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TABLE OF CONTENTS

SECTION 001 GENERAL REQUIREMENTS

SECTION 002 EARTHWORK AND SURFACE RESTORATION

SECTION 003 CONCRETE AND REINFORCING STEEL

SECTION 004 MATERIALS

SECTION 005 LAYING AND JOINTING OF SEWERS

SECTION 006 SEWER TESTING

SECTION 007 BUILDING WORKS

SECTION 008 PROTECTIVE COATINGS TO METAL WORKS

SECTION 009 MECHANICAL WORKS

SECTION 010 ELECTRICAL WORKS

SECTION 011 DESIGN

SECTION 012 STRUCTURAL STEEL

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SECTION 001
GENERAL REQUIREMENTS

PART 1 - GENERAL

This Standard Specification has been prepared to cover sewerage construction

contracts.

The Instruction to Bidders, Bid Form, Contract Drawings and/or Performance

Specifications describes the extent of alternatives that may be used for each
Contract.

1.1 Scope of Work

The Contractor shall furnish plant, temporary works, labor, equipment and material
required to complete all Work in acceptable manner, including structures,
conveyance system and all ancillary work for complete in-place sewer
network/sewage treatment plant in accordance with the Contract Documents.

1.2 Rejection

Material or work that fails to conform to the requirements of the

Specifications/Contract Drawings shall be rejected, and the Engineer shall notify the
Contractor accordingly.

1.3 Marking

Each pipe, tubing, valve and fittings and all other products shall bear the following
markings as applicable:

 manufacturer’s name or trademark

 the letters “MAYNILAD”

 year of manufacture

 nominal diameter size

 pressure rating in bars or MPa and

 the reference standard such as AWWA or ISO, or both.

Fittings shall also be marked to indicate the true vertical axis.

All markings shall be of permanent nature.

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1.4 Packaging

All pipes, tubing, valves, fittings and all other products shall be packed in such a
manner as to prevent damage in ordinary handling and transportation. Each box,
bundle or crate shall be legibly marked identifying the contents, and giving the name
and address of the manufacturer, consignee, and the day of dispatch.

1.5 Transportation and Handling

When pipes, fittings or appurtenances could not be loaded or unloaded individually

by hand, they shall be lifted by means of a mechanical lifting equipment or other
suitable lifting devices. Slings, hooks or pipe tongs shall be applied at the correct
lifting points along the length of the pipe or fitting section and shall be suitably
padded in such a manner as to prevent damage to the coating or lining of the pipe or
fitting.

Pipes shall be stockpiled on timber cradles on level ground to prevent damage to any
part of the pipe and shall be placed in parallel rows, with bells and plain ends
alternated. The interior and all sealing surfaces of pipes, fittings and appurtenances
shall be kept free of dirt and foreign matter.

Plastic pipes and fittings, and rubber gaskets shall be stored in such a manner that
they shall be protected from excessive exposure to heat and direct sunlight.

Pipe products damaged during transportation, handling or stockpiling shall be

satisfactorily repaired or reworked to meet the specified requirements, or otherwise
replaced if the damage is serious or beyond the capability of repair.

1.6 Signages

A. General Sign

To inform the general public and the residents of a particular subdivision, village
or area that Maynilad project will be undertaken in their jurisdiction, the
Contractor shall furnish a signboard as required by Maynilad.

B. Street Signs

In addition to the general signboard, the Contractor shall also furnish signboard
containing the following information:

A MAYNILAD PROJECT BEING UNDERTAKEN

BY (NAME OF CONTRACTOR)

PROJECT : _________________________________

CONTRACT NO. : _________________________________

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DATE STARTED : _________________________________

EXPECTED DATE OF
COMPLETION : _________________________________

CONTRACTOR’S
ADDRESS AND
TELEPHONE NOS. : _________________________________

_________________________________
Signboards shall be displayed in every street where construction is in progress,
clearly visible to the public.

1.7 Traffic Maintenance and Management

Traffic maintenance and management shall be as required in each Contract

Documents.

1.8 Temporary Facilities

The Contractor shall within fourteen (14) calendar days after receipt of the award of
the Contract, submit to the Engineer for review a plan of the layout of his temporary
facilities. The plan shall include drawings showing the proposed locations and
arrangements of the Contractor’s temporary facilities.

The plan shall include at least the following:

A. Contractor’s offices, shops, storage areas, parking and first aid facilities;

B. Engineer’s field office and parking;

C. If proposed, camp and temporary housing; and

D. Disposal and stockpile area.

1.9 Removal of Temporary Facilities

Within thirty (30) calendar days following the issuance of Certificate of Completion,
the Contractor shall, with the Engineer’s approval, remove all temporary facilities.

1.10 Sanitary Precaution and Control

The Contractor shall employ the services of a licensed Sanitary Engineer to direct
and supervise all sanitary engineering work in accordance with the provisions of
Republic Act No. 1364 known as the Sanitary Engineering Law.

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The Contractor shall be responsible for, and shall exercise all sanitary precautions
and control at the jobsite to safeguard the public health and the living conditions of
his men. The sanitary regulations issued by the Engineer shall be strictly complied
with.

1.11 First aid Facilities

First-aid facilities are available at various hospitals and centers in the vicinity of the
works. The Contractor shall confirm that these facilities will be available, or shall
make alternative arrangements to ensure first-aid facilities available during all hours
that work is in progress, including maintenance of equipment.

Details of these arrangements shall be advised to the Engineer within fourteen (14)
calendar days after receipt of the award of the Contract.

The Contractor shall have available at a central location basic first-aid materials and
equipment adequate to treat minor injuries such as may be incurred in the execution
of the work of the Contract. Basic first-aid kit recommended by the manufacturer
shall be as suitable for a 40-man industrial work force.

1.12 Power and Lighting

The Contractor shall at his own cost provide all appurtenances and make all
necessary applications and arrangements and pay for all fees and charges for
electrical energy, for power and light necessary for the execution of the work. There
shall be sufficient electric lighting so that all work may be done in workmanlike
manner when there is no sufficient daylight or during night work.

1.13 Engineer’s Field Office, Equipment and Services

The Contractor shall provide field office, equipment and services for the use of the
Engineer in the administration of the Contract. Requirements shall be as specified in
the Contract Documents.

1.14 As-Built Drawings

The Contractor shall prepare “As-Built” Drawings for all construction work. The “As-
Built Drawing” shall be drawn to the same scale as the Contract Drawings. The “As-
Built” Drawings shall be submitted both as the work progresses and again after
completion of the Work. As-built drawings shall show elbows, tees (in pump stations)
or other changes in sewer network direction, valve boxes, manholes, interceptor
boxes, pipe size and type. All features shall be shown with survey tie-ins to fix above
ground points on permanent structures.

The following data/drawings shall be specified in the “As-Built” drawings for sewer
network or as required in the Performance Specifications:

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1. Vicinity or location map showing the correct northing

2. Plans
 Northing
 Scale (if applicable)
 Call-outs (for details, tie-ins, etc.)

3. Pipes data that includes:

 Material
 Diameter
 Length
 Brand/Supplier
 Date installed

4. Appurtenances data that includes:

 Type (check valve, butterfly valve, etc.)
 Brand and Supplier

5. Road cross sections (whenever there are changes on road width) showing:
 Road dimensions, centerline
 Underground utilities (i.e. pipes, PLDT, etc.)
 Pipe location, depth and distance (from curb and gutter, edge of road or
whatever is applicable)
 Pavement type (at the time of installation)

PART 2 - PIPE MATERIAL AND DESIGN

2.1 SEWER PIPELINES

2.1.1 Pipe Material Selection Factors

The following considerations are the important factors to be considered before

selecting or approving any pipe material and pipeline system for sewer networks:

a.) Resistance to acidic condition of which is prevalent in sewer networks in

tropical climates.
b.) Resistance to sulphate attack from aggressive soils and groundwater.
c.) Resistance to corrosion in contaminated soils.
d.) Resistance to severe abrasion from sewage flow and usual cleaning
methods.
e.) Resistance to groundwater entry (infiltration) and sewage escape
(exfiltration) through joints.
f.) Resistance of the joint material to corrosion and microbiological
degradation.
g.) Structural damages and other damages that may occur during handling.
h.) Handling lying and jointing care difficulties.

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i.) Methods of pipe embedment to ensure good structural performance.

j.) Maintenance of structural strength and performance in service.
k.) Methods of maintenance and repair.
l.) Cost of supply, transportation and installation.
m.) Range and suitability of fittings for smaller diameter sewers.
n.) Previous local experience.
o.) Local availability.
p.) Pipe pressure ratings.
q.) The design life of the pipe shall be at least 50 years.
r.) All bolts and nuts shall be stainless steel (SS) 304
s.) Where necessary, special tools and trained personnel shall be made
available during the handling and installation of pipes.

Additionally, the following factors should be considered before selecting or

approving any pipe manufacturer or supplier.

a.) Compliance of products to standards.

b.) Compliance to additional material and product requirements specified by
Maynilad.
c.) Quality control and assurance practice by the manufacturer and supplier to
ensure good pipe product quality from manufacturing to delivery.

2.1.2 Pipe Selections

Except where otherwise specifically approved by Maynilad, the pipe materials to be

used for a specific type of sewer are listed below:

1.) Gravity Sewers

a.) Rigid Pipes
i.) Reinforced Concrete (RC)

b.) Flexible Pipes

i.) Polyvinyl Chloride (PVC)
ii.) Ductile Iron (DI)
iii.) High Density Polyethylene (HDPE)

2.) Force Mains (Rising Mains)

i.) Polyvinyl Chloride (PVC)

ii.) Ductile Iron
iii.) Acrylonitrile Butadiene Styrene (ABS)
iv.) High Density Polyethylene (HDPE - Solid)
v.) Steel

There are specific requirements such as pipe class, joint type, lining etc. which the
above approved pipe materials must meet in order to suit the above applications.

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Also, there are certain limitations for the use of each pipe type. These requirements
and limitations are specified in the following sections.

The selection and use of sewer pipe material shall be specified by Maynilad or as
indicated in the Contract Documents.

For other pipe materials not listed above, their use will be given consideration in
special circumstances. However, only pipes and fittings from manufacturers and
suppliers approved by Maynilad are permitted to be used for sewerage applications.

2.1.3 Requirements and Limitations for used of Certain Pipe Material

Unless otherwise granted by Maynilad, the limitations or requirements shall be

followed when selecting the pipe material:

I.) Gravity Sewer

a.) RC
i). Pipe sizes shall be as specified in the Contract Drawings.
ii). Flexible joints are recommended or as specified in the drawings.

b.) Polyvinyl Chloride (PVC)

i). Pipe sizes shall be as specified in the Contract Drawings.
ii). Pipe shall be elastomeric ring seal or solvent cement sockets and
spigots as specified in the applicable standards.

c.) Ductile Iron (DI)

i.) The use is only allowed for applications where high pipe strength is
needed.
ii.) Pipe protection linings and coatings are required.
iii). Polyethylene sleeving is required for all buried applications.

d) High Density Polyethylene (HDPE)

i). Pipe shall not be used in ground contaminated with high concentration
of chemicals such as solvent that can degrade the pipe.
ii). Pipe shall not accept any industrial or other aggressive discharges that
may affect the pipe integrity
iii). Only pipe with profile wall is permitted.

II.) Force Mains

a.) Polyvinyl Chloride (PVC)

i.) Pipe sizes shall be as specified in the Contract Drawings.
ii) Pipe shall be elastomeric ring seal or solvent cement sockets and
spigots as specified in the applicable standards.

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b) Ductile Iron (DI)

i). Pipe shall not be used in unstable ground.
ii). Pipe protection linings and coatings are required.
iii). Polyethylene sleeving is required for all buried applications.
iv). Flexible joints are recommended.

c) Acrylonitrile Butadiene Styrene (ABS)

i). Where Reinforced Concrete pipes are not suitable.
ii). Only for nominated projects or as specified in the Contract Drawings.

d) High Density Polyethylene (HDPE)

i). Pipe shall not be used in ground contaminated with high concentration
of chemicals such as solvent that can degrade the pipe.
ii). Pipe shall not accept any industrial or aggressive discharges that may
affect the pipe integrity.

e) Steel
i). Pipe is allowed only for sizes 700 mm or above.
ii). Pipe protection linings and coatings are required.

2.1.4 Sewer Design-General Requirements

The design of a sewage system shall generally be in accordance with the principles
set out in this Specification.

The sewerage system shall be suitably designed to carry all sewage flows including
sullage to the approved disposal point. Unauthorized connections of surface waters
or excessive infiltration to the sewerage system are not permitted.

Unless otherwise approved by Maynilad, all sewers shall be sited in public road
reserve so that access can be gained for maintenance purposes. Under special
circumstances where the sewer cannot be sited in public road reserve, then
vehicular access for the sewer line of at least 3 m in width and road bearing
capacity of not less than 5 tons shall be provided.

Sewer pipes should not be constructed on slope or within slope failure envelope. In
the event where it is unavoidable, the said structures must be designed not to
encounter settlement or the sorts and at any time at risk of collapse during its
operating lifespan.

An overflow pipe shall be provided at the last manhole before network pump station
and/or sewage treatment plant. Otherwise it should be located at the manhole sited
at the lowest ground level.

2.1.5 Flow Rate Estimations

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Few principal considerations when selecting the diameter and gradient of a sewer
are:

a) to cater for peak flow

b) to ensure that there will be a sufficient velocity during each day to sufficiently
cleanse the sewer of slime and sediment
c) to limit the velocity to avoid scouring of sewers

I) Average Flow

The volume of sewage that needs to be treated per day is based on

an assumed contribution per population equivalent of 130 liters from
various types of premises where the contribution from each premise
type is defined in terms of a population equivalent.

II) Peak Flow

The flow used to determine the diameter and gradient of the pipeline
is the peak flow. Peak flow is the most severe flow that could occur
on any day when considering daily flow fluctuations and infiltrations.
The peak flow is derived from the average flow by applying a peak
factor for daily flow fluctuations. The peak factor shall be estimated
from the following formula:

Peak Factor = 4.7 (PE/1000)-0.11

Where PE = assumed population equivalent

III) Infiltration

Infiltration is the amount of groundwater that enters sewers through

damage in the network such as cracked pipes, leaked joint seals and
manhole walls, etc. There are many variables affecting infiltration
such as quality of workmanship, joint types, pipe materials, height of
water table above pipeline, soil type, etc. The peak factor above has
included the contribution of infiltrations. The maximum allowable
infiltration rate shall be 50 liters / (mm diameter. km of sewer length.
day).

2.1.6 Sewer Cleansing Velocities

The principal accumulants in sewers are slimes and sediments. The hydraulic
requirements for cleansing the sediments of a sewer differ from those required for
cleansing the slimes of a sewer.

I) Sediment Cleansing

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For the removal of sediments, the traditional design approach has been to
set a minimum velocity to be achieved at least once daily.

Minimum velocity values at full bore of 0.8 m/s are commonly specified.
However, it has been found that larger pipe diameters require higher
velocity to cleanse the sediment. This is mainly due to higher sediment
depths in large diameter pipes.

The movement of sediment is mainly a function of shearing stress needed

to dislodge sediment off the pipe wall. Similarly, shear stress is a function of
pipe diameter. The type of sediment (i.e. grain size, specific gravity,
cohesiveness) also influences the movement of sediment and, thus, the
amount of required shear stress. For design purposes however, only a
single sediment type needs to be assumed.

II) Slime Cleansing

The removal of slime depends on the stress needed to shear sections of

slime from each other or from the pipe wall. However, the shear stress
required to remove slimes is not a function of pipe diameter. The necessary
shear stress depends on the thickness of slime to be removed and the pipe
material. The degree of removal of slimes in any pipe material varies with
the sewage velocity.

Removal of large portion of slimes requires high sewage velocities. It has

been found that 85% or more of the sulphide producing slimes are removed
when the grade of the sewer is 2.5 times of that for sediment cleansing. In
many instances, it may not be practical to design a sewer to achieve such
velocities due to the excessive cost of constructing such a deep and steep
sewer. Although increasing the velocity up to the critical velocity will
increase the amount of slime being sloughed off, the rate of sulphide
production remains substantially unaffected by the thinner slime layer.
Therefore, the selection of steep gradient to achieve velocities for full slime
stripping is not a design requirement.

2.1.7 Pipe Roughness

Except for very high velocities, slime will always be present, which will increase the
pipe roughness. Abrasion by sediments will also impart a permanent increase in
roughness. Pipeline roughness decreases as the velocity increases. However,
there is insufficient data to accurately determine the pipeline roughness for a wide
range of velocities or at small incremental changes in velocity. In addition, the
velocity of the sewage flow varies due to the factors such as daily fluctuations,
different type of catchment, different stage of catchment maturity, etc. Therefore, it
is not possible to select the pipe roughness with great accuracy.

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Conservative roughness values as given in Table 2.1 shall be referred to when

determining sewer discharge capacity.

Table 2.1a Normal Pipe Roughness for Gravity Sewer

Roughness, ks (mm)
Pipe Material
New Old
Concrete: 0.15 3.0
Plastic 0.06 0.6

Old and new roughness values shall be used to determine the sewer cleansing and
maximum design velocities respectively.

Table 2.1a Normal Pipe Roughness for Force Mains for All Pipe Materials

Mean Velocity, V (m/s) Roughness, ks (mm)

0.8 ≤ V < 1.5 0.6
1.5 ≤ V < 2.0 0.3
V ≤ 2.0 0.15

2.1.8 Design of Gravity Sewer

Unless special arrangements have been agreed for the structural protection of
pipes, the minimum depth of soil cover over the sewer shall be 1.2 m. Sewers are
not to be constructed under buildings.

The minimum size of public gravity sewers shall be 200 mm in diameter. The
minimum size of domestic connections to the public sewer shall be 150 mm in
diameter. The maximum design velocity at peak flow shall not be more than 3.0
m/s.

The design shall be based on the worst case scenario. The selection of the gravity
sewer diameter and gradient to cope with the peak flow shall be based on the
following equations:

1. Colebrook – White Equation

where:

V = velocity
S = hydraulic gradient (m/m)
v = kinematic viscosity of water (m2/s)
D = internal diameter (m)

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g = acceleration due to gravity (m/s2)

k1 = roughness coefficient (m)

Typical ks values for various types of sewer pipes are presented in Table 2.2 below:

Table 2.2 Typical Roughness Coefficient, ks

Material Roughness Coefficient, ks (mm)

Concrete 0.3 to 3
Cast iron 0.26
Asphalted cast iron 0.12
Ductile iron 0.046

2. Manning Equation

where:

V = velocity (m/sec)
S = hydraulic gradient
R = hydraulic radius
n = Manning coefficient

Typical n values for various types of sewer pipes are presented in Table 2.3 below:

Table 2.3 Typical Manning Coefficient, n

Manning Coefficient, n
Material
Good Condition Bad Condition
Uncoated cast-iron 0.012 0.015
Coated cast iron 0.011 0.013
Ductile iron 0.012 0.015
Concrete 0.012 0.016

3. Hazen – Williams Equation

V = 0.849 C R0.63 S0.54

where:

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V = velocity (m/sec)
S = hydraulic gradient
R = hydraulic radius
n = Hazen – Williams coefficient

Typical C values for various types of sewer pipes are presented in Table 2.4 below:

Table 2.4 Typical Hazen-Williams Coefficient, C

Material Hazen-Williams Coefficient, C

Top quality pipes, straight and smooth 130 to 140
Smooth masonry 120
Old cast iron 100
Old cast iron in bad condition 60 to 80

Colebrook-White Equation has been deemed to give the most accurate results.
However, the other equations, such as Hazen-Williams Equation and Manning
Equation are easier to use and may be used too. Various design charts and tables
have been developed elsewhere to aid the manual computations.

2.1.9 Design of Force Mains

The minimum diameter of force mains (also known as rising mains) shall be 100
mm diameter. There shall be no reduction in force main diameter with distance
downstream.

All bends on force mains shall be securely anchored to resist lateral thrusts and
subsequent joint movements.

Air release valves and washouts shall be provided at appropriate locations along
the longitudinal profile.

For long and undulating force mains, hydraulic pressure transient analyses may be
required to ensure that the force main can cope with water hammer pressures.

Retention times in force mains must not exceed 2 hours without special precautions
to mitigate septicity.

All force mains shall be designed to withstand at least 1.5 times the working
pressure. Approval from Maynilad in required if any force main is to be designed to
withstand pressure less than the pressure stated above.

Where retention times in the force mains exceed two hours and where concrete
pipes are laid downstream of the force mains, an induct vent shall be provided at
manholes receiving pumping discharges.
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Friction losses are normally calculated using either Darcy-Weisbach (Colebrook-

White) Equation or Hazen-Williams Equation. The forms of the equations are
different from the forms used to design gravity sewers. The equations are listed
below:

1. Darcy-Weisbach Equation

where:

hf = Friction loss
f = Coefficient of friction
V = Velocity in the pipe
g = Acceleration due to gravity
D = Equivalent diameter of the pipe
L = Length of pipe

The value of f is known to depend on the Reynolds number, Re, pipe roughness, k s,
and pipe diameter, D, through the Colebrook-White equation as follows:

The Reynolds number is defined as follows:

where v is the kinematic viscosity of the fluid, typically equal to 1 x 10 -6 m2/s for
sewage.

The above equations together with the Moody Diagram are used to determine the
coefficient of friction, f.

2. Hazen-Williams Equation

where:

hf = Friction loss

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C = Hazen-Williams Coefficient (refer to table 2.4)

V = Velocity in the pipe
L = Length of pipe
D = Equivalent diameter of the pipe

Force mains shall be designed to handle the full range of flows from present
minimum to future peak.

The design velocity shall fall within the range of 0.8 to 3.0m/sec over the range of
design flows.

The hydraulic resistance of force main fittings and bends shall be included in the
hydraulic design.

2.1.10 Structural Design of Sewers

The structural design of a buried sewer can be divided into the following two
categories:

a) Rigid pipe
b) Flexible pipe

All two structural designs shall take account of how the sewer is supported to
determine the loading which the sewer can safely withstand.

The structural design of a buried sewer normally considers only the structural
integrity of the pipe cross section. Although not as critical as the structural integrity
of the pipe cross section, the considerations for this frictional support of soil column
causes the load on the flexible pipe to be less than the weight of soil directly above
the pipe. This frictional support may be lost with time and the design using prism
load represents a conservative design.

Where vehicles will pass over the sewer and the sewer is laid with a cover depth of
less than 2.5 m, the pipe will be subjected to additional loads from such vehicles.
The Boussinesq Theory should be used to determine the loads from vehicles in the
design approach in this standard.

The ultimate vehicle load to which the pipe will be subjected to shall be used for
structural design. Where the pipeline may be subjected to construction traffic or
have a temporary shallow cover during installations, structural design must examine
such loading conditions to ensure the pipe can withstand such temporary vehicle
loadings.

The structural design of flexible pipe support must be in accordance with the
modified form of Spangler’s equation for the determination of pipe deflection. This

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Spangler equation incorporates Leonhardt’s factor to account for the change in

support provided by surrounding soil stiffness when the trench width is varied.

For force mains with shallow cover, structural design of flexible pipes may not be
necessary. However, when the structural design of flexible pipe for such a force
main is undertaken, the re-rounding effect of internal pressure should be ignored to
allow for the worst case design, which occurs when the line is out of service.

2.2 MANHOLE

2.2.1 General

Pre-cast concrete manholes shall conform to ASTM C76 Class IV Wall C. Manholes
shall be constructed with pre-cast concrete sections surrounded by an in-situ
concrete surround. Internal surface of manhole exposed to hydrogen sulfide gas
attack or chemical reaction shall be coated with epoxy suitable for corrosion
protection. Only materials and application processes approved by Maynilad may be
used.

Brick manholes shall not be used, due to the high risk of excessive infiltration.

Details of manhole types and construction are shown in Contract/Standard

Drawings. Straight back type taper top shall be used while reducing slabs type is
acceptable as alternative. Any other type of pre-fabricated manhole will require the
approval of Maynilad.

An induct vent shall be provided at manholes receiving pumping discharges where

retention times in the force mains exceed two hours and where concrete pipes are
laid downstream of the force mains. The induct vent shall have a diameter of
approximately one half of the force mains but shall not exceed 300 mm in diameter.
The top of the concrete support of the vent shall be built up above flood level.

Provision of drop manhole shall be as specified in the Contract Drawings.

2.2.2 Manhole Location

Unless otherwise approved by Maynilad, all manholes shall be sited in public road
reserves so that access can be gained for maintenance purposes. Manhole shall be
provided for the following locations:

a) The starting end of all gravity sewers, this may be replaced by a terminal layout.
b) Every change in direction or alignment for sewers less than 600 mm in diameter.
c) Every change in gradient
d) Every junction of two or more sewers
e) Every change in size of sewer

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Unless adequate modern cleaning equipment is used for the maintenance of the
sewer, the spacing between manholes shall not be more than 100 m for sewers less
than 1.0 m in diameter. For sewers with diameter larger than 1.0 m, the spacing
between manholes shall not be more than 150 m.

Where site conditions prevent manhole construction on the existing public sewer, a
manhole shall be provided on the connection pipe as near to the public sewer as
possible.

The connections, details, and methods of manhole construction shall be in

accordance with the Contract /Standard Drawings.

2.2.3 Pipe Lengths from Manhole

To prevent the differential settling of the manhole and the connecting sewer from
breaking the sewer pipe, rotational flexibility in the sewer close to the manhole is
required. A single flexible joint placed immediately outside the entry to the manhole
is not sufficient to solve the differential settlement problem, unless graded
(governed by gradient permissible range) to connect directly to match invert level of
manhole channel, if unable to match invert level. A short length of “rocker pipe”
having a flexible joint at both ends shall be provided. A 600 mm length short “rocker
pipe” is sufficient to provide the rotational flexibility required for most circumstances
in small diameter pipelines (≤300mm). For larger pipe, a 900 mm length short
“rocker pipe” shall be provided. Refer to Contract Drawings/Standard Drawings.

2.2.4 Structural Design Considerations for Manhole

a) Concrete used in situ shall be 25 MPa Portland cement unless otherwise

specified in the Contract Drawings.
b) Cement blinding with a minimum of 50 mm thickness shall be placed before
pouring the concrete manhole base.
c) The base of the manhole shall not be less than 300 mm thickness, which is
measured from the channel invert or as specified in the Contract Drawings.
d) Channel inverts shall be laid accurately to meet entry and exit pipe inverts.
e) The channel invert shall be graded evenly between the entry and exit pipes.
f) Flexible joints shall be provided at the exit and entry of the manholes and shall
be placed immediately outside any poured-in-situ concrete surround.
g) Joints between the pre-cast chamber rings shall be sealed with suitable mortar,
which can be high alumina cement mortar or equivalent.
h) The top of the benching shall be sloped at 1 in 12 towards the channel.
i) The finish surfaces of cast in-situ concrete structures shall be toweled smooth
without poke holes or exposed aggregate.

2.3 DESIGN OF NETWORK PUMP STATIONS

2.3.1 Specifying of Network Pump Stations

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Network pump stations shall be provided only where:

i.) Sewage flow by gravity is not allowed by the topography.

ii.) Excessively deep and expensive excavation for sewer installations will be
required.
iii.) Sewage needs to be delivered from an area that is outside the natural
drainage catchment of a sewage treatment plant.

2.3.2 General Requirements

i.) Network pump stations shall be preceded by screens to protect pumps from
being drained or clogged.
ii.) The type of pump used must be suitable for sewage application. Water pumps
must not be used as they are not designed to transfer sewage.
iii.) Drainage of dry wells and valve pits shall be provided. Drainage lines shall be
equipped with back flow protection to ensure that the chamber is not flooded.
iv.) Wherever possible, the wet-well shall not be housed within building structure
with insufficient ventilation.
v.) Where separate valve pits are used, the connecting pipes shall incorporate at
least two flexible joints to allow for differential settlement.
vi.) The designer shall ensure that his designs comply with all relevant legislation,
standards, guidelines and requirements, and their latest amendments.
vii.) Access and appropriate parking shall be provided at all times for emergency
vehicles, maintenance vehicles and ancillary equipment.
viii.) Adequate protection against lightning shall be provided.

2.3.3 Buffer Requirements

In order to minimize the nuisance of odors from pumping stations, buffer zones shall
be provided at all sides. The zone shall be at least 20 m from the pumping station
fence to the nearest habitable building fence. The presence of a pumping station in
any development may draw negative visual impacts. To minimize the visual impact
of surface structures of the pumping station, landscaping shall be provided.
Landscaping shall comprise of trees that are non-shedding to minimize
maintenance.

Under conditions where there exists the potential of odor nuisance to the nearest
habitable building property line within residential and commercial development
despite having minimum buffer zone, such odor shall be minimized to the lowest
possible level and in compliance with the Environmental Quality Act.

2.3.4 Pipeworks Requirements

i.) Pipeworks shall be of ductile iron with approved internal lining. Other approved
material by Maynilad may be used.
ii.) External surface of pipeworks in chambers and wells shall be epoxy coated.
iii.) Buried ductile iron pipe shall have polyethylene sleeving.

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iv.) Pipeworks shall be adequately supported.

v.) Flanges shall be located at least 150 mm away from structures.
vi.) Dismantling joints such as bends shall be provided.
vii.) Pumping thrust shall be resisted using pipe supports.
viii.) All internal pipeworks within the pump station shall have flanged joints unless
the pipe selected has special jointing requirements.
ix.) Flexible coupling should be used where they will facilitate dismantling and
accommodate vibration.

2.3.5 Wet-well Requirements

i.) Suction channels shall be designed to avoid “dead zones”, i.e. prevent solids
and scum accumulation.
ii.) Minimum hopper bottom slope shall be 1.5 vertical to 1.0 horizontal.
iii.) Automatic flushing of grit and solids is required for plants of PE > 2000.
iv.) The difference between stop and start levels shall be a maximum of 900 mm
and a minimum of 450 mm.
v.) The difference in level between start and stop of duty and assist pumps shall
be greater than or equal to 150 mm.
vi.) Benching shall be designed to minimize deposition of solid matter on the floor
or walls of wet-wells. The minimum slope of benching shall be 45° to the
horizontal.
vii.) Benching shall preferably extend up to the pump intake.
viii.) Self-cleansing pumps shall be provided.
ix.) Access into wet-wells can be by vertical rung ladders with a maximum height
of 6 m. When the height exceeds 6 m, intermediate platforms shall be
provided, with a change of direction of the ladder. Safety cages shall be
provided for ladders exceeding 6 m.
x.) Access covers shall have a minimum clear opening of 600 m diameter and be
sufficiently large to withdraw pumps vertically.
xi.) Access covers shall be capable of being lifted by, at most two operators.
xii.) On small pump stations (PE < 500), the practice is to provide difference
between the cut-in and cut-out levels, the storage volume equal to 2 to 3 times
the peak flow into the wet-well in liters per minute merely to protect the starting
equipment from overheating and failure caused by too frequent starting and
stopping.
xiii.) Emergency bypass shall be provided either at any suitable manhole or wet-
well. The discharge of the bypass is preferred to the nearest watercourse and
not to the perimeter drain of the pumping station. However, if this is not
available, then discharge to the nearest surface drain is allowed.
xiv.) All wet-wells shall be opened and shall come with stainless steel or other non-
corrosive handrails. If stainless steel tubing is used, it shall be in-filled with
concrete.

2.3.6 Dry-well Requirements

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i.) The size of a dry-well depends primarily on the number and type of pumps
selected and on the piping arrangement.
ii.) The requirement of pump installation is to provide at least 1.0 m from each of
the outboard pumps to the nearest side wall and at least 1.2 m between each
pump discharge casing.
iii.) Sufficient room is required between pumps to move the pump off its base with
sufficient clearance left in between the suction and discharge piping for site
repairs, inspection or removal from the pit to the surface for repairs.
iv.) Consideration should be given to the installation of monorails, lifting eyes in
the ceiling and A-frames for the attachment of portable hoist cranes and other
devices.
v.) Provision should also be made for drainage of the dry-well to the wet-well.

2.3.7 Structural Requirements

i.) Substructure shall be constructed of reinforced concrete with sulphate

resistant cement to resist aggressive soils and groundwater.
ii.) Below ground walls shall be waterproofed and protected against aggressive
soils and groundwater.
iii.) Safe and suitable access to the wells shall be provided.
iv.) Internal walls shall be made resistant to sulphate corrosion by coating with
high alumina cement or equivalent coatings.
v.) A penstock shall be installed upstream of the wet-well to isolate the pump
station.
vi.) For safety and operational reasons, a double penstock system may be
required at specific plant.
vii.) The penstock spindle shall extend to pump station ground level and shall be
suitably positioned to allow unrestricted operation of the penstock.
viii.) Access platforms shall be provided at all locations where dismantling work
takes place.
ix.) Access covers shall be hinged with a lifting weight not exceeding 16 kg.
x.) Internal walls shall be made resistant to sulphide corrosion by coating with
high alumina cement mortar lining, PVC lining or epoxy coating. Other
materials used under special circumstances are subjected to approval from
Maynilad.
xi.) Penstock greater than 610 mm x 610 mm shall be made motorized and come
with manual overwrite switches. The actuator shall be located above ground
level and above flood level for easy access in the event of flooding.
xii.) Protection against falling shall be provided by means of handrails at walkways
and other working areas, where the fall equals or exceeds 1.5 m.
xiii.) Edge protection by means of kick plates of at least 50 mm in height shall be
provided, where the drop equals or exceeds 2.0 m.
xiv.) Proper drainage shall be provided at the collection bin area to ensure that
liquid collected could be channeled back to the pump sump.

2.3.8 Ventilation Requirements

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i.) Ventilation shall be provided for all hazardous zones of the pump station.
ii.) Cover pits shall have mechanical ventilation.
iii.) Separate ventilation shall be provided for wet-wells and dry-wells.
iv.) Lighting systems shall be interconnected with ventilation.
v.) uPVC pipe is not permitted to be used as ventilation ducting between wet-well
and dry-well.

2.3.9 Odor Control

i.) The potential for odor generation, its impact and treatment, shall be
considered in all aspects of design.
ii.) Isolate odorous gasses from general ventilation exhausts by containing
identified odor generating sources with a separate local exhaust system.
iii.) Containment of the odor sources shall be by installing lightweight and
corrosion resistant covers/enclosures designed for practical operation and
maintenance works.
iv.) The local exhaust odorous air shall be conveyed through well designed and
balanced ductworks by a centrifugal fan to an effective odor treatment
equipment.

2.3.10 Requirements for Lighting and Electrical Fittings

i.) Wet-wells and dry-wells shall be adequately lit.

ii.) Electrical installations shall be waterproof, vapor proof and explosion proof.
iii.) If lights are fitted outside the well, then a spotlight system may be used to
provide adequate illumination.
iv.) If portable lighting is used, proper ancillaries shall be made available.
v.) Equipment shall be sited above the highest water level.

2.3.11 Acceptable Pump system (Fixed Speed Pumps Only)

The acceptable pump types are:

i.) Centrifugal
ii.) Screw
iii.) Screw Centrifugal

Pumps are to be equipped with an auto restart mechanism to allow for automatic
pump restart after power supply has resumed from a power failure. Pumps shall be
equipped with protection accessory, e.g. thermal sensor, leakage sensor, etc. Dry-
well mounted pumps shall be equipped with auxiliary services such as cooling and
gland seal water supply.

Guide rail, lifting device and other wet-well fittings must be fabricated of stainless
steel that is corrosion resistant. The use of hot dip galvanized iron is not
recommended.

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Pre-fabricated pump stations are acceptable for small installations of PE less than
or equal to 2000.

2.3.12 Requirements for Level Controls

i.) Floats, electrodes or ultrasonic level controls may be used for stop level of
pumps. Those level controls with environment friendly features are
recommended.
ii.) Ultrasonic level control is recommended due to its clog-free nature
iii.) Non-mercury type floats are recommended.
iv.) Hollow tube electrodes are not acceptable.
v.) Level controls shall be placed where they are not affected by the turbulence of
incoming flow and where they can be safely removed.
vi.) When floats are used, cable hanger shall be installed.

2.3.13 Requirements for Alarms

i.) Provision of alarms shall be considered inclusive of flammable gas, fire, high
water level, bearing temperature, motor temperature, pump temperature,
pump failure, power failure and vandalism.
ii.) An alarm system should have an emergency power source capable operating
for at least 24 hours in the event of the failure of the main power supply and
shall be telemetered thereto.
iii.) Where no such facility exists, an audio-visual device shall be installed at the
station for an external observation.

2.3.14 Requirements of Hydraulic Design and Performance

The following items shall be provided:

i.) System curves

ii.) Pump curves
iii.) Operating point of pumps with respect to flow and total dynamic head (TDH).
iv.) Operating characteristics such as efficiency, horsepower, motor rating and Net
Positive Suction head (NPSH).

2.3.15 Maintenance Considerations

i.) Mechanical and electrical equipment selected shall be robust and reliable and
shall require minimal maintenance.
ii.) Consideration should also be given to the availability of spare parts.
iii.) The provision of appropriate lifting hoists and beams, and lifting eyes or similar
features on heavy equipment, shall be considered.
iv.) Complete sets of current general arrangement and sectional drawings,
operational, maintenance and service manuals, circuit diagrams and parts lists
shall be supplied and be available at all times.

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2.3.16 Hazard and Operability (HAZOP)

i.) All pumping station designs shall give consideration to all potential hazards
and operability of design.
ii.) HAZOP study may need to be conducted for pumping station design to identify
the hazard and operability issues.
iii.) The need for HAZOP study shall comply with the requirements stipulated in
the Performance Specifications.

**END OF SECTION**

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SECTION 002
EARTHWORK AND SURFACE RESTORATION

PART 1 – GENERAL

1.1 Scope of Work

The WORK includes the guidelines for miscellaneous earthwork from clearing and
grubbing, test pitting, excavation to surface restoration.

1.2 Related Sections

Not used

1.3 Specifications and Standards

Except as otherwise indicated, the current editions of the following Standards (or
equivalent International Standards) shall apply to the WORK of this Section:

ASTM C31 Making and Curing Concrete Test Specimens

in the Field

ASTM C39 Compressive Strength of Cylindrical Concrete

Specimens

ASTM C42 Obtaining and Testing Drilled Cores and

Sawed Beams of Concrete

ASTM C94 Ready-Mixed Concrete

ASTM C150 Portland Cement

ASTM D698 Laboratory Compaction Characteristics of Soil

Using Standard Effort

ASTM D1241 Materials for Soil-Aggregate Subbase, Base

and Surface Courses

ASTM D1556 Density and Unit Weight of Soil in Place by the

Sand-Cone Method

ASTM D1557 Laboratory Compaction Characteristics of Soil

Using Modified Effort

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ACI 318 Building Code Requirements for Reinforced

Concrete

DPWH Standard Specifications Volume II - Highways, Bridges and Airports

1.4 Submittals

The Contractor shall submit the following:

A. Contract drawings/ plans showing the type of sheeting and bracing for
excavations.

B. Name and designation of experienced blaster/s licensed by the Philippine National

Police and all personnel who will handle explosives or work in areas where
explosives shall be used.

C. Samples of materials (gravel, excavated materials, concrete, etc.) as required by

the applicable Reference Standards.

1.5 Quality Assurance

The Contractor/Supplier shall be responsible for the performance of all tests and
inspection required by this Standard Specification. The Contractor shall furnish the
Engineer copies of test records certified by an independent laboratory indicating that
samples representing a particular batch have been tested and have complied with all
applicable requirements of this Standard. The Contractor shall, at his own expense,
replace all rejected materials for failure to comply with this Specification. However, the
Engineer reserves the right to perform any or all prescribed tests and inspection
where such is deemed necessary to ensure that delivered materials conform to the
specifications.

PART 2 – PRODUCTS

NOT USED

PART 3 - EXECUTION

3.1 GENERAL

3.1.1 Clearing and Grubbing

The pipeline route shall be cleared and grubbed prior to performing any excavation or
placing any fill.

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Clearing and grubbing refer to brush, roots, stumps, vegetation, pavement, sidewalks and
surface obstruction of any kind that are required to be temporarily or permanently removed
and that lie within the actual areas to be excavated.

No trees shall be felled, destroyed, or interfered with by the Contractor without the approval
of the Engineer.

