ws.7338 – adams reservoir no. 6

Construction of a 10.0 Mℓ Concrete Reservoir for Adams Mission 6 in Ward 67 Contract No: WS.7338

Addendum No. 4

WS.7338 – Adams Reservoir No. 6

ADDENDUM NO 4 CLOSING DATE EXTENDED

• The Tenderers are to note that the closing date has been extended to Friday, 15 July 2021 at or before 11:00.

VOLUME 1 ADAMS 6

• Attached herewith pages 141 to 245 forming part of Volume 1 to Tender WS.7338. The tenderer is to

include this as part of the contract document.

• Attached herewith please find Cathodic Protection Standard Specifications. The tenderer is to include

this as part of the contract document. Please Sign and Return with Tender Document as well as sending mail to: [email protected]– confirming receipt.

Company : ______.

Name : .

Date : .

Email : .

Signature _______ .

Construction of a 10.0 Mℓ Concrete Reservoir for Adams Mission 6 in Ward 96 Contract No. : WS 7338

Scope of Work

Project Specification (Volume 1) 141

TABLE OF CONTENTS

PSA GENERAL - SABS 1200 A ..................................................................................................... 148

PSA.3 Materials (Clause 3) ................................................................................................................ 148

PSA.3.1 Quality (Clause 3.1) ................................................................................................................ 148

PSA.4 Plant (Clause 4) ...................................................................................................................... 148

PSA.4.2 Contractor’s Offices Stores and Services (Clause 4.2) .......................................................... 148

PSA.4.2.1 Contractor’s Camp (Clause 4.2.1) .......................................................................................... 148

PSA.5 Construction (Clause 5) .......................................................................................................... 151

PSA.5.1 Survey (Clause 5.1) ................................................................................................................ 151

PSA.5.3 Protection of Structures (Clause 5.3) ...................................................................................... 151

PSA.5.4 Protection of overhead and underground services (Clause 5.4) ............................................ 152

PSA.5.5 Dealing with Water (Clause 5.5) ............................................................................................. 152

PSA.5.7 Safety (Clause 5.7) ................................................................................................................. 152

PSA.7 Testing (Clause 7) ................................................................................................................... 152

PSA.7.1 Checking (Clause 7.1.1) ......................................................................................................... 152

PSA.8 Measurement and Payment (Clause 8) .................................................................................. 153

PSA.8.1.1 Method of Measurement (Clause 8.1.1) ................................................................................. 153

PSA.8.3.5 Other General Fixed and Time-Related Charge Items ........................................................... 154

PSA.8.3.5 Fixed-charge Items (Clause 8.3.5)......................................................................................... 154

PSA.8.4.6 Time-related Items .................................................................................................................. 154

PSA.8.3.6 Fixed-Charge Items (Clause 8.3.6) ......................................................................................... 154

PSA.8.4.7 Time-related Items (Clause 8.4.7) .......................................................................................... 155

PSA.8.5 Sums Stated Provisionally (Clause 8.5) ................................................................................. 155

PSA.8.5.1 Contingencies (Clause 8.5.1) .................................................................................................. 156

PSA.8.5.2 Contract Price Adjustment (Clause 8.5.2) .............................................................................. 156

PSA.8.5.3 Materials for Dayworks (Clause 8.5.3) .................................................................................... 156

PSA.8.6 Prime Cost Items (Clause 8.6) ................................................................................................ 156

PSA.8.6.1 Acceptance Control Testing (Clause 8.6.1) ............................................................................ 156

PSA.8.6.2 Salary for Labour Desk Officer (Clause 8.6.3) ........................................................................ 156

PSA.8.6.3 Office Consumables for Engineer’s Site Facility (Clause 8.6.4) ............................................. 157

PSA.8.6.4 Electronic Equipment for Engineer’s Office (Clause 8.6.5) .................................................... 157

PSA.8.6.5 Relocation of Existing Services (Clause 8.6.6) ....................................................................... 157

PSA.8.6.6 Specialized Services (Clause 8.6.7) ....................................................................................... 157

PSAB ENGINEER'S OFFICE - SABS 1200 AB ............................................................................... 158

PSAB.3.1 Name Boards (Clause 3.1) ..................................................................................................... 158

PSAB.3.2 Office Building (Clause 3.2) .................................................................................................... 158

PSAB.5.4 Telephone (Clause 5.4) .......................................................................................................... 158

PSAB.5.5 Survey Assistants (Clause 5.5) ............................................................................................... 159

PSAB.5.5.1 Survey Assistants (Clause 5.5.1) ............................................................................................ 159

PSAB.5.5.2 Survey Equipment (Clause 5.5.2) ........................................................................................... 159

PSAB.7 Testing (Clause 7) ................................................................................................................... 160

PSAB.7.1 General (Clause 7.1) ............................................................................................................... 160

PSAB.7.2 Laboratory Equipment (Clause 7.2) ........................................................................................ 160

PSC SITE CLEARANCE – SABS 1200 C ...................................................................................... 161

PSC3.1 Disposal of Material (Sub-clauses 3.1 and 8.2.1) ................................................................... 161


Scope of Work


PSC5.1 Areas to be Cleared and Grubbed (Clause 5.1) ..................................................................... 161

PSC5.2.3 Preservation of Trees (Sub-clause 5.2.3) ............................................................................... 161

PSC.4 Freehaul and Overhaul (Clause 4).......................................................................................... 162

PSC.8 Measurement and Payment (Clause 8) .................................................................................. 162

PSC.8.2.8 Demolish and remove pipeline (Sub-clause 8.2.7) ................................................................. 162

PSC.8.2.8 Demolish and remove existing structures/buildings (Sub-clause 8.2.8) ................................. 162

PSC.8.2.9 Transport materials and debris to unspecified site and dump (Sub-clause 8.2.9) ................. 163

PSD EARTHWORKS – SABS 1200 D ........................................................................................... 164

PSD.3.1 Classification for Excavation Purposes (Clause 3.1) .............................................................. 164

PSD.3.1.2 Method of Classifying (Clause 3.1.1) and Classes of Excavation (Clause 3.1.2) .................. 164

PSD.3.2 Classification for Excavation Placing Purposes (Clause 3.2) ................................................. 165

PSD.3.2.1 Material Suitable for Embankment and Terraces (Clause 3.2.1) ............................................ 165

PSD.3.2.2 Material Suitable for Replacing Over Break (Clause 3.2.2) .................................................... 165

PSD.3.3 Selection (Clause 3.3) ............................................................................................................. 165

PSD.4 Plant (Clause 4) ...................................................................................................................... 165

PSD.5 Construction (Clause 5) .......................................................................................................... 165

PSD.5.1.1.2. Safeguarding of Excavations (Clause 5.1.1.2) ....................................................................... 166

PSD.5.1.1.3 Explosives (Clause 5.1.1.3) .................................................................................................... 167

PSD.5.1.4.3 Disposal of Surplus Material (Clause 5.1.4.3 and 5.2.2.3) ..................................................... 168

PSD.5.1.6 Accommodation of Traffic (Clause 5.1.6) ............................................................................... 168

PSD.5.2.2.1 Working Space beyond Perimeters of Structures (Sub-clause 5.2.2.1b) ............................... 169

PSD.5.2.2.2 Borrow Pits (Sub-Clause 5.2.2.2) ........................................................................................... 169

PSD.5.2.5.1 Free haul and Overhaul (Sub-Clause 5.2.5.1) ........................................................................ 169

PSD.7 Testing (Clause 7) ................................................................................................................... 169

PSD7.2 Taking and Testing of Samples (Clause 7.2) .......................................................................... 169

PSD.7.3 Subgrade Materials Quality (Clause 7.3) ................................................................................ 170

PSD.8 Measurement and Payment (Clause 8) .................................................................................. 170

PSD.8.2.1 Computation of Quantities and Schedule Items (Clause 8.2.1) .............................................. 170

PSD.8.2.1 Restricted Excavation and Compactive / Backfill Equipment (Clause 8.2.1) ......................... 170

