in height. No sharp material or vegetation shall be permitted on this surface at the time of laying of the filter fabric. The filter fabric shall be laid out in rolls as supplied by the manufacturer in accordance with the manufacturer’s instructions and with the specified overlap.


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4.02 GROUTED STONE PITCHING

4.02.1 GROUTED STONE

The stone used shall be rock spalls or boulders of dense, sound, durable material with minimum nominal size 250mm. Minimum thickness of the stone shall be the thickness of the pitching. Where located in drains and waterways allow for 20MPa concrete grouting. Otherwise mortar shall be 1:3 mix.

4.02.2 BEDDING The stone shall be based at a depth of 75mm minimum below design finished surface level at the foot of the pitching and shall be firmly bedded on compacted earth. All voids between the stones and voids between the stone and earth bedding is to be filled with mortar or concrete as appropriate. Joints shall be nominally 12 to 40 millimetres and are to be raked to a depth of 10mm. Where pitching is higher than 300mm a continuous subsoil drainage pipe is to be installed behind the pitching at the finished ground level in front of the stone pitching, and discharge pipe as shown or to the surface as shown or directed. Allow for drainage medium 300mm around the pipe for its full length. Where pitching is greater than 300mm, weepholes are to be provided at the surface of the pitching at 3 metre centres. Allow for geofabric wrapped 12mm aggregate behind the weephole of size 300mm cube. Clean down stone upon completion. Pitching to be finished to an even surface, producing a surface suitable as a moving strip at the appropriate edges.

4.03 ON FARM WORKS

4.03.1 FARM DAMS Where farm dams are located on the route of the proposed drain, replacement dams shall be constructed by the Contractor outside the line of the drain at locations shown on the Drawing or as directed by the Superintendent. The dams shall be of comparable size to the dams replaced. The location and overall dimensions of replacement dams will be set out by the Superintendent and indicated on the ground by stakes set at the corners. Stakes will indicate the depth required and dams will be generally rectangular 1:5 slopes on the longer sides and 1:3 slopes on the ends. The bed and batters of replacement dams shall be trimmed to neat uniform lines and all loose earth must be removed from the dam.


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4.03.2 FENCING Fencing is to be undertaken in accordance with the drawings and the relevant Murray Irrigation Limited Ltd. specifications standards. Materials are to conform to the relevant Australian Standards and workmanship is to conform with industry accepted “best practice”.

4.03.3 STOCKSTOPS The rate tendered for this item shall be paid for all work to construct each stock stop (including all Fencing, Strainer Post, Stays, Mesh, Gates etc.) as detailed on the attached drawing.

4.03.4 TEMPORARY STOCK STOPS - FENCING Mesh: “89030” Ringlock fence and one top barb wire erected to the manufacturers instructions. Maximum steel post spacing is 3 meters with a post at every location where a permanent post is specified.


Specification.doc

SECTION 5 - STRUCTURES

5.01 GENERAL The construction of all structures are to comply with the requirements of the clauses in this Section and appropriate Australian Standards. Structures are to be constructed at the locations shown and to the dimensions alignments and elevations detailed on the Drawings. Where pipes are to be cast into concrete structures including concrete headwalls, collar blocks and cut-offs, the surface of the concrete pipe shall be scabbled to expose the aggregate to provide a bond with the concrete. The exposed ends of the pipe shall be finished smooth, rendered and trowelled. Where pipes are to be cast into headwalls a maximum 1.22 metre length of pipe shall be used. For structures other than drainage inlets, pipes shall be laid such that the invert of the pipe is between half and one third of the normal pipe diameter below the bed of the drain and to the elevation shown on the drawing. Drainage inlets shall be placed such that the pipe invert at the outlet to the drain is at the design bed level. Concrete cut-offs shall be provided at locations shown on the Drawings. the cut-offs shall be as shown on the drawings and extend a minimum 450 mm into solid material at the floor and walls of the trench. F102 reinforcing mesh shall be used in cut-offs.