Except for those materials or structures that are to be temporarily removed and later
restored to their original state, all debris, refuse, vegetation, and demolished materials shall
be entirely removed from the site and disposed of by the Contractor in a satisfactory
manner.

Materials and structures temporarily removed for later reinstatement and restoration shall
be properly stored and protected.

3.1.2 Removal and Disposal of Water

The Contractor shall provide and maintain the means and equipment for dewatering and
properly disposing the water entering the excavation and other parts of the Work. All
excavations shall be maintained in a dry condition and no foundation material, pipe or
concrete shall be placed in water except with the approval of the Engineer. Water shall be
disposed of in a manner satisfactory to the Engineer, to avoid damage to property and
inconvenience to the public. If the Contractor elects to provide underdrains, these shall be
subject to the Engineer’s approval.

All dewatering of trenches and other excavations shall be done in a manner that will protect
adjacent structures, utilities, and roadways against settlement or other damage. Any
accident or damage occurring from dewatering shall be the sole responsibility of the
Contractor. Any review by the Engineer of the procedures, designs, or activities for the
purpose of dewatering shall not relieve the Contractor of his responsibility for any injury,
death, or damage resulting from the use of the said procedures, designs, or activities.

3.1.3 Diverting Sewage

During the construction of the works and until their completion, the Contractor shall execute
all works required to prevent injury to private property or to existing or new works by
sewage and/or septic tank effluent and arrange for its diversion to the satisfaction of
MAYNILAD.

3.1.4 Test Pitting

Test pitting, as indicated in the plan or as ordered by the Engineer, shall be conducted right
after the issuance of the Notice to Proceed (NTP), and shall be backfilled and restored
within 48 hours from excavation.

Test pits subject to future re-excavation shall be restored with asphalt, whereas test pits,
which will not be subjected to re-excavation, shall be restored with the same type as the
existing pavement.
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Failure of the Contractor to backfill and/or temporarily restore the said test pits will compel
the Engineer to undertake the remaining works and backcharge the costs to the Contractor.

3.2 SURFACE AND TRENCH EXCAVATION

3.2.1 General

Prior to excavation, the Contractor shall remove all surface materials and properly store,
guard and preserve such quantities as may be required for restoration of disturbed areas.
All surfaces disturbed by the Contractor in the course of excavation and in other work areas
shall be restored to their original state, or better. Following the restoration, the Contractor
shall check monthly any depression that may occur along the line of restoration due to
settlement which shall be brought to final grade at no additional cost to MAYNILAD.

Excavation shall include the removal of all materials of whatever nature encountered that
would interfere with the proper execution and completion of the Work.

The removal of the said materials shall conform to the lines and grades shown on the
standard or contract drawings.

Rock and other excavated materials that are classified by the Engineer as unsuitable for
backfill shall be removed from the site.

The Contractor shall supply, install and maintain work area, shoring system, sloping of the
excavation, sheeting, bracing or other methods on the walls and faces of all excavations on
unstable ground as maybe necessary to protect the workers and to prevent any movement
of earth which could cause injury, delay of work or danger to adjacent structures.

3.2.2 Landscaped Areas

In existing landscaped areas, the Contractor shall properly store, protect and preserve all
parts of the landscape affected by the installation of pipelines, for later restoration of the
areas.

Should the landscaping or any portion of it be damaged and could no longer be restored,
the Contractor shall supply and install an acceptable replacement.

3.2.3 Grassed Areas

Topsoil or loam shall be piled separately from other excavated materials, and later restored
in place to a compacted depth equal to the original condition.
Where grass areas will be cut by trench excavation or will be damaged by equipment, the
sod shall be removed and preserved during construction operations, and re-laid after
completion of backfilling.

Where turf becomes unsuitable for relaying due to the Contractor’s operations, the
Contractor shall supply and lay new turf or fertilize, seed, and maintain the area until new
growth is established. Over any areas to be seeded, the topsoil shall be replaced, raked
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and rolled to uniform grade with all stones and debris removed. All reconstituted areas
shall be watered and maintained by the Contractor until the grass is well established to
provide a surface comparable to previously existing conditions.

3.2.4 Protection of Existing Structures

Where necessary, manual excavation shall be employed to protect existing structures,

utilities, poles, trees or pavements.

In areas of proximity to existing fuel and gas lines or facilities, the Contractor shall exercise
precaution to avoid rupturing, disturbing, or otherwise causing any damage to such lines or
facilities. He shall further exercise care and precaution against the presence of fuel and
gas fumes that may have permeated the soil or may have been disturbed during excavation
and pipeline operations.

3.2.5 Classification of Excavated Materials

3.2.5.1 Class I

Class I excavation covers all loose earth materials including sand, sandy soil, clay, silt,
muck, mixture of stones/gravel, broken bituminous pavement, macadam pavement and
isolated pieces of rocks, adobe or concrete with volume not exceeding one fourth (1/4)
cubic meter, occurring not more than three (3) pieces per meter of excavation and spaced
not closer than an average of 0.20 m clear distance.

3.2.5.2 Class II

Class II excavation includes the following:

a. Any solid mass exceeding one fourth (1/4) cubic meter and having an unconfined
compressive strength from 1.0 MPa to 10 MPa.
b. Layers of solid masses (including pieces of concrete, rock and boulders) with volume
ranging from 0.005 to 0.25 cubic meter and with an average unconfined compressive
strength of not less than 1.0 MPa. To be considered as layer of solid mass, the
average clear distance between pieces shall be less than 0.20 m.
c. Unbroken bituminous concrete pavement within the excavation zone.

3.2.5.3 Class III

Class III excavation covers any solid mass (including concrete and sedimentary rocks)
exceeding one fourth (1/4) cubic meter and having an unconfined compressive strength
greater than 10.0 MPa up to 25.0 MPa. Sub-layer of concrete pavement need not be
tested for unconfined compressive strength.

3.2.5.4 Class IV

Class IV includes rocks exceeding one fourth (1/4) cubic meter and having an unconfined
compressive strength greater than 25.0 MPa. To be considered under this classification,
rock need not be tested for unconfined compressive strength because of sampling difficulty.
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The mere fact that this can not be economically and practically broken by an 82 to 85 cfm
jack hammer as certified by the Engineer is a sufficient proof of its classification.

3.2.6 Limits of Rock Excavation

Isolated points of rock shall not be within 100 mm radius from the pipe wall. At pipe joints,
sufficient room shall be allowed for properly making the joint.

Rock underneath structures shall not protrude above the bottom of the base slab or the
granular or sand cushion or drainage layer where such cushion or drainage layer is
required.

3.2.7 Unauthorized Excavation

The Contractor shall not excavate outside the lines and grades shown on the Contract
Drawings unless directed by the Engineer. Any unauthorized excavations shall be
backfilled with suitable material as directed by the Engineer. Where, in the judgement of
the Engineer, such unauthorized excavation requires use of lean concrete or crushed
stone, the Contractor shall furnish and satisfactorily place such materials at no extra cost to
the Owner.

3.2.8 Excavation Below Normal Grade

Where the depth of excavation shown on the Contract Drawings is found to be unstable or
to include muck, silt, ashes, cinders, refuse, vegetable or other organic material, which in
the judgment of the Engineer should be removed, the Contractor shall excavate and
remove such unsuitable material to the width and depth ordered by the Engineer.

Excavation below normal grade shall be filled with well compacted selected sandy material,
bank run gravel, or sand fill, up to the lower level of the bedding for the structure or pipe, as
shown on the Contract Drawings. Backfill for excavation below normal grade shall be
placed in thoroughly compacted layers, each not to exceed 150mm in thickness.

3.2.9 Length of Open Excavation

Open trench for one pipelaying crew shall not be more than one hundred (100) meters.

Trench excavation shall be completed at least ten (10) meters in advance of pipelaying.
For trenches within national and other major roads, excavation and backfilling shall be
performed on a 24-hour basis or the trenches shall be fully backfilled at the end of each day
or covered with heavy steel plate adequately secured, braced and capable of supporting
vehicular traffic.

3.2.10 Sheeting and Bracing

The Contractor shall design, furnish, install, and maintain such sheeting and bracing as
may be required to support the sides of excavations. Prior to installation, Contractor shall
submit shop drawings showing the type of sheeting and bracing to be used, and his
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intended method of placing and maintaining it as required. For any excavation deeper than
1.5m, the Contractor’s Safety Officer shall approve the sheeting and bracing scheme. Care
shall be taken to prevent voids outside the sheeting; but if voids are formed, they shall be
immediately filled and rammed.

All sheeting and bracing not left in place shall be carefully removed without endangering
new installations, existing utilities, or adjoining properties. All voids caused by withdrawal
of sheeting shall be immediately refilled with sand and compacted by ramming with suitable
tools, by watering, or as otherwise directed.
Wood sheeting shall not be withdrawn, if driven below the spring line of any pipe, and
under no circumstances shall any wood sheeting be cut off at a level lower than 0.30m
above the top of the pipe.

For the purpose of preventing injury to structures, utilities, or properties, the Contractor
shall leave in place, to be embedded in the backfill, all sheeting, bracing, etc. which the
Engineer has directed in writing to be left in place or as shown in the Contract Drawings.

The right of the Engineer to order sheeting and bracing to be left in place shall not be
construed as an obligation on his part to issue such order; and his failure to exercise his
right to do so shall not relieve the Contractor from liability for damages to persons or
properties occurring from or upon the work occasioned by negligence or otherwise, due to
failure of the Contractor to leave in place sufficient sheeting and bracing to prevent any
caving-in or moving of the ground.

3.2.11 Hauling to Stockpile and Disposal of Excess Excavated Materials

Excavated materials shall not be deposited on the roadway or sidewalk. All excavated
materials shall be transported to Contractor’s spoil areas approved by the Engineer and re-
hauled, if necessary, for backfilling purposes. The Contractor shall trim and grade the
designated spoil areas to meet the requirements of the Engineer. All excavated materials
that are not suitable for backfill or are in excess of those needed for the work shall be
disposed by the Contractor in a manner approved by the Engineer.

3.3 SURFACE RESTORATION

3.3.1 Bedding and Backfilling Materials

3.3.1.1 General

Backfilling shall include the supply, installation and compaction of all materials used to fill
pipe trenches and excavations for other structures.

Trench width, height of bedding and backfilling and other details shall be in accordance
with the Maynilad Standard/Contract Drawings.

Excavated material that is suitable for backfill shall be used for that purpose provided the
specified compaction as per cent of maximum soil density is attained.

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3.3.1.2 Backfill Materials

3.3.1.2.1 Native Backfill

Native backfill materials (except clay, silt and muck) that are substantially free of wood,
trash grass, roots, brush or other vegetation may be used as native backfill. It shall not
contain boulder, stone or rock pieces larger than 75 mm in any dimension. It shall not
contain broken concrete, masonry, rubble, asphalt pavement or other similar materials.
Native backfill shall have physical properties such that it can be readily spread and
compacted during filling.

3.3.1.2.2 Imported Backfill

Any earth material (except clay, silt, and muck) satisfying the specification for native
backfill may be used to replace unsuitable native materials.

3.3.1.2.3 Selected Sandy Material

Material that is free from organic matter, does not contain stone or rock fragments larger
than 10mm in greatest dimensions and is non-cohesive shall be used as selected sandy
material. Not more than 50% of the material shall pass the No.200 sieve. The material
shall lend itself to ease of compaction and shall be placed at a moisture content
approaching its optimum for compaction.
3.3.1.2.4 Bank Run Gravel

Material shall be durable and graded soil- aggregate conforming to Type I gradations A
through D of ASTM D1241.

3.3.1.2.5 Gravel Bedding

Gravel bedding material shall be hard, durable crushed rock or gravel, free draining, free
from organic matter and graded to comply with the limits shown in Table 1, Class A or B.
3.3.1.2.6 Sand fill

Sand fill shall consist of clean, inert, hard, durable grains of quartz or other hard durable
rock, free from loam or clay, surface coatings, and deleterious materials. The allowable
amount of material passing a No. 200 sieve shall not exceed ten (10) per cent by weight.
The maximum particle size shall be 6mm.

Table 1 – Grading Requirements for Gravel Bedding

Sieve Size Per Cent by Weight Passing

(mm) Class A Class B
38 - 100
25 100 90-100
20 90-100 10-50
15 10-50 0-20

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Sieve Size Per Cent by Weight Passing

(mm) Class A Class B
10 0-20 0-5
5 0-5 -

3.3.1.2.7 Embankment Material

Embankment material shall be free from brush, roots, grass or other organic material.
Cobbles and rock pieces having maximum diameter less than 75mm may be used. The
amount of material passing a No.200 sieve shall not exceed 50% by weight.

3.3.1.2.8 Sub-base Course

Sub-base course shall conform to the requirements of Item 200, DPWH Standard
Specifications for Highways, Bridges and Airports, latest edition.

Aggregate for sub-base shall consist of hard, durable particles or fragments of crushed
stone, crushed slag, or crushed or natural gravel and filler of natural or crushed sand or
other finely divided mineral matter. The composite material shall be free from vegetable
matter and clay lumps, and shall be of such nature that it can be compacted readily to form
a firm, stable sub-base.

The sub-base material shall conform to the grading requirements of Table 2.

Table 2 – Grading Requirements

Sieve Designation

Standard, mm Alternate US Mass Per Cent

Standard Passing

50 2” 100

25 1” 55 - 85

9.5 3/8” 40 - 75

0.075 No. 200 0 - 12

The aggregate sub-base material shall be placed as a uniform mixture on a prepared sub-
grade in a quantity which will provide the required compacted thickness.

Where the required thickness is 150mm or less, the material may be spread and
compacted in one layer. Where the required thickness is more than 150mm, the aggregate
sub-base shall be spread and compacted in two or more layers of approximately equal
thickness, and the maximum compacted thickness of any one layer shall not exceed
150mm. All subsequent layers shall be spread and compacted in a similar manner.
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The moisture content of sub-base material shall be adjusted prior to compaction by

watering with approved sprinklers mounted on trucks or by drying out, in order to obtain the
required compaction.

Compaction of each layer shall continue until a field density of 100% of the maximum dry
density, determined in accordance with ASTM D1557, Method C has been achieved.

3.3.1.2.9 Base Course

Base course shall conform to the requirements of Item 201, DPWH Standard Specifications
for Highways, Bridges and Airports, latest edition.

Aggregate for base course shall consist of hard, durable particles or fragments of crushed
stone, crushed slag or crushed or natural gravel, and filler of natural or crushed sand or
other finely divided mineral matter. The composite material shall be free from vegetable
matter and lumps or balls of clay, and shall be of such nature that it can be compacted
readily to form a firm, stable base.

The base course shall conform to the grading requirements of Table 3.

Table 3 – Grading Requirements for Base Course

Sieve Designation Mass Per Cent Passing

Standard (mm) Alternate US Standard Grading A Grading B

50.0 2” 100 -

37.5 1 ½” - 100

25.0 1” 60 - 85 -

19.0 ¾” - 60 - 85

12.5 ½” 35 - 65 -

4.75 No. 4 20 - 50 30 - 55

0.425 No.40 5 - 20 8 - 25

0.075 No. 200 0 - 12 2 - 14

Placing, spreading and compacting shall be as specified in subsection for sub-base

material.

The field density required for each layer shall not be less than 100% of the maximum dry
density determined in accordance with ASTM D-1557, Method C.

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3.3.2 Backfilling and Compaction

3.3.2.1 Pipe Zone

Backfilling materials for pipe zone shall be as shown in Table 4 and the degree of
compaction shall be as shown in Table 5.

Compaction of granular materials maybe achieved by tamping or using vibratory

compactors. Pipe zone material shall be placed and compacted at layers not to exceed
150mm thickness and the height of backfill shall be kept uniform on both sides of the pipe.
The height of the pipe zone shall be as shown on the contract/standard drawings.

Table 4 – Materials for Bedding and Backfill in the Pipe Zone

Pipe Material Bedding Material Pipe Zone Material

PVC Sandfill Selected Sandy Material

PE Sandfill Selected Sandy

Material

Steel Pipe Sandfill Native or Imported Backfill

Ductile Iron Pipe Sandfill Native or Imported Backfill

Reinforced Concrete Sandfill Native or Imported Backfill

3.3.2.2 Above Pipe Zone

For all pipe alternatives, backfill above pipe zone shall consist of native or imported
material defined in this section.

Backfill above the pipe zone shall be placed in horizontal layers not to exceed 150mm in
thickness. Each layer shall be moistened, tamped, puddled, rolled and compacted to the
specified compaction as shown in Table 5.

3.3.2.3 Embankment

Before placing embankment, the topsoil shall be stripped and the base surface shall be
scarified to 300mm depth. All grass and roots shall be removed. After scarification, the
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base shall be compacted by rolling and the backfill shall be placed with maximum lifts of
300mm. Compaction of the base and the embankment fill shall not be less than 90 % of
the maximum dry density. Moisture content shall be as uniform as possible and suitable for
the compaction required. Finished side slopes shall be covered with 150 mm of topsoil,
stripped prior to placing of fill.

3.3.2.4 Field Density Test

Backfill on roads subject to traffic load shall be tested by the Contractor or an accredited
independent laboratory in the presence of the Engineer for the required compaction using
the test procedures specified in ASTM D1556. The reference maximum soil density shall be
as determined from ASTM D698, Method D.

Test for backfill other than sand or gravel fill shall be mandatory.

Test frequency shall be at least one group of three in-situ density tests for every 150 linear
meters of backfill and for all layers.

Test hole volumes are to be as large as practicable to minimize errors and, will in no case,
be smaller than the volumes indicated in Table 6.

Table 5 – Minimum Compaction Requirements

Material Minimum % Compaction

(% of Maximum Dry Density)
Base and Sub-base Course
- in National Highways 100
- in Interior Roads 95

Selected Sandy Material 95

Sub-grade / Ordinary Backfill 90

Table 6 – Minimum Test Hole Volumes Based on Maximum Size of Included Particle

Maximum Particle Size Minimum Test Hole Volumes

mm in cm³ ft³

12.5 ½ 1420 0.05

25 1 2120 0.075

50 2 2830 0.10

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3.3.3 Pavement

3.3.3.1 Asphalt Pavement

Asphalt pavement shall be in accordance with Item 310, DPWH Specifications, latest
edition.

The bituminous mixture shall have a minimum dry compressive strength of 1.4 MPa (200
psi) and a mass per cent air voids with the range of 3 to 5. The proportion of bituminous
material, on the basis of total dry aggregate, shall be from 5.0 to 8.0 mass per cent.

3.3.3.2 Concrete Pavement

Concrete pavement shall be in accordance with Item 311, DPWH Standard Specifications.

1) Material Requirements

a. Portland Cement : Only Type I Portland Cement in accordance with ASTM C150
shall be used unless otherwise specified.

Cement which, for any reason, has partially set or which contains lumps shall be
rejected.

b. Fine Aggregate: It shall consist of natural sand, stone screenings or other inert
materials with similar characteristics, or combinations thereof, having hard, strong
and durable particles. Fine aggregate from different sources of supply shall not be
mixed or stored in the same pile nor used alternately in the same class of concrete
without the approval of the Engineer.

The fine aggregate shall be well graded in accordance with Table 7.

c. Coarse Aggregate: It shall consist of crushed stone, gravel, blast furnace slag, or
other inert materials of similar characteristics, or combinations thereof, having hard,
strong, durable pieces and free from any adherent coatings.

It shall contain not more than one (1) mass per cent of material passing the
0.075mm (No. 200 sieve), not more than 0.25 mass per cent of clay lumps, nor
more than 3.5 mass per cent of soft fragments.

If the coarse aggregate is subjected to five (5) cycles of the sodium sulfate
soundness test, the weighted loss shall not exceed 12 mass per cent.

Only one grading specification shall be used from any one source. Grading shall be
as shown in Table 8.

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Table 7 – Grading Requirements for Fine Aggregate

Sieve Designation, mm Mass Per Cent Passing

9.5 (3/8”) 100

4.75 (No.4) 95 - 100

1.18 (No. 16) 45 - 80

0.300 (No. 50) 5 - 30

0.150 (No. 100) 0 - 10

0.075 (No. 200) 0–3

Table 8 – Grading Requirements for Coarse Aggregate

Sieve Designation Mass Per Cent Passing

Standard,mm Alternative
US Grading A Grading B Grading C
Standard
75.0 3” 100 - -

63.0 2-½” 90-100 100 100

50.0 2” - 90-100 95-100

37.5 1-½” 25-60 35-70 -

25.0 1” - 0-15 35-70

19.0 ¾” 0-10 - -

12.5 ½” 0-5 0-5 10-30

4.75 No. 4 - - 0-5

d. Water: Water used in mixing, curing or other designated application shall be

reasonably clean and free of oil, salt, acid, alkali, grass or other
substances injurious to the finished product.

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2) Strength of Concrete

It is the intent of this specification to require approximately 9.0 bags of cement per cubic
meter of concrete based on a 40 kg. bag of cement. However, the Engineer shall
determine from laboratory tests of the materials to be used, the cement content and the
proportions of aggregate and water that will produce workable concrete having the
following properties:

Slump
a) If not vibrated 40-75 mm (1 ½” – 3” )
b) If vibrated 10-40 mm ( ½” – 1 ½” )

Flexural Strength at 14 days

a) By third point loading method 3.8 MPa (550 psi) min.
b) By mid-point loading method 4.5 MPa (650 psi) min.

Compressive Strength at 14 days 24.1 MPa (3500 psi ) min.

for pavements on public roads

3) Testing and Acceptance of Concrete

Testing and acceptance of concrete shall be as per DPWH Stnadard Specifications for
Highways, Bridges and Airports, Volume II, latest edition.

** END OF SECTION **

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SECTION 003
CONCRETE AND REINFORCING STEEL

PART 1 – GENERAL

1.1 Scope of Work

The WORK includes providing concrete, reinforced and unreinforced, for structures
other than pavements.

1.2 Specifications and Standards

Except as otherwise indicated, the current editions of the following Standards apply to
the WORK of this Section:

ASTM A615 Deformed and Plain Billet Steel Bars for Concrete
Reinforcement

ASTM C31 Making and Curing Concrete Test Specimens in the

Field

ASTM C33 Concrete Aggregates

ASTM C39 Compressive Strength of Cylindrical Concrete

Specimens

ASTM C42 Obtaining and Testing Drilled Cores and Sawed

Beams

ASTM C94 Ready-Mixed Concrete

ASTM C150 Portland Cement

ASTM C805 Rebound Number of Hardened Concrete

ASTM D412 Tension Testing of Vulcanized Rubber

ASTM D570 Water Absorption of Plastics

ASTM D792 Specific Gravity and Density of Plastics by

Displacement

ACI 318 Building Code Requirements for Reinforced Concrete

ACI 347 Recommended Practice for Concrete Formwork, U. S.
Corps of Engineer CRD C-572

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PNS 49 Philippine National Standard-

Steel Bars for Concrete Reinforcement

1.3 Submittals

A. Bar bending schedule for reinforcing steel

B. Samples and certificates as required in PART 3 - EXECUTION of this

Specification

C. Drawings

1.4 Quality Assurance

The Contractor is responsible for the performance of all tests and inspection required
by this Standard Specification. However, Maynilad Water Services, Inc. (Maynilad)
reserves the right to perform any or all prescribed tests and inspection where such is
deemed necessary to ensure that the Work conforms to Specifications. The
Manufacturer shall furnish Maynilad compliance certificate and certified copies of
records showing that the materials have been tested and have complied with all
applicable requirements of this Standard. The Contractor shall, at his own expense,
replace all unacceptable materials for failure to comply with this Specification.

PART 2 PRODUCTS

2.1 Cement

Cement shall be Type I with Fly Ash or Type II Portland Cement conforming to ASTM
C150, except as otherwise specified in the Drawings.

Physical requirements shall be as follows:

Table 1 – Physical Requirements of Cement

Test Requirement

Compressive Strength for ages indicated, min.

3 days 12.0 MPa
7 days 19.0 MPa

Time of Setting by Vicat Method

Initial Set, minimum 45 minutes
Final Set, maximum 375 minutes

Fineness, by turbidimeter test, minimum 160 m²/kg

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2.2 Aggregates

1. Fine aggregate shall consist of washed natural sand and graded within the
following limits, conforming to the requirements of ASTM C-33:

Table 2 – Grading Requirements for Fine Aggregates

SIEVE DESIGNATION WEIGHT PER CENT PASSING

9.5mm (3/8) 100

4.75mm (No.4) 95 - 100

2.36mm (No.8) 80 - 100

1.18mm (No.16) 50 - 85

0.60mm (N0.30) 25 - 60

0.30mm (No. 50) 5 - 30

0.15mm (No.100) 0 - 10

0.075mm (No. 200) 0–3

2. Coarse Aggregate shall be well-graded crushed stone conforming to ASTM

C33, Size No. 67 as shown in Table 3.

Table 3 – Grading Requirements for Coarse Aggregate

SIEVE DESIGNATION WEIGHT PER CENT PASSING

25mm (1”) 100

19.0mm (3/4”) 90 - 100

9.5mm (3/8”) 20 - 55

4.75mm (No.4) 0 - 10

2.36mm (No. 8) 0-5

0.075mm (No.200) 0-1

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2.3 Water: The mixing water shall be clean, and free from deleterious amounts of acids,
alkalis, oils or organic matter.

2.4 Admixture

Admixtures may be used upon approval of the Engineer in writing, to control the
time setting, to effect water reduction and to increase workability. The admixture
may be a hydroxylated carboxylic acid type or a hydroxylated polymer type, but
shall contain no calcium chloride. The use of an admixture shall not change the
required quantities of cement specified under Item 2.2 A of this section. The
quantity of admixture used and method of mixing shall be in accordance with the
manufacturer’s instruction.

2.5 Reinforcing Steel

Reinforcing steel shall be deformed, new billet steel bars conforming to ASTM
A615, Grade 40, substantially free from mill scale, rust, dirt, grease or other foreign
matter.

Mechanical Properties: Mechanical requirements shall be as specified in ASTM

A615.

Table 4. Tensile Requirements

Tensile Strength, minimum (MPa) 500

Yield Strength, minimum (MPa) 300

Elongation in 203.2mm, minimum (%)
Bar Designation No.
# 10 11
# 13 12
# 16 12
# 19 12

Chemical Composition: The percentages of carbon, manganese, phosphorus, sulfur

and silicon on finished bars shall conform to the specified values in PNS 49, Grade
275 as shown in the following table.

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Table 5. Chemical Requirements

Chemical Composition, Percent Maximum

Element
Hot-Rolled Non- Hot-Rolled Weldable
Weldable Deformed Deformed or Plain
Steel Bar Steel Bar
Carbon - 0.38

Manganese - 1.26

Phosphorus 0.0625 0.058

Sulfur 0.0625 0.058

Silicon - -

The following reinforcing steel bar sizes shall be used for all reinforced concrete
design under this Contract.

Table 6 – Reinforcing Steel Bar Sizes

Bar Designation Approximate Approximate

Cross Sectional Area Unit Weight
(mm²) (kg/m)

#10 78 0.616

#12 113 0.888

#16 201 1.579

#20 314 2.466

#25 492 3.854

#28 615 4.833

#32 804 6.313

#36 1018 7.991

Should the Contractor wish to use reinforcing steel bars having areas different
from those shown (with consequent different designations), the following
requirements shall apply:

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1. If the proposed substitute bar has an area of 97% to 105% of the designated
bar, a direct substitution may be made without changes in bar spacing.

2. If the proposed substitute bar has an area less than 97% of the designated
bar, substitution may be allowed provided bar spacing is reduced to not less
than the minimum clear distance between bars.

3. If the proposed substitute bar has an area more than 105% of the designated
bar, changes in spacing may be proposed by the Contractor. Changes shall
be implemented upon approval by the Engineer of the reinforcing arrangement
drawings required as shop drawings, which shall be finalized upon issuance
by the Engineer of the guidelines on related criteria, as maximum and
minimum spacing and bond strength.

Approval by the Engineer of bar size substitutions does not relieve the Contractor
of other specified requirements, including grade and bar deformations.

2.6 Tying Wire

Tying wire for steel reinforcement shall be Gauge 16, GI wire conforming to ASTM-
A82.

2.7 Cover Blocks and Spacers for Reinforcement

Cover blocks and spacers shall be designed to maintain the correct clear cover of
concrete over steel reinforcement, shall be as small as possible, consistent with
their purpose and of a shape acceptable to Maynilad.

Concrete cover blocks shall be manufactured with a 10mm aggregate size and
otherwise produced to the same specification as the surrounding concrete. Wire
cast in the block for the purpose of tying it to the reinforcement shall be Gauge 16
GI wire in accordance to ASTM A82.

Spacers shall be of rustproof material and shall not produce staining or otherwise
be detrimental to the concrete or steel.

2.8 Dowel Bars

Dowel bars for expansion joints shall conform to the requirements of AASHTO M31
(ASTM A615) or AASHTO M42.

Dowel bars shall be straight, free from burrs or other deformations restricting
slippage in the concrete. Before delivery to the site of work, a minimum of one half
(1/2) length of each dowel bar shall be painted with one coat of approved bitumen
paint.

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The sleeve for dowel bars shall be metal of an approved design to cover 50 mm
plus or minus 10 mm of the dowel, with a closed end of the sleeves at least 25 mm
from the end of the dowel bar. Sleeves shall be of such design that they do not
collapse during construction.

2.9 Waterstop and Joint Sealant

Waterstop material shall be made of elastomeric plastic compound, with polyvinyl

chloride basic resin complying with the requirements
given in Table 7.

Waterstops shall be fabricated by extrusion, such that it will be dense,

homogeneous and free from holes and other imperfections. The cross section of
the waterstop shall be uniform and symmetrical along its entire length.

Waterstop manufacturers shall furnish current test reports and written certification
that waterstop material complies with this standard.

Joint sealant shall be a two component, polyurethane-base, elastomeric self-

leveling sealer, suitable for water application.

Primer shall be as recommended by the sealant manufacturer.

Table 7 – Material Requirements for Waterstop

Property Test Method Requirement

Tensile Strength ASTM D412 12.4 MPa minimum

Elongation at ASTM D412 300 % minimum
Break
Specific Gravity ASTM D792 1.4 maximum
Water Absorption ASTM D570 0.5 %

2.10 Concrete

A. Concrete Quality

Concrete shall be designed and prepared to meet the requirements listed in Table
8.

The mix design shall be submitted to the CO for approval at least fifteen (15) days
prior to placing of concrete.

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Water shall be kept to a minimum to obtain a dense and watertight concrete and
the quantity of cement to be used shall not be less than 310 kg per cubic meter for
Class A concrete.
Table 8 – Concrete Quality Requirements
Total Minimum
Concrete Class Slump Air Concrete Compressive Strength
(mm) Content Temperature at 28 days
(%) (Max., °C) (Mpa)

Class A 50 - 100 3-6 32 24

(all concreting
works)

Class B 50 - 100 3-6 32 17

(Concrete cradles,
encasement & thrust
blocks; lean
concrete)

B. Small Construction Concrete

In miscellaneous work involving small quantities of concrete, and where permitted

by the CO, one bagger mixer may be used. Concrete shall be mixed for at least
1-1/2 minutes after all the materials are in the mixer drum.

C. Ready mixed Concrete

Production methods and facilities for ready-mixed concrete shall conform to ASTM
C-94 and to the requirements herein stated.

The Contractor shall submit certificate of compliance from the ready-mix supplier,
certifying that concrete supplied meets the requirements of this specification.

Concrete shall be mixed until there is uniform distribution of the materials. The
mixer shall be rotated at a speed recommended by the mixer manufacturer;
mixing shall be continued for at least one and one-half (1 1/2) minutes after all the
materials are in the mixer. Each batch shall be completely discharged and the
mixer thoroughly cleaned and washed before reloading.

Concrete shall be mixed only in quantities required for immediate use. Concrete
that has been re-tempered by adding water or other materials shall be rejected.

Ready-mixed concrete shall be tested in accordance with the following methods:

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Table 9 – Sampling and Test Methods for Ready-Mixed Concrete

Applicable
Sampling/Test Method
ASTM Standard

1. Compression Test Specimens C 31

2. Compression Tests C 39
3. Yield, Unit Weight C 138
4. Air Content C138 / C 173 / C 231
5. Slump C143
6. Sampling Fresh Concrete C 172
7. Temperature C1064

2.11 Formworks

Concrete shall be placed in forms, unless otherwise approved by the Engineer.

The forms shall be of wood, plywood, steel or other approved materials; free from
roughness and surface irregularities, substantially watertight and adequately braced
and tied to prevent sag or movement when concrete is placed.

Formwork shall be constructed in such a manner as to enable the forms to be

removed without hammering or prying against the concrete. Exposed exterior
corners shall have 50mm chamfers.

Wire ties shall not be allowed to extend to the surface where concrete will be
exposed to water or weathering.

Forms shall be thoroughly cleaned before using. For concrete surfaces that will not
be subsequently waterproofed, forms shall be treated with a light and clear paraffin-
based oil, which will not discolor or injuriously affect the concrete surfaces. Forms
for concrete surfaces that are to be waterproofed shall be wetted prior to concreting.

PART 3 - EXECUTION

3.1 Placing Concrete

No concrete shall be placed until the depth and character of the foundation, the
adequacy of the forms and falsework, and the placement of steel reinforcement and
embedded items have been inspected and approved by the Engineer. Before
depositing concrete, all debris, foreign matters, dirt and water shall be removed;
surfaces of any concrete previously placed, such as manhole base or horizontal
construction joint, shall be cleaned and then brushed with cement paste.

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Unless otherwise approved by the Engineer, all concrete shall be placed during
daytime and placing of concrete in any portion of the work shall not be started unless
the whole work can be completed in before night time. If permission has been
granted for the Contractor to carry-on work during night time, an adequate lighting
system must be provided.

The method and manner of placing concrete shall be such as to avoid the possibility
of segregation of concrete materials or displacement of the reinforcement. When
troughs or chutes are used in placing concrete, their angle of inclination with respect
to the horizontal shall not exceed 30°. When pipe is used, it shall be kept full of
concrete with its discharge-end submerged, and used in the same manner as a
tremie. Troughs, chute or pipe shall be kept clean and free from hardened concrete.
Open trough or chute shall be of metal or metal lined.

Concrete shall not be allowed to drop into place from a height exceeding one and one
half (1-1/2) meter inside the forms for walls, nor from a height exceeding two (2)
meters on floor slabs. Concrete shall be evenly distributed to avoid deposition or
concentration of a large quantity at any one point. Concrete shall be placed in
horizontal layers as near as practicable up to its final elevation. Coarse aggregates
shall be worked back from the face of the forms, and concrete forced under, around,
and between inserts, piping and reinforcement without disturbing them.

Concrete shall be deposited in a continuous operation as far as it is practicable to do

so, with concrete poured evenly on all sides in a manner that will avoid initial setting in
any part of the work before fresh concrete is placed on it.

Mechanical vibrators or other suitable tools shall be used to the extent necessary to
obtain proper consolidation and finish of concrete; but care shall be taken to avoid
segregation of aggregates by excessive vibration.
Concrete placed adjacent to forms and around pipe stubs shall be well spaded or
rodded.

3.2 Protection and Curing

Fast flowing water shall not be permitted to flow over the surface of fresh concrete
within four days after its placing.
Careful attention shall be given for proper curing and protection of all new concrete.
The work shall be protected from dangerous elements and fast flowing water and
from defacement. As soon as the concrete has sufficiently hardened, it shall be
covered with damp, close-woven burlap or similar materials, or with clean sand, which
shall be kept thoroughly saturated with water over a period as shown in Table 10.

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Table 10 – Curing Time of Concrete

Curing Time
Type of Structure (days)

1. Vertical walls and roof slabs of 14

manhole chambers and valve vaults

2. Thrust blocks 7

3. Bedding concrete 3

4. Supports of existing services 14

5. Other minor structures 7

Thrust Block and Bedding Concrete can be backfilled after concrete has hardened
sufficiently to permit removal of forms, but pipe can not be filled with water until 7
days have passed.

Where wood forms are used, they shall be kept wet for the same period to prevent
openings at the joints and drying out of the concrete.

3.3 Removal of Forms and Shores

Forms shall not be disturbed until the concrete has sufficiently hardened. Shoring
shall not be removed until the supported concrete has acquired
adequate strength to support its own weight and the load upon it. Concrete subject to
additional loads during construction, shall be adequately shored to sustain all
resulting stresses. Removal of forms shall be in accordance with ACI-347 and shall
be accomplished in such a manner and sequence as will prevent injury to the
concrete. When, in the opinion of the Engineer, conditions of the work or the weather
justify, forms may be required to remain in place for longer periods.

3.4 Concrete Finish

As soon as forms have been stripped, form ties, if employed, shall be removed, and
recesses left by the ties shall be filled with cement mortar. Any defect, such as
honeycombs, in the surface of the walls shall be chipped out and repaired in a
suitable manner.

Defective concrete, where it occurs, shall be cut out to a minimum depth of 25mm,
brushed with neat cement grout, and then filled with mortar in the proportion of one
part cement to two and one half (2-1/2) parts of water. Mortar in large patches shall
be applied and allowed to assume a partial set, following which, it shall be stuck off
flush with the adjoining surface. Patches shall be made on concrete that is not
exposed to direct sunlight and kept moist for several days to ensure proper curing.

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Mortar for filling form tie recesses shall be mixed to a slightly damp consistency,
pressed into the recesses, and troweled smooth.

Concrete surfaces that are not exposed in the completed work will require no special
finish other than what is necessary to leave them smooth and impervious.

Concrete pouring and finishing shall be scheduled so that all finishing work is done by
capable and experienced men before the concrete has attained its final set.

Exterior concrete slabs, interior platforms and interior concrete steps shall be finished
by tamping the concrete with suitable approved tools to force the coarse aggregate
away from the surface and to bring the surface to the required uniform finished level.
While the concrete is still wet, but sufficiently hardened to bear a man’s weight without
deep imprint, the surfaces shall be wood-floated to a true even surface.

Exterior concrete steps and walkways shall be wood-floated and then given a
broomed finish surface by lightly brushing in one direction with a soft hair broom to
produce a non-skid surface of uniform appearance.

All other unformed slab surfaces as interior slabs to which no other surface as interior
slabs to which no other surface finish is required, bottoms of tanks or any other
surface over which liquid flows, shall receive a steel-trowel finish. Such surfaces shall
first receive a wood float finish, followed then by hand trowelling with steel trowels to
bring the surface to a uniform, smooth, hard, impervious surface free from marks and
blemishes. Trowelling shall not be started until all water has disappeared from the
surface and over-trowelling shall be avoided. Dusting with dry cement or other
mixtures or sprinkling with water will not be permitted.

All exposed vertical or formed faces of concrete shall be finished by carefully

removing the forms at the proper time; immediately wetting, pointing –up, removing
any projections or fins, and rubbing them down with suitable abrasive blocks until a
uniform finish is achieved.

3.5 Concrete Reinforcement

Reinforcement shall be accurately fabricated to the dimensions indicated on the

Drawings, placed in exact positions shown, and secured with annealed iron wire ties
or suitable clips at intersections against displacement. A clear space of 50 mm
between the steel and face of concrete shall be maintained, unless otherwise
indicated. Wire ties passing through the forms for the purpose of holding the steel in
proper position will not be allowed.

All bars shall be bent cold. Stirrups and tie bars shall be bent around a pin having a
diameter not less than two (2) times the bar diameter except for bars larger than
25mm diameter, which shall be made around a pin of eight (8) bar diameters.

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Reinforcement bars of the same size and shape shall be shipped to the work in
bundles, with metal identification tags giving size and mark securely wired on. The
identification tags shall be labeled with the same designation as shown on submitted
bar schedules and shop drawings. All bars shall be stored off the ground and
protected from moisture, dirt and damage.

Unless otherwise shown, splices in reinforcement shall be lapped not less than 24 bar
diameters. Bar splices shall be of two different diameters, the length of slap shall be
based on the larger diameter bar.

Before being placed in position, reinforcement shall be thoroughly cleaned of rust,

dirt, grease, paint or other coatings. Where there is delay in depositing concrete after
reinforcement is in place, bars shall be re-inspected and cleaned.

Reinforcement which is to remain exposed for future extension of the work shall be
coated with cement grout.