PSD.8.3 Scheduled Items (Clause 8.3) ................................................................................................. 170

PSD.8.3.7 Additional Lateral Support (Clause 8.3.7) .................................................................................... 170

PSD.8.3.11 Maintenance of Grassed Areas (Clause 8.3.11) .......................................................................... 171

PSDB EARTHWORKS (PIPE TRENCHES) - SABS 1200 DB ......................................................... 172

PSDB.3 Materials (Clause 3) ................................................................................................................ 172

PSDB.3.1 Classes of Excavation (Clause 3.1) ........................................................................................ 172

PSDB.5.1.4 Existing Services (Sub-Clauses 5.1.4) ................................................................................... 172

PSDB.5.2 Trench Widths (Clauses 4.1 and 5.2) ..................................................................................... 172

PSDB.5.5 Trench Bottoms (Clause 5.5) .................................................................................................. 172

PSDB.5.6.3 Disposal of Excavated Material (Clauses 5.6.3 and 5.6.4) ..................................................... 173

PSDB.5.6.8 Freehaul and Overhaul (Clause 5.6.8) ................................................................................... 173

PSDB.5.7.2 Areas Subjected to Traffic Loads (Clause 5.7.2) .................................................................... 173

PSDB5.9.4 Reinstatement of Existing Bitumen Surfaced Roads (Clause 3.6 and 5.9.4) ......................... 173

PSDB.8 Measurement and Payment (Clause 8) ............................................................................... 174

PSDB.8.1 Basic Principles (Clause 8.1) .................................................................................................. 174

PSDK GABIONS AND PITCHING - SABS 1200 DK ......................................................................... 175

PSDK.3.1.4 Geotextile (Clause 3.1.4) ........................................................................................................ 175

PSDK.3.2.1.2 Pitching (Sub-Clause 3.2.1.2) ................................................................................................. 175


Scope of Work


PSDM EARTHWORKS (Roads, subgrade) - SABS 1200 DM ........................................................... 176

PSDM. 3.2.1 General - Road Traffic Control (Clause 3.2.1) ......................................................................... 176

Temporary drainage works and temporary deviation of services ........................................... 176

PSDM.5.2.8.2 Disposal of Surplus Material (Clause 5.2.8.2) ........................................................................ 176

PSDM.5.2.8.2 Overhaul (Clause 5.2.8.2) ....................................................................................................... 176

PSDM.5.2.4.3 Grass or Other Vegetation (Sub-Clause 5.2.4.3) .................................................................... 176

PSDM.7 Testing (Clause 7) ................................................................................................................... 177

PSG CONCRETE (Structural) - SABS 1200 G ............................................................................. 178

PSG.2 Interpretations (Clause 2) ....................................................................................................... 178

PSG.2.1 Supporting Specifications (Clause 2.1) ................................................................................... 178

PSG.3 Materials (Clause 3) ................................................................................................................ 178

PSG.3.1 Approval of Materials (Clause 3.1).......................................................................................... 178

PSG.3.2 Cement (Clause 3.2) ............................................................................................................... 178

PSG.3.2.1 Applicable Specifications (Clause 3.2.1) ................................................................................ 178

PSG.3.2.3 Storage of Cement (Clause 3.2.3) .......................................................................................... 179

PSG.3.3 Water (Clause 3.3) .................................................................................................................. 179

PSG.3.4 Aggregates (Clause 3.4) ......................................................................................................... 180

PSG.3.4.1 Applicable Specification (Clause 3.4.1) .................................................................................. 180

PSG.3.5 Admixtures (Clause 3.5) ......................................................................................................... 180

PSG.3.5.1 Approval of Admixtures Required (Clause 3.5.1) ................................................................... 180

PSG.4 Plant (Clause 4) ...................................................................................................................... 180

PSG.4.1 General (Clause 4.1) ............................................................................................................... 180

PSG.4.2 Batching Plant (Clause 4.2) .................................................................................................... 181

PSG.4.3 Mixing Plant (Clause 4.3) ........................................................................................................ 181

PSG.4.3.1 General Requirements for Mixing Plant (Clause 4.3.1) .......................................................... 181

PSG.4.5 Formwork (Clause 4.5) ........................................................................................................... 181

PSG.4.5.1 Design (Clause 4.5.1) ............................................................................................................. 181

PSG.4.5.3 Ties (Clause 4.5.3) .................................................................................................................. 181

PSG.5 Construction (Clause 5) .......................................................................................................... 181

PSG.5.1 Reinforcement (Clause 5.1) .................................................................................................... 181

PSG.5.1.1 Bending (Clause 5.1.1) ........................................................................................................... 181

PSG.5.1.1.4 Add the following (Clause 5.1.1.4): ......................................................................................... 182

PSG.5.1.2 Fixing (Clause 5.1.2) ............................................................................................................... 182

PSG.5.1.3 Cover (Clause 5.1.3) ............................................................................................................... 182

PSG.5.2 Formwork (Clause 5.2) ........................................................................................................... 183

PSG.5.2.1 Classification of Finishes (Clause 5.2.1) ................................................................................. 183

PSG.5.2.2 Preparation of Formwork (Clause 5.2.2) ................................................................................. 187

PSG.5.2.5 Removal of Formwork (Clause 5.2.5) ..................................................................................... 187

PSG.5.2.5.2 Replace the entire contents with the following (Clause 5.2.5.2): ............................................ 187

PSG.5.2.5.6 Thermal Shock and Thermal Contraction Cracking (Clause 5.2.5.6) ..................................... 188

PSG.5.4 Pipes and Conduits (Clause 5.4) ............................................................................................ 188

PSG.5.5 Concrete (Clause 5.5) ............................................................................................................. 188

PSG.5.5.1 Quality (Clause 5.5.1) ............................................................................................................. 188

PSG.5.5.1.4 Chloride Content (Clause 5.5.1.4) .......................................................................................... 188

PSG.5.5.1.7 Strength Concrete (Clause 5.5.1.7) ........................................................................................ 189

PSG.5.5.1.8 Bleeding (Clause 5.5.1.8) ....................................................................................................... 189

PSG.5.5.1.9 Shrinkage (Clause 5.5.1.9) ..................................................................................................... 189


Scope of Work


PSG.5.5.1.10 Temperature of Concrete (Clause 5.5.1.10) ........................................................................... 189

PSG.5.5.1.11 Rate of Hydration (Clause 5.5.1.11) ....................................................................................... 189

PSG.5.5.2 Batching (Clause 5.5.2) .......................................................................................................... 190

PSG.5.5.2.2 Water (Clause 5.5.2.2) ............................................................................................................ 190

PSG.5.5.2.3 Aggregates (Clause 5.5.2.3) ................................................................................................... 190

PSG.5.5.3 Mixing (Clause 5.5.3) .............................................................................................................. 190

PSG.5.5.3.1 Mixing at Construction Site (Clause 5.5.3.1) .......................................................................... 190

PSG.5.5.3.2 Ready Mixed Concrete (Clause 5.5.3.2) ................................................................................. 191

PSG.5.5.4 Transportation (Clause 5.5.4) ................................................................................................. 192

PSG.5.5.5 Placing (Clause 5.5.5) ............................................................................................................. 192

PSG.5.5.5.1 Structural Concrete (Clause 5.5.5.1) ...................................................................................... 193

PSG.5.5.6 Compaction (Clause 5.5.6) ..................................................................................................... 193

PSG.5.5.7 Construction Joints (Clause 5.5.7) .......................................................................................... 194

PSG.5.5.7.3 (b) Construction Joints when concrete is more than 24 hours but not more than 3 days old

(Clause 5.5.7.3)....................................................................................................................... 194

PSG.5.5.7.4 Add the following new clause (Clause 5.5.7.4) ....................................................................... 194

PSG.5.5.7.5 Water Proofing of Concrete Joints (Clause 5.5.7.5) ............................................................... 195

PSG.5.5.8 Curing and Protection (Clause 5.5.8) ..................................................................................... 197

PSG.5.5.9 Adverse Weather Conditions (Clause 5.5.9) .......................................................................... 198