5.02 PRECAST CONCRETE HEADWALL UNITS AND PRECAST

REINFORCED CONCRETE BOX CULVERTS

5.02.1 GENERAL All precast concrete work shall be carried out by a specialist firm, experienced and qualified in the manufacture of such works. The Contractor shall arrange for access to be made available to the Superintendent to inspect the precasting yard and the manufacturing of units if so requested by the Superintendent. The concrete surface finish for the exposed surface of precast concrete units shall be Type 7 or better. Precast Reinforced Concrete Box culvert sections as required shall comply with AS 1597.2 – 1996.


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5.03 EXCAVATION AND FOUNDATIONS

5.03.1 CONTRACT LIMITS All work within the limits of the designated earthworks paylines and the underside of pavements as marked on the drawings, represent the extent of the work to be included in the lump sum of the tender item.

5.03.2 NATURE OF MATERIAL The data shown on the drawings or otherwise indicated as to the nature and depths of the various classes of material underlying the site of the structure are approximate only and are given merely for the information of the Contractor. The Contractor shall satisfy himself as to the character of the material to be penetrated and shall assume all responsibility and risks involved therein.

5.03.3 COFFER DAM Coffer dam shall be sufficiently watertight to prevent damage to the concrete by percolation through the sides and shall be taken sufficiently below the level of the foundations to prevent loosening of the foundation materials by water rising through the bottom of the excavation. Coffer dams shall be adequately braced and shall be so constructed that removal with not damage or weaken the structure. For spread footing, capping of pile foundations, and such other cases as may be approved, the coffer dam may be constructed to the actual size of the work used to mould the concrete and then be left in place. Where a smooth finish is called for the interior dimensions of the coffer dam shall be such as to give sufficient clearance for the construction of forms and the inspection of their exteriors and to permit pumping outside the forms. The details of the coffer dam and formwork and the clearances shall be subject to the approval of the Superintendent, but the Contractor shall be held responsible for the design and for the successful construction of the works. Coffer dams which are tilted, or have moved laterally during sinking, shall be righted or enlarged to provide the specified clearances at the Contractor’s expense. No timber or bracing shall be left in the concrete of the finished structure. Unless otherwise provided for in the Specification or ordered by the Superintendent, coffer dams including temporary piles, shall be removed to the level of the stream bed after completion of the structure.

5.03.4 EXCAVATION (i) General The work shall include all clearing and grubbing of the site of the proposed work and the excavation of foundation pits, coffer dams, cylinders, and other foundations in all material, including rock. The digging of drainage trenches, and all pumping, bailing, draining, sheeting, bracing, or other operations necessary for the proper execution of the work are also included in the Contract. Excavation for anchor beams or anchor blocks shall be executed in such a manner that the anchor beam or block can be poured directly into the excavation, or, if side forms are used, the space remaining when forms are removed shall be filled with 20 MPa strength concrete. No extra payment will be allowed for this work.


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(ii) Earth Foundation Unless otherwise shown on the drawings, earth foundations shall be finished horizontally, care being taken to avoid disturbing material below foundation level. All soft material shall be removed and replaced by approved sound material, or the foundations shall be further excavated, as may be directed, until a firm foundation of uniform bearing value is obtained. All loose material shall be removed before placing the concrete. Backfilled materials under the foundation shall be compacted to the density of the original undisturbed material. Except for anchor beams or anchor blocks, forms shall be provided for all vertical surfaces, unless otherwise shown on the drawings or directed by the Superintendent. (iii) Removal of Water Water shall be removed from the excavation before concrete is placed, unless otherwise directed by the Superintendent. The Contractor shall perform at his own expense any additional work necessary to divert, for such time as the Superintendent may direct, any surface or soakage water clear of the area on which concrete is to be placed. (iv) Inspection of Foundations No concrete shall be placed until the foundations have been inspected and passed by the Superintendent or his representative. The Contractor shall provide proper facilities for such inspection. (v) Mass Concrete Before any reinforced concrete footings are poured on earth foundations, a layer of mass concrete of the same strength as that specified for the foundations, and not less than 50mm thick shall be placed over the earth surface, which shall have been excavated to a correspondingly greater depth and made wet. The mass concrete shall be brought to an approximately level finish and shall be allowed to harden sufficiently to preclude damage to the layer by subsequent operations.