No reinforcing steel that has been placed into structural position shall be covered with
concrete until it has been checked by the Engineer and his permission received to
proceed with the concreting.

3.6 Construction Joint and Waterstops

Construction joints shall be provided as shown in the Drawings or as approved by the

Engineer. Special care shall be employed in preparing concrete surfaces at joints
where bonding between two sections of concrete is required. Unless otherwise
indicated in the Drawings, such bonding will be required at all horizontal joints in
walls.

3.6.1 Surface Preparation

The surface of concrete upon or against which the placement of contiguous concrete
or masonry is later required shall be struck off true to the elevations indicated in the
Contract Drawings after the concrete has been placed. Thereafter as soon as the
condition of the concrete permits, and before the concrete has hardened appreciably,
i.e. normally within 2 hours after being deposited, all water, scum, laitance and loose
aggregate shall be removed from the surface by means of wire or bristle brooms in
such a manner that the coarse aggregate is left slightly exposed, and the surface
cleaned. No raking will be permitted.

The Contractor shall then take all necessary precautions to ensure that all surfaces
prepared shall be kept free from storage piles, drippings, staining or foreign matter,
which could adversely affect the concrete or the bond between the concrete layers.

3.6.2 Joints

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Tapered joints between precast concrete removable covers shall be filled with
elastomeric joint sealant as shown in the Contract Drawings. Cleaning of tapered
joints, priming, handling and the application of the sealant shall be in compliance with
the manufacturer’s instructions.

3.6.3 Waterstops

Waterstops for all joints shall be continuous around the corners and at intersections,
either in horizontal or vertical direction. Field splices and joints shall be made in
accordance with the waterstop manufacturer’s instructions, using a thermostatically-
controlled heating iron.

Holes to tie waterstops to the reinforcing steel bars shall be drilled as recommended
by the manufacturer and tied with steel tying wire.

A sufficient number of tie wires shall be installed to ensure that the waterstops remain
in their original position during the placement of concrete.

3.7 Manholes, Interceptor Boxes and Pump Stations

Manholes, interceptor boxes and pump stations shall be located and constructed in
situ to the details shown on the Contract Drawings. Irrespective of the method of
construction the wall thickness of manholes and interceptor boxes shall not exceed
the specified dimension by more than 10%.

The covers and frames shall be to, and installed in accordance with, the details
shown on the Contract Drawings and the manufacturer’s instructions. The covers
shall neatly fit the frames and shall not rock in the frame. The frames shall be firmly
fixed to the surround to prevent any movement and to provide a watertight joint.

The concrete surface of each cover, frame and surround shall be finished flat and
even with a wooden float to a non-slip surface. Positioning marks in both cover and
frame are to be clearly visible.

Prior to fixing the frames the top surface of the manhole and interceptor box wall shall
be thoroughly cleaned down and roughened. All forms used for placing in-situ
surrounds shall be of metal, well braced and be capable of being stripped without
damaging the concrete. Precast frames shall be bedded on a layer of an approved
epoxy-resin based mortar.

Where it is necessary to connect a new manhole or interceptor box directly into an

existing sewer at least 3 days notice shall be given to the Engineer and his approval
obtained to the proposed procedure before work commences. Breaking into the
existing sewer and construction of the new manhole shall be carried out to the
direction of the Engineer.
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The Contractor shall prevent foreign material entering the existing sewer or
immediately remove any material so entering.

3.8 Testing

3.8.1 Compressive Strength Test

The Contractor shall make six (6) cylinder samples from each 50 cubic meters of
concrete, or fraction thereof, poured during the day for compressive strength test;
following which samples are turned- over to the Engineer for storing, curing and
testing. Concrete test specimens shall be made and tested in accordance with
ASTM C31 and C39.

At least one set of samples for strength test shall be made for each class of
concrete.

The required test specimens may be waived for small concreting works with volume
up to two (2) cubic meters per day. However, such waiver shall not relieve the
Contractor from its responsibility of ensuring that the required strength is attained.

3.8.2 Slump, Air Content and Temperature Determination

Slump, air content and temperature tests shall be made during placement of
concrete at the option of the Engineer and as often as necessary for control checks.
These tests shall be made when specimens for strength tests are taken.

If the measured slump or air content falls outside the specified limits, a check test
shall be made immediately on another portion of the same composite sample. In
the event of a second failure, the concrete shall be considered to have failed the
requirements of the specification and the whole batch shall be rejected.

3.8.3 Basis of Acceptance / Rejection

Final acceptance of all concrete will be based on satisfactory results of

compressive strength tests.

Strength tests representing each class of concrete must meet the following two
requirements:

1. The average of any three consecutive strength tests shall be equal to, or greater
than the specified strength.

2. No individual strength test shall be more than 15% below the specified strength.

Except as provided below, acceptance criteria will be as outlined in ASTM C94 and
ACI 318. Concrete which achieves the required compressive strength will be

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accepted as satisfactory for payment provided placement, finish and tolerance meet
the specified requirements.

Concrete with average strength deficient by not more than fifteen per cent (15%) of
the required strength may be accepted, subject to cost reduction given in the
following schedule:

Table 11 - Cost Reduction Schedule

Per cent (%) Deficiency Per cent (%) of
In Average Strength Unit Price Reduction

Less than 3 0

3 to less than 5 15

5 to less than 10 30

10 to 15 40

more than 15 100

Concrete represented by test results wherein the average strength indicated a

deficiency of not more than fifteen percent (15%) but with an individual test deficient
by more fifteen percent (15%) will not be eligible for payment but may be accepted
or ordered replaced at the discretion of the Engineer.

Concrete represented by compressive strength tests which fail to achieve the

required strength as specified, shall be liable to rejection and subsequent removal
and replacement.

However, if any strength test falls below the specified value by more than 15%, or
an individual test is deficient by more than fifteen percent (15%), and load carrying
capacity has been significantly reduced, tests of cores drilled from the area in
question may be required in accordance with ASTM C42, wherein L/D ratio is not
less than 1.25 prior to capping. In such cases, three (3) cores shall be taken for
each strength test more than 15% below the required value.

If concrete in the structure will be dry under service conditions, cores shall be air
dried for 7 days before test and shall be tested dry. If concrete in the structure will
be more than superficially wet under service conditions, cores shall be immersed in
water for at least 40 hours and be tested wet.

Concrete in an area represented by core tests shall be considered structurally

adequate if the average of three (3) cores is equal to at least 85 % of the specified
strength, and if no single core is less than 75 % of the minimum requirement.
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Additional testing of cores extracted from locations represented by erratic core

strength results shall be permitted.

Acceptance and subsequent payment of concrete in question shall be based on the

results of such tests, provided the complete operation has been supervised by the
Engineer.

Rebound hammer test in accordance with ASTM C805 may be carried out by the
Contractor prior to drilling core samples from the structure in question, but the
results of such rebound tests shall not be used as basis for acceptance or rejection
of the concrete.

** END OF SECTION **

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SECTION 004
MATERIALS
PART 1 – GENERAL

1.1 Scope of Work

The WORK includes providing sewer pipes, fittings, other materials and all
appurtenant work complete in place.

1.2 Related Sections

Other Sections of the Specifications shall also apply to the extent required for
proper performance of this WORK.

Section 006 Sewer Testing

Section 005 Laying and Jointing of Sewers

1.3 Specifications and Standards

Except as otherwise indicated, the current editions of the following Standards (or
equivalent International Standards) apply to the WORK of this Section. The
specification requirement referred to by this Standard shall be regarded as the
minimum requirement.

ASTM A48 Gray Iron Castings

ASTM A82 Steel Wire, Plain, for Concrete Reinforcement

ASTM A153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A185 Steel Welded Wire Fabric, Plain, for Concrete

Reinforcement

ASTM A276 Stainless Steel Bars and Shapes

ASTM A307 Carbon Steel Bolts and Studs, 60,000 PSI Tensile
Strength
ASTM A496 Steel Wire, Deformed, for Concrete Reinforcement

ASTM A615 Deformed and Plain Billet-Steel Bars for Concrete

Reinforcement

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ASTM C33 Concrete Aggregates

ASTM C76 Reinforced Concrete Culvert, Storm Drain, and Sewer

Pipe

ASTM C150 Portland Cement

ASTM C443 Joints for Circular Concrete Sewer and Culvert Pipe,
Using Rubber Gaskets

ASTM D2729 Poly(Vinyl Chloride) (PVC) Sewer Pipe and Fittings

ASTM D2751 Acrylonitrile-Butadiene-Styrene (ABS) Sewer Pipe and

Fittings

ASTM D3034 Type PSM Poly(Vinyl Chloride)(PVC) Sewer Pipe and

Fittings

ASTM D3350 Polyethylene Plastics Pipe and Fittings Materials

ASTM F593 Stainless Steel Bolts, Hex Cap Screw and Studs

ASTM F594 Stainless Steel Nuts

ASTM F894 Polyethylene (PE) Large Diameter Profile Wall Sewer

and Drain Pipe

AWWA C104 Ductile Iron and Gray Iron Fittings, 3 in. through 48 in.
for Water

AWWA C110 Cement Mortar Lining for Ductile-Iron Pipe and Fittings
for Water

AWWA C151 Ductile-Iron Pipe, Centrifugally Cast, for Water

AWWA C200 Steel Water Pipe 150 mm (6 in.) and Larger

AWWA C203 Coal Tar Protective Coatings and Linings for Steel
Water Pipelines – Enamel and Tape – Hot Applied

AWWA C205 Cement Mortar Protective Lining and Coating for Steel
Water Pipe 100 mm (4 in.) and Larger – Shop Applied

AWWA C210 Liquid Epoxy Coating Systems for the Interior and

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Exterior of Steel Water Pipelines

AWWA C602 Cement Mortar Lining of Water Pipelines In Place 100

mm (4 in.) and Larger

ISO 4427 P Polyethylene (PE) Pipes for Water Supply

ISO 4435/PNS Plastics piping systems for non-pressure underground

1952 drainage and sewerage –Unplasticized poly(vinyl
chloride) (PVC-u)

1.4 Submittals

The Contractor shall submit the following:

A. Shop drawings and/or material sample for approval by Maynilad

B. Manufacturer’s brochures showing technical data and instructions for

installation and jointing.

C. ISO 9000 Certificate in the manufacture of sewer pipes and fittings, if any

1.5 Quality assurance

The Contractor/Manufacturer is responsible for the performance of all tests and

inspection required by this Standard Specification. The Contractor/Manufacturer
shall furnish Engineer copies of test records certified by an independent laboratory
indicating that materials required by this specification have been tested and
complied with all applicable requirements of this Standard. The Contractor shall,
at his own expense, replace all rejected materials for failure to comply with this
Specification or for failure to satisfactorily meet the expected performance during
actual installation. The Engineer shall witness any or all prescribed tests and
inspection at the manufacturer’s plant if such tests are not available at any
accredited independent laboratory to ensure that delivered materials conform to
the specifications.

PART 2 – PRODUCTS

2.1 General

The type of material for pipes and fittings including other materials shall be as
specified in the Contract Documents or as approved by the Engineer.

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2.2 Material

2.2.1 Reinforced Concrete Sewer Pipe

Reinforced Concrete Sewer pipe shall be designed in accordance with ASTM

C76M and is classified according to pipe crushing test load or the three-edge
bearing strength which varies with wall thickness and reinforcement.
The cement used to manufacture concrete pipe shall conform to ASTM C150 Type
II. Aggregates shall meet the requirements of ASTM C33 except that the
requirement for gradation shall not apply. Steel reinforcement shall be either
conforming to ASTM A82 or ASTM A496 or of wire fabric conforming to ASTM
A185 or ASTM A497 or of plain billet-steel bars conforming to ASTM A615M.

The reinforced concrete sewer pipe joints shall be bell and spigot or tongue and
groove with flexible, watertight rubber gasket joints conforming to ASTM C443 or
as specified in the Drawings.

Fittings for use with reinforced concrete pipe shall be of equal thickness of wall
and minimum cover for reinforcement as required for pipe. Fittings shall be shop
fabricated unless otherwise specified or shown on the drawings.

2.2.2 Unplasticized Polyvinyl Chloride (uPVC) Pipe and Fittings – Sewer

Unplasticized PVC pipes and fittings for sewers and drains shall be made from
PVC 12454B or PVC 12454C conforming to the provisions of ASTM D2729.

Dimensional requirement shall be in accordance with ISO 4422-2.

For gravity sewer and drain pipes, the Standard Dimension Ratio (SDR) for
unplasticized PVC pipes shall be equal to or less than SDR 34 for pipe with an
earth cover equal to or less than 6 meters.

For force mains, the Standard Dimension Ratio (SDR) for unplasticized PVC pipes
shall be equal to or less than SDR 21 for depth of cover not greater than 6 meters.

The tolerances for outside diameter and wall thickness for unplasticized PVC
sewer and drain pipes shall be in accordance with ISO 11922-1.

PVC pipes joints shall be elastomeric ring seal for sizes 110mm and above or
solvent cement for sizes 110 – 200mm as specified in PNS 1952. The
manufacturer shall indicate the type of joints in the shop drawings.

Color shall be orange brown approximately RAL 8023.

2.2.3 Unplasticized Polyvinyl Chloride (uPVC) Pipe and Fittings – Water

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Unplasticized PVC pressure pipes and fittings shall comply with the provisions of
ISO 4422 and PNS-65.

Pipe rating shall be Series 8 minimum conforming to PNS-65 or ISO 4422.

Joints shall be push-on-type joints or plain end or couplings.

2.2.4 Ductile Iron Pipe (Gravity and Pressure Sewer) and Fittings

Ductile Iron (DI) pipes shall conform to AWWA C151. Pipes and fittings shall be
cement mortar lined in conformance with AWWA C104 and shall have an exterior
bituminous coating conforming to the requirements of AWWA C110.

DI pipe is permitted for force mains and internal piping of pump stations. DI pipe
shall be used for gravity sewers only where it is needed, to take the advantages of
the high strength of ductile iron, e.g. shallow cover sewers subjected to high live
load or sewers of above ground applications.

Pipes shall have flexible joints, i.e. spigot-socket rubber seal joints or mechanical
joints, except for pump station pipe works and valve connections where flange
shall be used.

Unless otherwise approved by Maynilad, all fittings and accessories shall be

provided with external and internal epoxy coating.

Polyethylene sleeving shall be used for all the buried pipes and fittings.

2.2.5 Steel Pipes and Fittings

Steel pipes and fittings shall comply with the provisions of AWWA C200. Steel
pipes will undergo corrosion when in contact with aggressive soil and sewage and
thus, require an internal lining in the shop in accordance with AWWA C205 0r
AWWA C210 or in place in accordance with AWWA C602 and external coating
either in accordance with AWWA C203 (bituminous enamel) or AWWA C205
(cement mortar lining and coating).

Pipe joints are normally welded, utilizing either spigot-socket ends, plain ends, or a
collar. Flanged and mechanical joints are also applicable.

Steel pipes are permitted only for inverted siphons (depressed sewers) and
internal pump station pipeworks. For force main larger than 700 mm, steel pipe
may be used if the approval from Maynilad is obtained.

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A spigot and socket joint welded both externally and internally shall be used for
pipe joints except for pump station pipeworks and valve connections where flange
joints shall be used. Mechanical joints are only permitted for cut pipe lengths,
where internal cement mortar lining at joints is not possible and where movement
of the pipeline is to be allowed for.

Following the completion of pipe jointing, exposed steel and joints shall be
protected from corrosion by manually applied external tape wrap and internal
cement mortar lining.

Minimum Wall Thickness for Steel Pipes (for depth of cover of 1.2m to 2.5m only
shall be as follows:

Nominal Diameter (mm) Nominal wall Thickness (mm)

400 - 600 4.76
750 6.35
900 - 1050 7.93
1200 8.10

Acceptable joints shall be:

a) 400mm to 500mm – Joints shall be flanged, or shall be plain end on

sleeve type coupling.

b) 600mm and above – Welded joints will be acceptable, provided the

Contractor can demonstrate his ability to restore lining in-situ in
advance of the work being undertaken.

2.2.6 High Density Polyethylene (HDPE)

2.2.6.1 Solid Wall HDPE Pipe

Polyethylene (PE) pipe is resistant to sulphuric acid of concentrations that might

be found in septic sewage under the worst conditions. Thus, high density PE
(HDPE) is used for sewerage applications. The color of the Polyethylene (PE)
pipe shall be orange brown approximately RAL 8023 or as approved by
Maynilad.

This pipe is normally butt fusion jointed. PE pipe is classified by pressure rating
with static working pressures up to 1.6 MPa.

Since PE pipes are flexible, the design of the pipe trench system is more critical
than for rigid pipe materials. Compared to rigid pipes, the stability of flexible
pipes relies more on the side support of the earth backfill around the pipe.

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Consequently, in an urban environment, where the side support may be

removed during future adjacent construction of underground services, pipe
failures could be more frequent. Ground conditions which provide poor pipe side
support are unsuitable for flexible PE pipes.

Solid wall HDPE pipes are suitable for buried pressure sewer installations. Butt
fusion joints shall be used for PE pipes. Solid wall pipes for pressure main
application shall be of minimum PE100-PN10. The use of specific strength shall
depend on the depth and nature of the soil as confirmed by the Designer.

2.2.6.2 Profiled Wall PE Pipe

A profiled wall pipe is a pipe with a plain inside surface and with a ribbed or
corrugated outside surface. The ribs or corrugations are normally either aligned
circumferentially or helically. These corrugated or ribbed profiles optimize the
pipe ring stiffness to weight ratio. The pipe can be designed with double-wall
profile or triple-wall profile.

Profiled wall pipe shall withstand an earth load of 6 meter minimum. Pipes shall
be in accordance with ASTM F894 – Polyethylene (PE) Large Diameter Profile
Wall Sewer and Drain Pipe. Pipe material shall conform to ASTM 3350 or ISO
4427 classified as PE 100.

The standard joint is a flexible spigot-socket joint with rubber seal.

Pipes from specific manufacturers in this category may be permitted by Maynilad

to be used for gravity sewers where special circumstances require the benefits
of such pipes.

2.2.7 Acrylonitrile Butadiene Styrene Pipe

Acrylonitrile Butadiene Styrene (ABS) pipe is a thermoplastic pipe.

ABS pipe is classified by internal pressure resistance. It comes in various static

working pressure ratings up to 1.5 MPa. Minimum PN rating shall be 10 bars.

The most common jointing method is by solvent cementing. The cementing

jointing process is more complex than the jointing process of uPVC pipe. A
spigot/socket rubber ring joint is generally not available. Because of the care
required to make a solvent cement joint, particularly in larger diameters, the
jointing of ABS pipe requires special trainings.
ABS, like uPVC and PE, is resistant to corrosion in the most corrosive sewage
environment that could occur. ABS is used in a range of applications requiring
pressure pipe. Because of its excellent resistance to abrasion and UV

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degradation, ABS has found use in industrial and mining applications and also in
treatment plants for sewage and water.

ABS pipes may be permitted for force mains under special circumstances which
require the benefits of such pipes. If used, the approval of Maynilad is required.
ABS pipes may be permitted for use in buried forced mains and buried
interconnecting pipe-works in pump stations.

2.2.8 Pre-Cast Concrete Manholes

Pre-cast concrete sections shall conform to ASTM C76, Class IV Wall C or Wall
B. Sections shall have tongue and groove joints.

Pre-cast concrete manhole units of circular section shall comply with the relevant
provisions of ASTM C76, Class IV, Wall C/B. Units, which fit into bases, shall be
designed and manufactured so that the imposed vertical loads are transmitted
directly through the full wall thickness of the unit. Section shall have tongue and
groove joints.

2.2.9 Manhole Frames and Covers

Manhole covers and frame casting shall comply with ASTM A48 Class 30C for
cast iron and ASTM A563 for ductile iron.

Manhole covers and frames shall have a minimum clear opening of 600mm or
900mm as specified in the contract documents. All covers shall be non-rocking.

Locking keys and lift handle or pry bar hole shall be provided with the frames
and covers.

Frames and covers shall be designed to carry AASHTO H-20 traffic loading.

2.2.10 Manhole Step Iron (Ladder Rungs)

Ladder rung for sewage treatment plants and sewer manhole shall be 20mm
diameter stainless steel in conformance with ASTM A276 Type 304.

Steps shall have a serrated drop section surface designed for non-slip use and
fixed at 400mm vertical center, not more than 150mm from the top of the
manhole chamber and not more than 400mm from the bottom.

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2.2.11 Marker Tapes

Marker tape for buried sewer mains shall be colored green PVC or polyethylene
mesh or ribbon at least 50mm wide, incorporating a corrosion resistant tracing
system.

The marker tape shall be printed with the words “WATER PIPES BELOW “ or
“SEWER PIPES BELOW” in bold capital letters at intervals not exceeding
500mm.

2.2.12 Nuts, Screws, Washers and Bolts

Bolts, anchor bolts, nuts and washers shall be of low carbon steel, grade B of
ASTM A307 and shall be hot-dipped galvanized in accordance with ASTM A153.
Bolt head and nut shapes shall be hexagonal and shall conform to ISO 272.
Each bolt shall be long enough to extend entirely through the nut but not more
than four (4) threads beyond. Washers shall be provided under nuts and under
the heads of bolts.

Bolt length shall be sufficient to ensure that nuts are full threaded when
tightened in their final position.

Stainless steel nuts, screws, washers and bolts shall generally be used
throughout the Works and shall comply with the relevant provisions of ASTM
F593 and ASTM F594.

Where bolting is incompatible with the material being fixed, suitable isolating
washers and sleeves shall be used.

2.2.13 Rubber Gaskets for Mechanical and Push-On Joints

Rubber gaskets for mechanical and push-on joints shall be continuous ring-type,
made of special composition rubber in accordance with the respective pipe
standard specifications. Each gasket shall have a dense, homogenous section,
a smooth surface free of blisters, pits and other imperfections and shall be of
sufficient volume to fill the groove when the joint is assembled to make the joint
watertight.

2.2.14 Rubber Gaskets for Flanged Joints

Gaskets for flanged joints shall generally be of the inside-bolt-circle type. They
shall have a nominal thickness of 3mm and shall be EPDM Rubber or SBR.

2.3 MARKINGS

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Where applicable, pipes and fittings shall bear permanent identification markings
that will remain legible during normal handling, storage, installation and service
life. Markings shall be applied in a manner that will not reduce the strength nor
otherwise damage the products.

Markings shall include the following information:

A. Manufacturer’s name and/or trade mark

B. Nominal size (DN) in mm and class or SDR

C. Year of manufacture

D. Type of Material (i.e. Ductile Iron. PVC, HDPE, etc.)

E. The word “Maynilad”

PART 3 – EXECUTION

3.1 Installation

Unless otherwise specified in the Contract, the use, installation, application or

fixing of materials and components shall be in accordance with all applicable
standards for each type of material and or recommendations of the manufacturers.
Where appropriate, the Contractor shall make use of any technical advisory
services offered by manufacturers.

3.2 Testing

A. Shop Testing

Inspection and test of pipes and fittings shall be in accordance with the
following:

1) Reinforced Concrete Sewer Pipe (RCP): ASTM C76

2) Unplasticized Polyvinyl Chloride Pipe (uPVC): ASTMD2729, ISO 4422,

PNS 1952, ASTM D3034 for fabricated fittings and ISO 4435 for molded
fittings

3) Ductile Iron Pipe (Gravity and Pressure Sewer) and Fittings (DI): AWWA
C151, AWWA C104, AWWA C110.

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4) Steel Pipes and Fittings (SP): AWWA C200, AWWA C203, AWWA C205,
AWWA C210 and AWWA C602

5) High Density Polyethylene (HDPE): ISO 4427

6) Acrylonitrile Butadiene Styrene Pipe (ABS): ASTM D2751

B. Field Testing

Field testing shall be in accordance with Section 006.

** END OF SECTION **

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SECTION 005
LAYING AND JOINTING OF SEWERS

PART 1 – GENERAL

1.1 Scope of Work

The Work of this Section includes standard methods of pipelaying, jointing and
their appurtenances for sewer network in conformity with the lines and grades
shown on the Contract Drawings or as established by MAYNILAD.

.
1.2 Related Sections

Other Sections of the Specifications shall also apply to the extent required for
proper performance of this Work.

Section 001 General Requirements

Section 004 Materials

Section 006 Sewer Testing

Section 008 Protective Coatings to Metal Works

1.2 Specifications and Standards

Except as otherwise indicated, the current editions of the following Standards (or
equivalent International Standards) shall apply to the WORK of this Section. The
specification requirement referred to by this Standard shall be regarded as the
minimum requirement.

AWWA C206 Field Welding of Steel Water Pipe

AWWA C210 Liquid Epoxy Coating Systems for the Interior

and Exterior of Steel Water Pipelines

AWWA Manual M9 Installation of Concrete Pipe

AWWA Manual M11 Steel Pipe Design and Installation

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1.3 Submittals

A. Shop Drawings

The Contractor shall submit the following shop drawings for review and approval
of the Engineer:

1. Manufacturer’s recommendations for sewer pipelaying

2. Sewer pipelaying schedule
3. Layout diagrams
4. Construction Method of jacking
5. Construction Method of Crossing Rivers and Esteros
6. Flanges
7. Sleeve Type Couplings / Alternative Flexible Coupling
8. Flange Adaptors
9. Joint Harnesses
10. Thrust and Anchor Blocks

B. Welding Procedure

The Contractor shall submit proposed welding procedures for each type of
welding job.

PART 2 – PRODUCTS

Pipe material shall conform to the requirements specified in Section 004 – Materials.

All pipes shall be of sufficient wall thickness and strength to withstand the cross
sectional (ring) and longitudinal stresses and deflection or deformation resulting from the
critical loading condition of earth load, live load, unbalanced lateral external pressure,
external and internal hydrostatic pressure; acting independently or in combination with
one another.

For pipe material which cannot be provided with restrained joints that can withstand the
thrust at bends, tees, valves and dead ends, the design and construction of the required
thrust blocks shall be the responsibility of the Contractor. The cost thereof shall be
imputed into the cost of the pipeline. The design shall be subject to the approval of
Maynilad.

The Contractor, though complying with such minimum thickness, shall not be relieved
from its liability under the Civil Code of the Philippines, for damages due to pipe failure
attributable to the Contractor’s failure to construct the required thrust blocks/supports in
accordance with sound engineering practice; and to provide the allowance to
compensate for his manufacturing and construction imperfections.

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When the location of manufacturing plants allow, the plants will be inspected periodically
for compliance with specified manufacturing methods, and material samples will be
obtained for laboratory testing for compliance with materials quality requirements.

Prior to and during incorporation of materials in the work, these materials will be
subjected to the latest inspection, tests and approval of Maynilad.

PART 3 – EXECUTION

3.1 GENERAL

The correct installation of sewer system is critical to the efficient and effective
sewer system operation. Poor construction practice causes defects in the sewer at
joints, along pipe barrels, at manholes, transition points (e.g. pipe to manhole), etc.
Adequate site supervision in reference to the approved design drawings shall be
required.

3.2 PIPE HANDLING AT SITE

a.) Pipes shall not be dragged or pushed over the ground.
b.) Pipes and fittings shall not be dropped in any way.
c.) Pipes and fittings shall not knock against each other or any other objects.
d.) The pipe lifting shall be controlled, where necessary, using ropes or by hand
to ensure they do not knocked against other objects.
e.) When rolled, pipes shall be rolled on smooth timber bearers, which are free of
nails, fasteners, etc., and sufficiently raised above the ground to prevent
hitting any rocky ground, tree roots, etc.
f.) When rolled on timbers, pipes shall not be pushed with a machinery bucket.
g.) Pipes with external coatings shall not be rolled. Instead, these pipes shall be
lifted into place.
h.) Pipes and fittings shall be lifted using approved slings.
i.) Pipe lifting equipment shall be of sufficient strength and reach to lift the
intended individual pipe or crate of pipes.
j.) Mechanical lifting units (cranes, backhoes etc.) shall be stable or properly
stabilized prior to lifting operations to ensure they would not tip the damage
pipes and fittings.
k.) The slings or chains used for lifting the load shall be secured to the load in
the right manner to ensure the load does not slip or tilt excessively.
l.) All other safe lifting procedures not covered above shall be adopted.
m.) The lifting and moving of all the steel pipes and any pipes that contain
internal linings shall follow the manufacturer’s instructions.
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3.3 PIPE STORAGE

a.) The pipe and fittings storage area shall be away from traffic and shall not
obstruct any property access or pedestrian route.
b.) The pipe and fittings storage area shall be at a location that allows lifting
machinery to position easily and safely for lifting pipes and fittings.
c.) Pipes shall be stacked on a flat and level firm ground or the base of the pipe
stack shall be made level using additional solid timbers under base bearers.
d.) There shall be no rocks, tree roots, etc. under the pipe stack, which may
cause point load.
e.) The sockets shall be alternated to different ends for each pipe stack layer.
The sockets shall be protruded out of the stack.
f.) The base timber bearers shall be sound and without protrusions. The cross
section of each timber shall be at least 75mm by 75mm. The base bearers
shall provide support near the pipe ends, but placed behind sockets. The
placement of base bears shall not be more than 1.5m apart.
g.) RC, DI and Steel pipe layers shall be separated using timber spacers of at
least 50mm wide and 50mm thick. These spacers shall not be placed more
than 1.5m apart. These spacers will prevent pipes in each layer from touching
pipes in the next layer.
h.) For RC pipes that are not crated, the pipes shall not be stacked more than
three (3) pipes high. The pipe stacked shall be wedged to prevent them from
rolling of the stack.
i.) Thermoplastic pipes (PVC, PE and ABS) shall be stacked in such a way to
prevent them from being twisted or bowed.
j.) Thermoplastic pipes shall be either stacked in a pyramid with no more than
1m high or in a square with vertical side supports for more than 2 pipes high.
k.) Plastic pipes and fittings shall be kept under a cover that prevents direct
exposure to sunlight.
l.) Plastic pipes and fittings shall not be covered with plastic sheeting.
m.) Plastic pipes and fittings shall be stored away from oils, greases, solvents
and other aggressive chemicals.
n.) Plastic pipes shall be stored away from sources of heat such as engine
exhausts.
o.) Care shall be taken to prevent scoring and scratching of plastic pipes and
fittings.
p.) Joint lubricants, rubber rings and other jointing materials shall be stored in a
secured area that cannot be accessed by the public.

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q.) Any safe pipe stacking procedure not covered above, but recommended by
the manufacturer, shall be adopted.
r.) The rubber rings that are not delivered fitted to the pipe socket or sleeve shall
be stored away from direct sunlight or continual artificial light. Also, the rubber
rings shall be stored in a cool area that is away from oils, greases or other
petroleum products.
s.) When rubber rings are delivered fitted to a pipe socket or sleeve, the pipe
ends with the rubber ring shall be shielded from sunlight using a cloth.
t.) Rubber rings shall be retained in the original sealed packaging until they are
required.

3.4 PIPE DAMAGE

a.) Pipe fittings (including coatings and linings) and rubber rings shall be
inspected for damage during delivery, immediately before laying and after
laying.
b.) Damaged pipes and fitting shall be identified and marked with an indelible
marking of “Damaged” in a clearly distinguishable color.
c.) Damage rings shall be cut through completely to prevent inadvertent use.
d.) Damaged pipes, fittings, and rubber rings shall be set aside and separated
from the undamaged components.
e.) Pipes or fittings shall only be repaired if they can be restored back to a
satisfactory state. Approval for repair shall be sought from Maynilad before
the repair.
f.) Pipes or fittings that are damaged and are in repairable state shall be
repaired according to the manufacturer’s instructions.
g.) Damaged pipes and fittings that are not permitted to be repair shall be
removed from the site as soon as possible.
h.) PVC, PE and ABS pipes with damage in the barrel, shall have the damaged
section at least 100mm either side of the damage cut from the barrel.
i.) Repaired pipes and fittings shall be used only after the approval for reuse
from Maynilad is granted.

3.5 PIPELAYING

3.5.1 Pipe Bedding

a.) Only approved materials are allowed to be use for pipe embedment. They
shall be in accordance to the approved longitudinal and cross-sectional sewer
profile drawings, which shall also, provided details of the designed beddings
types.

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b.) The bedding material shall be placed as soon as possible after the base of
the trench is prepared and excess water has been removed.
c.) Granular bedding shall be placed, compacted and graded so that it offers
continuous support to the sewer. The compacting, where required, shall
achieve a uniform density.
d.) A small hole shall be left in granular bedding for each socket, jointing sleeve,
flange, etc. that may project into the bedding. The holes shall be of size that
is just sufficient for projections to be clear of bedding. Long and large holes
that may undermine the pipe barrel support are not allowed.
e.) A recess shall be made in the bedding to permit the withdrawal of the sling
without disturbing the remaining bedding.
f.) Where the bedding is disturbed, the pipe shall be raised again to repair the
bedding.
g.) Pegs of other temporary aids to leveling shall be removed before pipelaying.

3.5.2 Pipe and Fittings Placement

a.) Before lowering the pipes into the trench, pipes shall be placed next to the
trench away from the trench edge. The pipes shall be placed on the opposite
side of the spoil beside the trench with their sockets facing upstream. Where
required, the pipes shall be blocked or chocked to prevent any rolling.
b.) Pipes and fittings (including linings, sheathings and protective paintworks)
shall be checked for damage before and after laying in the trench.
c.) Pipe and fittings shall not be dropped into the trench. Instead, pipes shall be
lowered into the trench using approved slings.
d.) Pipes shall be laid from the downstream end towards the upstream end or in
accordance with the Contractor’s methodology approved by Maynilad.
e.) The laying of pipes shall proceed carefully to ensure the line; level and grade
are within the specified tolerances.
f.) Pipes shall not be dropped or impacted forcefully into the bedding to obtain
the specified level or grade.
g.) Concrete pipes with elliptical reinforcement shall be laid with the load line on
the vertical axis at the top or bottom position.
h.) Holes made in granular bedding for projections of sockets, flanges, etc. shall
be lightly filled where necessary without pushing the pipe/fitting off line, level
or grade.
i.) Bedding shall be checked to ensure continuous support along the pipe barrel.
Further bedding material shall be placed to an even height and uniformly
compacted across the trench to ensure the full support of the pipe haunch.

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j.) Pipes that are laid on concrete, grout, cement stabilized bedding or
connected to a concrete structure shall consist of a flexible joint at the
upstream end immediately outside such a zone.
k.) Pipe level, grade and alignment shall be sighted using sight rails and boning
rod or laser and target. They shall be in accordance to the approved
longitudinal and cross-sectional sewer profile drawings, which shall be
submitted for approval before work at site is allowed to begin.
l.) The invert level of each pipe laid shall be checked during laying and
immediately after laying completion, and with reference to the approved
contract drawings.
m.) Boning rods shall have a foot to rest on the pipe invert with a vertical spirit
level attached and shall not be more than 45m apart.
n.) The pipe interior shall be cleaned after laying and kept clean and free of
water.
o.) The pipes ends shall be sealed with a tightly fitting plug immediately after
laying, cleaning of the pipe interior and at the end of the day after pipelaying.
p.) The branch arm of the oblique branch junction fitting, if installed, shall be laid
in such a way that it is at approximately 45º off horizontal level.
q.) Junction fittings shall be properly supported using well-compacted crushed
rock (or, where required, concrete). The coverage of the support shall be
across to the trench wall and into the junction trench.
r.) Branch connections shall be sealed with an approved plug where
connections are to be made at the later time.
s.) Any pipe laid that is out of alignment either vertically or horizontally or shows
undue settlement shall be taken up and re-laid correctly.
t.) Photographs shall be taken during pipelaying and after sewer pipelaying for
all lengths of pipes and manholes.

3.5.3 Pipe Jacking

a.) Jacking method of pipelaying shall be employed only when the conditions
require such a method.
b.) The pipes used for jacking shall be able to withstand the laterally induced
jacking stresses without damage.
c.) The setting out of the guide rails for the pipe and the actual jacking
operations shall maintain a high accuracy level of the line and grade.
d.) The direction and grade for jacked sewer shall not deviate from the designed
alignment for more than 100mm for every 100meters of sewer.
e.) All the joint used for connecting the jacked pipes shall be watertight and
durable.
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3.5.4 Concrete Pipe Support

a.) Concrete used shall be 20Mpa Portland cement concrete with a slump no
greater than 80mm or as specified in the Contract Drawings.
b.) When purpose made pre-cast concrete blocks are used, the block shall have
approximately the same width as the trench and shall be positioned just
behind each pipe socket. A compressible packer of polystyrene or particle
board shall be placed between the pipe and the concrete block.
c.) Concrete shall be poured in one lift.
d.) Pipes shall be prevented from floating or other movement during concrete
pouring.
e.) A space shall be left between the concrete supports for the pipe socket by
use of the polystyrene spacer of 20mm minimum thickness. This is to retain
rotational flexibility at the joints.
f.) The concrete support shall fit the pipe closely after hardening.
g.) Concrete shall be allowed to cure for at least 7 days before applying any
load.
h.) Where the trench base is soft or puddly, a blinding layer shall be placed on
the trench base before the concrete is placed.

3.5.5 Pipe Cutting

a.) Only HDPE, ABS and DI pipes are permitted to be cut in the field. However
prior approval from the Engineer is required should the HDPE helically wound
profile wall pipe needs to be cut in the field. All pipes shall be cut in
accordance to approved methods.
b.) Rough edges and burrs shall be removed from inside and outside of HDPE
and ABS pipe with a rasp or file.
c.) Pipes shall be cut in a neat and skillful manner by workers experienced in
pipe cutting.
d.) Pipes shall be cut perpendicularly to the pipe axis.
e.) Any damage to the cement lining of DI pipes shall be repaired to the
satisfaction of Maynilad.

3.6 PIPE JOINTING

3.6.1 Flexible Joints

a.) Joint components (i.e. spigots and sockets or sleeves and rubber seals) shall
be checked for damage after delivery, before and after delivery, before and
after usage.
b.) Every part of the rubber ring shall be bent by hand to detect cracks.

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c.) Steel sleeve collars used for jacking pipe shall be checked for damage to the
coating.
d.) Pipe jointing surfaces and rubber seals shall be wiped clean immediately
before jointing using a clean cloth.
e.) The rubber ring shall be placed correctly around the pipe joint.
f.) The rubber ring shall not be twisted in any way prior to jointing and shall be
seated in the correct position.
g.) For skid type of joints (i.e. the sealing rings remains stationary and does not
roll into place), the spigot shall be lubricated with an approved lubricant.
h.) The pipe to be jointed shall be aligned with the laid sewer before pushing in
the joint.
i.) The pipe to be laid shall be oriented so that the offset inside the pipe at the
joint is minimize at the invert.
j.) The pipe that is already laid and to be connected to another pipe shall be
restrained to prevent its pipe joints being further stressed and to prevent the
laid pipe from being pushed off grade or alignment.
k.) Pipe joints shall be connected using a bar and block (crow bar and a block of
wood to protect the pipe end) or a pipe puller.
l.) A machine bucket shall only be used to connect a pipe joint where approval is
given by Maynilad. This method shall only be used for large diameter pipes
(larger than 600mm diameter pipe) where the jointing compression force
makes it possible to use a bar and block or pipe puller. A timber shall be
place across the pipe end to protect the pipe from damage. Pressure shall be
applied by the bucket gently while the insertion shall be carefully monitored
and directed by a person next to the joint.
m.) No excessive force shall be applied to make the joint.
n.) After pushing the spigot into the socket, the seal shall be checked to ensure
the seal is correctly located and the spigot is properly inserted. No
contaminants are allowed between jointing surfaces. The joint or pipe shall
not have damage from jointing.
o.) Any allowable deflections at joint shall only be made after the pipe jointing is
made.
p.) Where a pipe is to be deflected at a joint, the deflection shall not exceed the
allowable limit for the specific type of joint.

3.6.2 Solvent Weld Joints

a.) The socket and spigot shall be checked for damage before and after jointing.