PSG.5.5.9.2 Delete Reference to 32° and Replace 30°C (Clause 5.5.9.2) ................................................ 198

PSG.5.5.9.4 Weather Station (Clause 5.5.9.4)............................................................................................ 198

PSG.5.5.10 Concrete Surfaces (Clause 5.5.10) ........................................................................................ 199

PSG.5.5.14 Defects (Clause 5.5.14) .......................................................................................................... 199

PSG.5.5.14.3 Patching and Repair (Clause 5.5.14.3) ................................................................................... 199

PSG.5.5.16 No-Fines Concrete (Clause 5.5.16) ........................................................................................ 200

PSG.6 Tolerances (Clause 6) ............................................................................................................. 201

PSG.6.2 Permissible Deviations (Clause 6.2) ....................................................................................... 201

PSG.6.2.3(a) Replace with the following (Clause 6.2.3): .............................................................................. 201

PSG.6.2.3 (h) Add: ......................................................................................................................................... 201

PSG.7 Tests (Clause 7) ...................................................................................................................... 201

PSG.7.1 Facilities and Frequency of Sampling (Clause 7.1) ................................................................ 201

PSG.7.1.2 Frequency of Sampling (Clause 7.1.2) ................................................................................... 201

PSG.7.1.2.2 Replace the entire contents of the clause with (Clause 7.1.2.2): ........................................... 201

PSG.7.3 Acceptance Criteria for Strength Concrete (Clause 7.3) ........................................................ 202

PSG.7.3.1 Strength Concrete (Clause 7.3.1) ........................................................................................... 202

PSG.7.3.5. Replacement or Strengthening of Concrete (Clause 7.3.5) .................................................... 203

PSG.7.3.6. Table 8 - Acceptance criteria for concrete cover (Clause 7.3.6) ............................................ 203

PSG.7.3.7 Costs of Tests (Clause 7.3.7) ................................................................................................. 204

PSG.7.3.8 Durability Index Tests (Clause 7.3.8) ...................................................................................... 205

PSG.7.3.9 Water Tightness Testing (Clause 7.3.9) ................................................................................. 206

PSG.8.9 Miscellaneous Work Other Than Metal Work Unit: as Scheduled (Clause 8.9) ..................... 207

PSH.1 Scope (Clause 1) ................................................................................................................... 208

PSH.5.2 Drawings and Shop Details (Clause 5.2) ................................................................................ 208

PSH.5.7.1 Handrails (Clause 5.7.1) ......................................................................................................... 208

PSH.5.3.4 Welding (Clause 5.3.4) ........................................................................................................... 208

PSL MEDIUM PRESSURE PIPELINES - SABS 1200 L ............................................................... 209

PSL.2.1.2 Supporting Specifications (Clause 2.1.2) ................................................................................ 209

PSL.3 Materials (Clause 3) ............................................................................................................... 209


Scope of Work


PSL.3.1 General (Clause 3.1) ............................................................................................................... 209

PSL.3.4 Steel Pipes, Fittings and Specials (Clause 3.4) ...................................................................... 210

PSL.3.4.1 General (Clause 3.4.1) ............................................................................................................ 210

PSL.3.4.2 Pipes of Nominal bore up to 150 mm (Clause 3.4.2) .............................................................. 210

PSL.3.4.3 Pipes of Nominal Bore over 150 mm (Clause 3.4.3) .............................................................. 210

PSL.3.4.4 Fittings and Specials (Clause 3.4.4) ....................................................................................... 210

PSL.3.8 Jointing Materials (Clause 3.8) ............................................................................................... 211

PSL.3.8.3 FLANGES AND ACCESSORIES (Clause 3.8.3) .................................................................... 212

PSL.3.8.3.1 Bolted Connections (New Sub-Clause) (Clause 3.8.3.1) ....................................................... 212

PSL.3.9 Corrosion Protection (Clause 3.9)........................................................................................... 213

PSL.3.9.2.3 Repairs to Coatings and Linings (Clause 3.9.2.3) .................................................................. 213

PSL.3.9.2.3.1 Making Good of Field Welded Joints, Repairs & Puddle Pipes .............................................. 219

PSL.3.9.6 Corrosion Protection to Buried Joints, Couplings and Flanges (Clause 3.9.6) ...................... 220

PSL.3.9.6.1 Surface Preparation (Clause 3.9.6.1) ..................................................................................... 220

PSL.3.9.6.2 Primer (Clause 3.9.6.2) ........................................................................................................... 220

PSL.3.9.6.3 Mastic Blankets (Clause 3.9.6.3) ............................................................................................ 220

PSL.3.9.6.4 Denso Wrapping (Clause 3.9.6.4)........................................................................................... 220

PSL 3.9.6.5 Polyethylene Wrapping (Clause 3.9.6.5) ................................................................................ 221

PSL.3.9.6.6 Spark Tests on Completed Wrapped Joints (New Sub-Clause) ............................................ 221

PSL.3.9.7 Preparation and Cleaning of Pipe (Clause 3.9.7) ................................................................... 221

PSL.3.9.7.1 Preparation of Pipe (Clause 3.9.7.1)....................................................................................... 221

PSL.3.9.8 Coating and Lining of Fabricated Steel Specials (Clause 3.9.8) ............................................ 222

PSL.3.9.8.1 Thickness of Coating (Clause 3.9.8.1) .................................................................................... 222

PSL.3.9.8.1.1 Corrosion Protection Coating and Linings for Steel Specials ................................................ 222

PSL.3.9.8.1.2 Solvent Free Epoxy and Lining (Clause 3.9.8.1.2) ................................................................. 223

PSL.3.9.8.3 Thermoplastic Powder Coating and Lining (Clause 3.9.8.3) .................................................. 224

PSL.3.9.8.4 Rilsan Coating and Lining (Clause 3.9.8.4) ............................................................................ 225

PSL.3.9.8.5 Protective UV Coating and Coating of Permanently Exposed Pipe ....................................... 225

PSL.4 Plant (Clause 4) ...................................................................................................................... 225

PSL.4.1 Handling and Rigging (Clause 4.1) ......................................................................................... 225

PSL.5 Construction (Clause 5) .......................................................................................................... 226

PSL.5.1 Laying (Clause 5.1) ................................................................................................................. 226

PSL.5.1.1 General (Clause 5.1.1) ............................................................................................................ 226

PSL.5.1.2 Damage (Clause 5.1.2) ........................................................................................................... 226

PSL.5.1.3 Keeping Pipelines Clean (Clause 5.1.3) ................................................................................. 227

PSL.5.2 Jointing Methods (Clause 5.2) ................................................................................................ 227

PSL.5.2.2 Flanges (Steel Pipelines) (Clause 5.2.2) ................................................................................ 227

PSL.5.2.3 Welding (Steel Pipelines of Diameter 200 mm or greater) (Clause 5.2.3).............................. 228

PSL.5.3 Setting of Valves, Specials and Fittings (Clause 5.3) ............................................................. 229

PSL.6 Tolerances (Clause 6) ............................................................................................................. 231

PSL.7 Testing (Clause 7) ................................................................................................................... 231

PSL.7.1 General (Clause 7.1) ............................................................................................................... 231

PSL.7.2 Initial Tests on Welded Steel Pipes (Clause 7.2) .................................................................... 231

PSL.7.2.1 Dye-Penetrant Test (Clause 7.2.1) ......................................................................................... 232

PSL.7.2.2 Radiographic Examination (Clause 7.2.2) .............................................................................. 232

PSL.7.3 Standard Hydraulic Pipe Test (Clause 7.3) ............................................................................ 232

PSL.7.3.1 Test Pressure and Time of Test (Clause 7.3.1) ...................................................................... 232

PSL.7.4 Tests on Epoxy Coatings (Clause 7.4) ................................................................................... 233


Scope of Work


PSL.8 Measurement and Payment (Clause 8) .................................................................................. 234

PSL.8.2 Scheduled Items (Clause 8.2) ................................................................................................. 234

PSL.8.2.1 Supply, Lay and Bed Pipes Complete with Couplings (Clause 8.2.1) .................................... 234