5.03.5 BACKFILL All timbering bracing, and rubbish of all descriptions shall be removed before backfill is placed. Except where specified to the contrary, spaces excavated for foundations and not occupied by permanent work shall be backfilled to the level of the surrounding ground with material approved by the Superintendent, such as sound earth free from timber or rubbish, and compacted to the same degree as the original undisturbed material and neatly graded. When filling is being placed against walls, compaction shall commence at the wall in order to avoid the development of excessive pressure due to wedged action between the wall and any filling which may have been compacted previously.

5.04 RECEIPT OF STEEL OR PRECAST CONCRETE

MEMBERS

5.04.1 GENERAL The Contractor for the manufacture, supply and delivery of the steel or precast concrete members shall deliver such members to the site after all tests and inspections have been satisfactorily completed and permission to deliver has been granted by the Superintendent.


Specification.doc

5.05 FABRICATION AND ERECTION OF MINOR STEEL ITEMS

5.05.1 MATERIALS

(i) Specifications Structural grade steel shall conform to the requirements of AS 3678 & AS 3679 Structural Steel - Hot Rolled. The dimensions of hot rolled structural steel sections with the exception of rolled steel piling beams shall conform to the requirements of AS 3679, Dimensions of Hot Rolled Structural Steel Sections. The dimensions of rolled steel piling beams shall conform to those given in the BHP publication “Rolled Sections and Plates” (current edition). The steel shall be supplied in accordance with the provisions of AS 3678 & AS 3679 General Requirements for Structural Steel. Structural steel hollow sections conform to the requirements of AS 1163, Structural Steel Hollow Sections. Excessively rusted, bent or damaged steel will be rejected. (ii) Testing of Materials The Contractor shall supply evidence satisfactory to the Superintendent that all materials or parts conform with the tests required by the standard specifications referred to herein and with other tests called for by this Specification and/or otherwise as may be specified by the Superintendent. Test certificates shall show the results of mechanical tests and chemical analysis (where applicable) of the material or parts used in the work. No material or part shall be used in the work until it has been identified with the tests to the satisfaction of the Superintendent. The cost of all testing shall be borne by the contractor. (iii) Storage of Materials All steel, whether fabricated or not, shall be stored above the ground on platforms, slabs or other supports, and adequately protected against corrosion.

(iv) Mass of Steel Work The mass of steel work to be used in the calculation of quantities for payment shall be the net mass calculated from the finished dimensions shown on the Drawings on the basis 7850 kg/m3.

5.05.2 WELDING All welding shall conform to the Specification AS/NZS 1554.

5.05.3 CUTTING AND SPLICING Steelwork may be cut by flame cutting, sawing or shearing unless specified otherwise. Surfaces produced by such cutting shall be finished square (unless a bevelled edge is called for) true and smooth to the required dimensions.


Specification.doc

Where the finish of cut edges is not satisfactory, the edges shall be ground or machined to the satisfaction of the Superintendent. All corners on exposed edges shall be rounded to a radius of approximately 2mm. Unless approved by the Superintendent splices will not be permitted other than at points shown on the Drawings. Should the Contractor desire to splice any members elsewhere, details of the design and position of the proposed splices shall be submitted for approval. Fabrication of the members concerned shall not proceed until this approval has been obtained.

5.05.4 RAILINGS All components of railings shall be jig manufactured unless approved otherwise by the Superintendent. In order that adjoining parts may be identified in the field, match markings shall be stamped on all component parts. The match markings shall not be visible after the final assembly of railings.