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b.) Damage spigot ends shall be cut from the pipe with 100mm clearance to the
damage. The spigot end shall be cut perpendicularly to the pipe and burrs
shall be removed.
c.) The spigot shall be inserted up to the witness mark.
d.) If a witness mark is not already on the pipe, the mark shall be made to ensure
that the spigot is inserted to the appropriate length.
e.) Witness marks drawn on site shall be made with a soft pencil or felt pen
marker that would not score or scratch the pipe.
f.) The witness mark shall be of the depth of the socket and shall be measured
from the pipe end.
g.) A dry fit of the joint shall be made before the jointing.
h.) Jointing surfaces shall be wiped clean and dried with a clean cloth.
i.) Jointing surfaces shall be primed using an approved priming solution. The
priming shall be applied with a clean cloth or swab freshly dipped in the fluid
immediately before jointing.
j.) A thin surface and even coat of solvent cement shall be applied to the socket
and the spigot, which should then be inserted up to the witness mark.
k.) The jointing surfaces shall not be contaminated with water, dirt, etc.
l.) The jointing shall be made immediately after the application of solvent
cement.
m.) After the spigot is pushed firmly into the socket, the joint shall be hold in the
same position for at least 30 seconds without moving.
n.) The jointed shall not be move for at least 5 minutes after jointing. The jointed
pipes shall be handled with extreme care for at least another hour.
o.) Joints shall be left to dry for at least 24 hours before pressure testing.
p.) Containers of solvent cement and primer shall be kept tightly sealed when not
in use.
q.) Solvent cement and priming fluid are highly flammable. Therefore, the
solutions shall be stored in a cool place away from any source of spark or
fire.

3.6.3 Flanged Joints

a.) Flanges particularly flange faces and rubber seal shall be checked for
damage before and after jointing.
b.) Appropriate metal backing plates shall be used on plastic flanged pipe.
c.) Screwed-on flanges shall have the screw thread sealed with a compound
suitable for sewers.

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d.) Flanged ends shall be correctly aligned before jointing.

e.) A steel bar or similar object shall not be used as a lever through the flange
holes to bring the bolt holed into line prior to bolting.
f.) The rubber seal between flanges shall be made for an approved compound
and shall meet the specified requirements.
g.) The flange faces and the rubber seal shall be wiped clean with a cloth
immediately before jointing.
h.) Bolts shall be tightened evenly and gradually in rotation.
i.) Bolts and nuts shall be tightened with a torque trench set at an appropriate
torque.
j.) Plastic flanges shall not be distorted before or after jointing.

k.) After pressure testing, metal flanges shall be painted with two coats of
bituminous coating.

3.6.4 Steel Pipe Welded Joints (Field Welding)

a.) The welded joint shall use a socket-spigot joint with taper sleeve wherever
possible.
b.) Welding surfaces shall be cleaned to a bright metallic finish before welding.
c.) Welders shall be qualified in accordance with the requirements of AWS
Standards.
d.) Welding procedures shall be tested, qualified and approved in accordance
with the American Welding Society standards.
e.) Welds shall be inspected and tested in accordance with AWWA C206.
f.) After welding, exposed external surfaces shall be cleaned by sand blasting or
wire brushing. The dry surface shall be wrapped in an approved manner with
an approved wrapping tape to provide corrosion resistance.

3.6.5 Polyethylene Butt Weld Joints

a.) The pipes to be joined shall be of the same grade of polyethylene and of the
same wall thickness.
b.) The butt-welding machine shall be of an approved type and shall be fit for
use.
c.) The welding machine shall be sheltered from wind and rain during the
welding process.
d.) A practice weld shall be performed and discarded to check the operational
effectiveness of the machine.
e.) The pipe ends shall be trimmed square.
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f.) The ends to be jointed shall be kept free of dirt, grease and moisture after
trimming.
g.) The heating plate shall be brought into contact with the pipe ends only after it
is at the correct temperature.
h.) The pipe ends shall be held against the heating plate of the specified time
appropriate for that pipe size.
i.) Immediately after removal of the heating plate (no longer than 15 seconds
after heating), the pipe ends shall be pressed together with an appropriate
pressure for a specified time appropriate for that pipe size.
j.) The joint shall be maintained clamped and pressurized in the machine for a
suitable period of cooling time (approx. 10 minutes minimum).
k.) After removed from the machine, the joint shall not be stressed until it has
completely cooled (approx. 10 minute minimum).
l.) The weld shall not be artificially cooled with cold air or water.
m.) The external bead shall carefully be removed. The joint zone shall be
thoroughly checked.
n.) A pipe end that has undergone a complete heating cycle but not joined shall
not be reheated. The unjoined pipe end shall be cut off to at least 250mm
from the end.

3.7 SPECIAL REQUIREMENTS FOR SEWER

3.7.1 Thrust blocks for Pressure Pipelines

For pipe up to and including 300 mm diameter, thrust or anchor blocks shall be provided
to tees, plugs, caps and at bends of 11 degrees or larger.
Blocks shall be Class B concrete (17 MPa) and placed against solid undisturbed ground
in a manner that will allow accessibility to the joints for repair.

Assumed soil bearing pressure shall be 100 kPa unless another value is designated by
Engineer for a particular soil.

Where thrust blocks are not allowed as indicated below or when thrust blocks are not
permitted due to utilities and other interferences, joints are to be restrained to the
required length “L” on both sides of the bend and on upstream run of a dead end.

Where joints are to be restrained, the length “L” shall be computed by the following
formula:

L = 1.25 Pt A sin  / 2
F ( Wp + Ww + We )

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Where

L = Length to be restrained (m)

Pt = Internal pressure during field hydrostatic test (kgf /

mm²)

A = Cross-sectional area of pipe (mm²)

Wp = Weight of pipe (kg / m)

Ww = Weight of water inside pipe (kg/m)

We = ( ) x (Bc) x (Ha), weight of earth cover (kg/m)

 = Submerged unit weight of soil (kg/m³)

Bc = Outside diameter of conduit (m)

Ha = Depth of soil between top of pipe and top of pipe

zone (m)

Ø = Deflection angle of bend in degrees

F = Friction coefficient = 0.40

1.25 = Safety factor

a.) The thrust block shall be extended to approximately 180º around the fitting.
b.) The thrust block shall not cover a flexible joint.
c.) The thrust block shall be constructed equally around the centerline of the
fitting.
d.) The thrust block shall bear firmly against a recess at the side of the trench.
e.) The trench face which the thrust block bears against shall be freshly cut and
undisturbed.
f.) Each thrust block shall have sufficient bearing areas.
g.) Thrust block shall be cast-in-place with 20Mpa concrete.
h.) For plastic pipe or pipe with a protective coating, a compressible membrane
of rubber, felt or cork shall be placed on the pipe to protect it from damage
from its movement in the thrust block.
i.) Formwork shall be used to cast the thrust block to the required dimensions.

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j.) Formworks shall be removed before any testing.

k.) Reference shall make to the standard drawings for thrust block to ensure
proper shape size, which must be designed for each individual thrust blocks.

3.7.2 Pipe Restraints and Bulkheads on Steep Slopes

a.) A bulkhead to prevent soil erosion shall be used where the gradient of the
sewer is steeper than 1 in 40.
b.) A restraint to prevent sewer slippage shall be used where the gradient of the
sewer is steeper than 1 in 6.
c.) The restraints or bulkhead shall be placed at the downstream side of the
socket.
d.) Concrete bulkheads shall be keyed into the base and sides of the trench by
at least 100mm
e.) A weep hole with the upstream end covered with a geotextile filter shall be
provided through a bulkhead immediately above pipe invert to allow drainage
of groundwater.

3.7.3 Pipe Embedment and Overlay

a.) The embedment material type and its grading shall take considerations of the
sewer type or length.
b.) Reference shall be made to the approved longitudinal and cross-sectional
drawings of the sewers showing the bedding types, which shall be designed,
based on supporting soil reports.
c.) Embedment material shall not be contaminated with other soils.
d.) Embedment material shall be brought up evenly in layers on each side of the
pipe.
e.) Each embedment layer shall be placed to a depth that permits the
compaction equipment to achieve the specified density.
f.) The pipe shall not be pushed of alignment, level or grade while placing the
embedment.
g.) Where the embedment requires tamping, tamping equipment shall not come
into contact with the pipe.
h.) Temporary trench wall support shall be lifted when the embedment is
compacted.
i.) While placing the embedment for the pipe haunches, unnecessarily voided
areas shall be avoided.
j.) At least 300mm of cover shall be placed over the pipe before light mechanical
compaction, such as a hand-operated whacker, can commence.

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3.7.4 Sleeving of Ductile Iron Pipe

a.) Plastic sleeve shall be secured immediately behind the second spigot jointing
witness mark with three overlapping turns of adhesive tape. After that, sleeve
shall be tightly wrapped around the pipe by folding over surplus sleeving.
Then, the sleeving shall be further secured with three winds of overlapping
adhesive tape at one-meter intervals.
b.) The pipe shall be placed in the trench with the folding of the sleeve located at
the top of the pipe.
c.) After the pipe jointing, the sleeve of the preceding pipe shall be brought over
to cover the socket and the cover shall follow the socket outer surface
closely.
d.) The sleeve of the preceding pipe shall overlap the sleeve of the next pipe.
The sleeve overlap shall be secured with three overlapping winds of tape.

3.7.5 ‘Rocker ‘ Pipe Connections to Manholes

a.) The ‘rocker’ pipe connecting sewers to manholes shall have sufficient cast in-
situ concrete surround and extended concrete base as in typical manholes
drawings shown in the Contract Drawings.

** END OF SECTION **

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SECTION 006
SEWER TESTING
PART 1 – GENERAL

1.1 Scope of Work

The WORK includes procedures for the conduct of test for sewer mains.

1.2 Submittals

The Contractor shall submit a sketch for each section of sewer line to be tested.
The sketch shall include the section schematically in profile; and show point of air
release or water injection and the point of observation.

PART 2 – PRODUCTS

Not used.

PART 3 – EXECUTION

3.1 GENERAL

Sewers and ancillary works shall be tested and inspected for water-tightness to
prevent infiltration and exfiltration and to ensure the pipes are laid correctly
according to the design straightness and grade. The testing of the sewers and
ancillary works before backfill will facilitate the replacement of any identified
faulty pipes and joints. The testing of the sewers and ancillary works after backfill
will reveal the leakages cause by the displacement of joints and subsequent
damage. The testing shall be conducted by the Engineer in the presence of the
Contractor.

3.2 TESTING OF NON-PRESSURE PIPELINES

Non-pressure pipelines laid in open excavation shall be tested after they are
jointed and before any concreting or backfilling is commenced, other than such
as maybe necessary for structural stability while under test.

The pipelines shall generally be tested by means of an air or water test or in

certain circumstances by a visual or closed circuit television (CCTV) examination
as required by Maynilad, in length determined by the course of construction, in
accordance with a schedule approved by Maynilad.

Final test shall be carried out after the backfilling is complete.

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The tests that are required to be conducted are listed as follows:

a.) Gravity Sewer

i) Ball Test (100mmØ rubber ball for pipe sizes 150mm and above)
ii) Exfiltration/Infiltration and Pressure Test

b.) Force Main

i.) High pressure water test (60 psi minimum)

ii.) High pressure leakage test (following high pressure water test)

c.) Manholes and others

i.) Visual Inspection

ii) Water tightness test (when required)

3.2 WATER TEST OF NON-PRESSURE PIPELINES (EXFILTRATION)

The test pressure for non-pressure pipelines up to and including 750 mm shall
not be less than 1.2 m head of water above the pipe soffit or ground water level,
whichever is the higher at the highest point, and not greater than 6 m head at the
lowest point of the section. Steeply graded pipelines shall be tested in stages in
cases where the maximum head, as stated above, would be exceeded if the
whole section were tested in one length.

The pipeline shall be filled with water and a minimum period of two hours shall be
allowed for absorption, after which water shall be added from a measuring vessel
at intervals of 5 minutes and the quantity required to maintain the original water
level noted. The length of pipeline shall be accepted if the quantity of water
added over a 30-minute period is less than 0.50 liter per linear meter per meter of
nominal diameter.

3.3 AIR TEST FOR NON-PRESSURE PIPELINES

Non-pressure pipelines shall be air tested by suitable means until a pressure of

100 mm head of water is indicated in a U-tube connected to the system. The
pressure shall be maintained for two minutes to allow temperature of the air to
come to equilibrium with the pipe walls.

The pipeline shall be accepted if the air pressure remains above 75 mm head of
water after a period of 5 minutes without further pumping, following a period for
stabilization. Failure to pass the test shall not preclude acceptance of the pipeline
if a successful water test can subsequently be carried out in accordance with
Clause 3.2.

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3.4 CCTV INSPECTION FOR NON-PRESSURE PIPELINES

Where internal inspection of pipelines by CCTV is required, the Contractor shall

provide all necessary equipment, including suitable covered accommodation for
viewing the monitor screen, together with personnel experienced in the operation
of the equipment and interpretation of results.

The intensity of illumination within the pipe and the rate of draw of the camera
shall be such as to allow a proper examination of the inside of the pipe.
Provision shall be made for the movement of the camera to be stopped and its
position recorded and for permanent photographs to be taken at any point
requested by Maynilad.

3.4 INFILTRATION

Non-pressure pipelines (including tunnels) and manholes shall be tested for

infiltration after backfilling. All inlets to the system shall be effectively closed, and
any residual flow shall be deemed to be infiltration.

The pipeline, including manholes, shall be accepted as satisfactory if the

infiltration, including infiltration to manholes, in 30 minutes does not exceed 0.50
liter per linear meter per meter nominal diameter.

Notwithstanding the satisfactory completion of the above test, if there is any

discernible flow of water entering the pipeline at any point, which can be, located
either by visual at CCTV inspection, the Contractor shall take such measure as
are necessary to stop such infiltration.

- END OF SECTION -

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SECTION 007
BUILDING WORKS
PART 1 – GENERAL

1.1 Scope of Work

The WORK includes the provision for building works and all related materials
complete in place.

1.2 Specifications and Standards

Refer to each material’s specifications and standards as indicated in PART 2 -

PRODUCTS of this Specification.

1.3 Submittals

Samples, shop drawings and certificates as required in PART 2 - PRODUCTS of this

Specification.

1.4 Quality Assurance

The Contractor is responsible for the performance of all tests and inspection required
by this Standard Specification. However, Maynilad Water Services, Inc. (Maynilad)
reserves the right to perform any or all prescribed tests and inspection where such is
deemed necessary to ensure that the Work conforms to Specifications. The
Manufacturer shall furnish Maynilad compliance certificate and certified copies of
records showing that the materials have been tested and have complied with all
applicable requirements of this Standard. The Contractor shall, at his own expense,
replace all unacceptable materials for failure to comply with this Specification.

PART 2 - PRODUCTS

2.1 Brickwork and Blockwork Generally

Brickwork and blockwork shall comply with the relevant provisions of the ASTM A36
Standard Specification, Part 1. Stone work shall comply with relevant provision of
ASTM C 503-69 and ASTM 568-89. The moisture content of the bricks shall be
adjusted so that excessive suction is not exerted on the mortar.

Bricks in each course shall be break joints correctly with the bricks underneath. The
courses shall be laid parallel with joints f uniform thickness and shall be kept straight
or regular curved as required. Vertical joints shall be in alignment as required by the

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bond and both vertical and horizontal joints shall have an average thickness of 10mm.
Bricks forming reveals and internal and external angles shall be selected for
squareness and built plumb.

Brickwork and blockwork shall rise uniformly, corners and other advanced work shall
be raked back and not raised above the general level more than 1.00 m. No brickwork
or blockwork shall be carried up higher than 1.50 m in one day. No bats or broken
bricks shall be incorporated in the work unless essential for bond. Where cut blocks
are required, all cutting be carried out with a mechanical cutting disc.

Completed brickwork and blockwork shall be protected at all times from scaffold
splash, mortar droppings, grout leakage from suspended slabs and the harmful effects
of weather. Brickwork and blockwork shall be allowed t set thoroughly hard before
cutting or chasing is carried out.

The required class of mortar and type of cement shall be described in the Contract or,
shall comply with the relevant provision of the DPWH Standard Specifications, Item
705.

No drawing are included. The thickness and bond for brickwork and blockwork should
be approved by Maynilad.

2.2 Brickworks and Blockwork, Jointing and Pointing

Bricks and blocks shall be laid in mortar, properly bedded and jointed and all joints
filled with mortar at every course.

Where the surface of walling does not provided an adequate key, the joints on faces
of walls to be plastered shall be raked out 12 mm.

The type of jointing and pointing shall be described in the Contract.

Provision shall be made in the Contract for sample area of different wall types and
finishes.

2.3 Damp Proof Course

Construction of damp proof courses shall comply with the manufacturer’s instruction
and requirements, and shall be described in the Contract Specific Documents.

Damp proofing shall comply with the relevant provisions of ASTM D41, ASTM D43,
ASTM D226, ASTM D227, ASTM D449 and ASTM D450.

2.4. Corbelling

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Over sail corbelling shall not exceed 30mm on each course.

2.5 Bonding to Concrete

Where brickwork or blockwork is to be bonded to concrete, this shall be achieved by

means of metal ties evenly spaced at 600mm to vertical and 800mm to horizontal of
the wall surface, and brickwork and blockwork shall be brought up subsequent to the
concrete.

Additional ties shall be provided near the sides of all openings such that there is one
for each 300mm height of the opening.

2.6 Underpinning

Underpinning in brickwork or blockwork shall be carried up to within one course of the

underside of the existing structure and allowed to set. The remaining course shall be
bedded in mortar and wedged with state pieces tightly against the existing structure.

2.7 Centering and Lagging

Centering and lagging used for the construction of brickwork and blockwork shall
remain in place for such time as is necessary for the brickwork to develop sufficient
strength to prevent sagging or cracking of joints.

2.8 Preparation for Plastering

The surface of the in-situ concrete shall be cleaned of dust, loose particles and other
matters. Surfaces shall be wetted immediately before plastering is commenced.

2.9 Cement Plastering

Cement plastering shall normally be applied in one coat and batches shall be used as
soon as possible after water has been added. The total thickness of the coat shall be
of the order of, but hall not exceed, 20mm.

Where the finished thickness of the plaster is to be greater than 20mm, then 2 coats
shall be used and the thickness of the base coat’s shall not be less than 13mm.

Concrete masonry and hollow block surfaces shall be dampened by brushing or

spraying with clean water, mixed 1 part bonding agent to 5 parts water.

The plastering mortar shall be a mixture of Portland cement and washed sand by
volume in the proportion of 1 volume cement to 3 volume of sand, together with 1 part
of liquid boning additive to 3 parts of water. The dry cement and sand shall be
thoroughly mixed before the mixture of the liquid additive with water of the proper

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proportions, is added to the dry mortar mix. The complete mixture shall then be mixed
into a workable mortar paste.

Before the base coat has hardened, it shall be evenly scored to assist in bonding the
finish coat. /when the base coat has hardened enough to received the finish coat, it
shall be dampened and the finish coat applied. The finish coat shall be finished to give
the appearance of a rubbed, or as otherwise required to match the surrounding
surface.

Plastered surface shall be shielded from the direct rays of the sun for two (2) days and
shall be kept moist.

2.10 Other Floor Wall and Ceiling Finishes

Other floor, wall and ceiling finishes, where required by the Contract are specified on
the Drawings or as approved by Maynilad.

2.10.1 Ceramic Tiles

a. General

All tiles shall be installed by competent tradesmen and in accordance with the best
practice of the trade. Finished surfaced shall be produced in the true plans, free of
damage, scratches, or otherwise faulty tile in all places solidly backed up and firmly
secure. All tiling works shall be laid out so that field or pattern is exactly centered on
the area to preclude the use of tiles less than full size; do any cutting along edges of
area. Joints of uniform standard width and in true alignment shall be maintained
throughout; completely fill with grouting or pointing mortar and finish smooth and
flush with tile. Cut and drill without marring tile, smooth cut edges with a fine stone.
Fit carefully around pipes, outlets and similar items so that cover plates or trim will
cover the cut edges. Remove surplus mortar and grout from tile surfaces before
these have set.

Samples. Duplicate samples of each color and kind of tile shall be submitted to
Maynilad for approval. All materials installed in the work shall match the approved
samples.

b. Materials

Ceramic tile for toilet walls shall be white glaze ceramic tile, size 300 mm x 300 mm
(12” x 12”). Caps, inside and outside corners, and other molding, as required, shall
be provided.

Ceramic tile for toilet floors shall be vitrified unglazed, 300 mm x 300 mm (12” x 12”).

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Acid resistant vitrified tile shall be used in the laboratory.

Portland Cement shall be standard brand per ASTM C-150.

Tile adhesive and grout shall be of approved brand and quality.

c. Installation

All tiles shall be delivered to the site in sealed containers with labels intact.

All tiles shall be set in full mortar bed with all joints plumb and to indicated heights.
Mortar bed for floor tiling shall be spread until the surface is level or stopped for
drainage and as large an area that can be tiled before the mortar has reached initial
setting. Vertical tiles shall be plumb. The back of all tiles shall be covered with tile
adhesive to make the bed full and even. All tiles shall be soaked in water for twenty-
four (24) hours before laying.

For wall tile, spread Portland Cement paste with a trowel on the back side of the tiles
and set on the prepared walls, true to line and plumb.

Set wall tile with slight twisting motion to assure suitable contact with the wall.

Caulking. At completion of tile work, clean cut joints between files of excess
adhesive and finish with cement paste.

Clean-up. Excess adhesive materials shall be removed from face of the tile with soft
cloth dampened with water or kerosene as the case may be.

2.10.2 Plain Cement Finish

a. General

Colored cement shall be delivered in carton, cans or kegs to the building site with
the labels intact and seals unbroken, subject to inspection by Maynilad before
being opened.

Sample. Where colored cement and colored floor hardener cement finish and
surface finish are required, samples shall be submitted to Maynilad for approval.
Final choice shall be his.

b. Materials

Fine aggregate shall consist of sand, stone screenings or other approved inert
materials with similar characteristics or a combination thereof, having clean, hard,
strong, sound, durable, uncoated grains, free from injurious amount of dust, lumps,

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soft or flaky particles, shale, alkali, organic matter, loam or other deleterious
substances.

The use of beach sand is prohibited without the written consent of Maynilad.

Gradation shall be as follows:

Percent Passing Sieve Limit

No. 10 (2.00 mm) 100
No. 16 (1.18 mm) 95 to 100
No. 100 (150 mm) 25 max.
No. 200 (75 mm) 10 max.
Fineness modulus 1.6 to 2.5
Water/cement, ratio by weight 0.65 max.

If the fineness modulus varies by more than 0.20 from the value assumed in
selecting proportions for the mortar, the aggregate shall be rejected unless suitable
adjustments are made in proportions to compensate for the change in grading

Portland Cement. In accordance with the requirements of TS Section 003.

Floor Hardener. Non-metallic aggregate hardeners, inorganic pigments and

binders, non-slip and colored by Armor top or approved equivalent at the rate of 60
lb per square foot or equivalent, to medium traffic mixture.

c. Installation

The concrete sub-floor shall be cleaned and then moistened but not soaked, after
which dry cement shall be sprinkled over the surface and the mortar spread on the
setting bed. Tamp to assure a good bond over the entire area and screed to
provide a smooth and level bed at proper height. Mix mortar one (1) part Portland
cement to two (2) parts sand.

To finish the surface with colored, sprinkle enough quantity that will assure
average. Finish with mason pallet joints. Keep free for 48 hours.

2.10.3 Vinyl Tiles

a. General

Submit one piece sample of vinyl tile to be used.

Deliver all materials in good condition to the job site in manufacturer's original
unopened containers with label information clearly marked thereon.

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Install flooring after all other trades, including painting, have been completed. All
surfaces to receive resilient flooring finishes shall be dry, clean and smooth.

b. Materials

Provide 3/32” gauge 12” x 12” tile.

Tile shall be resistant to alkali, grease and oils and shall withstand static loads of
50 psi.

Install tile with conventional full-spread system with S-89

c. Execution

Inspection:

Examine substrate and condition under which flooring is to be installed. Do not

proceed with installation until unsatisfactory conditions have been corrected.

Preparation:

Concrete shall be smooth with no more than 1/8” variation from the plane within
any ten (10) feet. Grind down all ridges and other irregularities. Fill all cracks,
holes and depressions with latex cement underlayment (patching compound) as
recommended by the flooring manufacturer. Remove all paints, oils, waxes,
sealers (and curing compounds not compatible with the adhesives employed).
Organic solvent are to be avoided.

Moisture test:

Determine the suitability of the concrete subfloor for receiving the resilient flooring
with regard to moisture content (curing compounds) by a bond test as
recommended by the floor manufacturer.

Subfloor cleaning:

Broom or vacuum clean subfloor prior to the installation of the flooring material.

Installation:

Layout:

Lay flooring material with a minimum number of seams consistent with prudent
use of the materials. Avoid cross seams.

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Adhesive application:

Mix and apply the adhesives following the manufacturer's instruction, observing
the recommended trowel notching, spread rates and open times.

Flooring installation:

Install the flooring in strict accordance with the manufacturer's written instruction.
Seal all seams in the flooring, using tools, materials, methods and sequence of
works in conformance with the written instructions of the flooring manufacturer.
Finish all seams flush to the floor and free from voids, recesses and raised area.

Cleaning protection:

Remove all excessive adhesives from the surface of the flooring.

2.10.4 Plywood

Plywood shall have a thickness of 6 mm.

Plywood 19 mm thick and thinner shall be at least three ply. Face wood shall be
Tanguile. All plies shall be bonded by the hot plate method with urea (white) glue.

Plywood specified to be waterproof plywood shall be bonded with water resistant

thenol (red) glue.

Plywood shall be formed using presses that exert a minimum of 1.0 <Pa pressure.
The pressure shall be maintained for 15 minutes.

Plywood panels be prefinished on both sides. The grade of finish shall be firstgrade
according to local practice, unless otherwise specified.

2.10.5 Acoustic Ceiling Systems

a. Materials:

Acoustic Tiles: Acoustic Mineral Board Ceiling shall be 600 mm x 1200 mm x 16

mm lay-in regular of “Armstrong” Brand.

1. Design

a. Armstrong – Mineral Board for offices

2. Armstrong Retention clip

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Primary Suspension Members

Wire Hanger Inserts: 5 millimeter diameter galvanized wire loop and 0.6 millimeter
thick galvanized shell or 2 millimeter thick galvanized steel strap with 8 millimeter
hole.

b. Installation

Install material and systems in accordance with manufacturer's printed instruction.

Use procedures that will minimize damage or soiling of the units during installation.

Coordinate spacing of hanger, carrying channels, runners and molding with the
location of electrical fixtures and other items in or on the ceiling.

Seismic Bracing: Support ceiling suspension system within 2 meters of wall and at
4 meters on center in each direction with four 2.8 millimeter wires connected within
50 millimeters of an intersection of a main runner with a cross runner and sprayed
90 degrees from each other at an angle not exceeding 45 degrees from the plane
of the ceiling.

Center tile pattern both direction in each major space or room as indicated or
directed and where possible, adjust pattern so that edge pieces will be not less
than 50 millimeters in width.

Provide bracing above the ceiling plans as required to stabilized the ceiling system.
Do not attach runners to wall moldings.

Make exposed surface of acoustical units level and flush with joints straight and
true. Nearly cut all fit units around light fixtures and around other items protruding
through acoustical ceilings. Install exposed members with flush hairline joints.

Provide color coded tacks at access tiles to designate locations of mechanical and
electrical access.

c. Adjusting and Cleaning.

Clean or replace units that have been soiled or damaged.

2.11 Carpentry and Joinery

Framing members shall not be spliced between bearing points, and shall be free
from pronounced defects. Joints and splices shall be bolted r spiked together, and
shall occur over bearings only.

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Holes for bolts shall be of the same nominal diameter as the bolt. Plate washers
shall be installed under heads and nuts of all bolts in contact with wood. Nuts shall
be drawn tight and the threads burred to prevent loosening.

Screws shall be screwed and not drive into place. Pilot holes may be drilled for
screws the same diameter as the shank.

The sizes shown for wood on the Drawing are the nominal sizes. All dressed lumber
after plane shall not vary from the indicated dimensions by more than ten percent
(10%). Thickness and width of lumber shall be uniform throughout its length. Lumber
shall not be delivered to site in lengths shorter than 2.5 meters.

When wood frames are to be installed against concrete or masonry, the face of
wood in contact with masonry shall have two (2) coats of wood preservative
compound or asphalt as approved by MWSI, applied and allowed to dry before
fixing.

Generally, cutting and shaping of all timber shall be completed before preservative
treatment is carried out. When any cutting or shaping has to be carried out after
treatment, the cut or worked surface shall be given 2 coats of the preservative. After
treatment, timbers shall be thoroughly dried out before use.

Where timber is to receive decorative finishes, then, after the application of any
preservative and drying out, any knots or resinous areas shall have 2 coats of
knotting applied before finishes.

2.12 Roofs

Roof members shall be built in place or fabricated and erected and as shown in the
Contract Drawings or as approved by Maynilad.

Flats and gutters shall be covered with Type WBP plywood or tongued and grooved
rot boarding laid diagonally, fir to falls of not less than 1 in 120 for lead and copper
and 1 in 60 for bitumen felt or, as described in the Contract or as approved by
Maynilad.

2.13 Timber Floors

Floor joists shall be either built into brickwork or blockwork, or held in galvanized
steel joist hangers, and shall be trimmed as described in the Contract or as directed
by Maynilad. Bridging shall be spaced at every 1.80m apart and shall be 50mm thick
to the full depth of the joists or by 50mm herringbone strutting.

Boarding shall be cramped up and nailed with cut flooring nails. Trimmed openings
shall have mitred boarders 75mm in width.

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2.14 Door Frames

Door frames shall be fitted into prepared openings, drilled and plugged at 3 points
per jamb and shall have 100mm by 12mm diameter galvanized steel dowels to posts
let into flooring and bedded in non-shrink or epoxy grout.

The joint between external door frames and adjacent walls shall be continuously
pointed with gun-applied butyl or other approved non-setting mastic.

2.15 Windows

Window frames shall be securely fixed to openings in accordance with

manufacturer's instructions or, as described in the Contract Specific Specifications
and, shall be continuously pointed with gun applied butyl or other approved non-
setting mastic.

2.16 Glazing

1. General

a. Work Quality

All works shall conform to the recommendation of the glass manufacturers.

b. Glass Thickness

Thickness of glass specified are minimum thicknesses. Thicker glass shall be

used where required by governing codes.

c. Accessories

Glass and glazing system shall be installed complete with all stops, blocks,
channels, beads, sealants and glass to form a completely installed watertight
installation.

d. Leak Test

After the installation is complete, all exterior glazing shall be given a leak test
by flooding the glazing from bottom to top using 20 mm (minimum) hose with
nozzle under 3 bars water pressure.

e. Warranty

The Contractor shall guarantee that all work performed under this Section will
be free from defects in materials and workmanship and will remain watertight

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for a period of two (2) years from date of building acceptance. Upon receipt of
written notice of defect or leakage within the guarantee period, the Contractor
shall, at his expense, make necessary repairs or replacement of the defective
work.

f. Manufacturer's Label

Each piece of glass shall bear the manufacturer's label showing grade,
thickness and type of glass and all labels shall remain until the glass has been
set and inspected.

g. Certification of glass Thickness and Grade

When glass is not cut to size by the glass manufacturer, the Contractor shall
furnish an affidavit stating the grade, thickness and type of glass and
manufacturer of the glass furnished.

2. Submittal

Stock samples of glass along with manufacturer's literature and installation

instruction shall be submitted to MWSI for review and approval.

3. Materials

a. General

Sealant shall be as recommended by the glass manufacturer and the window

manufacturer. Sealant such as 2-part polysulfides for view window shall be as
recommended in the publication of the glass manufacturer, sealant
manufacturer, gasket manufacturer and glazer for the intended use.

Setting channels and/or blocks shall be neoprene, 85 +5 durometer hardness

chemically compatible with sealant use and recommended by glass
manufacturer.

Glazing compound shall be as recommended by the glass manufacturer for job

conditions.

Glazing beads and seals shall be black neoprene or vinyl chloride conforming
to ASTM 2287.

Glazing tape shall be polymerized butyl, rubber tape, coiled on release paper,
manufacturer's standard and shall be as recommended by the glazing sealant
manufacturer.

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Glazing compound for use with wood shall be an elastomeric type

recommended for wood and glass use.

b. Glass Types

Type A : Tinted colored tempered float glass shall be heat-treated safety glass
6 mm minimum thickness used for exterior window wall tiles. The glass color
shall be bronze.

Type B : Clear tempered float glass shall be heat-tempered safety glass and
shall not be less than 6 mm thick. This glass type shall be used for interior
windows and windows wall lites within 0.40 m of floor, entrance doors and
door lites.

Type C : Mirrors shall be 6 mm select mirror glazing quality mirrors.

4. Execution

a. Inspection
Areas to received glass and glazing shall be inspected and defects shall be
reported to Maynilad. All glazing shall be done in accordance with the
applicable Referenced Standards.
b. Manufacturer's Recommendations

Preparation work such as priming and cleaning shall be done with materials
and procedures recommended by the manufacturers.

c. Surfaces

Surfaces shall be dry and free from dust, dirt, and film. All priming shall be
completed and throughly dried before glazing.

d. Unfavorable Weather Conditions

No work shall performed in damp, foggy or rainy weather.

e. Concealed Edges

Concealed edges of glass shall be clean, straight cut and free from chips and
fissures. All glass shall be shop-cut and allowances shall made for maximum
grip on all edges, Nipping glass on the job will not be allowed. Glass shall be
accurately cut to size of opening. Glass shall be set with equal bearing on
entire width of pane. Large sheets of glass shall be positioned with setting
blocks. Glass shall not move or rattle.

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f. Glazing Beads

Glass in glazing beads or channels shall be in accordance with manufacturer's

printed installation instruction. Materials shall not be stretched.

g. Stop Glazing

Glass set with stop glazing shall be set on glazing tape. All voids around
perimeter and between glass and stop shall be filled with glazing compound to
provide a completely watertight installation. Tape and compound shall be
trimmed flush to sight line.

h. Sealant

Sealant shall be applied on inside glass surface blow glazing bead. Void below
vinyl to bottom of glazing reglet shall be filled to maintain weather tight seal.

i. Metal Glazing Beads

Where metal glazing beads occur, the glass shall be set completely bedded in
glazing compound. Metal glazing beads furnished by the manufacturer shall be
installed in accordance with manufacturer's printed instructions. Compound
shall be trimmed flush to sight line.

j. Identification for Safety

Glass, glazing panels and glazing shall be protected by clear identification by

indicating devices which indicate the presence of glass to other workers and
materials handlers. Taping or marking on the glass which would cause a
permanent stain shall not be used.

k. Workmanship

Glass and glazing shall be left in perfect condition and ready for final cleaning.

l. Acceptance

Prior to acceptance of the work, broken, defective or scratched glass shall be

promptly replaced, and damaged glazing compound shall be repaired.

2.17 Handrails and Balusters

Handrails and balusters shall be manufactured from material complying with the
provisions of the appropriate Philippine Standards.

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After manufacture, mild steel and aluminum handrails and balusters shall be hot dip
galvanized or anodized, as appropriate, in accordance with ASTM A51

2.18 Safety/Gate Chains

Mild steel chain shall be 8mm nominal size non-calibrated chain. After manufacture,
mild steel shall be hot dip galvanized in accordance with ASTM A513. When tested
each chain shall withstand a breaking force of 30 KN and a proof force of 15 KN.
Chain links shall be welded and have an internal length not exceeding 45mm and an
internal width of between 12mm and 18mm. The fins caused by welding shall be
removed and the weld shall be smoothly finished all round.

2.19 Painting

All painting shall be carried out by craftsmen who are qualified and skilled in the
trade.
Manufacturer's printed instruction shall be strictly followed in the application of
proprietary coatings.

Wood surfaces to be painted shall be first cleaned of dirt, oil or other foreign
substances with mineral spirits, scrapers, sandpaper or wire brush. Coatings shall
be applied only on thoroughly dry surface and during periods of favorable weather,
not in extreme heat, nor in dust or smoke-laden air, nor in damp or humid weather.

No consecutive coat of paint shall be of the same shade, with the exception of white.
Each coat shall be given a minimum drying time of 72 hours and shall be inspected
by Maynilad prior to application of the next coat. Areas found to contain runs,
roughness, or other signs of improper application shall be required to be recoated in
accordance with the instruction of Maynilad.

Woodwork shall be sanded smooth where nail holes and minor imperfections shall
be filled with putty between first and second coat; color of putty shall match stain in
the case of stained work.

Drop cloths shall be placed where required to protect floors and equipment from
splatter and droppings.

2.20 Roof Coverings

Galvanized Steel Roofing

Roofing Panels: Shall be rib-type having a cross sectional profile and depth as
specified and indicated in the drawings or as approved by Maynilad. Roof panels shall
be capable of supporting design loads between unsupported spans with deflection not

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greater than 1/180 of the span width on roofs, but in no case shall the wall thickness of
the sheets for the panels be less than specified herein. Where gauges are specified,
they are subjected to normal manufacturing tolerances. Roofing or an approved equal,
with a total coated thickness of not less than 0.60 mm utilizing a double baked-on
epoxy primer and high grade polyester color finish.

Accessories: Sheet metal flashing, trim, moldings, closure strips, caps, splash pans,
and other similar sheet metal accessories used in conjunction with preformed metal
panels shall be made of the same materials and finish as used for the panels, except
that such accessories which will be concealed after installation, may be provided
without the finish if they are aluminum or zinc-coated steel. Thickness of the metal
shall be not less than that used for the panels. Molded closure strips shall be closed-
cell or solid-cell synthetic rubber, neoprene, or polyvinyl chloride pre-molded to match
the configurations of the preformed metal panels. Finish color for flashing, trims,
molding, caps, and other exterior metal components shall be as selected and
approved by Maynilad.

Fasteners: Fasteners for attaching panels to structural supports and to adjoining

panels shall be a approved and in accordance with the manufacturer's
recommendations. Unless specified otherwise, the fasteners shall be either self-
tapping screw, bolts and nuts, self-locking rivets, self locking bolts, end-welded studs,
bolted or riveted studs, or step rivet held by steel straps. Design the fastenings system
to withstand the design loaded indicated. Fasteners, with exception of those having
integral hexagonal washer heads and those having aluminum drive caps, shall have
composite metal and neoprene washers. Fasteners having integrated hexagonal
washer heads and fasteners having aluminum drive caps shall have polychloropene
washers.

Screw. Not less than No. 14 diameter self-tapping type or self-drilling and self-tapping
type.

Blind Rivets: Stainless steel with 5 mm (6/16 inch) nominal diameter shank or
aluminum with 5 mm (3/16 inch nominal diameter shank. Use treaded-stern-type rivets
for other than the fastening of trim. Rivets with hollow stems shall be closed.

Bolts: Not less than 6 mm (¼ inch) diameter, shouldered or plain shank required, with
nuts.

Joint Sealing Materials: Shall be as recommended by roofing panel manufacturer.

Installation: Install in accordance with the manufacturer's approved erection instruction

and diagrams, except as specified otherwise herein. Panels shall be in full and firm
contract with support and with each other at side and end laps. Where sheets are cut
in the field or where any of the factory-applied covering or coatings are abraded or
damaged in handling or installation, they shall, after the necessary repairs have been

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made with materials of the same type and color as the weather coating, be approved
before installation. All cut ends and edge, including those openings through the sheets,
shall be sealed completely. Correct defects or errors in the materials in an approved
manner. Remove materials which cannot be corrected in an approved manner and
provide non-defective materials. Provided molded closure strips where indicated and
whenever sheets terminate with open ends after installation.

Roof Sheets: Apply roofing sheets with the configurations parallel to the slope of the
roof and as indicated on drawings. Provided roofing sheets in the longest lengths
obtainable, with end laps occurring only at structural members with no transverse joints
except at the juncture of ventilators, roof hatch, and similar openings. Lay all side laps
away from the prevailing wind and seal side and end laps with joint sealing materials.
Flash and seal the roof at the ridge, at eaves and rakes, at projections through the
roof, and elsewhere as necessary. Accomplish the placement of closure strips,
flashing, and sealing material in an approved manner that will assure complete
weather tightness.

Flashing: all flashing and related closure and accessories in connection with the
performed metal panels shall be provided as indicated and as necessary to provide a
watertight installation. Details of installation which are not indicated shall be in
accordance with the panel manufacturer's printed instruction and details or the
approved shop drawings. Installation shall allow for expansion and contraction of
flashing.