PSL.8.2.2 Extra-over 8.2.1 for the Supplying, Laying, and Bedding of Specials Complete with Couplings

(Clause 8.2.2) .......................................................................................................................... 235

PSL.8.2.3 Extra-over 8.2.1 for the Supplying, Fixing and Bedding of Valves ......................................... 235

PSL.8.2.11 Anchor blocks/Thrust blocks and pedestals (Clause 8.2.11) .................................................. 235

PSL.8.2.16 Pipeline Marker Posts (Clause 8.2.16) ................................................................................... 235

PSL.8.2.17 Cathodic Protection (Clause 8.2.17) ....................................................................................... 235

PSLB BEDDING (PIPES) - SABS 1200 LB ..................................................................................... 236

PSLB.3 Material (Clause 3) .................................................................................................................. 236

PSLB.3.2 Selected Fill Material (Clause 3.2) .......................................................................................... 236

PSLB.3.3 Bedding (Clause 3.3) .............................................................................................................. 236

PSLB.3.3.1 Rigid Pipes (Clause 3.3.1) ...................................................................................................... 236

PSLB.3.3.2 Flexible pipes (Clause 3.3.2) .................................................................................................. 236

PSLB.3.4.2 Material not Available from Trench Excavation (Clause 3.4.2) ............................................... 236

PSLB.3.4.2.1 Ordinary Backfilling (Clause 3.4.2.1) ...................................................................................... 236

PSLB.5.2.1 Class A Bedding (Clause 5.2.1) .............................................................................................. 237

PSLB.5.4 Concrete Casing to Pipes (Clause 5.4) .................................................................................. 237

PSLB.6 Tolerance on Compaction of Bedding Material (Clause 6) ..................................................... 237

PSLB.7 Disposal of Displaced Material (Clause 7) .............................................................................. 237

PSLB.8 Overhaul (Clause 8) ................................................................................................................ 237

PSLD SEWERS - SABS 1200 D ....................................................................................................... 238

PSLD.3.1 Pipe Material (Clause 3.1) ...................................................................................................... 238

PSLD.3.5.2 Manholes (Clause 3.5.2) ......................................................................................................... 238

PSLD.3.6 Marker Posts (Clause 3.6) ...................................................................................................... 238

PSLD.5.2 Laying Of Pipes (Clause 5.2) .................................................................................................. 238

PSLD.5.3 Cleaning the System (Clause 5.3) .......................................................................................... 239

PSLD.5.4 Connections to Manholes (Clause 5.4) ................................................................................... 239

PSLD.7.2.6 Watertightness of Manholes (Clause 7.2.6) ............................................................................ 239

PSLD.8.2.7 Measurement and Payment: Encasing Of Pipes in Concrete (Clause 8.2.7) ......................... 240

PSM ROADS (GENERAL) - SABS 1200 M .................................................................................... 241

PSM.3 Sources of Material (Clause 3) ............................................................................................... 241

PSM.5.2.2.3 Cut To Spoil (Clause 5.2.2.3) (SABS 1200 DM, Clause 5.2.2.3(b)) ....................................... 241

PSM.5.2.4.3 Spreading of Top Soil (Clause 5.2.4.3) (SABS 1200 DM, sub-clause 5.2.2.3(a)) .................. 241

PSM.5.2.8.2 Overhaul (Clause 5.2.8.2) (SABS 1200 DM) .......................................................................... 241

PSME SUBBASE - SABS 1200 ME .................................................................................................. 242

PSME.3.2.1 Regional Factor (Clause 3.2.1) ............................................................................................... 242

PSME.3.5.1 Source of Subbase Material (Clause 3.5.1) ............................................................................ 242

PSME.5.4.1 Thickness of Layers (Clauses 5.4.1 and 6.1.4) ...................................................................... 242

PSME.5.7.2 Transport - Overhaul (Clause 5.7.2) ....................................................................................... 242

PSME.5 Testing (Clause 5) ................................................................................................................... 242

PSME.6 Process Subbase Material by Stabilisation (Clause 6) ........................................................... 242

PSMJ SEGMENTED PAVING - SABS 1200 MJ .............................................................................. 243

PSMJ.3.1.2 Class (Clause 3.1.2) ............................................................................................................... 243

PSMJ.3 Degree of Accuracy (Clause 3) ............................................................................................... 243


Scope of Work


PSMJ.5.4 Laying of Units (Clause 5.4) .................................................................................................... 243

PSMK KERBING AND CHANNELLING - SABS 1200 MK .............................................................. 244

PSMK.1 Cast In-Situ Kerbing (Clause 1) .............................................................................................. 244

PSMK.4.1 Equipment for Machine Placing (Clause 4.1) ......................................................................... 244

PSMK.3.7 Mix Design for Extruded Kerbing (Clause 3.7) ....................................................................... 244

PSMK.7.2 Testing of Extended Kerbing (Clause 7.2) .............................................................................. 244

PSMK.5.6 Soilcrete Lining (Clause 5.6) ................................................................................................... 244

PSMM ANCILLARY ROADWORKS - SABS 1200 MM .................................................................... 245

PSMM.1 Scope of the Works: Road Markings (Clause 1) .................................................................... 245

PSMM.4.2.1 Mechanical Equipment for Road Markings (Clause 4.2.1) ..................................................... 245

PSMM.8.3 Scheduled Items for Permanent Road Signs (Clause 8.3) ..................................................... 245


Scope of Work


PSA GENERAL - SABS 1200 A

Add the following to the sub-clauses.

PSA.3 Materials (Clause 3)

Add the following to Clause 3.

The Contractor shall deliver to the Engineer, for his consideration, quality assurance programmes

(as obtained from all the Contractor’s proposed suppliers of pipes, valves and specials) prior to

the Contractor’s appointment of any suppliers.

PSA.3.1 Quality (Clause 3.1)

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

material, bear the SABS mark. Alternatively, the Contractor shall furnish the Engineer with

certificates of compliance of materials, which bear the official mark of the appropriate standard.

PSA.4 Plant (Clause 4)

Add the following to Clause 4.

Except where the use of plant is essential in order to meet the specified requirements by the Due

Completion Date, the Contractor shall use only hand tools and equipment in the construction of

those portion(s) of the Works that are required in terms of the Scope of Works to be constructed

using labour intensive construction methods. Due consideration shall be given for the protection

of the structures in the selection of resources and plant.

PSA.4.2 Contractor’s Offices Stores and Services (Clause 4.2)

Add the following to Clause 4.2:

PSA.4.2.1 Contractor’s Camp (Clause 4.2.1)

The Contractor is responsible to provide a suitable site for his camp and to provide available to

the Contractor, such site with accommodation for his personnel and labourers.

(a) Contractor's Camp Site / Store Yard

Space for office accommodation within the fenced reservoir site might be allowed. Contractor

to establish adequacy of space within confines of space within fenced area. An area may

also be made available adjacent to the construction site for the Contractor to establish his

construction camp. The contractor shall be responsible to provide a temporary fence and

security for the area as if it was within the existing fenced area.

The Employer shall be indemnified in all respects as a result of the occupation and use of the

land and buildings, including any claims from third parties.


Scope of Work


The allocated and occupied land and buildings is to be used only for site offices and for

storage of materials and strictly for work pertaining to this contract.

The Contractor is fully responsible for any damage caused to the land and buildings, or

improvements on it including services and for reinstating it to its former condition when

vacated.

Should the Contractor want to occupy any portion of land not indicated by the Engineer, the

required approval for same has to be obtained from the Engineer who will evaluate the

request in terms of legislation and by laws applicable,

The Contractor shall ensure that the conditions of the EMP are met for all site offices and

fabrication yards.

All tendered rates shall be deemed to include for all costs related to Site Offices and

Fabrication Yards, regardless of their location.

The land and buildings used for the Contractor’s camp shall be cleared and vacated by the

Contractor within 14 days of the date of completion of the contract. The recommended

position of the camp site/store yard will be pointed out by the Engineer. However the

Contractor may, if he prefers to have a camp site at another location of the work, site it

elsewhere provided that he first obtains the written permission of the landowner, and

subsequently the Engineer, to do so.