5.05.5 PACKING AND DELIVERY

(i) Marking for Final Erection Each part shall be marked with approved distinguishing marks and stamped with durable markings. Paint of different colour shall be used to distinguish similar parts. Two copies of drawings showing these markings shall be supplied free of charge to the Superintendent when the steelwork is despatched. (ii) Packing and Marking All open joints, ends and projection parts shall be protected from damage in transit in such manner so to stiffen the member and prevent distortion. Shipping marks shall be carefully stencilled on each piece in a conspicuous position. Members shall have their weights clearly marked upon them. (iii) Transport and Handling The method of transporting and of handling the steelwork shall be subject to the approval of the Superintendent. Special care shall be taken in the packing and methods of support and lifting during transport and handling of all steelwork to prevent distortion and damage to the steelwork and its protective coating.

5.05.6 ERECTION OF RAILINGS Railings shall be straight and shall follow the finished grade and done as shown on the Drawings; unless otherwise shown on the Drawings, or directed by the Superintendent the posts shall be perpendicular to the concrete parapet or footway surface in the longitudinal direction and vertical transversely. Each line of the railing shall be first assembled in position, properly aligned and levelled, using the lower nuts on the anchor bolts, for the full length of the bridge for inspection by the Superintendent before being permanently bolted up and/or fixed to the deck. After inspection and approval, the line or railing shall be finally secured in


Specification.doc

position by bolting down and/or grouting into the prepared holes in the deck as shown on the Drawings, and to the satisfaction of the Superintendent. Care shall be taken that the line and levels of the rails and/or verticality of the posts is not disturbed.

5.06 PROTECTIVE TREATMENT OF STEEL WORK

5.06.1 GENERAL Protective treatment of steelwork shall be by the coating systems specified herein. The coatings shall be applied to dry surfaces and the coated surfaces shall not be exposed to rain or frost before they are dry. Also, coating shall not be carried out under conditions where moisture will condense on the surfaces before they are dry. Unless carried out indoors or under a satisfactory cover, abrasive blast cleaning and coating work will only be permitted when outdoor conditions (viz, moisture, wind, atmospheric pollution and temperature) are, in the opinion of the Superintendent, suitable. In cases where more than one coat of the same colour is to be applied, alternate coats shall be tinted to give contrast between coats. Where, because of local conditions, it is not possible to prevent contamination of the surface of intermediate coatings, the surface shall be cleaned down between coats. All marks and stamps for field assembly shall be carefully preserved and/or reproduced after cleaning and coating.

5.06.2 COATING SYSTEMS The general coating system, which shall be applied to all surfaces excluding shear connectors and the inner surfaces of fully sealed hollow sections, and also excluding bolts, nuts, washers, screws and items for which other treatment is specified, shall consist of: (a) abrasive blast cleaning, (b) applying one coat of an approved two-pack solvent borne self-curing inorganic

zinc silicate primer coating, (c) applying two coats of an approved epoxy polyamide cured coating which is

compatible with the primer, to the interior surface of the box girders, (d) applying two coats of an approved chlorinated rubber finishing paint which is

compatible with the primer to all other surfaces except as noted below: The surface which will be in contact with concrete in the finished work shall not receive the finishing coats specified in (c) and (d) above. All surfaces within 75mm of field welding shall not be primed until after the completion and approval of the field welding. These surfaces shall be masked to prevent coating with primer during the initial priming operations. Protection angles, footway cover plates and corrugated steel guardrail components shall be treated as follows:


Specification.doc

(a) abrasive blast cleaning or pickling (b) hot - dip galvanising No finishing paints will be applied to the surfaces of these items. All bolts screws, nuts and washers shall receive protective treatment as required by the Drawings and as specified herein. All pins, and associated washers shall be either galvanised or electroplated, as required by the Drawings and as specified herein. Surfaces of galvanised or electroplated components which will subsequently be coated with the finishing paint shall be degreased and wash primed prior to the application of the finishing paint. The inner surfaces of fully sealed hollow sections shall receive no protective treatment.