Fasteners: Fastener spacing shall be in accordance with the manufacturer's

recommendations and as necessary to withstand the design loads indicated. Install
fasteners in valleys or crows as recommended by the manufacturer of the sheet being
used. Install fasteners in straight lines within a tolerance of 12 mm in the length of a
bay. Drive exposed penetrating type fasteners normal to the surface and to a uniform
depth to seat gasket washers properly and drive so as not to damage factory-applied
coating. Exercise extreme care in drilling pilot holes for fastening to keep drills
perpendicular and centered in valleys or crowns, as applicable. After drilling, remove
metal fillings and burrs from holes prior to installing fasteners and washers. Torque
used in applying fasteners shall not exceed that recommended by the manufacturer.
Remove sheets deformed or otherwise damaged by over-torque fastenings, and
provide new sheets.

2.21 Lightweight Concrete Roof Screed

Lightweight concrete roof screeds shall be laid to the necessary falls and shall
comply with the relevant provisions of the DPWH Standard Specifications, Item 702.

2.22 Asphalt Roofing

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Mastic asphalt shall comply with relevant provisions of the DPWH Standard
Specifications, Item 702, and shall be laid on an underlay of sheathing felt, laid loose
and with joints lapped at least 50mm. The roof shall be set out with properly formed
high points, water lines and mitered bays where required.

2.23 Bitumen Felt Roofing

Built-up bitumen felt roof covering shall comply with the relevant provision of the
DPWH Standard Specification, Item 702.

2.24 Surface Treatment to Flat Roofs

Mineral aggregates for flat roofs shall be applied to flat asphalt and bitumen felt
roofs where so described in the Contract.

2.25 Plumbing

Installation of plumbing for domestic water supply and for sewer systems shall be
described in the Contract or as approved by Maynilad.

2.26 Opening in Walls, Floors and Ceilings

The Contractor shall box out and/or cut opening through walls, floors and ceilings for
the passage of pipes and cables and, where described in the Contract or as
approved by Maynilad shall provide and fix in position approved tube sleeves cut off
flush with the finished surface. All openings and ducts shall sealed on completion to
prevent the passage of toxic or explosive gases.

2.27 Tolerances for Building Works

Tolerances for building works, except where otherwise described in the Contract,
shall not exceed the permissible deviations from levels and dimensions for the
corresponding types of work given and described in the Contract or as approved by
Maynilad.

2.28 Fasteners

Nails shall not be driven closer together than ½ their length unless driven in drill
holes, nor closer to the edge of the member than ¼ its length. Holes drilled slightly
smaller than nail diameter shall be used when necessary to prevent splitting. The
nails shall penetrate the second or farther member to not less than ½ of the length
of nail. Common nails shall be used unless otherwise specified or shown.

2.29 Steel Casement and Awning Windows

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Frames shall set plumb and square in a true plane. Steel shims shall be provided
tight between frame anchors and structure, and rigidly attached. Metal shall not be
smaller than 6mm thick angular bar. Frames shall be of the welded unit-type. Special
frames, oversized frames, and frames with transom shall be provided where shown
or as approved by Maynilad.

All finished work shall be strong and rigid, neat in appearance, square, true, and free
of defects, warp, or buckle. Corner joints shall have all contact edges tightly closed,
with trim faces mitered, welded and finished smooth.

2.30 Illumination

Adequate illumination shall be provided while work is in progress. Whenever

required by Maynilad, the Contractor shall provide additional illumination to cover all
areas to be inspected.

2.31 Clean-Up

The Contractor shall, at all times, keep the premises free from accumulation of
waste material and rubbish caused by his employees or subcontractor's personnel.
At the completion of the painting, all tools, scaffolding, surplus materials shall be
removed from and around the building, and the paint work area shall be left “broom
clean”, unless more exactly specified.

Upon completion of the work, all staging, scaffolding and containers shall be
removed from the site or destroyed in a manner approved by Maynilad. Coating
spots and oil or stain upon adjacent surfaces shall be removed and the job site
cleaned. All damage to adjacent surfaces resulting from the work performed under
the Contract shall be cleaned, repaired or refinished to the satisfaction of Maynilad
at no additional cost to the Contract.

2.32 Warranty Inspection

A warranty inspection shall be conducted following completion of all coating and

painting work. The Contractor or his authorized representative shall attend this
inspection. All defective work shall be repaired in accordance with the specification
and to the satisfaction of Maynilad. Maynilad may, by written notice to the
Contractor, re-schedule the warranty inspection within the Contract
guarantee/defects liability period, or may cancel the warranty inspection altogether.

2.33 Welding

All welding shall be done by experienced welders using the metal-arc method or gas
shielded arc method as described in the American Welding Society's (AWS)
“Welding Handbook” as supplemented by other pertinent standards of AWS.

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Welding of parts shall be done only where shown, specified or permitted by

Maynilad.

In assembly or during welding, the component parts shall be adequately clamped,

supported and restrained to minimize distortion and for control of dimensions. Weld
reinforcement shall be as specified by the AWS Code. Upon completion of welding,
all weld splatter, flux, slag, and burrs left by attachment shall be removed. Welds
shall be repaired to produce a workmanlike appearance, with uniform weld contours
and dimensions.

2.34 Electrodes, Filler Rods and Wires for Welding

Electrodes, filler rods and wires shall be compatible with the grade of steel to be
welded and shall be in accordance with the steel or plate manufacturer’s
recommendation.

2.35 Access and Support Facilities

Walkways and platforms with connecting bridges where necessary shall be provided
for access to all plant components where regular inspection and maintenance is
necessary. Walkways and platforms shall be skidproof and provided with double
railings not less than 1 meter in height on both sides and around the outside of the
operating platform. Walkways shall not be less than 0.75 m wide. Shall also provide
kick plates/toe board 75 mm height all around.

Access stairways or ladder shall be provided wherever the difference in elevation

between adjacent structures or surroundings ground level is more than 0.60 m. Steps
shall be raised-pattern floor plate grating. Access ladders shall be 0.30 m wide
minimum with steps spaced at about 0.40 m center. Ladders shall be adequately
anchored at bottom top and at intermediate points. Requirements of stairway shall be
in accordance with prevailing local codes.

Handrails shall be provided on stairways, platforms, bridges and other points of

personnel access for operation and inspection. A handrail shall be provided around the
perimeter of the tank if the top of exposed sidewall is more than 1 meter above grade.
Handrails shall be 40 mm dia. And 25 mm dia. G.I. Pipe Schedule 40.

STP shall be provided with proper access lighting, ventilation and hoisting equipment
for maintenance purposes.

All submerged metalworks shall be stainless steel, Type 304, ASTM A276.

2.36 Site Development or Restoration Works

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Site development or restoration works where required or shown on the Drawings

shall be as described below:

(1) Access pavement/pathwalks shall be of at least 75 mm thick x 750 mm slab of

21 Mpa concrete;

(2) Perimeter and plant lighting shall be accordance with TS Section 010;

(3) Drainage shall be in accordance with TS Section 005.

(4) Electric lighting shall consist of 40 watts fluorescent lamp mounted on a 38 mm

diameter x 6 m hot dip galvanized iron pipe, schedule 40 with barb wires;

(5) Fence shall be of CHB & cyclone wires;

(6) Landscaping shall be in accordance with TS Section 011;

(7) Restoration works shall be in accordance with Item 2.30 of this Section.

2.37 Metal Doors, Windows and Frames

1. General

(a) Work Quality

All work shall be in accordance with manufacturer's published

recommendations and specifications.

(b) Work Coordinator

All work shall be coordinated with appropriate related work to assure proper
installation. Field conditions and dimensions shall be verify prior to
fabrication.

(c) Quality Standards

All works conforms to American Society for Testing and Materials (ASTM),
American National Standards Institute (ANSI), Underwriters' Laboratories,
Inc. (UL) Standards and other standards where applicable.

(d) Finish Hardware

Finish hardware shall be installed as per manufacturer's published directions.

All hardware shall be removed after fitting and the final installation of
hardware shall be made after the finish painting.

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2. Submittals

Shop drawings, manufacturer's literature and structural calculation that may be

required elsewhere in this Section shall be submitted to Maynilad for review and
approval. Shop drawings shall show details of the products and systems and
connections to adjoining materials. Schedules showing sizes, types, and locations
of louvers and glass shall also be submitted for approval along with manufacturer's
installation instructions.

3. Hollow Metal Doors, Windows and Frames

(a) General

All work shall be shop-fabricated and shop assembled where possible.

Temporary stiffeners, spacers, etc. necessary to facilitate handling and
accurate erection shall be provided.

All exterior doors, windows and frames shall be fabricated entirely of

galvanized materials.

After fabrication, all tool marks, and other surface imperfections shall be filled
and ground smooth.

Doors, windows and frames shall be chemically-treated to ensure maximum

paint adhesion and shall have all exposed surfaces painted with a rust-
inhibitive primer after fabrication. Prime coat shall be capable of passing 120-
hour salt spray test per ASTM B117 and 250-hours humidity test per ASTM
Standard D1735.

Door, windows and frames shall be fabricated from prime quality commercial
grade-cold-rolled steel conforming to ASTM A366, Type II or III.

Doors and frames shall be reinforced and drilled or tapped for fully templated
mortised hardware; and shall be reinforced with plates for surface-mounted
hardware, meeting ANSI 115 requirements.

(b) Products

1) Metal Frames

a. Pressed metal frames for doors and other opening shall be combination
buckled frame and trim of type and sizes as shown. Metal shall not be
lighter than 1.6 mm steel. Frames shall be of the welded unit type.

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Special frames, oversized frames, and frames with transom shall be

provided where shown.

b. Jamb depths, trim profile, and backbends shall be indicated on shop

drawings.

c. Frames for multiple or special opening shall have mullion and/or rail
members which are closed tabular shapes having no visible seams or
joints. All joint between faces of abutting members shall be securely
welded and finished smooth.

d. All finished work shall be strong and rigid, neat in appearance, square,
true, and free of defects, warp or buckle. Molded members shall be
clean cut, straight and of uniform profile throughout their lengths.
Corner joints shall have all contact edges tightly closed, with trim faces
mitered, welded and finished smooth. The use of gussets will not be
permitted.

e. Floor anchors shall be welded inside each jamb, with holes provided for
floor anchorage. Minimum thickness of floor anchors shall be 1.8 mm.

f. Frame for installation in masonry and/or concrete walls shall be

provided with adjustable jamb anchors of the T-strap, stirrups and
strap, or wire type. The number of anchors provided per jamb shall be
as follows:

Frames up to 2.30 m height 3 anchors

Frames 2.3 m to 2.45 m height 4 anchors
Frames over 2.45 m height 1 anchor for each 0.60 or fraction
in height

g. Frames to be anchored to previously placed concrete, masonry, or

structural steel shall be provided with anchors of suitable design as
shown on approved shop drawings.

h. Dust cover boxes or mortar guards of not less than 1 mm steel shall be
provided at all hardware mortises on frames to be set in masonry,
concrete or plaster walls.

2) Metal Doors

a. Metal doors shall be full flush design. Face sheets shall be not less
than cold rolled stretcher-levelled 1.4 mm steel, hollow metal
construction. All doors shall have flush seamless face sheets. The door
top and bottom shall be internally reinforced by steel members welded

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in place. Tops of exterior doors shall be provided with flush weather

tight tops.

b. Door louvers for metal doors shall be of metal of the type which
integrally framed the opening and can be securely attached. Lovers
shall be of the “Z” blades type for exterior and interior use. Exterior
louvered openings shall be provided with removable type insect
screens. Door louvers shall be uniformly located in doors and be of
sizes shown.

c. Glazed opening in doors, (size as shown), shall have mitered metal

stops.

d. Doors shall be rigid, and neat in appearance, free from warpage, or

buckle. Corner bends shall be true and straight and of minimum radius
for the gauge of metal used.

e. Double doors shall be provided with a “T” type steel astragals.

3) Metal Louver Windows

Metal louver windows shall be of the same gage and similar construction
to door louvers for metal doors.

(c) Execution

Frames shall be set plumb and square in a true plane. Steel shims shall be
provided light between frame anchors and structure, and rigidly attached.

Doors shall be installed plumb and square and level with the frames securely
anchored to the adjoining construction. Doors shall operate freely, but not
loosely. The door clearances shall be 2.3 mm plus or minus 1.0 mm and shall
not exceed the manufacturer's printed recommendations. Door after installation
shall be free from rattling in a closed position.

Finish hardware shall be installed in accordance with hardware manufacturer's

templates. Operable parts shall be adjusted for correct function. Hardware,
with the exception of prime coated items shall be removed, tagged, boxed and
reinstalled after finish painting is completed.

Frames installed into previously placed concrete, masonry or steel shall have
fasteners frame dimples filled with auto putty or equal. The fasteners and fillers
at dimple holes shall be ground smooth (non-visible) before painting. Fastener
locations shall not be visible when painting is finished.

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(d.) Guarantee

Any door that becomes warped in excess of 5.0 mm out-of-plane during the
12-month guarantee period under the contract shall be replaced.

4. Sound Doors

(a) General

Sound doors and frames shall be complete factory-built and laboratory tested
assemblies, complete with perimeter compression seals and automatic door
bottom seals at sill.

Sound door assemblies shall have a minimum STC rating of 47 db. The
Contractor shall provide a certification by the door manufacturer stating that
the STC rating is in accordance with ASTM E90 as conducted by a qualified
acoustical products testing laboratory.

(b) Construction

Doors shall be formed of 1.6 mm steel face sheets jointed by welding along the
vertical edges. Door tops and bottoms shall be reinforced and completely
closed with die-formed 1.6 mm steel channels welded in place. The core shall
be incombustible, non-coupling filler. An astragal shall be provided at pairs of
doors.
Frames shall be fabricated from 1.8 mm steel with the corners mitered, welded
and ground smooth. Strike, hinge and other hardware reinforcement shall be of
not less the 5.0 mm thick steel. The frame shall be provided with welded floor
anchors at each jamb and a minimum of three (3) wall anchors per jamb.

Perimeter seals shall be made of sturdy vinyl with a magnetic tape insert. The
hinge side shall be constructed so as to avoid pinching or other distortion of the
seal from opening and closing the door.

Automatic door bottoms shall close the entire gap between the door and the
floor. The seal shall be 50-60 durometer neoprene and the actuating
mechanism shall compress or retract the seal properly when the outer face of
the door is within 0.05 m of the strike jamb.

Doors, frame and seal retainers shall be thoroughly cleaned, phosphatized and
factory-primed with rust-inhibitive primer.

(c) Execution

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Frames shall be set plumb and square in a true plane. Steel shims shall be
provided tight between frame anchors and structure and rigidly attached.

Doors shall be shipped and stored with temporary stiffeners and spacers to
prevent distortion.

5. Steel-Reinforced PVC Door and Window System

(a) General

Materials and installation shall be in accordance with the following reference

standards:

ASTM D2287; Non-Rigid Vinyl Chloride Polymers and Copolymer Molding and
Extension Compound.

Manufacturer's printed recommendations, specifications and installation

instructions.

Shop drawings and sample of materials shall be submitted to Maynilad for

approval.

The Contractor shall verify all dimensions at the site to assure proper fit of the
materials. The drawing shall show the assembly and installation details
including anchoring and reinforcing. Samples of the frames, sash, and glazing
and accessories shall be furnished. Frame samples shall show the method of
connection for the various section and surface finish.

All materials for the Work of this Section shall be delivered, stored and handled
so as to prevent damage of any nature. Materials that have been damaged
shall be removed from the site and shall be replaced with good ones.

(b) Materials

The PVC section frames shown on the Drawings shall be steel-reinforced of

which the inner hollow box-shaped galvanized steel core shall be entirely
encased in the PVC extrusion material. The PVC material meet the
requirement of ASTM D2287.

The PVC shall be applied by an approved method so that all exposed surfaces,
including corners, rabbets and radii are coated to a uniform surface finish with
a minimum thickness of 0.15 mm at the webs and 0.25 mm at the flanges as
wide flat surfaces. PVC shall be cured in an oven continuously for 15 minutes
at 107o C.

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Vinyl weather stripping shall be furnished integrally with the coating to the
contours indicated on the Drawings.

All steel core sections shall be hot-dip galvanized zinc finished for protection
against corrosion, in accordance with ASTM A386.

Doors shall be of the top and bottom hung type, with no exposed seams.
Mechanical joints shall be accurately milled to hairline watertight joints. The
doors shall be fabricated to include the steel tension rods, top and bottom wool
pile weathering on the sides.

Glazing members for door and windows shall be so designed that they are
snapped in, eliminating the use of exposed screws. Glass shall be seated in a
gun grade, synthetic-rubber type putty for weather stripping, using neoprene
setting blocks.
Neoprene setting block shall be closed cell neoprene 85 + 5 durometer
hardness.

Hardware reinforcement on doors and windows shall be fastened in-place

without the attaching method being visible.

All exposed surface of the steel-reinforced PVC section door and windows,
including the sash and PVC framing shall be free from defects or other surface
blemishes. Edges of handles and appurtenances shall be ground-off smooth to
remove burrs.

(c) Execution

All concrete and masonry openings shall be prepared plumb and square. Door
and windows frames shall be installed plumb and in true alignment in the
opening.

Frames shall be firmly secure to the floors, walls, heads, ceilings and support
members by means of screws with expansion shields.

The Contractor shall protect all exposed surfaces against damage from
staining, abrasion or other injury and shall be responsible for the final cleaning
of the door and window installation.

6. Steel Windows

(a) General

Shop drawings and sample of materials shall be submitted to Maynilad for

approval.

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The Contractor shall verify all dimensions at the site to assure proper fit of the
materials. The drawing shall show assembly and installation details including
anchoring and reinforcing. Samples of the frames, sash, and glazing and
accessories shall be furnished. Frame samples shall show the method of
connection for the various section and surface finish.

Installation shall be in accordance with the manufacturer's printed

recommendations, specifications, and installation instructions.

All materials for the Work of this Section shall be delivered, stored and handled
so as to prevent damage of any nature. Materials that have been damaged
shall be removed from the site and shall be replaced with good ones.

(b) Materials

The steel frames shall be fabricated of 3 mm minimum thick hot-rolled steel

bars which are formed into solid Z-Section, 25 mm deep, having integrally
rolled weathering baffles to provide an uninterrupted perimeter contact
between the frame and the casement leaf members.

Corners of the frames and windows shall be mitered and electrically butt
welded with the exposed ground smooth. Head drips shall be provided where
the casement leaves extend to the top of the window. All casement leaves shall
be side hinged and shall be equipped with friction type hinges and washers
which shall be welded to the window and frame members. Windows shall be
designed for glazing from the outside and be provided with spring wire glazing
clips.

A polished bronze cam type locking handle shall be provided for each
casement leaf.

Standard mullions, stove bolts or screws with expansion shields shall be

provided for each windows.

Frames for screens shall be of formed steel and rewireable.

Screen cloth shall be of aluminum, 18 x 16 mesh, securely fastened to the

frames and held taut by removable plastic splines.

All window and frames shall receive a prime and finish coat of paint.

(c) Execution

All frames shall be installed using screws and expansion shields.

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After the setting and just before glazing, all windows shall be carefully adjusted
to assure proper alignment and a continuous weather tight seal between the
window and the frame.

Screen shall fit closely and neatly all around and shall be easily removable.

After erection of the windows, precautionary methods shall be employed to

adequately protect the exposed surfaces of installed windows from damage
due to installation of other work or from acid, cement or other harmful
compounds.

7. Aluminum Sliding Windows

(a) Scope

The work covered by this section consists of furnishing all equipment,

materials, and labor in the fabrication and installation of aluminum sliding
windows complete in accordance with the applicable drawings and
specifications.

(b) Materials

Frames and sash members shall be extruded from Alloy 6063-T5. Corners of
frame members shall be fitted to hairline joints secured by tapping screws
applied through integral screwpockets. The sill frame shall be of step down
design for easy water drain-off, achieved through adequately spaced baffled
weep holes. It shall have dual tracks having an arc line contact of 198” with the
rollers. Sash members shall be self-aligning with horizontals sleeving onto the
verticals held by tapping screws at each corner. The stiles shall be provided
with integral pulls notched neatly at the ends to clear the frames during
installation. Panel to panel engagement shall be achieved by a can action
operation for tighter seal.

Weather stripping: Weather-stripping shall be vinyl and wool pile and shall form
a continuous weather seal. They shall be installed snugly in integrally extruded
keyways and shall not be loosened nor removed by operating the windows.
Weather-stripping for the panels will be one piece channel shaped gaskets.

Hardware: Roller sheaves shall be of nylon having a groove of 1/16” radius.

They shall be adjustable and incorporate “Kilian” factory greased labyrinth
sealed radial ball bearings. The locking device shall be a spring loaded
extended larch that automatically engages special frame lips. The screen sash
shall slide on plastic shoe for easy operation. They shall be provided with
manually operated locking device.

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Screens: Frames for the screen shall be independent, but designed to mate to
the sliding window frames. The screen mesh shall be of aluminum installed in
extruded aluminum tubular frames. They shall be set tautly in integral keyways
held in place by vinyl splines.

Finished: Exposed aluminum surfaces shall be powder coated, white. Surfaces

shall be completely sealed requiring no further application additional coating or
preservatives.

(c) Execution

The frame are to be set plumb, level and square without forcing or distorting so
that sash panels shall slide easily and quietly. Sliding panels shall retain proper
weathering contact with each other and the frames are adjusted to ensure their
efficient and smooth operation. Plastic buttons and rubber bumpers shall be
installed on the jambs or stiles to secure proper centering of panels and the
elimination of metalic rings due to metal contact during sliding operations.

2.38 Wood Doors

(a) General

Doors shall be of the size and type indicated in the schedule and as specified
herein. Doors shall be of the quality and workmanship acceptable to the Engineer.
The Contractor shall guarantee finished doors against twisting, warping, crack
and such other defects due to construction and installation for a period of one
year after the final acceptance of the building.

(b) Solid Core, Hollow Core, Plywood Flush Type

1) Materials

Framing, lock blocks, cores, edging, plywood veneers, shall be a select-

grade tanguile or as indicated on the plans, and free from loose or unsound
knots or other imperfections that may impair its strength and appearance.
Lumber shall be kiln-dried with moisture content not to exceed 12%.

Doors shall be 44 mm (1-3/4”) thick and in accordance with the details shown
in the applicable drawings. Framing joints shall be mortised and tenoned.
Entire core for solid core shall be set close together and bonded to horizontal
frames (rails). Plywood shall be 6 mm (1/4”) thick of selected grade and
color. Face veneers of doors intended for exterior use shall be of waterproof
plywood. Provide edge strips around sash.

Doors frame, cores and plywood veneers shall be glued together and hot
pressed into a one piece panel with molazine waterproof glue. Edge strips

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shall be glued around edge of doors. Doors shall be held in retainers until
glue has set, then redried to remove moisture contained in glue. Assembled
door shall be drum sanded, then belt sanded into a smooth finish ready for
varnish or paint.

Where indicated, plywood flush doors shall be provided with louvers of slide
shown Louver blades shall be kiln-dried wood as indicated in the schedules.
Louver blades shall be uniformly cut finished and fastened to frame in an
approved manner.

Sufficient reinforcement shall be provided for installation of door closers

(c) Installation

Hinged doors shall be hung plumbed and fitted accurately allowing 1.5 mm (1/16”)
clearance at the jambs and heads and 3 mm (1/8”) over thresholds. Clearance at
the bottom of doors having no thresholds shall be 10 mm (3/8”). Lock stiles of
doors 35 mm (1-3/8”) thick and thicker shall be leveled 8 mm (1/3”). Knob locks
and latches shall installed 965 mm (38”) from the finished floors to the center.

- END OF SECTION -

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SECTION 008
PROTECTIVE COATINGS TO METAL WORKS

PART 1 – GENERAL

1.1 Scope of Work

The work includes the protective coating of all indicated surfaces including surface
preparation, pretreatment, coating application, touch-up, protection of surfaces not to be
coated, clean-up, and all appurtenant work complete in place.

1.2 Specifications and Standards

Except as otherwise indicated, the current editions of the following Standards apply to
the work of this Section:

SSPC Specifications Steel Structures Painting Council

1.3 Submittals

The Contractor shall:

A. Submit Manufacturer’s literature, including test results, showing that the material is
suitable for the use intended.

B. Furnish a Manufacturer's certificate of compliance for each coating material prior to its
use in the Work. The certificate shall include material identification, quantity, batch
number, and date of manufacture.

C. Submit samples of material in addition to the manufacturer's certification for the

purpose of inspection and testing. Samples shall be submitted at least sixty (60)
calendar days prior to intended use of the product in the Work.

1.4 Quality Assurance

The Contractor is responsible for the performance of all tests and inspection required by
the above Standards. However, Maynilad Water Services, Inc. (MAYNILAD) reserves
the right to perform any of tests and inspection prescribed by the said standards where
such is deemed necessary to ensure that materials and products conform to the
Specifications. The Contractor shall, at his own expense, replace all materials rejected
for failure to comply with this Specification.

PART 2 – PRODUCTS

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2.1 General

The Contractor may propose manufacturer products for approval by Maynilad. Materials
not conforming to the requirements of the specifications will be rejected Maynilad.

Colors, where not specified, will be selected Maynilad from manufacturer's samples
submitted by the Contractor.

Coating material shall be delivered to the jobsite in the manufacturer's unopened

containers, properly stored until required to be used in the Work.

Each container shall show the manufacturer's name, formula, specification number,
color, date of manufacture, and batch number, all in a legible form at the time the
material is used in the Work.

Materials shall be used within 12 calendar months of manufacture, and delivered to the
jobsite in sufficient quantities in advance of the time needed, in order that the Work shall
not be delayed.
All materials shall be properly stored under lock and key.

2.2 Material

Ungalvanized Ferrous Metal Protective Coating

Prime Coat - 50 microns

First Finish Coat - 50 microns

Second Finish Coat - 50 microns

Galvanized Ferrous Metal Protective Coating

Prime Coat - 50 microns

First Finish Coat - 50 microns

Second Finish Coat - 50 microns

Buried Miscellaneous Ferrous Surfaces, and Flanged Joints (insulating flanges)

Protective Coating

Wrap with a 500 microns thick adhesive PVC tape to a total thickness of 1000 microns,
with half width of the tape overlapping.

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Tape and primer shall be of a tape approved by Maynilad and both shall be applied in
accordance with the manufacturer's printed instructions or recommendations.

In lieu of wrapping with tape the Contractor may apply a final coat of coal tar enamel or
neat cement depending on the coating of the adjacent pipe. Minimum coating thickness
shall be 1000 microns.

Stainless Steel, Copper, Brass and Plastic Surfaces

These materials shall not be painted unless otherwise noted.

PART 3 - EXECUTION

3.1 General

All paint and coating work shall be carried out by craftsmen who are qualified and skilled
in the trade.

The manufacturer's written instructions or recommendations shall be followed in the

handling, mixing, and application of all coatings.

Except where factory applied finish coating is permitted in the Specifications, or by

Maynilad, all items to be finish-painted or coated shall be done in the field after
installation. Whether applied in the factory or in the field, coating shall conform to these
Specifications.

Coatings shall be applied only on thoroughly dry surfaces and during periods of
favorable weather or not in extreme heat, nor in dust of smoke-laden air, nor in damp or
humid weather.

Shop priming will be permitted in all cases. After installation, any damaged areas in
prime or finished coatings shall be repaired as directed by Maynilad.

Surfaces not to be coated shall be protected during the cleaning and coating of adjacent
surfaces, particularly during sandblasting and similar operations.

Except as otherwise provided, each coat shall be given a minimum drying time of 72
hours before the next coat is applied.

Successive coats of paint shall be of a different tint, each of a minimum dry film
thickness specified.

3.2 Surface Preparation

All surfaces to be coated shall be cleaned with approved equipment before the
application of coating material.

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All prepared surfaces will be inspected by Maynilad prior to the application of coating.
The prepared surface shall on no account be left overnight before coating is done.

Sandblasted surfaces shall receive the first coat on the same day the sandblasting is
done.

Any grit or dust remaining on the surface after cleaning operations shall be removed
before proceeding with the application of the coating.

Surfaces upon which rust forms, or which become soiled in the interval between
cleaning and coating, or between the application of the coats, shall be re-cleaned.

Damaged coatings shall be repaired by removing all loose non-adherent, wrinkled,

scarred, crazed, or otherwise defective coating, and preparing the surface in accordance
with these specifications and as directed by Maynilad.

Edges of remaining coating shall be feathered to provide for a smooth continuity of the
repaired coating. Adhesion of the remaining coating shall be such that it can not be
lifted as a layer with a knife blade applied under the leading edge.

Abrasions and bare spots in shop prime coatings shall be repaired with metal primer of
the same type.

Enamel undercoats shall be sand-papered by hand and dusted clean before applying
the next coat.

Surfaces to be epoxy-coated shall be sandblasted to near white metal in accordance

with Steel Structures Painting Council, Specifications SP-10.

Galvanized metal surfaces shall be treated with a phosphoric acid etching cleaner before
painting.

Surface preparation methods for the various coatings shall conform as applicable, or as
directed by Maynilad, to the following:

3.2.1 Solvent Cleaning

All oil, grease and wax shall be removed by wiping or scrubbing the surface with clean
rugs or brushes wetted with solvent and wiped clean with dry rags.

Mineral spirits or other approved low toxicity solvents shall be used for cleaning.

3.2.2 Hand Tool Cleaning

The surface shall first be cleaned as specified for solvent cleaning, after which all weld
flux, weld spatter, stratified rust and rust scale shall be removed by hand scraping,
hammering, or hand impact tools.

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Dirt, loose rust, loose mill scale and other foreign substances shall be removed by
vigorous hand brushing with steel wire brushes that have been washed in solvent prior
to use.

Tight mill scale that can not be lifted with a thin knife blade, and minor amounts of
residual rust that can only be removed by sandblasting, may be left.

3.2.3 Power Tool Cleaning

The surface shall be cleaned as for hand tool cleaning, except that power wire brushing
shall be used in place of hand brushing.

At the Contractor’s option, sandblasting may be used in lieu of power wire brushing if
better results can be achieved.

3.2.4 Near White Metal Sandblasting

All oil, grease, wax and dirt shall be removed as for solvent cleaning.

All welds shall be ground smooth and weld spatter removed.

After solvent cleaning, the surface shall be sandblasted to white metal using hard sharp
sand or steel grit to produce a uniform surface of gray-white metallic color.

The blasting material shall pass a 1180 micron square mesh sieve. The compressed air
used for blasting shall be free of oil and condensed moisture.

3.2.5 Water Wash

All oil and grease shall be removed as for solvent cleaning.

All contaminants and salt deposits shall be removed by scrubbing with stiff bristle
brushes and clean, fresh water, preferably under pressure.

3.3 Application of Paint / Coating

3.3.1 General

The Contractor shall be responsible for the protection of adjacent work or property from
his painting and coating operations and for restitution on account of any damage
incurred.

At the time of application, coating material shall be well mixed as recommended by the
manufacturer.

The use of thinners will not be permitted except by express approval of Maynilad. The
quantity and type of thinner shall be as recommended by the manufacturer.

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Each coat shall be free of runs, pinholes or sags, and shall be allowed to dry before the
next coat is applied.

Painting / coating may be done by brush or by airless spray equipment at the option of
the Contractor.

3.3.2 Epoxy Coating

Application of epoxy shall be in accordance with AWWA C550 and the manufacturer’s
instruction. If liquid epoxy is used, by approval of Maynilad, it shall be applied in not less
than three (3) coats to achieve the required total dry film thickness.

If small local epoxy repair work is found to be necessary, it shall be done with a liquid
epoxy recommended by the manufacturer of the originally used material, and applied in
accordance with the manufacturer’s written recommendations.

3.4 Testing

3.4.1 General

The Contractor shall give Maynilad at least 48 - hours advance notice of the start of any
surface preparation work or coating application work.

All such work shall be performed in the presence of Maynilad unless Maynilad has
granted prior written approval to perform such work in his absence.

Items of metal work which have shop applied coatings shall not be shipped until shop
coatings have been inspected and approved by Maynilad, unless this requirement is
waived in writing by Maynilad.

The Contractor shall conduct film thickness measurements and electrical inspection of
the coatings with Contractor - furnished equipment.

3.4.2 Epoxy Coating

After preliminary inspection / testing by the Contractor, Maynilad will inspect / test the
coating using the Contractor’s equipment.

Coating thickness shall be measured with a magnetic type dry film thickness gage.

A high voltage, low current, spark detector shall be used for electrical inspection of voids
and discontinuities in the epoxy coating.

Thin film coatings shall be checked with a low voltage detector of the wet sponge type.

**END OF SECTION**

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SECTION 009
MECHANICAL WORKS
PART 1 - GENERAL

1.1 Scope of Work

This Specification establishes the mechanical features with the highest level of quality
required for the permanent mechanical plant in this contract. All mechanical
equipment, valves and appurtenances shall be ISO certified and applicable for
industrial applications under Class D environment. In the event that the Contract
Performance Specification requirements conflict with the Standard Specification, then
the Contract Performance Specification requirements shall take precedence.

Wherever the supply and installation of submersible centrifugal pump is called for by
a pay item in the Price Schedules, it shall be construed to include the motor set,
complete with guide rails (including all support brackets); lifting chain (including
shackles and securing bracket); duckfoot bend (and support bracket); rising main and
the associated fittings (including check and isolation valves). The contractor shall note
that also included within the scope of supply for pumps weighing 25 kg or more is one
(1) lifting davit and socket suitably designed and sized by the Contractor for a load of
50 kg. A chain pulley block shall also be supplied as part of this Contract.

1.2 Reference

This specification shall be read in conjunction with the current edition of the following
standards:

AWWA C504 Rubber Seated Butterfly Valves

ASTM B62 Composition Bronze or Ounce Metal Castings

ASTM B584 Copper-Alloy Sand Casting for General Applications

ASTM A307 Carbon Steel Bolts and Studs, 60000PSI Tensile

Strength

ASTM A153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware

DIN 2532 Cast-Iron Flange, Nominal Pressure 10 ISO 2084-

1974(e) Pipeline Flanges for General Use – Metric Series
– Mating Dimensions.
ISO R261 ISO General purpose Metric Screw Threads – General
Plan

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ASTM A48/ASTM Gray Iron Casting for valves, Flanges, and fittings.
A126 Class B

ASTM A167 Stainless and Heat Resisting Chromium – Nickel Steel

Plate, Sheet and Strip.

ASTM A743/AISI Iron-Chromium, Ir0n-Chromium-Nickel, Corrosion

303 Resistant, for General Application

DIN 30677 T2 Internal and External Protection for Grey Cast Iron
Castings

ASTM A312 Seamless and Welded Austenitic Stainless Steel Pipes

ASTM D3935 Polycarbonate Standard

ASTM D3011 Polystyrene Standard

ASTM D4181 Acetal Standard

ANSI/ASTM D4066 Nylon Standard

1.3 Definitions

API American Petroleum Institute

ASHRAE American Society of Heating, Refrigerating and Air-
Conditioning Engineers, Inc.
ASME American Society of Mechanical Engineers
ASPE American Society of Plumbing Engineers
ASTM American Society for Testing and Materials
AWS American Welding Society
FRP Fiberglass Reinforced Polyester
PSME Philippine Society of Mechanical Engineers
TDH Total Dynamic Head
UHW-PE Ultra-high Molecular Weight Polyethylene
UV Ultraviolet

1.4 Submittals

1.4.1 Drawings

In addition to the drawing requirements, the following drawings and documents shall
be submitted for review:

a) Pump mounting and general arrangement drawing, complete with parts and
materials listing, dimensions and weight;

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b) Pump sectional drawing detailing all internal components and associated

parts lists;
c) Performance curves;

d) Pump data sheet;

e) Valve and actuator data sheets;

Each data sheet shall incorporate all relevant data associated with each specific
valve which shall include but not be limited to:

a) principal dimensions;

b) any pertinent construction details;

c) materials used for all parts;

d) torque limits;

e) pressure rating;

f) connection details.

1.4.2 Certification

The Contractor shall submit three (3) “fair” copies of all Test Certificates (including
results of tests) as required by the Contract.

PART 2 - PRODUCT SPECIFICATIONS

2.1 Submersible Pump-Sets

Submersible pumps shall suit the duty specified in the Bid Drawings (for Sewage
Lift/Pump Station) or in the approved Design Drawings (in the case of those to be
installed in the Sewage Treatment Plant). The pump shall be direct driven by a close-
couple electric motor. The maximum pump operating speed shall be 1800 RPM.

The casing shall be of close-grained cast iron to the requirement of ASTM B62,
designed for maximum heat transfer to the surrounding liquid. The casing shall be
fitted with renewable wear rings.

Cutter Impeller. The impeller shall be of tungsten carbide tip or approved equal to the
manufacturer's standard grade, preferably secured to the shaft by keying. It shall be
used for equalization tank and lift station.

Non-Clog Impeller. The impeller shall be of stainless steel to the manufacturer's

standard grade, preferably secured to the shaft by keying. Vortex or channel open

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impellers shall both be considered acceptable. The impeller shall be capable of

handling solids, fibrous materials passing a maximum of 100 mmØ solids. If not
capable of handling solids, fibrous materials that will pass a maximum of 100 mmØ
solids, cutter impeller shall be used.

The pump shall be fitted with a double mechanical seal arrangement, the first shall
be between the casing and the oil chamber and the second between the motor
housing and the oil chamber. All seals shall be selected for a long service life. The
choice of face material shall be suitable for the pumped media and to the
recommendation of the seal manufacturer. The Contractor shall submit this
information for review. However, it is envisaged that as a minimum the bottom
mechanical seal shall have silicon carbide faces whereas the upper will be
acceptable with stainless steel/carbon faces.

All bearings shall be heavy duty ball type grease packed and sealed-for-life and shall
be designed with minimum life of L10, 100,000 hours at the guaranteed duty point.

The pump-set shall be fitted with a lifting handle designed for simple, safe and
speedy removal of the pump-set using a permanently installed lifting chain and
shackle. Eyebolts shall be stainless steel.

The electric motor shall be fully submersible, continuously rated, with ingress
protection of minimum IP68, with class F (minimum) insulation, as detailed within the
Electrical specification (Section 010).

Characteristic curves for the pump-set performance shall be submitted by the

Contractor and appended to the completed data sheets.

The pump-set shall accommodate the variation in the water level as indicated in the
Bid Drawing (for Sewage Lift/Pump Stations) or as required by the particular
installation in the Treatment Plant.

Dual guide rails shall be provided to facilitate pump removal in the case of those
weighing more than 20 kg. Single rail systems shall be considered compliant,
provided that the pump is adequately restrained against any twisting forces inherent
to the pump operation. The guide rail(s) shall be adequately supported both top and
bottom to facilitate pump removal. The bottom shall be fixed to the duckfoot
discharge bend. The guide rail(s) and support shall be fabricated from a suitable
stainless steel corrosion free material.

Lifting chains shall also be provided to facilitate the removal of a pump-set weighing
20 kg or more. The top location point for the lifting chain shall be a Contractor's
designed securing bracket. The bottom shall be securely shackled to a suitable lifting
point on the pump-set (in accordance with the manufacturer's recommendation). The
length of the chains required to facilitate pump removal shall also be the
responsibility of the Contractor. The Contractor shall ensure that the chain length
shall be sufficient to allow Operator to remove the chain from its securing point on

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the top location bracket. The chain shall be secured by screwed shackles at the
pump and the upper location end. A further screwed shackle shall secure the chain
and pulley block to the lifting davit. The chain shall be capable of lifting 1.5 times the
dead weight of the pump-set, and shall be tested at 2 x the dead weight of the pump-
set. Test certification shall be submitted with the Operation and Maintenance
manuals. The material for the chain shall be the manufacturer's standard, provided
that it shall be adequately protected from corrosion within the environment of
application. The contractor shall design, supply and install the lifting davit, chain and
pulley block and submit details to the Maynilad for review. The pulley block shall
have a minimum of five (5) pulleys and be fitted with a self-locking mechanism.
Chain and lifting system steel materials shall be hot dip galvanized.