Any clearing of the site that is necessary and the making good after de-establishment will be

the responsibility of the Contractor.

In addition to the requirements the following conditions shall also apply:

i. None of the existing roads shall be damaged in any way.

ii. No waterborne sewerage facilities or potable water connection are available on the

site. The Contractor shall make his own arrangements in this regard.

iii. The Contractor is responsible to provide suitable temporary fencing and security for

the duration of the contract while the works is ongoing.

iv. It shall be the responsibility of the Contractor to make good any damage caused to the

camp site area or any improvements on it, including services, and for reinstating it to

its former condition when vacated. The standard of reinstatement must be to the

satisfaction of the Engineer; Director: Real Estate and/or Director of Parks, Recreation

and Beaches Department; or other owner. Particular attention should be directed to

these requirements and written clearances from the relevant Departments or other

owners will be required.

v. The Contractor’s tendered rates for the relevant items in the Bill of Quantities shall

include full compensation for all possible additional costs which may arise from this,

and no claims for extra payment due to inconvenience as a result of the modus

operandi will be considered.


Scope of Work


(b) Accommodation of Employees

No employees except for security guards will be allowed to sleep or be accommodated on

the site in urban areas.

No housing is available for the Contractor's employees and the Contractor shall make his

own arrangements to house his employees and to transport them to site.

No informal housing or squatting will be allowed.

The Contractor shall provide the necessary ablution facilities at his camp site and the site of

the works for the use of his employees. Chemical toilets only will be allowed where

temporary facilities have to be provided.

(c) Power Supply, Water and other Services

The Contractor shall make his own arrangements concerning the supply of electrical power,

water and all other services. No direct payment will be made for the provision of electricity,

water and other services. The cost thereof shall be deemed to be included in the rates and

amounts tendered for the various items of work for which these services are required, or in

the Contractor's preliminary and general items as the case may be.

i. Water for Works

The Contractor shall allow in his Establishment rates for the securing of a suitable water

supply, the payment of any connection fee and for any water charges for the duration of

the contract.

ii. Power Supply for Works

The power supply authority is eThekwini Electricity Service Unit. The Contractor will be

responsible for arranging for whatever temporary supplies may be required and he will be

required to bear all costs involved and to pay the ruling tariffs applicable to such supplies.

iii. Sanitary facilities

Water borne sewerage is not available on site. Chemical or flush water borne toilets with

on-site sewage disposal shall be provided and maintained for the use of the Contractor’s

personnel, the Engineer and representatives of the Employer at all camp sites that the

Contractor may establish for construction of the Works. In addition, the Contractor shall at

all times during construction of the Works provide adequate sanitary facilities on site so

that all employees are at all times within easy reach of a sanitary facility.

iv. Security

Although the Works will generally be executed within the perimeter fencing of the plant, the

Contractor shall maintain a fulltime security presence on Site for the full duration of the

construction period to protect the Contractor’s equipment and materials. The Contractor

shall also be responsible to control access to the Site/plant for construction activities and

shall implement a suitable access control system to prevent unauthorised entry to the Site.


Scope of Work


v. Services Connection Fee

Should the Contractor require either additional connection or an increased power supply

any additional costs shall be to the Contractor's account.

PSA.5 Construction (Clause 5)

Add the following to the sub-clause.

PSA.5.1 Survey (Clause 5.1)

Add the following:

The Contractor must note that a limited amount of survey control has been provided. The

Contractor will be required to verify the accuracy of such and shall be held responsible for any

errors in the setting out of the works which may arise from the usage of this survey control.

Survey for and preparation of, “As-Built” Drawings

The contractor shall provide the employer with a detailed survey of the final works as well as

detailed marked up drawings to indicate the “As-Builts” which should be certified by the

Engineer’s Representative.

Survey of Existing Services

All existing of existing valves, manholes, catch pits, and cable duct markers etc. shall be

surveyed and co-ordinated before commencement of the works.

PSA.5.3 Protection of Structures (Clause 5.3)

Add the following:

The Contractor is to note that work will be carried out in close proximity of informal and formal

housing and structures, as well as existing site facilities. Construction equipment ant tools shall

be so selected to ensure the safety of these structures. A detailed condition survey by an

approved engineer shall be carried out prior to any construction.

Prior to the commencement of any construction activities can commence the contractor will

Conduct a detailed Condition survey to identify the condition of the structures within 100m of the

site fence and include fences and houses, the survey to include home owner’s name, Structural

photos of all structures and a detailed report on the condition of the structures. Provide 3 copies

to the Engineer for review and acceptance.

The Contractor’s tendered rates for the relevant items in the Bill of Quantities shall include full

compensation for all surveys, temporary protections and possible additional costs which may

arise from this, The contractor to take out all necessary insurance should a claim arise as a result

of claims by the neighbouring residents, no claims for extra payment due to inconvenience as a

result of the modus operandi will be considered.


Scope of Work


PSA.5.4 Protection of overhead and underground services (Clause 5.4)

Refer to Section C3.2: PROJECT SPECIFICATION Clause (PS 2.5)

PSA.5.5 Dealing with Water (Clause 5.5)

Add to the Sub-Clause:

The Contractor shall accept all risks for any water affecting the works during the construction

period, whatever the source or cause may be, and shall properly deal with and dispose of all

water to ensure that the works are kept sufficiently dry at all times for their proper execution.

For this purpose the Contractor shall provide, operate and maintain in sufficient quantity such

pumping equipment, well points, pipes and other equipment as may be necessary and he shall

also provide any sumps, furrows, cross-embankments, coffer-dams and other temporary works

as may be necessary to minimise damage, inconvenience, or interference.

PSA.5.7 Safety (Clause 5.7)


All work and particularly work carried out in the proximity of formal and informal buildings,

bridges, tanks or other structures shall be carried out in conformance with the regulations framed

under the Occupational Health and Safety Act, 1993 and the Minerals Act, Act 50 of 1991,

including shoring where necessary, to ensure the safety of structures that are at risk.

The Contractor shall make available for the duration of the contract safety helmets, Gumboots

and any other necessary safety equipment for sole use by the Employer’s Representative and his

representative.

The Contractor is to be aware that the sites are bordered by busy roads and streets which are

subject to increase traffic volumes during peak hours. Interference with usual traffic flow is to be

kept to a minimum for the duration of the contract. If any such interference is unavoidable, for

example, during the supply or installation of any materials, then the Contractor shall provide all

necessary traffic control materials, equipment and personnel in compliance with the prevailing

Council Legislation and Bylaws.

PSA.7 Testing (Clause 7)

Add the following to the sub-clause:

PSA.7.1 Checking (Clause 7.1.1)

Add the following:


Scope of Work


a) All test results obtained by the Contractor in the course of his process control of the Works

shall be submitted to the Engineer or his Representative prior to requesting inspection of the

relevant portions of the Works.

b) The Contractor shall make suitable arrangements for process quality control prior to

commencement with the Works. Should he intend using site personnel for this purpose he

shall ensure that suitably trained and competent personnel take charge of the necessary test

work, and that the necessary equipment is at their disposal prior to commencement of the

Works. All equipment to be used shall have a valid calibration certificate, where applicable,

before any quality control tests may commence. Failure to comply with these requirements

shall be just cause for the Engineer to order suspension of the Works without additional

remuneration in terms of Clause 39 of the Conditions of Contract, or for him to recommend

termination to the Employer in terms of Clause 55 thereof.

PSA.8 Measurement and Payment (Clause 8)


PSA.8.1 Measurement (Clause 8.1)

PSA.8.1.1 Method of Measurement (Clause 8.1.1)

a) Monthly Progress Payment Certificates

Payment certificates shall be submitted to the Engineer's Representative on Site not later

than the 20th of each month (or as agreed between the Contractor and the Engineer).