5.06.3 SURFACE PREPARATION

(i) Abrasive Blast Cleaning Before painting, regardless of any pre-cleaning of steelwork which may have been carried out prior to or during fabrication, all surfaces of the steel shall be thoroughly cleaned by abrasive blast cleaning to white metal. The surface finish shall be in accordance with AS 1627.4 Class 3 and shall have a surface roughness or “maximum profile height” of between 0.015mm and 0.045mm. A dry blast process shall be employed. The abrasive may be either metallic or non-metallic but shall be of an approved type to produce the surface roughness specified. The use of coarse steel angular grit, copper slag or any other material which will give a high surface profile or could contaminate the surface is not permitted. All compressed air used in blast cleaning and blowing down after cleaning shall be free from oil and moisture. (ii) Pickling All weld areas are to be abrasive blast cleaned to the standard of AS 1627.4 Class 3 before pickling. Pickling shall be carried out in accordance with AS 1627.5.

5.06.4 PRIMERS

(i) Approved Primers The primer coating shall be a two-pack solvent borne self-curing inorganic zinc silicate coating which must consist substantially of finely divided metallic zinc and partially hydrolysed ethyl silicate solution. The formulation must be such that the ratio by weight of metallic zinc to all other non-volatile compounds in the product shall exceed 4 to 1 when the zinc content is determined by the method of analysis prescribed in British Standard No. BS 3982 (1966). The primer coating shall be tinted a distinctive green or such other colour as approved by the Superintendent so as to be readily visually distinguishable from the prepared steel surfaces.

(ii) Application of Primer


Specification.doc

Before any deterioration of the blast cleaned surface is visible, and in any case within four hours after grit blasting, all surfaces of steelwork, as specified in clause 7.06.02, shall receive one coat of the approved primer. Any surface showing deterioration before being primed shall be re-cleaned at the Contractor’s expense. All surfaces within 75mm of field welds shall be masked to prevent coating with primer. The primer shall be applied so as to produce a smooth even coating and shall be sprayed or brushed into all corners and crevices. Wrinkling, blistering, air holes, lumps or other blemishes will not be allowed, and where the Superintendent so directs, the primer shall be removed by abrasive blast cleaning and replaced at the Contractor’s expense. The primer manufacturer’s directions for mixing and application shall be adhered to strictly. Where necessary the relative humidity in the vicinity of the spraying shall be increased by artificial means to ensure proper curing of the coating.

(iii) Coating Thickness The minimum dry film thickness of primer shall be follows: (a) surfaces which will not be subsequently coated with 100 micrometres finishing paint (b) surfaces which will be subsequently coated with 75 micrometres finishing paint (c) surface which will be subsequently in direct contact 30 micrometers with concrete (except shear connectors) (d) shear connectors nil The minimum dry film thickness shall be measured by means of an approved thickness meter.

5.06.5 METALLIC COATING (i) Galvanising The material used for galvanising shall be zinc metal specially made for this purpose and shall be at least 98 - 112% pure. The process shall be carried out to the satisfaction of the Superintendent. The minimum thickness of coating shall be 100 micrometres. The actual thickness of the zone applied shall be measured by means of an approved thickness meter. Should any doubt arise, in the opinion of the Superintendent, as to the quality of the applied coating, tests shall be required and these shall be carried out in accordance with Australian Standard AS 1650. (ii) Electroplating All parts which are to be electroplated width zinc or cadmium, shall be plated in accordance with AS 1789,Fe/Zn 12c Type C, or in accordance with Australian Standard AS 1790, Fe/Cd 12c Type C.


Specification.doc

5.06.6 REPAIR OF DAMAGED PRIMER AND METALLIC COATINGS

(i) Damaged Primer Coats Scratched and slightly damaged areas of the primer coat shall be touched up to the satisfaction of the Superintendent, using an approved cleaning process and an approved two-pack epoxy zinc-rich coating to the minimum dry film thickness specified for the primer. Badly damaged areas of primer coat shall be abrasive blast cleaned and re-coated with the approved primer in accordance with the requirements for these processes. Damaged Metallic Coatings Scratched and slightly damaged areas of galvanised and electroplated coatings shall be touched up to the satisfaction of the Superintendent using an approved cleaning process and an approved two pack epoxy zinc-rich coating to the minimum coating thickness specified. Badly damaged galvanised and electroplated surfaces will not be accepted.

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