Bolts required for fixing shall be stainless steel grade 316 complete with nylon
washers to prevent galvanic reaction. It shall not be painted.

2.2 Air Blower

Air Blowers shall be designed to suit the duty specified in capacity for Sewage
Treatment Plant. The maximum blower operation speed shall be 2500 RPM.

Casing: The cylinder and headsplated shall be manufactured from high grade cast
iron.

Impeller and Shafts: Impeller shall be ductile iron with integral shafts or steel stubs
shafts and shall be dynamically balanced to close tolerances. It shall be made of 3
lobe type impeller blower. To reduce the noise and power loss, it shall be provided by
wrap-around plenum.

Bearing: The bearing shall be of generous proportions to give long operational life. Oil
lubricated cylindrical roller bearings shall be used at the drive and gear end of the
blower. In addition to normal duty of carrying radial loads associated with the
differential air pressure on the rotating impellers, bearing shall be provided with axial
location of the impellers. All bearings shall be heavy duty type grease packed and
sealed-for-life and shall be designed with minimum life of L10, 100,000 hours at the
guaranteed duty point.

Lubrication: Both drive end and gear end shall be splash oil lubricated. It shall be
provided with maintenance free oil throwers fitted behind each bearing in the gear-
case to prevent leakage of oil.

Direction of Rotation: It shall be detachable mounting feet enable the blower to be

positioned for either vertical or horizontal airflow. Standard machines shall have a left
hand drive shaft, top inlet, for vertical airflow and a bottom drive shaft, left hand inlet,
for horizontal air flow.

Package Units: It shall be enclosed type unit suitable for the system and as per
manufacturer's standard. The unit shall be designed as prime package units. All

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package units shall be designed to achieve sound pressure levels below 80 DBA
(measured at 1 meter) without the use of inlet or discharge silencers.
Characteristic curves for the aerator performance shall be submitted by the
Contractor and appended to the completed data sheets.

Bolts and nuts required for fixing shall be stainless steel grade 316 complete with
nylon washers to prevent galvanic reaction. It shall not be painted.

2.3 Pipework

All pipework associated with pumping unit and associated fittings shall be flanged to
PN 16 or greater in accordance with ISO 7005-2.

The pipework design shall include sufficient flanges or unions to allow for the
disconnection of the major items of plant without disturbing the main pipework. The
Contractor shall supply flexible coupling as necessary to achieve this requirement.

Flange gasket shall be natural rubber or equivalent suitable for river water application
for the wash-down pump.

All pipework installed shall be adequately supported with pipe support of an

acceptable design. These supports shall allow for removal of any section of pipework
for maintenance purposes. Adequate clamping and guides shall be designed and
installed.

Pipe Sleeve shall be provided for floor and wall partition. For cast in place, it shall be
provided with mild steel 4 mm puddle flange. For block-out installation, 4 mm thick
puddle flange with 75 mm (maximum) non-shrink grout all around. Pipe sleeve shall
be made of SS304. It shall be provided with flanges at both ends for ease of
maintenance.

PIPING SYSTEM
PIPES VALVES
DESIGNATION LOCATION ISOLATION CHECK
MATERIALS SUPPORT COLOR
VALVE VALVE
Above Stainless Stainless Butterffy Swing
Green
Ground Steel Steel Valve Type
Aeration
Inside the
HDPE/ABS
Tank
Knife
Above Stainless Stainless Ball
Orange Gate/Ball
Ground Steel Steel Type
Valve
Sewage/Sludge Inside the
HDPE/ABS
Tank
Stainless
Lift Station CI/DI
Steel

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PIPING SYSTEM
PIPES VALVES
DESIGNATION LOCATION ISOLATION CHECK
MATERIALS SUPPORT COLOR
VALVE VALVE
Compressed Stainless Butterffy Swing
SGP Yellow
Air Steel Valve Type
Drinking Water Eye PVC Stainless Green Gate Valve Swing
Wash/Toilet Steel Type
Chlorine Chemical HDPE/Teflon Hot Dipped White Gate Valve Swing
Room Galvanized Type
Steel
Diesel Fuel Generator SGP Yellow Gate Valve Swing
Room & Black Type

Notes: 1. Valve shall be with dismantling joint or combi flange.

2. Bands and Arrows color shall be as per PSME code 2003 Edition, page 230
3. Materials mentioned in the above table are subject to change upon instruction
of Maynilad.

The Contractor shall be responsible for the detailed design and dimensioning of the
pipework.

2.4 Valve Specifications

The Contractor shall be responsible for the design, selection and procurement of all
valves required under this project.

All valves shall be designed for a pressure rating of 16 bars and a test pressure of 1.5
times the pressure rating.

The Contractor shall submit for review a complete valve schedule including manual
and actuated valves.

The Contractor shall submit the specifications of each valve for review before
procurement.

Valve ends, mating dimensions and drilling shall be in accordance with ISO 7005-2,
Class PN-16.

All manually actuated valves shall be clockwise closing and shall have the direction
arrow to signify opening.

All manually operated and actuated valves shall be supplied with permanently
installed handwheels oriented in such a position as to allow easy operation. All
handwheels shall be manufactured from cast iron, or equivalent, and shall be located
via a keyway onto the shaft. A locking not shall secure the handwheel to the shaft.

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Bronze interior parts of valves shall be manufactured from “85-5-5-5” bronze (except
valve stems) and shall conform to the requirements of ASTM B62 unless otherwise
stated.

The composition, sampling and testing shall be in accordance with ASTM B62. All
valves shall be coated over 100% of the interior of the valve by a powder epoxy
coating. Where because of the nature of the item being coated, it would be impossible
to use the powder epoxy method without causing damage to the item, the use of a
liquid epoxy shall be permitted. The minimum dry coating thickness shall be 250
microns provided, however, that the thickness of coating in the grooves for valves or
fittings designed to receive a rubber gasket shall be approximately 125 microns.

All valves shall include, but not be limited to, the following markings, which shall be
raised and cast in a prominent position into the main valve body.

a) Manufacturer's name and address,

b) Identification and/or serial number,

c) Month and Year of Manufacture,

d) Working and Test Pressure,

e) The direction of flow in the form of an arrow.

2.4.1 Knife and Wedge Gate Valves

All Gate Valves, whether knife or wedge gate, shall conform to AWWA C500. All knife
gate valves shall be water type with full metal seating, the gate shall be manufactured
from stainless steel grade 304 or better. All gate isolation valves shall be of the wedge
type.

Valves shall be ductile iron bodied with a high tensile bronze spindle and trim
mounted with double discs, parallel seating and bottom wedging. Double disc valves
with inclined seats will not be allowed. The valve shall have a 50 mm square
operating nut with the word “OPEN” and an arrow on showing that the valve opens by
turning the operating nut counterclockwise with a maximum operating effort of 13 kg
push/pull (i.e. Total 26 kg).

For valves up to and including Ø 150 mm the stem shall be sealed with a minimum of
two (2) “O” ring seals, of which at least one (1) shall be above the stem collar and
replace under full working water pressure while the valve is in the fully open position.
Above this size, all gate valves shall be packed glands for stem sealing.

Manually handwheel operated isolation and actuated valves shall be of the non-rising
spindle type.

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2.4.2 Butterfly Valves

All pump control valves shall be of the butterfly type, designed and manufactured in
accordance with AWWA C504 Class 150 B or ISO 10631 standards and in
accordance with the following:

a. The actual waterway diameter of any valve shall not be less than 95% the
nominal diameter. Lever Arm Handle shall be hard plastic or stainless
suitable to the system.

b. Each valve disc shall be ductile iron with no external ribs transverse to the
direction of flow and shall be of material in accordance with AWWA C504 or
ISO 185, 1083 or 5922. The disc shall seat at 90o to the axis of the pipeline.

c. The shafts shall be manufactured from stainless steel grade 304 or better,
and designed for both torsional and shearing stress when the valve is
operated under its greatest dynamic or seating torque.

d. Shafts seals of valve with exposed shaft to the water shall be designed to
allow replacement or adjustments without removal of valve shaft or operator
assembly. Rubber lined butterfly valves without any internal packing gland
will be preferred.

e. The valve body and flanges shall be made either of cast-iron conforming to
ASTM A-48 Class 40; or ductile iron conforming to ASTM A-536 grade 65-
45-12, fabricated from steel plate conforming to ASTM A-36 or cast steel
conforming to ASTM A-27

2.4.3 Non-Return Valves (Reflux Check Valves)

All check valves shall be of the ball/swing type, and shall comply with the applicable
AWWA/ISO standard. Valves shall be double flanged to ISO 7005-2 PN 16. The seat
ring shall be cast from 85-5-5-5 bronze or approved equal. The body seat ring shall
be accurately threaded and screwed into a machine seat within the body. The face of
the ring shall be machine finished.

Non-return valves shall typically protected via the supplier’s standard finish. However
any valve associated with pipelines designed to convey sludge shall receive a fusion
bonded coating in accordance with the Specification.

Upon completion and testing of the installation, the Contractor shall apply touch-up
coating to rectify scratches and chips in the valve coating.

2.4.4 Flap Valves

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A ductile iron flap valve, internally coated with fusion bonded epoxy to a minimum
thickness of 300 microns, shall be fitted to the discharge pipe to prevent backflow and
shall be mounted on a flat vertical wall. Flap valve shall be of the double hinged type
and shall be supplied complete with incorporating frame, frame seals, door, hinge
brackets, links, hinge pins and fixing bolts.

The flap valve shall have an inclined sealing face to ensure a positive seal is
maintained. Sealing faces shall be phosphor bronze.

The valve frame, door and hinge links shall be manufactured from ductile iron
conforming to ISO1083 or ASTM A536.

Hinge pins shall be stainless steel Type 316.

2.5 Aeration Diffuser

Disc or tubular membrane diffuser shall be used. It shall be fine bubble diffuser and
shall have high oxygen transfer rate. It shall be non-clog type and self-cleaning.
Select larger size diffuser to reduce maintenance cost.

Membrane shall be made of high grade EPDM material. Retaining ring/clamp and
fastening screw be made of stainless steel grade Type 316. Operating temperature
range shall be 0 to 100 oC or greater.

2.6 Clarifier Tank

Contractor shall provide a written guarantee detailing overflow and under flow
predictions. This guarantee shall be based on the basis of laboratory settling tests or
on-site pilot tests or past operating experience. If the guarantee is based on past
operating experience, documentation of that experience shall be submitted. All lab
test summaries shall also be submitted.

Bolts and nuts required for fixing shall be stainless steel grade Type 316 complete
with nylon washers to prevent galvanic reaction. It shall not be painted.

2.7 Chlorine Dosing

Chlorine dosing shall be provided with high quality metering pump & HDPE tank.

Metering Pump: The unit shall be weather proof motor. It shall be suitable to the
system. It shall be 220 V, 60hz. Power shall be designed above maximum
requirement as per manufacturer's standard and it shall be in conjunction with flow
and total dynamic head of the system.

HDPE Tank: The tank shall be UV stabilized to withstand prolong exposure to sunlight
and shall be suitable for Chlorine operation. All of the Chlorine pipework detailed

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above shall be suitably supported and restrained from excessive movement. All
brackets shall be included within this Contract and shall be corrosion resistant. The
tank should be installed onto smooth flat surface making sure that the whole base is
fully supported. It shall be corrosion proof, durable, lightweight high performance and
high quality. The tank shall be provided with sight glass with appropriate volume level
indicator on it. Sight glass shall be protected with stainless guard (tube type). Both
end of sight glass shall be provided with gauge cock. Gooseneck type air vent with
appropriate insect screen shall be provided. Tank shall be provided with drain.

Pipe: All of the Chlorine pipework detailed above shall be suitably supported and
restrained from excessive movement. All brackets shall be included within the
Contract and shall be corrosion resistant.

Valves: All valves, gate valves (for isolation/control) and check valve (for isolation),
shall be included within this scope of works and shall highlight their positions in the
design drawings to be submitted for approval.

The Contractor shall submit the design and location of the said system for the
approval of Maynilad. All fittings and pipework shall be from a suitable material
suitably selected for a chlorine application and to endure external impact. Details of
said coating and pipeworks materials shall be for review by Maynilad.

The facility shall have a chlorine recovery tank (Bund Wall) which can hold 1.1 tankfull
of chlorine in case of accidental spillage.

2.8 FCU, ACCU, RAC and Fans

The Contractor shall be responsible for the design, supply, and installation of air
conditioning/ventilation system and associated pipework including base/support and
electrical system. For air conditioning system room shall be designed minimum of 18
tons of refrigeration per square meter.

2.8.1 Fan-coil Unit:

Cooling coil shall be a direct expansion coil constructed with copper plate and fins
mechanically bonded to the copper tubing with all joints brazed, suitable for the
refrigerant involve. Filters shall be provided in accordance with ASHRAE Standard
52.1 and filters sizes shall be as indicated on the drawing. They shall be mounted at
the return air grille of the unit. Dimensions: entire assembly shall fit the space
provided. Unit shall include condensate pan.

Fan coil units shall be provided where shown, complete with all necessary
components, including coils, dampers, outlet and return air grills, drip pans, fans,
motor, etc. Size and type of units shall be as scheduled on the drawings. The casing
shall be lined with 25mm thick glass fiber sound and thermal insulating blanket as per
manufacturer standard or approved equal. Units shall be ceiling mounted. Filters shall
be disposable type. Coils shall be seamless copper tubing expanded into aluminum

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plate fins, tested at 1.0 Mpa. Fans shall be forwardly-curve centrifugal type, either
direct-connected or belt-driven. Motors shall be single phase, long life permanent split
capacitor type with built-in impedance protection and permanently lubricated ball
bearing with 100,000 hour life. Direct-connected motors shall be 3-speed type. Belt
driven units shall be furnished with fan shafts mounted on permanently lubricated
rubber-mounted ball bearings and adjustable motor sheaves suitable for a +-30%
adjustment of fan speed. Provide fuse start overload device for motor protection,
disconnect witch and permanent green field connections to motor.

A. Housing

Exposed units shall be 1.3mm (minimum) steel, phosephatized, prime coated and
finished with baked enamel.

B. Control

Electric type as indicated, interlock valves with fans so that valves shall be de-
energized and fluid flow stopped when fans are turned off. Fan control shall have
a minimum of two speed adjuster. Thermostat shall be wall mounted electric type
that close or opens the valve to control the room temperature. Thermostat shall
have set point adjuster and temperature indicator. Digital remote control adjuster
as per manufacturer standard is an advantage.

2.8.2 Air Cooled Condensing Unit:

The unit shall contain sufficient refrigerant charge for the complete system and
equipped with all refrigerant line fittings, which shall permit mechanical or sweat
connections. Brass service valves with fittings and gage ports shall be located on
the exterior of the unit. The coil shall be designed and tested after assembly at
pressure specified in ASHRAE Standard 15 for the refrigerant employed in the
system. Condenser coils shall be of circular construction. Tubes shall be
nonferrous with mechanically bonded copper plate fins. Condenser fans shall be
propeller type, direct driven and arrange for vertical or horizontal air discharge.
Fans motors shall be factory lubricated, inherently protected and resiliently
mounted. Controls shall be factory wired and located in a ready accessible
location on the units swing-out service door. The compressor motor shall have
both thermal and current-sensitive overload devices. Solid-state compressor
protection control system shall prevent short cycling on safety devices or power
interruption by limiting the compressor starts at 4 to 6 minutes intervals depending
on the reason for shutdown. Other protective devices shall include crankcase
heater, high and low pressure safety switches, filter drier and liquid line sight
glass, etc. Plug-in wiring connections to control shall be provided. The unit shall
include an indoor fan relay, thermostat with sub-base, tubing package, etc.

A. Refrigerant Piping

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Refrigerant piping and condensate drain piping shall be furnished and installed
complete with all fittings, joining materials, hangers, supports, anchors, and
other necessary appurtenances.

B. Condensate Drain Piping

Condensate drain piping shall be polyvinyl chloride (PVC), schedule 40.

C. Pipe Insulation

Insulation materials shall be installed in strict accordance with the

manufacturer's recommendation. Installation shall be installed in a smooth,
clean, workmanlike manner. Joints shall be tight and finished smooth. Cracked
or chipped sections shall not be used in the work. Insulation shall fit tightly
against surface to which it is applied.

2.8.3 Window-type Units

The contractor shall supply window-type air conditioning units, complete.

All electric motors shall be wired for 220-volts, 60 hertz, single phase.

The condenser coil shall have staglled seamless copper tubes and mechanically
bonded aluminum fins spaced approximately 12 per 25 mm.

The compressor unit shall be of the hermetically sealed type refrigerant gas-cooled
and driven by a high torque motor.

Air filters shall be washable type, approximately 6.35 mm. Minimum thickness and
with a size which will suit the equipment supplied.

Controls shall be factory wired including thermostat control, on and off station.
Controls shall be an integral part with the equipment and shall include compressor
contractor motor protectors, starting and running capacitors and control relays.

2.8.4 Propeller Fan

Propeller fans shall be furnished complete with single or two speed motors, drive
equipment and fan guards. Fans and motors shall be mounted on resilient support
and a heavy metal frame. Provide the angles and/or plates required to mount the
fans and dampers in the opening provided. Each unit shall also be provided with
gravity type back draft type damper of same manufacture as fan to open and close
automatically with the fan start and stop. It shall also be provided with adequate wall
cap.

2.8.5 Ventilation Equipment

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GENERAL

a. Fan shall be capable of giving the specified performance when tested.

Although estimated values of the resistance to air flow of items of equipment
may be indicated this does not relieve the contractor of the responsibility for
providing fans capable of delivering the required air volume through the
system.
b. Each fan shall be capable of continues operation.
c. The contractor shall be responsible for the design supply and installation of
ventilation system.
d. Air change for STP building shall be based on 100% outside supply air,
which shall exhausted, and air change calculation shall be based on the
minimum ventilation rate of 6 air change per hour which is conform to NFPA
standard.

● Ductwork and Accessories

a. This section sets out the requirements of materials and standards of

construction with respect to ducting and accessories.
b. The contractor shall responsible to check the actual spaces available on site
for ductwork installation, prior to fabrication of the ducts.
c. All ductwork shall be properly supported and anchored to the building
structure in approved manner using steel hangers, Anchors, brackets and
support which shall be fixed.

● Reference/Standards

a. Applicable standards referred to this section include but are not limited to the
following

1 SMACNA Sheet Metal and Air Conditioning Contractors

National Association of United States of
America
2 ASHRAE American Society of Heating, Refrigerating
and Air Conditioning Engineer, Inc.

PRODUCT

● Propeller Fans

a. Propeller Fans shall be mounted to suit the particular installation.

Wall mounted fans shall be supplied with wall boxes and plates
suitable for removal for cleaning. Fan and Motors shall be mounted
on resilient and a heavy metal frame. Each unit shall be provided
with gravity type back draft damper or similar shutters and wire
guards. It shall be provided with adequate wall cap.

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● Axial Fans

a. The Fans shall be the tube axial, manufactured from heavy gauge
metal of approved materials. Fan motor shall be direct driven, now
overloading over the characteristic curve at the required RPM to
deliver the specified airflow.
b. The casing shall be made of steel, flanged ends and shall
incorporate of an inspection door. The fans shall be complete with
resilient mountings, mounting feet or plates, connection spigots, wire
guard and dampers, noise restriction/silencer shall be included if
required to comply with noise restriction requirements.
c. The impeller shall be made of steel or approved materials. The blade
shall be fastened to the hub or the hubs and blade shall be formed in
one piece. The impeller shall be accurately balanced after assembly.
d. Fan shall be suitable for their particular service, position of fitting and
shall not exceed any specified noise levels. Extended lubricators
shall be provided with suitable size access panel for fans fitted in run
of ductwork.
● Centrifugal Fans

a. The fans shall be backward curved or airfoil multi blade centrifugal

type, statically and dramatically balanced and complete with
matching housing. Bearing shall be self-aligning ball type and with
factory sealed lubrication. The housing shall be fabricated from black
mild steel sheets.

● Ductwork

a. All ductwork shall be fabricated from fist class quality galvanized

sheet metal and all ductworks and fittings shall be constructed in
accordance with the practice as recommended by ASHRAE,
SMACNA or other equivalent authority.
b. The gauges of sheet metal, type of joints and bracing shall be
constructed in accordance with the SMACNA standard.

● Flexible Connection

a. All flexible joints other than fan inlet connection shall be between
flange ends. All flexible joint shall be securely held between the
metal flanges. Flat iron bands used with fan inlet shall be not less
than 4.5 mm thick. Flange material for flexible joint shall be made of
angle or flat iron.
b. Flexible joints shall consist of material having penetration time of at
least fifteen minutes. The material shall be of the glass fiber cloth
type.

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● Damper

a. Damper shall be provided and installed in the size, types and

location for proper operation on air circulation system.

● Screens and Louvers

a. Screen corrosion resistant type shall be grilles and opening where

this occur on the outside of building. They shall be suitable for
removal and for easy periodic maintenance cleaning. The screen
shall be constructed of stainless or aluminum.

EXECUTION

● Approved type of vibration isolator shall be used for vibration isolation.

● Canvas flexible connection shall be used for connection a rigid ductwork
to the ventilation fan.
● Silencer shall be provided for attenuation of noise generated by the
ventilation fan to acceptable level.
● Ductwork shall be machine bend and be free from buckles and waves.
Duct construction practice shall conform to ASHRAE.
● Ductwork support and opening

a. All ductwork shall be properly supported and supported rigidly from

building structure in an approved manner using steel hanger
anchors, and by means of inserts on expansion shields of adequate
size and number to support loads.
b. Where duct pass through floors, wall or partition, the free space shall
be adequately caulked with rockwool and a neat metal angle flange
arranged to cover the free space.
c. Ducts penetrate the roof construction, flashing shall be provided.

● Flexible Connections

a. Flexible joints shall be provided on fan inlet and outlet connections

and elsewhere on the ductwork where it required.

● Functional performance testing

a. Functional performance tests shall be conducted in the presence of

the engineer to demonstrate the performance of the mechanical
ventilation system.
b. Full range checks and test to determine that all component and
equipment operate in accordance with the specification.

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Upon satisfactory completion of all functional performance testing,

rectification works, and final commissioning report, the engineer shall
recommended for the acceptance of the STP air ventilation systems.

2.9 Diesel Generator Set/Fuel Storage

1. This specification established the features and minimum level of quality required
for the following works associated with the design, supply, installation, testing and
commissioning of a new prime generator, fuel storage tank, day tank and level
control system. System shall be as per NFPA Code.

The Contractor shall furnish and install one Diesel Generator Set. The diesel
generator set shall be factory mounted on a torsionally stiff structural steel sub-
base complete with all necessary engine and generator accessories, ready for
operation manual pushbutton start type, for emergency power supply rated for
standby operation under the conditions specified herein.

2. Submittals and Quality Assurance Manufacturer's test certificates shall be

furnished together with four (4) copies of operation and maintenance manual,
including list of recommended spare parts. Supplier's local agent shall be able to
supply supervision during installation.

3. The diesel generator set shall bear manufacturer's nameplate which shall show

Name of Manufacturer
Engine Model Number
Engine Rotation
Standard kW/kVA Rating @ 1800 RPM
Engine Serial Number
Power Factor
Frequency
Year Manufactured

The nameplates shall be securely mounted each engine where it can be plainly
viewed.

4. Acceptance Test/Commissioning. On completion of the installation, start-up test

and commissioning shall be performed by a factory-trained dealer/representative
of the manufacturer that Maynilad requirements and factory specification are
satisfactory met. Further the said representative shall devote at least two working
days for the proper training and orientation of operators assigned by the Maynilad.
A statement of satisfactory test and completion of the training of operators shall be
issued by the Maynilad to this effect.

5. Diesel Engine

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General – The engine shall conform to the standards and shall be of the
(Radiator) fan-cooled, heavy-duty, 4-cycle, industrial type and shall develop the
full continuous power required by the alternator using diesel fuel when operating
at a speed not exceeding 1800 RPM. The engine shall satisfy the following
operating characteristics:

a. Design speed -------------------- 1800 RPM

b. Maximum specific fuel consumption
(lbs/Bhp-hr ------------------------0.45

The engine shall be a manufacturer's current production model with aluminum

piston or light alloy connection removable type cylinder sleeved, heavy-duty
replaceable precision type bearings. The crankcase shall be a single piece, stress
relieved casting. The crankshaft shall be dropped forged, precision ground and
surface hardened statistically balanced and other features common to heavy-duty
engines.

Starter – The engine shall be equipped with a VDC solenoid engaged electric
motor starter. All necessary components for the safe, efficient and reliable starting
shall be included.

Cooling System – The cooling system shall consists of a belt driven water
circulating pump and an engine radiator. All necessary mounting brackets, hoses,
and connections shall be furnished and installed for a complete system.

Lubricating System – The lubricating system shall have forced lubrication a vane
or gear type oil pump, a full flow oil filter system with an oil cooler, an oil pressure
gauge and oil level indicator.

Exhaust System – The engine shall be equipped with a residential silencer, sized
in accordance with the engine manufacturer's recommendation. Maximum back
pressure measured at the exhaust header shall not be more than 350 mm ( 14 in.)
of water column. The silencer shall be installed with a flexible metal expansion
section of stainless steel and not less than 450 mm (18 in.) in length and or as
shown on the Manufacturer's Drawing and shall be designed together with all
pipes, bends, bolts, nuts and clamps, for temperatures not less than 1000° F

The entire exhaust assembly excluding expansion joint shall be insulated with
2.50 mm layer of magnesium or Rock Wool insulation or equivalent heat resistant
with aluminum lagging or cladding.

Air Suction Filters – Manufacturer's Standard

Fuel system – The fuel system shall include an injection pump, engine fuel
transfer pump, flexible fuel connections, fuel filters and shut-off valves. The fuel
system shall also include the following:

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a. Fuel Oil Storage Tank – the tank shall come complete with all accessories,
Suitable connections to fill the tank from either drums or from a bulk Supply
tanker. Inside surface of the tank shall be pickled or sandblasted to remove
all mill scale, thoroughly cleaned of all dust and foreign matter and lightly
coated with oil. All tank opening shall be sealed prior to shipping.

b. Fuel Level Gauge – The Contractor shall furnish and install float, valve a
level gauge on each fuel day tank for visual indication of the amount of fuel
remaining in the tank. The gauge shall be of either clear glass or plastic
materials resistant to normal diesel fuel corrosion. The level gauge shall be
provided with valves on both ends for isolation during routine maintenance
and replacements. The gauge shall be of appropriate length with
graduations calibrated in both liters and percentage of the total fuel tank
capacity.

1. It shall be provided with two (2) days capacity fuel storage tank and
associated supply pipework and valving to the eight (8) hour day tank.
2. The day tank shall supply the new generator. Fuel storage tank shall be
elevated to eliminate fuel transfer pumping from fuel storage tank to fuel
day tank.

3. The fuel storage fuel tank shall be fabricated in accordance with Chapter
15, Section 7 of the PSME Code 2003, classification Group A.
Construction shall be from mild steel plates with a minimum tensile
strength of 380 Mpa (55,000 psi) and shall be at least 5mm thick. All
welded joints shall be double welded joints and all electrodes shall be in
accordance with the ASME/AWS Codes. The general layout of the fuel
tank shall be in accordance with the contract drawing.

4. The Contractor shall be responsible for the surface preparation and

coating of the tank. However, as a minimum, all surface shall be shot
blasted to 2 ½ primed with a general purpose epoxy primer to a
minimum thickness of 75 microns followed by two further coats of high
build epoxy resin each coat being minimum of 200 microns. The finished
color of the tank shall be black base coat with yellow stripping.

5. The support legs shall be manufactured from mild steel that shall
conform to the specification as per the national structural code of the
Philippines (NSCP) Volume 1, third edition (1989), and shall be not dip
galvanized in accordance with ASTM A513. Welding of the structure
shall be in accordance with AWS D1.1 E70XX. Bolts for fixing of the
same shall be stainless steel grade 316 complete with nylon washers to
prevent galvanic reaction.

6. Furthermore, the Contractor shall be responsible for the design,

excavation and construction of one reinforced concrete bulk storage tank
support structures and retaining wall known as a bund. The volume of

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the bund shall be 1.1 x the volume capacity of the storage tank. The
bund shall be provided with a valved drainage point to a suitable local
drainage manhole. This shall be agreed between the Maynilad and the
Contractor.

7. The Contractor shall determine the number of silencers required suiting

the supplied generator. It shall be residential type. The silencer, exhaust
system and support brackets shall be manufactured from mild steel that
shall conform to the specification as per the National Structural Code of
the Philippines (NSCP) Volume 1, third edition (1989). All brackets shall
be hot dip galvanized in accordance with ASTM A513. The silencer shall
be fitted with a drain cock to allow any condensate to be removed from
the same. All welding of the silencer(s) and exhaust system shall be in
accordance with AWS-D1.1 E70XX. The Contractor shall pay particular
attention to the thermal expansion of the exhaust system and shall
design the clamps and guides accordingly. The silencer shall be either
coated with high temperature paints or clad with aluminum around a heat
retardant material. The external discharge point of the exhaust pipe(s)
shall be protected from rain intrusion. This may be in the form of a rain
cowl or a “flapper”. However, it shall be noted that whichever is preferred
by the Contractor shall not limit the flow of the exhausting gas from the
pipe(s). Details of the same shall be required to be submitted by the
Contractor for the approval of Maynilad.

Acoustic Lining. The Contractor shall be responsible for the

selection, supply and installation of an acoustic lining on internal
walls of both the generator rooms in accordance with the following:

Material High density cladding of rigid construction, glasswood board

designed for thermal and acoustic insulation of that flat concrete
surface where excellent compressive strength and high sound
transmission loss shall be supplied and installed. Details of the same
shall be submitted to Maynilad for approval.

Physical Characteristics

Normal Thickness - 25 mm
Standard size - 2,300mm x 1,200mm
Nominal Density - 80 kg/cu.m
Mass/ Unit area - 2.0 Kg/m2
Service Temperature - Sub-zero to 340° C
Thermal Conductivity - 0.032 W/mk at 20° C mean
temperature
Sound absorption coefficient - 1.02 @ 2000 Hz
Noise Reduction Coefficient - 0.7
Moisture Absorption - 0.1% by vol. When tested in an
atmosphere of 65% RH @ 20° C

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Alkalinity - pH 9, slightly alkaline (Neutral

pH 7)

Digital Instrument Panel – The engine shall be equipped with an instrument

digital panel mounted separately with that of the engine frame and must be
as mentioned together with the D.G. Control Box. The panel shall be
installed on a suitable instrument box in a location affording easy viewing
and access. The instrument panel shall include but not be limited to the
following instrument:
Ammeters/Voltmeters/Frequency Meters/Watt Meter/ Watt h meters
Lube Oil Pressure Gauge
Water Temperature Gauge
Tachometer
Hour Meter

Battery and charger – There shall be installed a battery complete with cables
for supplying appropriate DC power to the engine controls for starting the
engine. The battery shall have the necessary ampere-hour rating for
cranking the engine for 10 minutes. The battery charger shall be 220 volt
VAC input. It shall have an amperage output sufficient to recharge the
battery in 4 hours when the battery is 50% discharged. The charger shall
incorporate adjustable float and equalizing voltage potentiometers. A current
limit signal shall be supplied in the control circuit from the current sensing
resistor. It shall be of the full wave rectifier type and shall include all the
required standard components.

Miscellaneous Equipment – In addition to the item listed in the previous Sub-

clauses, the engine shall be equipped but not limited to with the following:

a. Dry-type or oil intake air cleaner or manufacturer's standard.

b. Flywheel, flywheel housing and stub shaft.
c. One (1) tool kit and any special tools required for maintenance, and
servicing of the engine.

6. Alternator

The alternator shall be rated for standby operation at its designed capacities 0.80
PF, 3- phase, 50 Hz, 1800 RPM, 230/460 volts, 50° C rise over 30° C ambient
temperature at 75 masl and shall be directly coupled to the engine. The alternator
shall be single bearing, synchronous type with brushless exciter and shall be built
according to applicable NEMA Standards. Class H insulation shall be further
protected with 100% epoxy impregnation and an overcoat of resilient insulating
material to reduce possible fungus and/or abrasion deterioration.

The exciter shall be self-regulating capable of maintaining rated voltage at 200%

rated current and sustaining under short circuit condition at 400% of rated current.
An alternator-mounted volts per hertz type automatic voltage regulator shall be

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provided to match the characteristic of the alternator and engine. Voltage regulator
shall be +2% from no-load to full rated load. Ready accessible voltage droop,
voltage level and voltage gain controls shall be provided. Voltage level adjustment
shall be a minimum of ±5%. The solid state regulator module shall be shock
mounted and epoxy encapsulated for protection against vibration and atmospheric
deterioration.

Alternator shall be capable of sustaining an overload capacity of 300% full load

current at zero power factor for a period of 10 seconds without damage to it Output
voltage recovery, after sudden application or rejection of rated load shall be within
0.3 seconds

Alternator shall be open, drip-proof construction with an over all efficiency of at

least 85% at full load, IP21 or IP22 Standard Waveform deviation less than 5%.

Alternator windings and electrical components shall be tropicalized.

The following Protection Relay shall be included:

1. Ground Fault
2. Over Voltage
3. Under Voltage
4. Over current
5. Short Circuit
6. Reverse Power

7. Generator Control Panel

A separately mounted engine-alternator control panel shall be supplied with the

diesel-generator set. The control panel shall be free-standing, dead front
construction, 14 gauge NEMA 4 (IP65) enclosure. Cabling and control wiring shall
be either top or bottom or MCCB Box shall be located in front of Generator
together with the control unit box. The panel shall contain the standard equipment
necessary for its complete and safe operation.

8. Genset building, foundation, retaining bund wall shall be under civil works.

9. Bolts and nuts required for fixing shall be structure steel ASTM A36 with hot-dip
galvanized ASTM A153 with lock washers.

10. Generator transfer switchboard

Transfer switch shall be rated 125% of standby rating of Genset. Enclosure shall
be NEMA 12, electrically operated pilot light indicator & push button.

PART 3 - EXECUTION

3.1 Health and Safety

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The Contractor shall observe all Health and Safety Regulation of the Philippines
throughout the course of his works.

The Contractor shall ensure that prior to the commencement of the site installation a
method statement of installation of all plant noting specific health and safety issues
shall be submitted in writing to Maynilad. Work may not start on site until approval of
the same is attained in writing.

3.2 Testing at the Plant before Delivery

All equipment supplied under this Contract shall be tested for quality of workmanship
at the manufacturer's premises. On delivery to site, Maynilad shall inspect all said plant
and any equipment not complying with the specification shall be immediately rejected.
The replacement costs of the same shall be the responsibility of the Contractor.

Pump-sets shall be tested to ISO 2548, class C.

The Contractor/Manufacturer shall conduct test and furnish three (3) original certified
copies of reports describing the procedures and results of test prior to delivery to the
site.

3.3 Installation

The Contractor shall install all the plant detailed herein and shall install the equipment
as indicated in the manufacturer's drawings. All written instructions from the equipment
supplier shall also be observed. Distance between wall and equipment shall not be
less then 1000mm.

The fixing of all frames and brackets shall be with stainless steel expanding bolts and
washers, unless otherwise noted.

The Contractor shall be required to fabricate any piping and supports required to install
the pumps, motors, and associated plant.

The Contractor shall also be responsible for all electrical works in accordance with TS
Section 010.

The Contractor shall be responsible for providing all power requirements and special
tools required undertaking the installation of the plant detailed herein.

3.4 Equipment Signage

The Contractor shall be responsible for the provision of the following sign on the
equipment to be used on the system:

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Permanent labels giving the item designation shall identify all items of equipment. All
labels shall be in English, engraved black lettering on white background. All necessary
warning labels to be engraved on approved material with white letter on a red
background. Provide signage arrow for the piping system.

Example: Chlorine Tank – Engraved “CHLORINE TANK” CT – 1”

3.5 Plant Operation and Maintenance Manuals

The Contractor shall furnish to Maynilad, at least fifty (50) days prior to the
commencement of commissioning and testing of the equipment, five (5) sets of
technical manuals for all equipment supplied or installed. Each set shall consists of
one or more volumes, each of which shall be bound in a standard size, lever arch file
hard cover binder suitable for bookshelf storage. Binder ring shall not exceed 75mm.

The manuals supplied shall cover the complete works and must be relevant to the
actual equipment installed. The operation instruction manual shall be comprehensive
and sufficiently detailed to ensure that the “equipment can be competently and
efficiently operated by Maynilad staff after commissioning and testing of the equipment
have been completed. The maintenance manual shall be in sufficient detail to enable
the overhaul and maintenance of all equipment to be effectively carried out by
Maynilad maintenance staff.

All manuals shall be supplied with detailed indices which will enable any specific item
to be quickly and accurately located.

The operating instruction manual shall be prepared separately from the maintenance
instruction manual and compiled such that reference to the maintenance instruction
manual is not necessary for the implementation of the operating instruction manual.

Where manufacturer's standard manuals are supplied for any equipment, they shall be
those applicable to the equipment installed and the relevant sections shall be clearly
marked. Trouble shooting manuals of the manufacturer's equipment should also be
furnished for future maintenance purposes.

The manuals shall include the following:

(1) A concise description of the equipment and the proposed method of control and
operation.

(2) A detailed description of each piece of equipment complete with performance

specification and mode of operation.

(3) Procedure to be followed for equipment start-up, operation and shut down.

(4) Procedures to be followed for installation, testing, maintenance and repair.

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(5) Fault-finding procedures for all equipment in the form of charts listing “fault”,
“possible causes”, and “remedy”.

(6) Instructions of dismantling, repair, re-assembly and adjustment of all equipment.

(7) Lubrication chart for all installed equipment, including lubrication schedules,
lubricant SAE grade and type, including frequency of required lubrication.

(8) Complete list of equipment installed showing the manufacturer's name,

manufacturer's nearest representative address, telephone and telex or fax
numbers.

(9) A comprehensive index of manuals supplied by equipment manufacturer's

indicating the equipment type, number and manufacturer's name.

(10) A comprehensive routine maintenance schedule for all equipment installed.

(11) Complete details of earthing system installed.

(12) Sufficient information to enable parts for any piece of equipment to be ordered
from the manufacturer.

(13) Other manuals mentioned in each Section.

(14) Drawing comprising of:

a. General Arrangement
b. Sectional Arrangement
c. Parts List
d. Performance Curves

All manuals submitted to Maynilad, which do not meet the requirement of this Section,
will be returned to the Contractor for improvement and resubmission within fourteen
(14) days.

3.6 Tools

A full set of any special tools required for the operation, maintenance, or repair work
on mechanical equipment shall be supplied.

3.7 Spares

A comprehensive set of spares is to be provided to maintain the mechanical

equipment for a period of not less than 24 months in operation.

3.8 Guarantees

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The Contractor shall guarantee that the mechanical systems are free from all
ground and from all defective workmanship and materials and will remain so for a
period of two (2) years from date of acceptance of the work. Any defects appearing
within the aforesaid shall be remedied by him at his own expense.

**END OF SECTION**

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SECTION 010
ELECTRICAL WORKS

PART 1 - GENERAL SPECIFICATIONS

1.1 Specific Conditions

The performance of the equipment and materials installed shall be as specified and
the quality of installation in accordance with the specification and good trade practice.

The works shall be carried out in accordance with the requirements of all authorities
having jurisdictions over the works and/or approval required therefrom. Such notice
shall be provided and the application shall be prepared accompanied by such plans
and information as may be called for and / or obtained such approvals.

Reference codes and Standards listed in the prefaces to those Standards and Codes
are applicable in respect of all materials and workmanship except where in conflict with
the provisions of this specification.

Where this specification expressly requires standards higher than or different from
those applicable under the relevant standard or documents, this specification will take
precedence.

Where special conditions exist which would make compliance with these specification
usually difficult, then details should be submitted in writing to Maynilad, who may grant
an exemption. Any such exemption granted shall be obtained in writing from Maynilad
by the party seeking the exemption.

Any items of equipment offered and not listed under “Preferred Equipment” must be
approved by Maynilad. Any such exemption granted shall be obtained in writing from
Maynilad by the party supplying the equipment.

All wiring and tests shall be carried out in strict accordance with the current edition of
PEC part 1 and 2 including amendments and rulings.