All quantity calculations and certificates submitted by the Contractor for checking shall be in

accordance with the standard forms will be provided electronically before the commencement

date.

b) Adjustment of Preliminary and General Items Due to Rain

An extension of time granted will not necessarily or automatically entitle the Contractor to

additional payments of time related items. Additional payments for specific time related items

after the granting of an extension of time must be motivated and substantiated by the

Contractor and shall be subject to the contractor having submitted detailed records, recorded

on site by the contractor and the approval by the Employer’s Representative.

Should the period for completion be automatically extended due to abnormal weather

conditions occurring during execution of the Contract as provided for in the Conditions of

Contract, no adjustment to the total for time-related preliminary and general items will be

applicable.

c) Adjustment of Preliminary and General Time-Related Items

An approved extension of time will qualify the Contractor to receive additional payment for

each relevant time related item at a unit rate based on the sum originally tendered for such


Scope of Work


item, and which shall be fair and reasonable as contemplated in Clause 5.12 of the General

Conditions of Contract.

PSA.8.2 Payment (Clause 8.2)

Add the following new Clauses (Clause 8.3.5 and 6) and (8.4.6 and 7)

PSA.8.3.5 Other General Fixed and Time-Related Charge Items

Add the following to Clauses 8.2.1 and 8.2.2

Add the following new sub-clause 8.3.5 - Other general time-related charge items

HEALTH AND SAFETY

PSA.8.3.5 Fixed-charge Items (Clause 8.3.5)

Add the following new Clause (Clause 8.3.5):

Unit

Compliance with the Occupational Health and Safety Act

(Act 85 of 1993) and its regulations and with the Employer’s

Health and Safety Specification. ............................................................................................. Sum

The fixed charge item shall include but shall not be limited to the following:

Preparation of Health and Safety Plan,

Establishment of Health and Safety File,

Health and Safety Training

Personal Protective Clothing and Equipment

Fences, Signs and Barricades

Establishment of Safety Administration

Other Health and Safety Fixed-charge Obligations

Engineers report and condition Survey of Structures within 100m of site

Add the following new sub-clause 8.3.5 - Other general time-related charge items

ENVIRONMENTAL MANAGEMENT PLAN

The Contractor shall comply with all the conditions of the Record of Decision and the

Environmental Management Plan bound into Annexure B (Section C3.5.3).

PSA.8.3.6 Fixed-Charge Items (Clause 8.3.6)

Add the following Clause (Clause 8.3.6):

Unit

Compliance with Environmental Management Plan and Record of Decision Sum


Scope of Work


The sum tendered shall cover all costs, overheads, profits and charges incurred in complying

with all the conditions of the Environmental Management Plan and Record of Decision bound into

Section C3.5.3.

PSA.8.4.6 Time-related Items

Add the following new Clause (Clause 8.4.6):

Unit

Compliance with the Occupational Health and Safety Act.

(Act 85 of 1993) and its regulations and with the Employer’s

Health and Safety Specification Sum

The time related item shall include but shall not be limited to the following:

The employment cost of all health and safety personnel including consultants, health and

safety officers, inspectors, supervisors and issuers required in terms of the Contractor’s

Health and Safety Plan.

Updating the Health and Safety Plan as needed.

Carrying out of periodic own audits and follow-up audits.

Compiling ongoing risk assessments and risk assessment reports as required by the

Works.

Convening of regular safety meetings with the Safety Representatives.

Accompanying and supporting the Employer or his Safety Agent during ad hoc audits.

Compilation of monthly safety reports and statistics for the Employer or his Safety Agent.

Implementation and maintenance of training.

Maintenance of personal protective clothing and equipment.

Maintenance of fences, signs and barricades.

Implementation and maintenance of safety administration.

Other Health and Safety time-related obligations.

PSA.8.4.7 Time-related Items (Clause 8.4.7)

Add the following Clause (Clause 8.4.7):

Unit

Compliance with Environmental Management Plan and Record of Decision Sum

The sum tendered shall cover all costs, overheads, profits and charges incurred in complying

with all the conditions of the Environmental Management Plan and Record of Decision bound

into Section C3.5.3.

PSA.8.5 Sums Stated Provisionally (Clause 8.5)

Add the following:


Scope of Work


PSA.8.5.1 Contingencies (Clause 8.5.1)

A Provisional Sum shall be included in the Summary of Schedules for contingencies. No

percentage mark-up will be applicable to any payments made using contingency money other

than the mark up included in prices for variations determined in terms of the Conditions of

Contract.

PSA.8.5.2 Contract Price Adjustment (Clause 8.5.2)

A Provisional Sum shall be included for Contract Price Adjustment in the Summary of Schedules

to make provision for contract price adjustment in terms of the Conditions of Contract. The value

of the Provisional Sum shall be based on the percentage of the subtotal value as specified in the

Summary of Schedules. No percentage mark-up will be applicable to any payments made in this

regard.

PSA.8.5.3 Materials for Dayworks (Clause 8.5.3)

A Provisional Sum has been included in Schedule 2 for materials to be used during the execution

of dayworks. In addition to the abovementioned amount, provision is made in Schedule 2 for a

mark-up on the materials used during the execution of the dayworks by the Contractor. Payment

made shall be regarded as full compensation for overheads, charges and profit on the materials

that are used when executing dayworks.

PSA.8.6 Prime Cost Items (Clause 8.6)

Add the following:

PSA.8.6.1 Acceptance Control Testing (Clause 8.6.1)

A Provisional Sum has been included in Schedule 2 for acceptance control testing ordered by the

Engineer to be undertaken by a commercial laboratory. Payment will be based on the actual

invoicing by the laboratory to the Contractor.

In addition to the abovementioned amount, provision is made in Schedule 2 for a mark-up on any

payments made by the Contractor in this regard. The mark-up shall be regarded as full

compensation for overheads, charges and profits as provided for in the Conditions of Contract.

PSA.8.6.2 Salary for Labour Desk Officer (Clause 8.6.2)

A Prime Cost Item has been included in Schedule 2 for a salary to be paid to the Labour Desk

Officer and Community Liaison Officer.

In addition to the abovementioned amount, provision is made in Schedule 2 for a mark-up on the

amount to be paid. This mark-up shall be regarded as full compensation for overheads, charges

and profits as provided for in Clause 6.6 of the Conditions of Contract for overheads, charges and

profits as provided for in Clause 6.6 of the Conditions of Contract.


Scope of Work


PSA.8.6.3 Office Consumables for Engineer’s Site Facility (Clause 8.6.3)

A Provisional Sum has been included in Schedule 2 for the appointment and payment of office

consumables for Engineer’s site facility.


amount to be paid. The mark-up shall be regarded as full compensation for overheads, charges

and profits as provided for in the Conditions of Contract.

PSA.8.6.4 Electronic Equipment for Engineer’s Office (Clause 8.6.4)

A Provisional Sum has been included in Schedule 2 for the appointment and payment of a

specialist sub-contractor for electronic equipment for Engineer’s site office.




PSA.8.6.5 Relocation of Existing Services (Clause 8.6.5)

A Provisional Sum has been included in Schedule 2 for the relocation of existing services by

specialists if and when required and ordered by the Engineer.




PSA.8.6.6 Specialized Services (Clause 8.6.6)

A Provisional Sum has been included in Schedule 2 for the appointment and payment for

specialized services if and when required. These may include all work required by the following

specialists:

Telemetry and CCTV;

Geotechnical surveys and inspections;

Land Surveyor; and

Acceptance control testing of pipework, coatings and linings.

In addition to the abovementioned amounts, provision is made in Schedule 2 for a mark-up on

the amount to be paid. The mark-up shall be regarded as full compensation for overheads,

charges and profits as provided for in the Conditions of Contract.


Scope of Work


PSAB ENGINEER'S OFFICE - SABS 1200 AB

Add the following to the sub-clauses:

PSAB.3.1 Name Boards (Clause 3.1)

One project notice board shall be supplied and installed by the contractor to the specifications as

per standard drawing no. 40137E.