If there is any conflict between Philippines Electrical Code Part I and II and other
standard, the most stringent rule shall apply.

All permit and electrical fees required for this work shall be obtained by and at the
expense of the Contractor. The Contractor shall furnish and transmit to Maynilad
copies of Certificates of Inspection and Approval after completion of the work. The
Contractor shall prepare all as-built plans and all other paperwork required by the
approving authorities.

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1.2 Codes and References

This specification shall be read in conjunction with the following documentation

a. Contract Documents and Standard References.

PEC : Philippine Electrical Code

IPCEA : Insulated Power Cable Engineering Association
NEC : National Electrical Code
NEMA : National Electrical Manufacturers Association
IP Ingress Protection
IEEE std. 141- : Protection and Coordination
1976
IEEE Pub. No. : Grounding of Industrial Power System
142
IEEE : Institute of Electrical and Electronics Engineers
IEC : International Electrotechnical Commission
UL : Underwriter Laboratories

1.3 Definitions

VFD : Variable Frequency Drive

SS : Soft Starter
RVAT : Reduce Voltage Auto transformer Type
ACB : Air Circuit Breaker
MCCB : Molded Case Circuit Breaker
PFC : Power Factor Capacitor
MCC : Motor Control Center
MCB : Miniature Circuit Breaker
FLC : Full Load Current
O/L : Overload
RSC : Rigid Steel Conduit
uPVC : Unplasticized Polyvinyl Chloride
ELCB : Earth Leakage Circuit Breaker

1.4 Technical specification

The following supply conditions apply:

Voltage 2.3 kV, 460 V, 230V

Frequency 60 Hz
Phases 3, 4 Wire
Neutral Earth Neutral Link at the star point of transformer
Control Voltage 110 VAC
No other control voltage shall be used unless
approved in writing by the Maynilad

1.5 Climatic Conditions

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Temperature Highest Maximum 45 degrees C

Humidity Average annual range 72-95% RH non-condensing

1.6 Degree of Protection

The degree of protection as listed below shall refer to NEMA or IP.

Switchboard NEMA 12 (Indoor Application)

Control Stations NEMA 12 (Indoor Application)
Field Devices NEMA 3R / 4X(Outdoor Application)

1.7 Protection from Water

All outdoor equipment shall be fitted with a cover to provide effective protection against
rain.

All enclosures housing electrical equipment must capable of preventing water

penetrating to live parts. Design must take into account the likelihood of deliberate
hosing in some locations.

Enclosures having doors or removable panels exceeding 0.4 m2 in area should, where
possible, be located indoors.

No electrical component is to be located where it will be permanently wet without

authority from Maynilad.

Thermostatically controlled low surface temperature heaters shall be provided where

necessary to prevent condensation of water.

1.8 Corrosion Protection

Carbon steel conduits, ducting, cable ladders, 'unistrut', etc . are all to be hot dip
galvanized, suitably plated or manufactured from non-corrodible material.

Fixing such as screws, rivets, bolts, brackets, etc are to be galvanized, suitably plated
or manufactured from non-corrodible material.

Cubicles and enclosures must be manufactured out of mild steel. Carbon steel or
glass filled polyester construction is permissible where indicated by Maynilad.

1.9 Spare Parts and Special Tools

Where a machine is fitted with components of a specialized nature, such as electronic

components, etc. for which spares are not already held at or are not held elsewhere
Manila (ex stock), or which cannot be replaced by other components dimensionally
and functionally identical, which are held or available in Manila (ex stock), then such
spares shall be provided as part of the original equipment.

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A full set of any special tools required for the operation, maintenance, or repair work
on electrical or instrumentation equipment shall be supplied.

PART 2 - PRODUCT SPECIFICATIONS

2.1 Color Coding

The colors shall be:

 Logical states of devices monitored and controlled by the control system shall
be differentiated by colors as follows:

Red - Danger, stop, emergency stop. Measures

required in emergency situations.
Yellow - Caution, take action to avoid danger, avoid
changes
Green - Safe start, on.
Black, white, gray - Neutral, can be used for all purposes except
those covered by red, e.g. Reset, inching.
Blue - Special, must not be used for purposes
covered by red, yellow, or green, e.g.
Thermal o/l light.

 Wire color

460 V 3 - phase Red, White, Blue

230 V single phase Phasor colour, when switched - red
Earth Green/Yellow
Neutral Black
24 VDC + VE Brown
-VE Violet

Multicore cable and their cores do not have to be colored as above but must be
uniquely identified at both ends.

 Label Colors

Labels shall be engraved black lettering on a white background. Warning labels

shall be white lettering of a red background.

2.2 Wiring and Terminal Identification

All single cores including individual cores of multicore cable to be identified at each
end with approved markers. The only exception to this requirements are short
lengths not exceeding 100 mm which are used to connect between C/B's and
contactors, or loops from one terminal on terminal strips or contact blocks – provide

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these short lengths are not loomed up or otherwise covered, one end only be
numbered.

Cable cores shall be identified at the rail terminals only.

All terminals should be clearly marked on outgoing side of terminal and common
type circuits shall be grouped logically i.e. Power, control, etc.

MCC/Panel Wiring

At every termination, the wire shall have a crimped connection.

The joining of any wire in the duct is expressly prohibited.

All external connections (with the exception of the supply and local submains) shall
be via terminals mounted on the mounting plate. All terminals shall be grouped in a
logical order.
Panel and Cubicle Wiring

Wiring within the panels and cubicles shall be installed in an approved PVC wiring
duct and any conductors not installed in these ducts shall be laced with PVC ties or
strips in an approved manner. The total cross sectional area of wiring within ducts
shall not be greater than 40% of the total cross sectional area of duct.

Unless otherwise specified, all wiring shall be stranded with minimum size of:

 (#16 AWG) 1.5mm² for Electronics/Instrumentation signals

 (#14 AWG) 2.0 mm² for controlled
 (#12 AWG) 3.5 mm² for Power and CT circuits

All ducts shall be terminated with suitable crimp lugs. No soldered or bare wires
shall be used as terminations.

All wiring shall be rigidly supported and where against metal, protective insulation
shall be provided. Wiring between hinged panels and fixed portion shall be securely
by insulating shelves at each side of the hinge and shall hinge freely without undo
flexing of the cable and in such a manner that the bunched cables or equipment on
the hinged panel cannot foul other parts.

2.3 Cables Identification

All circuits are to be uniquely identified by an alphanumerical cable numbers as

listed in the cable list, and cable cores shall be identified at the rail terminals only.

All sheathed cables shall be uniquely identified at each end by means of engraved
or embossed label firmly attached to the cable. For bottom entry this label should be
attached just after it enters the enclosure in which it is terminated.

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For top entry this label should be attached just before it enters the enclosures.

All power, control and instrumentation cabling shall be identified at all terminations
by use of a durable type tag and approved by .

2.4 Item Identification and Equipment Labeling

All electrical components shall have all terminals clearly and permanently marked.
All items of equipment shall be identified by permanent labels giving the item
designation.

All labels shall be in English, engraved black lettering on white background. All
necessary warning labels to be engraved on approved material with white letters on
a red background.

Characters shall be minimum height of 15mm for equipment label and 6mm for
electrical component, uppercase print type font, mechanically engraved.

Labels mounted inside electrical enclosures and switchboards may be mounted

using approved double-sided adhesive tape, and shall not be attached to removable
ducting tops.

Labels mounted outside electrical enclosures to be fixed with at least two screws,
rivets or drive parts on the permanent structure to which the component is mounted,
adjacent to the component and readily visible from in front of the component. Where
ready access is not available in front of a component then additional labeling that is
visible from a readily accessible position will be required, e.g. Solenoids, limit
switches etc. positioned behind panels, under machinery etc. are to be identified
also by labels mounted on external surfaces of the machine.

Instrumentation equipment may be identified by using cable the alphanumeric

identification Tag approved by Maynilad.

PART 3 - EXECUTION

3.1 General

All field wiring to motor, control stations sensors and actuators shall be wired using
cables. Conduit wire is not accepted. Single wires in conduit will not be accepted.

Connections of series contacts such as emergency and motor stops, safety

switches, etc. are not to be looped in the field. All wiring is to be brought back to a
common terminal and indication of the devise being operated is to be provided both
locally to the devise and at the approved area control station.

3.2 Mains/Power Cable

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Mains cable shall be THW/THWN single core stranded copper cables at 75° C
temperature rating min. (unless otherwise specified or approved by Maynilad)

3.3 Motor Cable

Motor cables shall have a minimum cross section of 3.5 mm2 and shall be a
multicore or single core PVC insulated, PVC sheathed multi stranded copper cable
at 75° C temperature rating minimum (unless otherwise specified or approved by
Maynilad).

3.4 Control Cable

Control cables shall be PVC insulated multicore cables having multi stranded
copper conductors with a minimum cross section area of 1.5 mm2 min. All control
cables shall be rated for a minimum of 600/1000V and 75° C.

3.5 Signal Cable

General purpose signal cable 4-20 mA or any other signals for electronic devices
shall be multicore, having stranded copper conductors with a minimum cross
sectional area of 1.5 mm2 (unless otherwise specified and approved by Maynilad)
and be PVC insulated overall screened, PVC outer sheath construction with a
maximum working voltage of 110 VAC/150 VDC.

3.6 Cable Installation

Single core power cables to be clamped in Trefoil Arrangement.

Cables shall be securely braced with cable clamps or ties as required.

Vertical rises of cables shall be secured at intervals no less than 1 meters, to allow
for cable expansion.

The arrangement of cables on ladder trays or brackets shall be such that where
cables join or leave the ladder or brackets there is not unnecessary crossing or
tangling of cables. Where cables are liable to mechanical or environmental damage
they shall be protected in a suitable manner.

Where cables pass through fire rated walls or floors a fire barrier or fire rated
sealing compound shall be used to seal the space after installation of the cables.

All cables, pipes and conduits shall be buried not less than 600 mm below finished
ground level in the center of a 150 mm layer of sand. Underground cables, pipes
and conduits shall be effectively protected with yellow PVC cable warning marker
tape (or equivalent) covered above the run of services 150mm below the surface.

Cable shall not be cast directly into concrete.

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All instrumentation/data cables shall be segregated from power cables, by a

minimum of 100mm and from control cables by a minimum of 50mm.

3.7 Cable Protection

Cables shall be fully protected from mechanical damage. The protection shall not
allow liquids to enter or accumulate within the protection.

All cables are to be protected where they pass through any openings, gaps, holes,
or over edges of metalwork, ladders etc. The contractor shall ensure that
surrounding surfaces are smooth and free of sharp edges etc., and that holes are
bushed with close fitting plastic bushes.

3.8 Cable Entrances

All cable entrances to equipment and buildings shall be vermin proof and shall be
firmly sealed to prevent ingress of weather and water.

3.9 Cable Glands

Where cables terminate in cubicles or auxiliary equipment boxes, the cable shall be
fitted with suitable cable glands. These cable glands shall grip the cable securely,
seal on the outer sheath of cable and be complete with locknuts. They shall for
armored cable include provision for securely bonding the earth.

3.10 Cable Terminations

All termination shall comply completely with the manufacturer's recommended

instructions.

Cables joints shall be made only in approved junction boxes.

All terminations of field cable cores shall be to individual terminal blocks mounted in
a group adjacent to each other.

Connection of control and signals cable, except thermocouples, shall be with

appropriate crimp pins or lugs.

Adjacent to motors (Aerators), motor cable shall terminate at a local isolator for the
motor. The isolator shall be rated to AC23. Cabling between the isolator and the
motor terminal box shall be enclosed in flexible conduits.

Cable or core termination shall under no circumstances be under mechanical stress

due to lack of support of the cable or vibration.

The connection of cable screens shall fan out from the signals power supply, with
the remote ends being insulated from earth. (Star connection) Screens on screened

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cables shall be insulated or sleeved and brought out as appropriate. Heat sink
sleeving shall then be fitted over the end of cable sheath.

All field sensors with molded in leads shall be held by compression glands at the
terminal boxes. Where leads are subject to mechanical damage, suitable sized
loose flexible or rigid conduit shall be fitted over this lead and fixed to support in a
appropriate manner.

The Contractor may be required to demonstrate his jointing technique, and, if in the
opinion of , the termination is faulty, the Contractor shall replace all other
terminations so jointed at no extra cost.

Cables, conduits or ducting entering cubicles junction boxes, motor terminal boxes
or like, shall be from the bottom, unless otherwise specified or approved by
Maynilad.

3.11 Cable Support System

Cable ladder racking, trays and ducting shall have a minimum of 20 percent space
capacity at the end of the contract.

All fixing to concrete or masonry shall be of the expansion type set in holes.
Explosive powder charge fixing shall not used.

Fixing to structural steelwork shall be by clamping, not welding or drilling, except

with the specific prior approval of Maynilad.

Cable support system shall be installed in accordance with the manufacturer

recommendations to five a maximum between support deflection of 10 mm when
carrying the final number of cables to be installed.

All steel supports, frames, hangers and the like shall be electroplated and in most
area hot dip galvanized.

All exposed threads on support systems, conduit and other places where the
galvanized finish has been removed shall be painted with galvanized paint. (do not
use spray cans type of paint.)

All lengths of the cable support system shall be bonded to earth.

The Contractor shall submit to Maynilad a layout of his proposed method of

reticulation throughout the Plant showing positions of all cable ladder, tray or
ducting system.

3.12 Cable Ladders

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Cable ladders shall be hot dipped galvanized steel with welded rungs. They shall be
completed with accessories including hot-dip galvanized hangers, brackets and
cable clips.

The contractor shall supply and erect all cable ladders and all brackets and
fabricated steelwork necessary to support the cable ladder and shall ensure that
they are adequate in all respects for the loading imposed.

All change in direction shall be made using purpose made slow radius bends and
cranks as manufactured for this purpose.

Cable ladders installed outside the building shall be provided with cover.

3.13 Cable Trays

Cable trays shall be hot dipped galvanized steel and securely fixed.

Cable Trays installed outside the building shall be provided with cover.

3.14 Conduit
Conduit shall be one size larger than is required by Regulation for the number of
cables to be drawn in and not less than 20 mm. It shall be of the high impact, rigid,
PVC pattern, resistant to ultra violet light.

All exposed conduits, embedded in concrete, conduit in plant room and equipment
area where exposed to damage shall be in Class 'B' screwed galvanized conduits.

Where steel conduits are used, they shall not be utilized as the earth continuity
conductor to plant and equipment.

All steel conduits shall be bonded to earth.

All conduit runs whether above ground or below shall utilize inspection
boxes/drawpits at every change in direction or/and every 50 meters, to enable the
cables to be routed through the conduits.

Where space allows, every conduit run shall include for a nylon draw rope to aid the
pulling in of additional cables at a later date.

3.15 Flexible Conduit (Water-tight)

PVC coated gray color flexible conduits shall be used for the final connection to
removable field apparatus such as motors, RTD probes and the like.

Conduit installed outside shall be stabilized against ultra violet light.

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Where mounted on moving parts of machinery or where subject to mechanical

damage the conduits shall be flexible PVC covered galvanized steel.

All flexible conduits shall be terminated in purpose built glands.

3.16 Cable Junction and Equipment Boxes

Boxes for equipment requiring more than 300 mm length of terminals shall be fitted
with a door.

Reference shall be made to the section on SWITCHBOARDS for details on

manufacture, equipment, wiring, labeling etc.

In wet processing area boxes shall be made of stainless steel. They shall be
mounted at a normal working height with a minimum floor clearance of 300 mm.

3.17 Guarantees

The Contractor shall guarantee that the electrical system are free from all ground
and from all defective workmanship and materials and will remain so for a period of
two (2) years from date of acceptance of the work. Any defect appearing with the
aforesaid shall be remedied by him at his own expense.

3.18 Post Contract Documentation

1. Operation and Maintenance Manuals

The Contractor shall submit to the Maynilad, five (5) copies of the approved
Operations and Maintenance Manuals. These manuals shall be in separate folders
and shall provide all information needed for the safe efficient commissioning,
operation, adjustment and maintenance of the plant.

The Contractor shall collate all the information relating to the enclosure(s) and its
associated equipment. Two (2) draft copies of each manual shall be supplied two (2)
weeks prior to the dispatch of the enclosure(s).

Operation Manual

The Operations Manual shall include:

 Index and references to enable the user to quickly find the relevant
information
 Electrical drawings which includes the ff:
 Cover
 Index
 Single Line Diagram
 General Arrangement/Plant Layout

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 Equipment Layout
 AC Distribution Diagram
 DC Distribution Diagram
 Control wiring Diagram
 Termination Diagram
 Cable Schedule
 Parts List

 Equipment manuals for various items necessary for the operator setting up
and adjustment of process variables in accordance with the control
philosophy.

 A detailed written description of the control philosophy including description

of the action to be taken by operators, with respect to operator controlled
devices, together with operator adjustable variables.

 The Operator Manual shall provide the Plant Operator with the information
required for successful start-up and Shut-Down Procedures, Operation of
Manual Interface, Operation of Local Interface, Plant Consideration,
Associated Document References.

Maintenance Manual

The maintenance Manual shall include:

 Index and reference to enable the user to quickly find the relevant
information.
 Schedule of drawings, showing title, revision, manufacturer's reference and
purchaser's reference.
 Plant and parts list giving manufacturers name, address, catalogue number
or re-ordering reference, and serial numbers of individual items.
 Setup, calibration, commissioning instruction for all items of plant, including
operating characteristics of all protective devices.
 Commissioning data for all settings and tests performed.
 Fault finding and rectification instructions.
 Results of all tests before delivery
 Results of all test on site
 The Maintenance Manual will provide the Maintenance Technician with the
information and reference for Preventive, Corrective and Condition-Based
Maintenance, Associated reference Documentation References, Preventive
Maintenance Procedures, Condition-Based Maintenance Procedures,
Corrective Maintenance Procedures and Fault Finding Techniques.
 Recommendation routine maintenance procedures.
 Recommended list of spares.

2. Tools

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A full set of any special tools required for the operation, maintenance, or repair work
on electrical or instrumentation equipment shall be supplied.

3. Spares

A comprehensive set of spares is to be provided to maintain the electrical or

instrumentation equipment for a period of not less than 24 months in operation.

4. Exemptions

Where special conditions exist which would make compliance with these
Specification usually difficult, then details should be submitted in writing to Maynilad,
who may grant an exemption. Any such exemption granted shall be obtained in
writing from Maynilad by the party seeking the exemption.

5. Preferred Equipment

Any items of equipment offered and not listed under 'Preferred Equipment' must be
approved by Maynilad. Any such exemption granted shall be obtained in writing form
Maynilad by the party supplying the equipment.

6. Location of Equipment

The location of all electrical equipment shall be such that it will allow both convenient
and safe access for service, testing, calibration etc., without the use of temporary
staging, ladders, the dismantling of other equipment or the removal of the component
itself. No apparatus or terminal block shall be mounted within 250 mm vertically from
the internal floor level.

3.19 Testing

1. General

Tests shall be pre-planned, scheduled, and carried in a safe and efficient manner.
Notification will be given at least three (3) days in advance to carrying out any tests
of the panels and field wiring so that a representative is able to plan witnessing of
each test at the following stages:

Equipment and cables support mounted within panel/in the field, but not wired. Fully-
wired and ready for test.

All test required by Statutory Authorities are to be carried out to proved that the
systems operate in accordance with appropriate codes and regulations.

Works and field testing shall be witnesses by the company representative and all
testing and results shall be recorded. The checklist (record sheets) shall be obtained
from the Electrical Engineer.

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2. Field Inspection and Testing

All plant provided under this contracts shall be available for inspection and testing as
required by Maynilad, during manufacture. The costs of the tests including the
provision of all necessary test equipment at the manufacturer's works shall be
deemed included in the Contract Price.

Prior to starting any test the Contractor is required to check that the installation,
electrical devices and instrumentation are strictly in accordance with the
Specification, electrical and instrumentation drawings.

All AC test instrument shall have a minimum accuracy of 0.5%. All DC test
instruments shall have a minimum accuracy of 0.1%

All other test instrument (pneumatic and electronic calibrators, temperature

calibrators etc.) shall have a minimum accuracy of 0.1%

Each test instruments shall be calibrated in accordance with acceptable international

standards. The calibration certificates shall not be more than 3 month old and shall
be presented to the Electrical Engineer prior commencing work.

Following completion of works and before the delivery, testing shall be performed by
the contractor to Maynilad satisfaction.

3. MCC and Switch gear Test

Test shall include but not limited to:

Cubicles shall be inspected to ensure that the quality of finish is to standard. The
correct apparatus and labeling have installed and the wiring has been carried out in a
neat and correct manner.

The equipment shall be carefully inspected to ensure that all electrical connections
are tight, particular attention should be paid to busbar connections and all clearances
should be adequate.

All wiring shall be checked against the schematic layout and all control switches
relay contacts, timer, etc. checked for correct polarities and mode of operation.

Operational tests of control, protection, relay and alarms equipment with all items of
auxiliary equipment for mounting remote, temporary wire-in for the tests.

Where certain control interfaces are not available, simulated signals shall be used to
test individual systems.

Checking phase sequence and voltage levels

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Sequential operational test of all control circuits including interlocks.

Insulation Test (Phase to phase, Phase to neutral and Phase to earth)

Checking the individual operation of all motors without load for rotation, bearing
lubrication, noise, vibration and temperature rise.

Recording the operating load current of all motors.

Measure and balance full load currents in each phase when the system is full loaded.

4. Cable Test

Test shall include but not limited to:

Every cable shall be tested for insulation (Megger), continuity compliance and earth
loop impedance. The results of all test shall be detailed on a signed test certificate
prior to submittal for review. The activation of each circuit shall not be allowed until
the test certification has been reviewed by Maynilad.

5. Transformer Test

All tests shall be in accordance with latest version of ANSI and NEMA standards.
The following standard factory test shall be performed but not limited to:

 Resistance measurements of all windings on the rated voltage connections

 Ratio test on the rated voltage connection and all tap connections
 Polarity ands phase-relation test on the rated voltage connections
 No-load test at rated voltage on the rated voltage connections
 Exciting current at rated voltage on the rated voltage connections
 Impedance and load loss at rated current
 Applied potential test
 Induced potential test

6. Instrument Checkout

Each instrument, including transmitter, shall be identified and compared with the
process diagrams to verify its function and operation.

Transmitting instrument containing or provided with protecting walls shall be verified

to have compatible components suitable for the service and application intended.

Analytical instruments shall be verified to the service intended. Solutions and/or

source elements shall not be installed until instrumentation is ready for re-wire
operation in final calibration.

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Spare parts furnished with instrument shall be checked, identified and stored with
identification tags attached. Spare parts shall not be used to complete initial
installation and start-up without re-ordering to ensure compete spare parts
complements.

Damage spare parts shall be returned immediately to vendor with corrective action
requested.

7. Instrument Inspection, cleaning & Testing

All instruments must be disconnected from the process piping and vessels during
hydrostatic testing of the process lines. Instrument process piping shall be
hydrostatically tested together with process piping and vessels.

All interconnecting wires from panel to field mounted devices shall be tested by
“ringing out”. Wiring pairs shall be disconnected at the transmitter and the panel
terminal blocks, joined in pairs at the transmitter, and tested from the panel
termination; Individual leads shall be tested using ground return, or common, to
verify continuity and identification.

If any changes in connections are necessary, wires shall be retag accordingly.

Signal wire polarities shall be verified by simulation of transmission signals.

Ground connections and shielding terminations shall be checked against drawings of

manufacturer's instruction. All control cable shielding shall be grounded at one end
only, with reference at the receiver station (control Panel).

Equipment (case) grounds shall be in accordance with drawings and manufacturer's

instructions.

Indicator scales on all transmitters and receivers shall be checked for correct range
and legend. Especially calibrated flowmeters shall be verified as to scale range and
information data sheets supplied.

3.20 Calibration

1. General

Electrical instrument calibration shall be performed on an individual instrument or

combination of instruments as required to complete the measurement or prove the
loop functional. Factory tested elements are not to be calibrated unless it is required
for critical service and facility is available. Functional checks shall be performed in a
manner to ascertain operational capability.

2. Calibration Data sheets

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Calibration data sheets shall be prepared and submitted for file reference for all
critical measurements.

3.21 Instrument Environmental Protection

Environmental protection shall be provided for all instrument equipment against

damage upon receipt, storage and during installation.

Instrument located outdoors, and subject to severe ambient condition including

moisture and corrosion shall be protected by installation in a weatherproof housing
or similar protective enclosure or shield.

The installation of protective housing, or enclosures shall not inhibit the functioning
of the instrument or in any way detracted from the ability to perform routing service
as required.

3.21 Commissioning

The contractor shall provide sufficient skilled staff, during commissioning phase, to
carry out necessary adjustment as they are identified. All settings and adjustments
to equipment shall be recorded.

All tests must be witnessed by Maynilad or Company Representative and carried

out to Maynilad satisfaction.

3.22 Training

The contractor shall provide training as per prepared (specified) training program for
the maintenance electricians so that they can efficiently maintain and fault find on
the equipment.

Commissioning shall not be completed until all training has been provided to
Maynilad satisfaction.

3.23 Low Voltage Switchboards

1. General

All equipment shall be designed, built, rated, tested and shall perform in accordance
with the latest edition of the applicable Standards.

The switchboard shall be free standing, totally enclosed, multi cubicle type, and shall
be constructed in mild or as specified.

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All electrical cubicles and boxes shall be suitable for bottom cable entry and front
access unless otherwise specified. Non magnetic gland plated shall be supplied for
all non stainless steel enclosures.

All enclosures mounted directly onto floors shall be supplied with a welded 75 mm
RMS hot dip galvanized plinth. In wet process areas hot dip galvanized steel stands
or legs shall be supplied

The heat generated within the cubicle shall not cause the air temperature around the
equipment to rise above the rating of this equipment. Air to air heat exchanges may
be used if required but not with refrigeration units.

All control items shall be DIN rail mounted where possible.

No inflammable or hygroscopic materials shall be used.

In all cases, equipment shall be designed, rated, tested and shall perform in
accordance with the latest edition of the applicable Standards.

It will be permissible to obtain access to live parts through a door or cover while the
equipment is alive by defeating mechanical interlock or using special tools. Such
interlock must be automatically restores on refastening the door or cover.

All doors shall swing about a vertical axis.

Any item of apparatus must be capable of being removed for replacement without
requiring any other item to be removed first. Captive nuts or treaded steel shall be
used so all apparatus can be replaced without removing the gear plates or other
parts of the cubicle. Self tapping screws are not applicable.

No equipment shall be mounted on the sides, top or bottom of the cubicle (internal
light exempted).

All field wiring shall terminated via terminal rail blocks, not connected directly to
control devices.

A minimum distance of 50 mm shall be allowed between cable and equipment for the
terminating of wires.

Conduit or cable entry shall not be made from the top.

2. Construction

Main switchboards to be fabricated from 2mm mild steel. Control panels to be

fabricated from 1.6 mm thick.

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All panels or doors supporting equipment in which large cutouts are required shall be
constructed of a least 2.0 mm sheet steel.

All joints shall be continuously welded and ground to be smooth finish.

All doors and covers shall be provided with compressible Neoprene gaskets.

Switchboard doors will be fitted with key lockable handles. Doors over 1500 mm high
will be fitted with two door handles at top and bottom. A single handle and locking
rods will not be accepted. Drawing pockets will be provided for each switchboard,
mounted on the inside of the cabinet door.

 Doors are to be effectively earthed by 6 mm 2 insulated flexible copper

bonding straps.

 Painting mild steel metalwork shall be as follows: After construction and all
cut outs completed, the sheet metalwork shall be thoroughly rubbed down to
a smooth blemish free surface free of all defects and rush. All metalwork
shall be Zinc Chromate primed and passivated, undercoated, two topcoats
of high gloss enamel paint “gray” exterior and white interior.

 The switchboard shall be so arranged that it may be ready extended in

either direction. Each shipping section shall have provision for top lifting and
lifting eyes or beams shall be provided.

 The manufacturer shall provide the internal fixing within the equipment
necessary for the holding down bolts.

 Workmanship shall be of a high standard in all cases and the finished

equipment shall present a neat and attractive appearance.

 All bolts, nuts, washers and spring washers used in the assembly of
components and cubicles shall be of adequate size for the duty required and
shall be zinc plated to prevent corrosion. Cadmium plated components shall
not be used.

 Cable ducting shall be so sized and arranged that the cables in the duct do
not exert pressure on the lid or cause deformation of the duct.

 Cable ducts are to be dedicated to electrical cables only. Under no

circumstances are pneumatic lines to run in these ducts.

 Any cables entering through the top of sides of an envelope shall pass
through cable glands. Where circuits or sub mains exceeds 100 Amps and
are single cored and gland plates shall be designed to prevent currents in
the plates.

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3. Main Switchboards

All main switchboards shall be of a type-tested design as defined in and of

comparative type construction.

Main switchboards supplied directly from transformers shall have;

 One voltmeter and ammeter with selector switch for phase and line voltage
selection.
 One multi function relay with the following minimum features:

 Phase failure relay

 Over/Under voltage relay
 Phase unbalance relay
 Ground fault relay
 Under load current relay
 Overload relay

4. Bus Bars

Phase Bars

Bus Bars shall be hard drawn, high conductivity copper supported on approved
insulation. The Bus Bar Assembly shall be rated based on short circuit calculation for
1 second minimum and have type tested certificates for an approved testing station.

Main busbars shall be rated for minimum of 25% greater than the total loading on
them.

Connections for demountable or withdrawable switch gear shall be so arrange as to

permit easy disconnection without disturbing the working condition of the busbar or
cable connections. The bushbar are to be pre-drilled to permit easy extension in
either direction.

Main connection and busbars shall be arrange and identified in either by painting,
PVC sleeving or other approved means.

Earth Bar

This shall be installed in line with the standards.

A suitable sized earth bar shall extend the length of the swichboard.

3.24 Motor Control Centers

1. General

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The work covered by this Specification includes the design and manufacture of motor
control center (MCC) equipment completely assembled.

The Vendor shall also provide technical assistance during the installation and
placement in service of the equipment, if requested by the Purchaser.

All equipment shall be designed, built, rated, tested and shall perform in accordance
with the latest editions of the applicable standard.

The standards and regulations of any body having jurisdiction over the equipment
particularly MERALCO shall apply.

Where the stipulation of this Specification, the data sheets and the drawings do not
comply with the minimum requirements of the applicable regulations and standards;
the latter shall prevail. Where the stipulation of this Specification, the data sheet and
the drawing are more exacting than the minimum requirements, the former shall
prevail.

2. Service Conditions

The MCC and all components therein, shall function in a satisfactory manner within
the rated capacity under the service conditions specified regardless of whether or not
all necessary specific performances are set forth in this Specification or in the
applicable standards.

3. Design Construction Details

General: The MCC within this Specification shall be compartmentalized.

Enclosure: The MCC shall be constructed with suitably folded and stiffened
corners and edges with an integral supporting structure, and shall
be manufactured form or mild steel 2mm thick as specified.

The MCC shall be free standing, front connected and front wired. The front of the
MCC shall have doors supported with chrome plated pintle hinges. The door shall
not extended more than 450 mm perpendicular to the MCC face. The door locking
shall be designed to prevent opening when subjected to forces caused by an internal
fault. Master locking system on all doors.

All openings shall be fitted with a suitable non-distorting compressible seal, which
shall engage onto the MCC panel's stiffened return surround on one side and the
door's rear face within the stiffened return on the other side.

Each section of the MCC shall be supported on the identical 75 mm RHS hot dip
galvanized plinth, fully braced and welded, turned outwards.

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Glands plates shall be fitted to the top and the bottom of the MCC and at the
incoming supply cable entry, this gland plate shall be 3.5 mm aluminum, and all other
gland plates shall be made out of the MCC construction material. All gland plates
shall be provided with gaskets and bolted.

Wiring diagram pockets shall be provided.

4. Component Arrangement

The MCC shall be 600 mm deep, 2200 mm high with plinth, width of a modular panel
shall be 1000 mm with door size of twin 450 mm.

All electrical equipment shall wherever possible be mounted on DIN rails on metal
mounting. If equipment has to be attached directly onto the mounting plate, they shall
be secured by screws in the pre-tapped holes, self-tapping screws are not permitted.

No apparatus or terminal block shall be mounted within 300 mm vertically from the
internal floor level.

All wiring shall wherever possible be wired in ducts. Cable ducting shall be so sized
and arranged that the total number of cables and wires to be installed in the duct do
not exert pressure on the lid or cause deformation of the duct. Signal wiring where
possible should be segregated from other wiring.
The minimum clearance between panel mounted equipment, cable looms, ducting,
terminals and MCC framework or panels shall be 50 mm.

5. Shipping

The MCC shall be delivered on site in sections not longer than 4M. Each section
shall be suitable braced and have lifting points so that during a crane lift no distortion
will take place. Assembly instruction shall accompany the equipment.

6. Other

Identification, test and inspection, drawings, wiring and approvals of MCCs shall
agree with the relevant sections within this Specification.

Instrument cubicles shall be separated, the layout shall be approved by Maynilad.

All fields wiring to remote control panels or instrument shall be terminated into a
terminal rail, not wired directly to devices.

3.25 Distribution Boards/Control Panel

1. Construction

The enclosure shall be constructed as per section on Low Voltage Switchboards.

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The door seal shall be of high quality and a pressured catch handle shall be
employed.

Exterior cables (power source cables as well as feeding cables) shall be directly
connected to the MCCB or isolator. Adequate space for exterior wiring shall be
provided.

A permanent connection diagram identifying the feeders shall be provided in holder

fitted with a transparent cover inside the door or completion of construction.

Provision for 25% spare space for future expansion shall be provided.

2. Bus Bars

Grounding Bar shall be provided. The sectional area of the neutral bar shall be equal
to the sectional area of the phase bar.

3.26 Components

1. General

All switches shall be of the fault make load break suitably derated for their enclosure.

2. Power Switches and Isolators

Switches are to be rated for AC3. They are to be lockable and have operating
indication of “OFF” and “ON”. Main cubicle switches shall be rated for at least the
same fault level as the busbars and shall be able to break the full load current or
make onto a fault.

3. Circuit Breakers

The main incoming terminals of the main switch shall be extended by copper 'take
offs'. The unit shall be lockable in the 'service', 'test' and 'isolated' position and when
the CB is 'Open/Off'.

ACB's shall be of the withdrawable type and equipped for manual sored energy
operation. They shall have shunt release coils. ACB's shall have at least two
normally open and two normally closed spare auxiliary contracts over and above
those required for operation of the scheme as detailed on the drawings.

All main CBS shall have thermal, instantaneous overcurrent and earth fault
protection with provision for single phasing, and delayed under voltage if required.

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Branch Circuit protective devices shall be molded case circuit breakers providing
complete circuit overcurrent protection by having inverse time and instantaneous
tripping characteristics.

Circuit breaker for general purpose convenience outlet shall be ELCB type rated at
30mA.

Circuit breakers shall be operated by a toggle-type handle and shall have a quick-
make, quick-break over-center switching mechanism that is mechanically trip free.
Automatic tripping of the breaker shall be clearly indicated by the handle position.
Contacts shall be non-welding alloy. A push-to-trip button on the front of circuit
breaker shall be provided local manual means to exercise the trip mechanism.

Each molded case circuit breaker microprocessor-based tripping system shall

consist of three current sensors, a trip unit, and a shunt trip.

4. Feeder Protection Relay

Protection Relays with the following minimum protection:

 Instantaneous overcurrent relay
 Ground fault overcurrent with time delay
 Thermal overload relay
 Load unbalance, phase sequence overcurrent relay

5. Motor Protection Relay

Motor protection shall be provided as specified in Soft Starter Section.

6. Metering

Three phase digital incoming metering shall be provided by a power quality meter.
Metering shall include A, V, W, Wh, var, VA, Hz, and PF.

For switch inputs shall be provided which can be programmed for relay activation,
counters, logic, reset and alarms. Four output relay shall be provided which can be
programmed to activate on alarms, set-points, switch inputs, kWh pulse or
communication control. These output relay shall also be able to use demand
metering value of A, var, W and VA to control load shedding. PLC interface shall be
provided via four isolated 4-20 mA outputs programmable from measured
parameters.

Local user interface shall include a keypad and display for entering all set-points and
reading all measured value, and LED indicators for output relays, communication
status and alarm status. An RS232 computer interface port shall be located on the
front panel.

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All metering shall be Solid state digital metering. Metering shall be panel mounted
type.

Ammeter and run hour meter shall be provided to all motors.

7. Pushbuttons

Pushbuttons shall have a heavy duty oil tight rating, be of the 22.5 mm diameter
mounting hole type and follow the colors, these being:
Push buttons should be of oil tight (hoseproof) type.

Pushbuttons shall be shrouded to minimize the possibility of accidental operation.

All buttons shall be clearly labeled.

8. Indication

Indicator light shall be of similar design as the pushbuttons with a 22.5 mm diameter
mounting hole, and should also be hoseproof. The lights shall be LED type or
transformer type.

9. Starters

General

Each starter is to have isolation, overcurrent and thermal protection, a contactor,

control voltage C/B and terminals for output power and control cables.

The power wiring shall be red, white and blue. The minimum size of all power wiring
shall be 3.5 mm2.

The overcurrent and thermal protection shall be coordinated so that both motor and
starter equipment is protected.

Required Starter

Below 7.5 kW DOL / Combination Magnetic Starter

7.5 to 11 kW Soft Starter or Auto Transformer
15 kW and above requirements Soft Starter with Variable Speed Drive
(depends on the process

10. Thermal Protection

The setting of the re4lay or starter will refer to the motor full load current.

Overload elements are required in all three phases. The overload shall be
temperature compensated, and have differential single phasing protection.

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Thermal overloads shall be fitted with two pairs of electrically separated auxiliary
contacts for indication and tripping purposes. (2 NO., 2 x NC)

11. Contactors

Utilization Category to be AC3.

Minimum rated current at duty specified is to be 9 amps.

All contactors shall be double air break with at least one auxiliary contact and
provision for adding more.

Reversing contactors shall be incorporated electrically and mechanically interlocking

where practical.

Contactors for power factor capacitor shall be provided with on delay relay.

12. Control Relays

All Control relays shall be of the plug in type held by retaining clips. All contacts shall
be rated for at least 5 amps. All relays shall be in sealed enclosures with means for
manual operation from the front. An indication to show relay operation is required.

13. DC Power Supplies

DC power supplies shall have isolated outputs, have regulation to control the voltage
within 0.5 % of the rated value over the full load range. The output ripple shall be
within 0.2 % peak to peak or less than 0.05 % RMS. The output shall be protected
against short circuits. The gear plate shall have a perforated steel cover mounted
such that the cover can be removed while the unit is alive without the possibility of
the cover touching live parts. The input and output terminals shall be of the type
described under Terminals and shall be rated for clamping on the outgoing side, two
cables each rated for the full current of the power supply. The power supplies shall
not exceed the nominal voltage at power up more than 1.5 V.

14. Timers

All timers shall have electronic timing. They shall be multi voltage and shall accept
12 to 240 volts AC or DC without any wiring or switch changes. They shall be multi
function giving delayed on and true delayed off as selected from a function switch.
The time range shall be adjustable between 0.6 seconds and 60 hours. A visible
indication shall be given when the timer has timed out. The timer shall have an 11
pin circular plug in base. The output shall be voltage free contacts rate for a
minimum of 5 amps inductive.

15. Terminals

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External wiring shall be terminated at terminal blocks within motor control centers
and control panels.

Terminal shall be 'Klippon' or Polyamide spring assisted type or approved equivalent.

Terminal blocks shall be rail mounted.

Terminal blocks shall be segregated in groups by barriers of blank space to separate

extra low voltage terminals from those of higher voltage. It is preferred that both
terminals and cables be color red to indicate voltages. This will improved safety and
make fault finding easier.

No more than 2 wire may be terminated in any tunnel or clamp type terminal.

Approved insulated crimp lugs must be used to terminate multi-strand flexible cables.
Requires one cord only in each lug.

The use of plug in type strip terminals is not permitted.

16. Control Circuits

The standard control voltage is 110V. Contactor coils shall operate on 110 volts
(phase to neutral) 60 Hz. Any other voltages shall not be used unless approved by
Maynilad.