Any other notices, signs and barricades (required in terms of Clause 8.1 of the General

Conditions of Contract) as well as advertisements may only be erected where approved by the

Engineer. The Contractor shall be responsible for their supply, erection, maintenance and

ultimate removal and shall make provision for this in his tendered rates.

The Engineer shall have the right to have any sign, notice or advertisement moved to another

location, or to have it removed from the Site of the Works, should it in any way prove to be

unsatisfactory, inconvenient or dangerous to the general public.

PSAB3.2 Office Building (Clause 3.2)

Add the following:

In addition the offices shall be fitted with:

a) A correctly sized air conditioning unit, In addition to this the air-conditioned accommodation

shall be made available for holding regular site meetings. This accommodation must

comfortably cater for up to 15 persons seated around a table.

b) an approved colour printer and scanner to print A3 documents

c) a lockable cabinet

d) 2 desks and 2 chairs

e) Two car ports which shall have a suitable roof and be enclosed on three sides. Carports

made of shade cloth offering 80% or more UV resistance will be acceptable.

The car ports shall be for the sole use of the Employers Representative.

PSAB.5.4 Telephone (Clause 5.4)

The terms of sub-clause 8.2 of SABS 1200AA shall apply.

Add to the Sub Clause:

The Tender is to include, under the Time-Related Charges, a sum of R2500.00 per month

for a period of time equal to the Time of Completion of the Contract to cover the cost of the

Employer’s Representative’s and assistants telephone calls and other costs relating to the

provision of a cellular telephone for the exclusive use by the Employer’s Representative or

Representative.


Scope of Work


A wireless internet service is also required for the duration of the contract with a minimum

data cap of 10 GB per month.

PSAB.5.5 Survey Assistants (Clause 5.5)

Add the following:

PSAB.5.5.1 Survey Assistants (Clause 5.5.1)

One suitably educated Survey Assistant shall be made available for the sole use of the

Engineer's Representative for the duration of the Contract. The assistant may also be

required to fulfil the function of Community Liaison Officer during the Contract should the

Engineer consider this arrangement to be in the interests of the Employer. The Survey

Assistants may therefore have to be appointed from the local communities. Transport shall be

supplied for the Survey Assistant/Community Liaison Officer by the Contractor for the duration

of the Contract should he be requested to do so. In such event payment will be made at

scheduled dayworks rates.

PSAB.5.5.2 Survey Equipment (Clause 5.5.2)

The survey equipment listed below shall be made available and be maintained in good

condition for the exclusive use of the Engineer or his Representative for the duration of the

Contract. Payment will be made as provided for in the Time Related Items included in

Schedule 1.

(a) Automatic surveyor's level complete with tripod and leather carry case

such as Zeiss N1-2 or equivalent 1 No.

(b) 20-second tachometer with optical plumbob complete with tripod and

leather carry case such as Sokkisha TM20C or equivalent. 1 No.

(c) Nylon-coated steel surveyor's tape 100m long and 10mm wide 1 No.

(d) 5m long steel tape 1 No.

(e) 5m long three-piece telescopic survey staves (metric double-face)

complete with angle bracket level 2 No.

(f) Survey books: Level 3 No.

(g) 2kg hammer with rubber handle 1 No.

(h) Steel pegs, 300mm long and 12mm dia 120 No.

(i) Aluminium tags, 100mm long, 15mm wide and 2mm thick 120 No.

(j) Reverse polar notation pocket calculator (Hp32SII or similar) 1 No.

(k) Change point 2 No.

(l) Measuring wheel 1 No.

(m) Tripod holders for ranging rods (heavy duty) 2 No.

(n) Optical square (Sokkisha or Wild), complete with telescopic aluminium rod

and bubble 1 No.

(o) “Rabone” steel tape 10 meters long and 13mm wide 1 No.

(p) Triangular change plate with chain 2 No.

(q) 100m long 50 kg strength fish line 1 No.

(r) One metre long spirit level 1 No.


Scope of Work


(s) Three metre aluminium straight edge 1 No.

PSAB.7 Testing (Clause 7)

PSAB.7.1 General (Clause 7.1)

No laboratory building or fittings are required by the Engineer. The Engineer will arrange

separately with a commercial laboratory of designate specialists to carry out all acceptance

control testing, excepting for density control test and moisture content determinations. The

Contractor shall remain responsible to carry out the process control testing required by the

Standardised, Particular and Project Specifications.

PSAB.7.2 Laboratory Equipment (Clause 7.2)

The Contractor shall supply the following equipment for the duration of the Contract.

(a) A Troxler nuclear system, complete with accessories will be made available when required

A detailed description of the unit and principals of operation should be given in the manual

for the nuclear instrument. The system should at all times have a valid calibration

certificate.


Scope of Work


PSC SITE CLEARANCE – SABS 1200 C


PSC3.1 Disposal of Material (Sub-clauses 3.1 and 8.2.1)

eThekwini Municipality’s spoil sites is at the Marian hill or Bisasar Road Landfill. Refer to

Approved tip below for arrangements in this regard.

Material obtained from the demolition of structures clearing and excavations must be disposed of

offsite by the Contractor at his expense. The Contractor will be held responsible for observing the

bylaws and regulations of the relevant local authority and for any injury to persons and damage to

property.

Approved Tip

The approved tip are at the Municipal refuse dump at Marian hill or Bisasar Road. The Contractor

will be permitted to dump material at this dump, free of charge, provided that he fulfils the

following requirements:-

a) The Contractor shall obtain a completed authorisation form for this purpose from the

Roads Provision Department beforehand.

b) Upon arrival at the refuse dump, each truck from the contract site shall present a copy of

the duly completed for.

c) The Contractor shall obtain a new authorisation form for each and every day that he

intends to dispose of material at the refuse dump.

Should the contractor fail to comply with these requirements, then charges may be levied for

dumping, for which the Contractor shall not be reimbursed.

The Contractor may only use other land as a tip site with the PRIOR WRITTEN APROVAL of

both the Engineer and the landowner. The Contractor may be called upon to prove when spoil is

being dumped. Weighbridge slips will be the only acceptable proof in the case of the Municipal

refuse dump.

PSC5.1 Areas to be Cleared and Grubbed (Clause 5.1)

The areas to be cleared and grubbed will be indicated by the Engineer. Should a portion or the

whole of the site have been cleared and grubbed by others prior to the start of construction then

no clearing and grubbing will be ordered or payment made with respect to the applicable portion

of the site.

PSC5.2.3 Preservation of Trees (Sub-clause 5.2.3)

The penalty in respect of every individual tree, designated as a tree to be preserved, that is

damaged or removed unnecessarily by the Contractor, shall be R5 000.00. Trees that fall within


Scope of Work


areas upon which the Works are to be constructed or within areas that the Contractor must

occupy for the proper construction of the Works will not be designated for preservation.

PSC.4 Freehaul and Overhaul (Clause 4)

Refer to clause PSD.7 in this regard.

PSC.8 Measurement and Payment (Clause 8)


PSC.8.2.7 Demolish and remove pipeline (Sub-clause 8.2.7)

Demolish and remove existing structures/buildings and dismantle steel and pipes

Unless otherwise stated, prices are to include for demolishing and removing from the site the

complete, etc, up to one meter below surface, including decommissioning and making good of

services reticulation up to main supply/feed

The tendered rate shall include transporting of pipes, concrete and steel rubble to an approved

tip/spoil site.

The unit of measurement shall be (m3) per structure for concrete and brick structures and rubble

and (m) for pipelines irrespective of type.

The rate shall cover the cost of removing, loading, transporting and disposal to spoil of all

materials as approved by Employer’s Representative. The rate shall take into account that this

work may have to be carried out in more than one operation depending on the Construction

programme and traffic accommodation.

The contractor is responsible for locating a suitable spoil area for all material to be carted away

from the site and is to allow for the haulage, royalty fees, etc in the rates for each item.