One leg of any coil, solenoid, relay, contactor, lamp or current consuming device,
must be connected directly the earth or neutral side of the supply.

Where control circuits are not isolated automatically when the phase supplies are
isolated or when multiple source supplies are used then prominent warning signs
shall be displayed together with instructions for de-engaging these circuits.

17. Capacitor

Capacitor shall be properly selected to attain 98% power factor.

Group of motors fed in motor control center shall be provided with capacitor bank if
required with automatic switching of controller for power factor correction.

Standard IEC 831 or Approved Equal

Type: Dry type Design
Frequency 60 Hz
Degree of protection IP 42
Execution Indoor
Discharge Resistor Permanently connected built-in discharge
resistors are to ensure safe discharge of the
capacitor to less than 50V in 1 min. after switch

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off.
Losses 0.5 W/kvar
Max. ambient temperature +50° C
Min. ambient temperature -25° C

3.27 Soft Starter

1. General

This section covers the general requirements applicable to the design, manufacture
of Soft Starter Drive to provide ramp starting and stopping of AC motor rated as
indicated in the drawing and its associated equipment and accessories completely
assembled.

The Vendor shall also provide technical assistance during the installation and
placement in service of the equipment, if requested by the Purchaser.

All equipment shall be designed, built, rated, tested and shall perform in accordance
with the latest editions of the applicable standard.

The controller shall provide a Soft start with selectable Kickstart and a soft stop
option.

The SS shall be selected to provide a successful start of the relevant connected load
by being able to provide sufficient current so that the motor is able to develop the
level of torque required.

The SS shall be of high efficiency and low maintenance.

The SS shall be equipped with Capacitor to improve the power factor to 98%.

2. Operating Conditions

The SS shall be capable of withstanding any combination of the following

environmental conditions in which it must operate without causing
electrical/mechanical damage or degradation of performance:

Ambient Temperature : Up to 40° C

Relative Humidity : Up to 90° C

The SS shall be equipped with Transient protection so that it will not cause damage
to power components upon absorbing an electrical transient. By-pass internal run
shall be available to prevent excessive heat built up within the enclosure. Motor
protection shall not be lost during the by-pass mode.

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The SS shall have built in cooling fans so that the SS can be forced air cooled to
operate within the above rated environmental conditions. The SS shall be housed in
a motor starter panel. Adequate ventilation must be allowed to ensure the internal
temperature of the enclosure does not exceed 40° C
The SS shall be equipped with Auto/Off/Manual control switch. In the manual mode
the SS will be controlled by local stop/start buttons. In the Auto mode the SS will be
controlled by remote 2 wire system.

Digital parameter adjustment shall be provided through a built-in keypad. A built-in

alphanumeric, back-light LCD display shall be provided for controller set-up,
diagnostics, status, and monitoring. Analog potentiometer adjustment is not
acceptable.

The SS shall have the following electrical characteristics:

Input Power Voltage 460 V ± 10%

Frequency 60 Hz ± 2 Hz
Output Power Voltage 460 V ± 10%
Efficiency 99.00%

3. User Adjustments

 The acceleration ramp time shall be adjustable from 0-30 seconds.

 The initial torque setting shall be adjustable from 0-90% of locked rotor
torque.
 Current limit starting shall be adjustable from 50-600% of the motor's full
load current.
 A selectable kickstart feature shall be available to provide a current pulse at
550% of the motor full load current rating. The time period shall be
adjustable from 0.0 to 2.0 seconds.

4. Protection and diagnostics

The SS shall incorporate, as standard the following protection features:

 Over voltage
 Under voltage
 Stall/Jam
 Overload
 Underload
 Phase Unbalance
 Phase Sequence
 Under current
 Motor Thermistor
 Starter Over temperature
 Line Fault
 Power loss
 Ground Fault

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Fault diagnostic shall be indicated in descriptive text on the built-in LCD display. The
exclusive use of fault code shall be unacceptable. An auxiliary contact that is
programmable for fault indication shall be provided.

5. Monitoring

The controller shall provide the following monitoring functions indicated through the
built-in LCD display:
 Three phase line current
 Phase-to-phase supply voltage
 Watts in kW
 kWH
 Elapsed time
 Power Factor
 Motor Thermal capacity
 SS status

The SS must make available the following output signals for the external controller in
addition to summary alarm voltage free contact:

 Run
 Start/Run
 Motor Current (4-20 mA)
 Motor Thermal Model (4-20 mA)
 Fault indication

The SS shall have RS485 as standard allowing the starter to be used in conjunction
with the external control system. Through this link the SS must be able to be
controlled and monitored.

The bypass cabinet shall include a door-interlock input circuit breaker or fused
disconnect switch, a UL rated isolation contactor, and a NEMA rated full-voltage
starting contactor (both contactors electrically interlocked), a thermal overload relay
to provide motor protection, and a control power transformer.

3.28 Low Voltage Frequency Drive (VFD)

1. General

The VFD manufacturer shall demonstrate at least five years experience in

manufacturing VFDs, to demonstrate their capability to provide parts and service
support. A users list of similar design equipment, complete with contact names and
telephone numbers, shall be furnished upon request.

The DFD shall have an efficiency of 97%. The efficiency shall exceed 90% at 50%
speed and load.

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The VFD shall maintain the line power factor at no less than 0.95, regardless of
speed and load.

The VFD shall be capable of operating existing motor induction motor, regardless of
manufacturer, with a horsepower and current rating as indicated.

The VFD shall be able to start into a spinning motor. The VFD shall be able to
determine the motor speed and resume operation without tripping.

Total harmonic distortion shall be calculated under worst condition in accordance

with IEEE standard 519-1992. The VFD shall comply with the total harmonic
distortion of the voltage and the line current limits as defined in IEEE 519-1992.

Harmonics compliance shall be verified with onsite field measurement of both

voltage and current harmonic distortion at the drive input terminals with and without
the VFDs operation. A recording type Fluke or equivalent harmonic analyzer and
total harmonic current and voltages must utilized.

2. Standard operating condition

Ambient temperature range: 0 to 40 °C

Elevation: Up to 3300 ft
Atmosphere: Non condensing relative
humidity to 95%
AC line Frequency Variation: ± 3%

3. Monitoring and Displays

The VFD display shall be LCD type capable of displaying three (3) lines of text and
indicators. The following are to be available for monitoring at minimum:

Output frequency
Output Speed
Motor current
Motor power in KW
Motor voltage or output voltage
Input voltage
Elapse time meter
Digital input/output status
Kilowatt hour meter

 VFD shall have the capability of communicating via an RS-232, RS-422 or

RS-485 port.
 VFD shall have integral Modbus communication capability.
 VFD parameters, fault log and diagnostic log shall be downloaded via the
RS-232, RS-422 or RS-485 port.

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4. Input/Output Features

Two programmable analog inputs (0-20mA/0-10V)

One programmable analog outputs (0-20mA)

Five programmable digital inputs (24VDC)

Two programmable digital outputs (form C, dry contact relays), All programmable
digital outputs can be programmed to give start and stop signal to other motor.
Autochange features capacity of changing the starting order of other drives shall be
available.

System program providing built-in drive control or application specific configuration

capability.

5. Protective Functions

The VFD shall include the following protective features at minimum:

Over current
Over voltage
Under voltage
Ground/Earth fault
Inverter fault
Phase loss
Output phase loss
Undertemperature/Overtemperature
Motor overload/underload

6. Enclosure

All VFD components shall be factory mounted and wired on a dead front, grounded,
MEMA-12 enclosure. If a free-standing enclosure is provided, it shall be suitable for
wall mounting.

7. Control Functions

The standards operator interface shall consist of a LCD keypad located on the front
of the VFD.

The operator shall be able to scroll through the keypad menu to choose between the
following:
1. Monitor
2. Operate
3. Parameter setup
4. Actual parameter values
5. Active faults
6. Fault History

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The following setups and adjustments, at a minimum, are to be available:

1. Start command from keypad, remote or communication port.

2. Speed command from keypad, remote or communication port.
3. Motor direction selection
4. Maximum and minimum speed limits
5. Acceleration and deceleration times, two settable ranges.
6. Multiple preset speeds adjustments
7. Catch a spinning motor start or normal start selection.

Other features:

 VFD Automatic Control

 PID utilization an internal or external set-point.
 Auto start function: On/Off, Operable from a 4-20mA signal of from the PID
output, command, or feedback signal.
 Programmable digital outputs (form C, dry contact relays). Digital outputs
can be programmed to give start and stop signal to other motor. Autochange
features capacity of changing the starting order of other drives shall be
available.

All drive setting adjustment and operation parameters shall be stored in a parameter
log which lists allowable maximum and minimum points as well as the present set
values. This parameter log shall be accessible via a RS-232, RS-422, or RS-485
serial port as well as on the keypad display.

8. Diagnostic Features and Fault Handling

The VFD shall include a comprehensive microprocessor based digital diagnostic

system which monitor its own control functions and displays faults and operating
conditions.

A “Fault Log” shall be accessible via RS-232, RS-422, or RS485 serial link as well as
line on the keypad display. The “Fault Log” shall record, store, display and output to
a serial port upon demand, the following for the most recent events:

 Date and time of day

 Type of fault
 A historic log shall record, store and output to a RS-232, RS-422, or RS-485
serial link port upon demand.

9. Drive Options

Provide the following option to the VFD. All special features shall be factory mounted
and wired within the VFD enclosure unless otherwise specified.

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 Pressure transducer in the VFD to convert a 0-100psi pneumatic signal to an

electrical signal for automatic speed control.
 The VFD shall be provided with circuit breaker for disconnecting power
supply. This will provides the ability to isolate the VFD for maintenance and
service. All switches include handle operators, door interlocking and are
lockable.

3.29 Dry Type Transformers

1. General

Furnish and install, single phase dry-type transformer of two-winding type, self-
cooled, with rating and voltage as indicated on the drawings.

Transformer shall be designed, manufactured, and tested in accordance with all the
latest applicable ANSI, NEMA and IEEE standards and shall be UL listed.

Transformer shall be designed for continuous operation at rated kVA, for 24 hours a
day, 365 days a year operation, with normal life expectancy as defined in ANSI.

2. Insulation System

Transformer shall be insulated at 220 °C insulation system.

Required performance shall be obtained without exceeding the above indicated

temperature rise in a 40 °C maximum ambient, with 30 °C average over 24 hours.

All insulation materials shall be flame-retardant and shall not support combustion as
defined in ASTM Standard Test Method.

3. Core and Coil Assemblies

All transformer cores shall be constructed of low loss, high quality, electrical grade
laminated steel. By design, the flux density is to be kept well below the saturation
level to reduce audible sound level and minimize core losses. The core volume shall
allow operation at 10% above rated primary voltage at no load without exceeding the
temperature rise of the unit.

Coil conductors shall be either aluminum or copper and must be continuous. The
entire core and coil assembly shall be impregnated with thermal setting varnish and
cured to reduce hot spots in the coils and seal out moisture. Coils with exposed
magnet wire will not be acceptable. Transformers shall have common core
construction.

Transformer shall be provided with six, 2.5% full capacity taps – two above and four
below.

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4. Enclosure

Transformer enclosure shall be constructed of heavy gauge sheet metal and coated
with a gray powder paint finish.

The enclosure construction shall be ventilated, NEMA 2, drip-proof, with lifting holes.
All ventilation opening shall be protected against falling dirt. On outdoor units,
provide suitable weather-shields over ventilation opening. To assure proper
ventilation, locate the unit at least 150 mm from the adjacent wall or structure.

5. Sound Levels

Transformer average sound levels shall not exceed 40 Db based on ANSI and
NEMA levels for self-cooled ratings.

6. Tests

The following tests shall be made on all transformers:

1. Ratio tests at the rated voltage connection and all tap connection.
2. Polarity and phase relation tests on the rated voltage connection.
3. Applied potential tests.
4. Induced potential tests.
5. Non-load and excitation current at rated voltage on the rated voltage
connection.

3.30 Earthing

The installation of copper earthing rods 3.0 meters long and a minimum of 15 mm in
diameter with the required number to achieve a ground resistance of 5.0 Ohms or
less. The earthing rods shall be arrange, driven into the ground and connected
together etc. to the manufacturer instructions. The earthing rods shall be connected
together and wired to a new main earth bar via suitably sized copper cable(s).

All metallic conduits, cabinets and equipment shall be properly grounded and
bonded by means of copper straps. The conduits of each system shall be grounded
by connecting to the metallic water service pipe. All ground connections shall have
clean contact surfaces and shall be tinned and seated while bolting. Unless
otherwise specified, exposed ground cables shall be installed in conduit and
connections made readily accessible for inspection. Connections shall not be made
underground or concealed in floors and walls.

All ground connection shall be clamped and brazed or cad welded.

The following equipment shall be grounded:

 Motors,
 Secondary main distribution panel,

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 Panels,
 All other equipment as, required by the National or Philippine Electrical Code.
 All grounding type receptacle outlets.

The resistance of the combined grounding system shall not exceed 5 ohms and
shall be in accordance with the standards of the National Electrical Code, Philippine
Electrical Code and all governing authorities having jurisdiction.

All earthing shall where possible include for green and yellow PVC sheaths.

The entire installation shall be free from improper grounds and from short circuits.
Insulation and earth loop impedance tests shall be made in the presence of the
Maynilad. Each panel shall be tested with mains connected to the feeder, branches
connected and switches closed all equipment in place and permanently connected.
Each individual power feeders shall be tested with the power equipment connected
for proper and intended operation. In no case shall the insulation resistance be less
than that allowed by the Regulation for Electrical Equipment of Building. Failures
shall be corrected in a manner satisfactory to Maynilad.

3.31 Motors

1. Standards and Frame Sizes

All motors shall be designed, manufactured and tested in accordance with the latest
applicable standards of NEMA and ANSI.

2. Enclosure and Protection

Motors shall be totally enclosed fan cooled and waterproof. Motor fans shall be bi-
directional. Motors shall be rated for continuous running at full rated load. (IP 56)

3. Thermistor

Thermistor to be fitted to all motors rated above 22 kW (30 HP)

Thermistor may be fitted to motors with variable speed drives (frequency converters).
Thermistor shall be PTC type.

4. Rating

Motor shall operate on a 230 / 460 Volts (as specified in the design), 3 Phase, 60 Hz
power. Written approval is required for all motors which deviate from this
requirement.

5. Starting

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Squirrel cage motors shall be suitable for direct on line starting however, all winding
ends shall be brought out.

Each motor shall be rated for the maximum frequency of starting. Starting or stall
current shall not be greater than 7 times the motor full load current.

6. Noise

Noise level shall not exceed 85 dB (a) at 1 M for all conditions.

7. Temperatures

Temperature rise to agree as per standard.

8. Insulation
Shall be class 'F' for 'B' temperature rise.

9. Power Connections

Above 5.0 kW both ends of each motor winding one to be brought out to the terminal
box such that the motor is suitable for SS / Star/Delta starting. Terminal boxes to be
of adequate size and shall be easily accessible in the installed position. Cable entry
to the terminal box shall be from at least two directions and terminating shall be into
suitably robust terminals or studs.

10. Motor Protection

The circuit employs an auto resetting overload.

3.32 Lighting and Small Power

1. General

General area lighting is to be located to allow access for re-lamping without the use
of temporary scaffolding. Suitable means of access are ladders not exceeding 2.1 M
in height, mobile work platforms or extension handles and lamp changer heads.

2. Distribution System

The circuit for lighting and power outlets shall be from a 460/380/230V, 3-phase, 4-
wire system with the neutral directly grounded.

3. Lighting Fixtures

Incandescent lamps shall be 230V Bayonet Cap (BC) type base.

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Fluorescent lamps shall be 230V, 60 Hz, with power factor 0.9 lagging or better, T5
or T8 Model

High pressure discharge lamps shall be 230V, 60Hz.

4. Illumination Levels

The standard illumination levels shall be based on the latest edition of PEC.

5. Indoor Lighting
Lighting for office, control room, rest rooms, etc. shall be provided by fluorescent
lamps, either directly mounted to the ceiling or by pendant suspension. For 6 meters
above, high bay lighting or approved equivalent shall be used.

6. Outdoor Lighting

Lighting for outdoor shall be high pressure sodium lamps mounted on steel
structures or steel poles (hot dip galvanized).

Automatic switching circuits shall be provided for outdoor lighting. Switching circuits
shall have an “automatic-manual” changeover switch. Automatic sensors shall be of
a solid state light sensitive type.

7. Emergency Lighting

Emergency lighting shall be provided where necessary in order to secure the

minimum lighting required with respect to equipment maintenance and personnel
safety.

For emergency lighting, fixtures with built-in batteries shall be used with sufficient
battery power to give one hour continuous running during power failures.

Emergency lighting shall be arrange so as to immediately switch on automatically in

the event of power failure.

8. Socket Outlets

All outlets located outside the plant shall be rated to IP 56 except in offices, 1-phase
230 V – 2 flat pin + E.

Breaker for outlets shall be RCD type.

3.33 Instrumentation and Controls

1. General

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Instrumentation for controlling and monitoring the process shall be of a robust design
and manufactured by recognized supplier. The manufacturer shall be represented in
the Philippines having both spare parts and engineering support.

All field instrumentation and junction boxes shall be rated to IP65

Analogue signals shall be 4-20mA DC for transmission on a 2 wire system.

Digital signals shall be of the 24V DC PNP type (unless otherwise specified or
approved by Maynilad).

Sensor installed to give signals for totalizing shall give digital output pulses. The
generation of pulse shall be integral within the unit together with calibration and
output signal pulse rate and width adjustment. Conversion of analogue signals to
pulses by either remote devices or software will not be accepted. These sensors are
usually required to give both analogue and digital signals such as flow and volume,
kW and kWh.

2. Flow and Level Transmitters

Pressure and differential pressure transmitters shall be electronic solid state type
instrument constructed from corrosion-resistant materials.

Wetted parts shall be of stainless steel for level or ceramic for flow, body shall be of
a non-corrosive material or alloy with screwed connections.

Span and zero adjustments shall be continuously adjustable. The span and zero
adjustment should be externally accessible.

Accuracy of the instrument shall be ± 0.25 % of span repeatability ±0.20% of span

3. Control Sensors and Equipment

All field sensors shall be of industrial quality and entirely suitable for their intended
purpose.

All field sensors shall be constructed of high impact non-corrosive material or

encased in stainless steel.

Digital signals from sensors shall switch the DC control voltage in either a positive
current driving mode (PNP type) or via clean contacts. Sensors having outputs of the
PNP type shall be 3 wire, and have protection against short circuits, overloads and
switching of inductive loads. All sensors are to have LED indication to show the
operated state.

Proximity switch or photocell shall have a terminal box attached to the body.

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All field sensor types to be approved by Maynilad.

3.34 Programmable Logic Controllers (PLC)

1. General

This specification has been developed to establish minimum requirements for a

solid-state programmable controller designed to provide high reliability in industrial
applications. The controller shall be supplied with the CPU, input/output scanner,
inputs, outputs, memory, power supply, and all power and interface cables
necessary to function as a complete and operable programmable controller system.
The PLC shall have ready access/provision for future Supervisory Control and Data
Acquisition (SCADA).

2. Service

The supplier shall provide operating instruction manuals with adequate information
pertaining to the following:

(1) System specification

(2) Electrical power requirements
(3) Application considerations
(4) Assembly and installation procedures
(5) Power up procedures
(6) Troubleshooting procedures
(7) Programming procedures
(8) Explanation of internal fault diagnostics
(9) Shut down procedures
(10) Recommended spare parts list

In case where the programming is done by the supplier, the supplier shall provide a
copy of all working programs on compact disc as well as a printed program listing.

The supplier shall provide a customer training program designed to teach the
customer's personnel in the understanding and application of the programmable
controller. The training program shall include training manuals and “hand-on”
programming experience on a programmable controller of a type similar to that
provided by the supplier.

The supplier shall have the capability to conduct on-site training programs at a
location provided by the customer.

Within the enclosure all I/O racks, processor racks, and power supplies shall be
grounded to meet the manufacturer's specifications.

3. Design Description

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Programmable controller system shall be its modular, field expandable design

allowing the system to be tailored to the customer's machine and/or process control
application. The capability shall exist to allow for expansion of the system by the
additional or hardware and/or user software.

The logic processor, power supply, I/O scanner, and communication interface as well
as input and output circuitry shall be of a modular design with interchangeability
provided for all similar module.

The programmable controller system shall be designed and tested to operate in the
high electrical noise environment an an industrial plant.

Each input and output module shall be a self-contained unit housed within an
enclosure. These input/output enclosures with their respective modules shall be filed
expandable.

**END OF SECTION**

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SECTION 011
DESIGN
1.1 APPLICATION

The following clauses apply to all elements of the Works. The Contractor has
design responsibility for the entire Works or as applicable.

1.2 DESIGN STANDARDS

Design shall be carried out to the requirements of the National Building Code of the
Philippines and National Structural Code of the Philippines.

Materials used and appearance of structures etc. shall be consistent across the
works regardless of the design origin. Plant shall be designed and manufactured to
ensure maximum standardization of individual components.

All plant and materials shall be suitable for use at ambient temperatures and
climate conditions at the site.

Where Maynilad has preference on subjective choices within standards these have
been specified below. If no choice is specified, the Contractor may recommend for
approval by Maynilad

The design shall avoid the creation of hazardous areas.

1.3 SLIDING

Throughout construction and overall life of the Works, concrete elements and
complete structures must have a factor of safety of at least 2 against the sliding
effect of applied forces.

1.4 OVERTURNING

Throughout construction and overall life of the Works discrete elements and
complete structures must have a factor of safety of at least 2 against the
overturning effect of applied forces.

1.5 FLOTATION

Throughout construction and the overall life of the Works, discrete elements,
complete pipework, and completed structures must have a factor of safety of at
least 1.1 against the uplift force caused by the displacement of ground water or
inundation from floodwater.

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1.6 SETTLEMENT

Throughout construction and the overall life of the Works settlement of structures
shall not cause observable cracks and shall not make the structure unserviceable.

1.7 CONCRETE STRUCTURES

Concrete structures shall be designed to the requirements of ACI-318 or ACI-350

and ACI-244 if applicable.

The following design crack widths shall be used:

0.1 mm All above ground works and roofs to tanks.

0.2 mm All below ground external walls and base slabs to water retaining
or excluding structures.

0.3 mm All internal division walls (including those subject to differential

water loading), baffle walls, columns and beams to water retaining
or excluding structures.

+ All elements in contact with chlorinated water shall be designed using W max
= 0.2 mm or 0.1 mm as appropriate.

1.8 BUILDING DESIGN

Buildings shall be designed to the requirements of the National Building Code of

the Philippines regardless of whether formal approval is required. If formal approval
is not required the Contractor shall complete the “Certificate of Design
Compliance”. Compliance with approved document M, access for disabled people,
is not required.

1.9 STRUCTURAL STEEL WORK

Structural steel work shall be designed to National Structural Code of the

Philippines and as specified in Section 012.

1.10 MASONRY

Masonry shall be designed to National Structural Code of the Philippines.

1.11 TIMBER

Timber shall be designed to National Structural Code of the Philippines.

1.12 FLOORING

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Open type and plate flooring together with support beams etc, shall be designed
to the relevant part of National Building Code of the Philippines for the loading it is
likely to experience with a minimum uniformly distributed load of 5 kN/m2
(unfactored).

Individual floor panels must be bolted down to prevent unauthorized removal and
prevented from sliding sideways by means of permanent steelwork or non-
removal locating studs.

Elevated areas of flooring shall have toe boards.

1.13 HANDRAILS AND BALUSTERS

Protective barriers shall comply with the provisions of National Building Code of
the Philippines with a minimum design imposed load value of 36 kN/m run.

Self-closing gates shall be provided at openings in handrails at ladder heads and

the like.

1.14 STAIRS AND LADDERS

Stairs and ladders shall be designed to the requirements of National Building

Code of the Philippines for semi-public locations. The clear width of stairs shall be
suitable for the intended use with a minimum of 800mm. Ship ladders will not be
permitted.

1.15 HYDRAULIC DESIGN

Conduits shall be designed using roughness factors, k appropriate for the pipe
material in good, average and poor condition. The reference from which the k
values are taken shall be stated in the calculations submitted.

Sufficient freeboard with a recommended minimum of 150mm shall be provided to

prevent overtopping of walls under all flow conditions and numbers of units in
service. Allowances shall be made for dynamic effects, flow round bends and
lateral inflow or outflow.

1.16 PIPELINES

Sewer pipelines shall be designed in accordance with TS Section 001.

Surge pressures shall be taken into account in the design of pressure pipelines.
Pressure pipelines shall normally be designed to remain full while in service,
inflow check valves shall be fitted where appropriate. Pressure pipelines shall be
laid at gradients not less than 1 in 200 either rising or falling.

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Air valves and air vents appropriate to the fluid in the pipeline and of adequate
airflow capacity are required at high points and significant changes in hydraulic
gradient.

Pipe work cast through the walls of structures shall be jointed either side of the
wall. Flange adaptors should be incorporated to allow removal of above ground
pipework. They shall be adequately supported and restrained.

Non-buried pipe work shall be supported in accordance with the manufacturer’s

instructions. Valves, meters, strainers and other equipment mounted in pipework
shall be supported independently of the pipes to which they are connected.

Formed bends shall be used in the conveyance of wastewater. Fabricated bends

are acceptable for clean water applications. Long radius bends shall be used in
pipelines conveying septage or sludge.

Pipelines conveying wastewater, chemical slurries, sludges, etc. shall be provided

with rodding points and/or inspection covers to facilitate clearing of blockages
without dismantling the pipework.

1.17 DRAINAGE

Surface water drainage shall be designed to accommodate the 1 in 20 year’s

rainfall event.

Where geotextiles are used to line drainage trenches they shall be designed as
filtering membranes.

1.18 MANHOLES

Manholes shall be provided on gravity pipework at each abrupt change of

horizontal or vertical direction. The minimum allowable manhole size is 1500mm
diameter.

1.19 OVERFLOWS

Overflows shall be sized to pass the maximum possible flow. Allowance must be
made for parallel plant items being out of service. Overflows shall be designed to
not operate until full utilization of the plant is achieved.

1.20 OUTFALLS

Outfall pipes of 300mm diameter and above must be protected by grilles. The
clear distance between the bars of grilles must not exceed 100mm. Grilles must
be secure but removable by authorized personnel to allow maintenance.

1.21 ROADS

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Road construction shall be designed for heavy vehicles with provision against
shove resulting from turning movements.

Road widths and minimum radii shall be designed to accommodate septage

tankers, large dump trucks and articulated delivery trucks.

Roads shall be designed to limit traffic speed to a maximum of 30 km/hr.

Road gradients shall generally not exceed 1 in 12 and nowhere shall exceed 1 in
8. Roads shall be cambered where necessary. Adverse cambers shall be
avoided.

Roads and hard standings in chemical delivery areas and sludge tanker points
shall be impermeable and have a “sleeping policeman” bund to prevent spillages
entering the general road drainage. Drainage from these bunded areas shall be
to a sewer or to the head of the works.

1.22 LANDSCAPING

Earthwork in general shall comply with National Building Code of the Philippines
and National Structural Code of the Philippines.

The Contractor shall furnish all plants, labor, materials, tools and equipment
necessary for the performance of all landscaping complete to include springing,
seeding, loaming, sodding, planting of trees, topsoil supply and spreading and all
other incidentals which are deemed necessary in the completion of this work
item. All unpaved areas shall be sodded. Border plants to be used shall be
subject for approval of Maynilad.

List of plants and landscaping materials shall be submitted together with

landscaping layout to be approved by Maynilad.

1. Plants shall be subject to inspection and approval or rejection by Maynilad at

place of growth and upon delivery to the site at any time before or during
progress of the work based on the following criteria:

 Quality, size and variety;

 Ball and root condition,

 Quantity of stock; and

 Latent defects and injuries resulting from handling, disease and

infestation.

2. Plant approved at pre-planting inspection shall still be subject to rejection

during planting if found to be below specifications.

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3. Rejected plants shall be identified in an obvious manner, removed from the

site and replaced with acceptable equals.

4. The Contractor shall submit for approval by Maynilad a certified report of an

approved analytical laboratory showing analyses of representative samples of
topsoil proposed for use. The topsoil shall be delivered to the site until
approval is received from Maynilad. Approved of the laboratory report shall
not constitute final acceptance. Topsoil shall be subject to rejection by
Maynilad on or after delivery if it is found not to meet the requirements of the
specification or does not conform to the laboratory test results.

5. Plants shall have been grown in nurseries which have been inspected by
Maynilad.

6. Each sample shall be labeled, bearing material name and quality, the
Contractor's name, date, project name and other pertinent data.

7. The decision of as to the quality and quantity of work and materials shall be
final and precedent to Contractor's right to receive any compensation
hereunder.

8. Maintenance of Landscape Planting Prior to Acceptance

(a) General

 The Contractor shall be responsible for protecting, wearing and

maintaining all planting and irrigation systems until final
acceptance of all work under the contract.

 At time of acceptance of the complete project, the lawn shall be

totally established with no bare spots, mowed a minimum of 4
times and grass is at least 40 mm to 50 mm in height.

(b) Watering

 Trees and shrubs shall be thoroughly soaked after planting and

provided with additional water at intervals as necessary to
provided for good health and growth of the planting.

 Upon completion of lawn seeding, the entire area shall be soaked

to saturation by a fine spray. The new planting shall be dept
watered by the watering system existing on the site during the dry
weather or whenever necessary for proper establishment of the
lawn. Care shall be taken to avoid excessive washing or pudding
on the surface and any damage caused thereby shall be repaired
by the Contractor at his own expense.

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(c) Protection

 The Contractor shall provide adequate protection to all newly

seeded areas including the installation of approved temporary
fences to prevent trespassing and damage as well as erosion
control until the end of the guarantee period.

 The Contractor shall replace at his own expense, and in

compliance with all applicable specification, any materials or
equipment damaged by himself, his employees or his sub-
contractors.

 Occupancy of the project or parts thereof shall not relieve the

Contractor of any of the requirements contained in these
Specifications.

(d) Mowing of Lawn Areas. The first mowing of lawn areas shall begin as
soon as the grass reached a height of 75 mm and subsequent
mowing shall be at least once a week, or as often as necessary to
maintain all lawn areas at uniform height of 40 mm to 50 mm.

(e) All lawns and landscaped areas shall be fertilized every 3 weeks with
0.15 kg of general-purpose complete commercial fertilizer per square
meter of area for the first 7 weeks and fertilized thereafter once each
5 months prior to acceptance and during maintenance and guarantee
period.

(f) Maintain plants in a vigorous, thriving condition by watering,

cultivating, weeding, pruning, spraying and other operations
necessary. No trees or shrubs will be accepted unless they are
healthy and show satisfactory foliage conditions.

(g) All planted areas shall be cultivated at least every 2 weeks and raked
smooth, to present a neat appearance, and conditional mulch shall
be added where necessary.

(h) Maintenance shall include, in addition to the above, cleaning, edging,

repairs to stake, wire and wrapping, repair of erosion and all other
necessary work of maintenance. Sidewalks and other paved areas
shall be kept clean when planting and maintenance are in progress.

(i) Any and all watering lines broken or disrupted during this
construction shall be replaced to proper working order prior to turn-
over of the Work to Maynilad.

(j) Final Inspection and Guarantee

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 Inspection of work of lawns and planting will be made at

conclusion of maintenance.

 Written notice requesting inspection shall be submitted to

Maynilad at least 10 days prior to the anticipated inspection date.

 Final acceptance of the work prior to guarantee period of the

contract will be accepted upon written approval by Maynilad, on
the satisfactory completion of all work, including maintenance, but
exclusive of the replacement of plant material.

 The Contractor shall replace, as soon as weather conditions

permit, all dead plants, and all plants not in a vigorous, thriving
condition noted at the end of the guarantee period.

 Plants used for replacement shall be of the same size and variety
specified in the plant list. Plants shall be furnished, planted, staked
and mulched as specified.

 All work done under this contract shall be left in good order to the
satisfaction of Maynilad and the Contractor shall without additional
expense, replace any trees, shrubs, etc., which develop defect or
die.

9. Maintenance and Guarantee Following Acceptance

(a) General

 The Contractor shall be responsible for a period of one year after

date of acceptance of all work under the contract for maintaining
all plantings including all necessary plant or tree replacements,
weeding, cultivating, fertilizing, pruning, controlling insects and
diseases, re-guying and performing all other operations incident
thereto. The Contractor shall provide a written guarantee to
Maynilad from the Landscaping Subcontractor embodying the
provisions of this Section of the Specifications. The guarantee
shall not be binding upon the Contractor if any failure should be
proved to the satisfaction of MayniladI to result from
circumstances or negligence of parties over whom the guarantor
has no control.

 The work covered by this subsection of the specification consists

of providing all replacements of plants, labor, materials, equipment
and supplies and in performing all operations in connection with
maintenance and guarantees.

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 The inspection of lawn areas is independent of the final inspection

and maintenance period. After then lawn has been accepted and
has been mowed 4 or more times, the responsibility for mowing
and irrigation will be turned over to Maynilad, the weeding,
fertilizing, and controlling of diseases of the areas shall remain the
responsibility of the Contractor for the remainder of the
maintenance period.

 All planting, planting materials and watering system required

under this contract shall be in conditions acceptable to Maynilad at
the end of the maintenance period.

 All water required during this maintenance and guarantee period

will be furnished by Maynilad.

(b) Maintenance

 The Contractor shall make any changes or adjustment necessary

to the watering system during the maintenance period.

 The Contractor shall replace any dead or diseased plants during

the maintenance period.

 All lawn and planting areas shall be fertilized during the

maintenance period with a complete N-P-K chemical fertilizer.
Amount of fertilizer applied shall be per fertilizer's written
instruction on the bag. Fertilizers applied to planting area shall be
cultivated into the topsoil.

 The Contractor shall clean-up and removed unused or waste

materials from the site and leave the area in a neat condition
satisfactory to Maynilad whenever he performs work during the
maintenance period.

(c) Final Inspection

 Maynilad and the Contractor shall make a final inspection at the

end of the guarantee period. Any plants and materials found
defective at time of final inspection shall be replaced within a time
agreed upon by both parties.

1.23 FOUNDATIONS

Rafts, piles etc. shall be designed to the requirements of National Structural

Code of the Philippines.

1.24 GROUND ANCHORS

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Ground anchors shall be designed to reset all likely forces with a safety factor of
at least 2.

1.25 BUNDS TO CHEMICAL TANKS

Bunds to chemical tanks must be sized to receive 110% of the volume of the
largest tank contained or all tanks that could empty as a result of a single failure.
Bund walls must not be lower than the bottom of the contained tanks. Bund walls
must be designed to contain “jets” issuing from holes in tank sides.

Other than preformed plastic bunds, all bunds to chemical tanks shall have
concrete floor and walls without expansion or contraction joints. Concrete bunds,
including those with liners, shall be designed to the requirements of ACI-224 and
ACI-350 using a design crack width of 0.2mm.

Concrete bunds shall be tested for watertightness. Tanks to be lined shall be

tested for watertightness before the liner is installed. Bunds shall not be put into
service until all cracks have healed or been satisfactorily repaired.

Where liners are to be used internal angles shall be filleted and the liner installed
by specialist contractors. Liners shall be spark tested as per the manufacturer’s
instructions.

Bunds must be blind. Outlets (including valves outlets) must not be provided.

All valves, pipework etc must be a minimum of 150 mm above the bund floor.
Dosing pumps shall be within the bund above the 110% volume level. No pipes
shall pass through the bund wall or base. Pipes conveying chemicals shall be
enclosed so as to contain leakage and drain it to the bund or other holding tank.
The pipe enclosure shall indicate the name of the chemical within.

All bunds shall have a sump. Alarmed level detecting probes must be installed
over the sump.

1.26 WORKING ROOM

Sufficient clearance must be available for all items of machinery, panels, valves
etc. to be operated, maintained and removed. All equipment must be positioned
so as to be accessible for operation and maintenance.

**END OF SECTION**

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SECTION 012
STRUCTURAL STEEL
PART 1- GENERAL

1.1 Scope of Work

The Work includes providing all labor, materials, equipment and incidentals
necessary to furnish and install all structural steel items including bolts, bearing
plates and miscellaneous shapes and plates required for proper erection of
structural materials.

1.2 Specifications and Standards

Except as otherwise indicated, the current editions of the following Standards

apply to the WORK of this Sections:

ASTM A36 Carbon Structural Steel

ASTM A307 Carbon Steel Bolts and Studs

ASTM A325 Structural Bolts, Steel, Heat Treated, 120/105 ksi

Minimum Tensile Strength

AISC Manual of Steel Construction- Allowable Stress

Design

ISO 261 General Purpose Metric Screw Threads

AWS A5.1 Mild Steel Covered Arc-Welding Electrodes

AWS D1.4 Structural Welding Code-Reinforcing Steel

1.3 Submittals

A. Detailed shop drawings of all structural steel items.

B Samples as required by the applicable Reference Standards.

1.4 Quality Assurance

The Contractor is responsible for the performance of all tests and inspection
required by this Standard Specifications. However, Maynilad Water Services
Incorporated (Maynilad) reserves the right to require any or all tests to ensure that
delivered materials conform to the specifications, and shall be paid for by the

012-1 STRUCTURAL STEEL

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Contractor. The Contractor shall furnish Maynilad certified copies of records

showing that each materials has been pre-tested, and complied with all applicable
requirements of this Standard. The Contractor shall, at his own expense, replace
all rejected materials for failure to comply with this Specification.

PART 2- PRODUCTS

2.1 Materials

All structural shapes, plates and bars shall comply with the relevant provisions of
the ASTM A36/DPWH Standard Specification, Item 712 or as described in the
Contract.

All members shall be cut to length by cold sawing.

Where a structural member is supported on masonry or brickwork, the minimum

length of bearing shall be 100mm.

End connections, base plates and other design requirements shall be shown on
the plans or, described in the Contract.

Where steelwork is to be galvanized, it shall be as described in the Contract.

No unplanned holes shall be cut on site in structural steelwork. Clamps shall be
used for supporting equipment from structural steelwork. Enlargement of bolt
holes on site shall be carried out (and their protective coating made good) to the
approval of Maynilad.

Welding rods shall conform to AWS A5.1.

Bolts Steel, Connections shall conform to ASTM A325.

Anchors Bolts shall conform to ASTM A307.

PART 3- EXECUTION

3.1 Fabrication and Erection

A. All structural Steel shall be fabricated and erected in a accordance with the
AISC Specifications and code of standard practice as amended to date.

All members shall fit closely together and shall be straight and true; the
finished work shall be free from burrs, bends, twists, and open joints.

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Welding electrodes shall be E70XX, and in accordance with AWS Standards.

B. All holes, angles, supports, and braces shall be provided as required. Any un-
matched holes shop assembly of field connections shall be reamed and the
pieces match marked before disassembly.

Drift pins shall be used only for bringing members into position and not to
enlarge or distort holes.

Any pieces weakened by reaming to compensate for eccentricity to a point

where the strength of the joints is impaired will be rejected and a new and
satisfactory piece shall be provided by the Contractor.

C. Anchors bolts shall be accurately located on the base plates and welded in
position.

3.2 Field Connections

Base plates where required shall be accurately placed in position. Field

connections shall be made by welding or high strength bolting. Field welding
shall not allowed except for tanks shells and as approved by Maynilad.

3.3 Welding

Welding of parts shall be in accordance with the Structural Welding Code D1.1
of the AWS and shall not be done by welders certified as to their ability to
perform welding in accordance with the locally accepted requirements.

The Contractor may substitute field bolting where field welding is shown,
provided bolting details have been approved by Maynilad.

3.4 Bolting

High-strength bolts shall conform to ASTM A325.

Anchor bolts shall be A307 steel unless otherwise shown on drawings with
hexagonal nuts. Threads shall be clean cut and conform to ISO 261. Anchor
bolts shall be hot dip galvanized and shall be accurately set before the concrete
is poured unless specifically permitted otherwise by Maynilad. To facilitate the
setting of anchor bolts, the Contractor shall use screed plates, or may substitute
wooden templates instead of screed plates upon written approval by Maynilad.

** END OF SECTION **

012-3 STRUCTURAL STEEL