PSC.8.2.8 Demolish and remove existing structures/buildings (Sub-clause 8.2.8)

Add to the Sub-Clause

Demolish and remove existing structures/buildings and dismantle steel and pipes

Unless otherwise stated, prices are to include for demolishing and removing from the site the

complete structures including surface beds, foundations, bases, structural steel, cladding,

brickwork, services, etc, up to one meter below surface, including decommissioning and making

good of services reticulation up to main supply/feed

The tendered rate shall include transporting of pipes, concrete and steel rubble to an approved

tip/spoil site.


Scope of Work


The unit of measurement shall be (m3) per structure for concrete and brick structures and rubble

and (m) for pipelines irrespective of type.

The rate shall cover the cost of removing, loading, transporting and disposal to spoil of all

materials as approved by Employer’s Representative. The rate shall take into account that this

work may have to be carried out in more than one operation depending on the Construction

programme and traffic accommodation.



PSC.8.2.9 Transport materials and debris to unspecified site and dump (Sub-clause 8.2.9)

Add to the Sub-Clause




Scope of Work


PSD EARTHWORKS – SABS 1200 D


The Contractor is to note that work will be carried out in close proximity of informal and formal

housing and structures, as well as existing site facilities. Construction equipment ant tools shall

be so selected to ensure the safety of these structures.

PSD.3.1 Classification for Excavation Purposes (Clause 3.1)

PSD.3.1.2 Method of Classifying (Clause 3.1.1) and Classes of Excavation (Clause 3.1.2)


"The classification of material other than 'soft excavation' shall be agreed upon before excavation

may commence.

The Contractor shall immediately inform the Engineer if and when the nature of the material

being excavated changes to such an extent that a new classification is warranted for further

excavation. Failure on the part of the Contractor to advise the Engineer in good time shall entitle

the Engineer to reclassify, at his discretion, such excavated material.

“Notwithstanding the provisions, No Intermediate Excavation will be measured.

Delete clause 3.1.2 (a) and clause 3.1.2 (b) and replace with the following:

3.1.2 (a) Soft excavation:

“All material that is not classified as hard rock excavation in terms of clause 3.1.2 (c), boulder

excavation class A in terms of clause 3.1.2 (d) or boulder excavation class B in terms of clause

3.1.2 (e) shall be classified as soft excavation”

In clause 3.1.2 (c) (1), replace the words “equivalent to that specified in (b) (1) above” with the

words “of mass approximately 35 t, fitted with a single-tine ripper suitable for heavy ripping and of

fly wheel power approximately 220 kW.”

In the last sentence of clause 3.1.2 (d), replace the words “intermediate excavation” with the

words “soft excavation.”

In the last sentence of clause 3.1.2 (e), replace the words “or intermediate excavation, according

to the nature of the material” with the word “excavation.”


Scope of Work


PSD.3.2 Classification for Excavation Placing Purposes (Clause 3.2)

PSD.3.2.1 Material Suitable for Embankment and Terraces (Clause 3.2.1)

Material that is, in general, for embankments and terraces will be material having a CBR of at

least 25% at the maximum specified density compacted at OMC and PI not exceeding 10, and

hard rock or rock material having a maximum dimension of 100mm.

PSD.3.2.2 Material Suitable for Replacing Over Break (Clause 3.2.2)


Excavation carried out in excess of the specified depth, unless authorised by the Engineer, shall

be made up with concrete class 15/26 or other approved material, as directed by the Engineer, at

the Contractor’s expense.

Where the sides of foundations are specified on the drawings as being cast against in-situ

ground, the excavations shall be carried out to the neat dimensions of the base and any over

break shall be backfilled with the same class of concrete as that in the base or with mass

concrete fill as specified or directed by the Engineer. Where the bottoms or sides of excavations,

against which concrete is to be cast, are softened due to rain or other causes the softened

material shall be removed and replaced by concrete or other approved material as directed by

the Engineer at the Contractor’s expense provided always that the material forming the sides of

the excavation is initially capable of standing unsupported at the required slope.

The maximum allowable over break shall be 150 mm.

PSD.3.3 Selection (Clause 3.3)

No amendments.

PSD.4 Plant (Clause 4)


PSD.4.1 General (Clause 4.1)

Plant shall be suitable for the production of the end result required under the conditions

applicable to the Site. Careful consideration should be given to the selection considering the

close proximity of existing structures.

The compaction equipment shall be restricted to the equivalent of a "Bomag 90" under static

compaction, or similar approved plant.

PSD.5 Construction (Clause 5)



Scope of Work


PSD.5.1.1.2. Safeguarding of Excavations (Clause 5.1.1.2)

The Contractor will be held responsible for the prevention of injury to workmen, locals and

damage to adjoining works and property.

The methods used for excavating shall be such that the surrounding material is preserved in

the soundest possible condition. The Contractor shall, at his own expense, make good any

slips or falls of earth or any part, due to the inadequate support and long periods of exposure

of the excavation, rains, wind, stormwater flow or other reasons.

Any cavities which are formed in the sides of the trenches or excavations shall be made good

and refilled in the manner directed by the Engineer.

Should any part of the excavation through insufficient or careless timbering or any other cause

collapse or give way, the Contractor shall forthwith remove all the materials which have fallen

in and if, in the opinion of the Engineer, there is a possibility of a newly constructed pipeline

having been damaged or disturbed by such collapse, the pipeline shall, at the expense of the

Contractor be laid bare, retested and any damaged lengths reconstructed to the Engineer's

satisfaction.

Adequate protection must be provided both during the day and night to prevent persons and

vehicles from falling into excavation.

Where the Contractor decides to timber trenches, he shall determine the method to be

adopted and will be entirely responsible for the effectiveness thereof. All timbering in trenches

shall be such as will permit of ready laying and jointing and the Engineer's decision as to this

shall be binding upon the Contractor, who shall rectify any timbering that is deemed by the

Engineer to be of such character as will impede or impair work.

Where trenches are timbered they shall be left thus until the laying and jointing and testing of

structures, and the Contractor's prices must provide for, and will be held to be inclusive of, the

cost of the full duration of use of such timbering.

Timbering that is ordered by the Engineer to be left in the trench and covered in will be paid

for at the rate to be quoted by the Contractor under the item provided for this purpose in the

Schedule of Quantities.

The Contractor's attention is drawn especially to the requirements of and compliance with

Government Gazette no. 667 Vol X (Regulations Gazette no. 261) with regard to the

protection and shoring of excavations.

Any cost the Contractor may undergo in ensuring the safety of excavations or any additional

excavation and backfilling he may have to undertake due to the unstable sides of excavations

and trenches shall be held to his account and the various rates for excavation and trenching

included in the Schedule of Quantities shall include full compensation therefore.


Scope of Work


PSD.5.1.1.3 Explosives (Clause 5.1.1.3)


a) General

Blasting shall not be carried out without the prior consent of the Engineer. This consent will

not be given where in the opinion of the Engineer, blasting may give rise to unnecessary

risk or damage to surrounding property when other means of excavation are available to

the Contractor. Where consent to blasting is given, such consent shall in no way relieve

the Contractor of any of his liabilities under the contract. The Contractor shall notify the

Engineer 21 days in advance of any blasting to be carried out on site.

b) Blasting Near Formal and Informal Dwellings/Installations/Services and Structures

i) Prior to any blasting being carried out, representatives of both the Employer and the

Contractor shall thoroughly inspect each private property surrounding the site of the

works for any structural defects.

ii) Prior to the commencement before any construction activities can commence the

contractor will Conduct a detailed Condition survey to identify the condition of the

structures within 100m of the site fence, the survey to include fences and houses,

the survey to include home owner’s name, Structural photos of all structures and a

detailed report on the condition of the structures. Provide 3 copies to the Engineer

for review and acceptance

iii) The Contractor is to submit to the Engineer for approval a professional report on the

proposed method of blasting to be adopted for the works.

iii) During the initial blasting on site the Engineer shall arrange for a survey to be

carried out in order to monitor the magnitude of the blast vibrations and to establish

the most vibration sensitive point on the perimeter of the site. Should it be required,

the Contractor shall modify the adopted method of blasting as instructed by the

Engineer.

iv) The Contractor shall keep full records of every blast on site, e.g. number, depth and

size of holes, amount and type of explosive used per hole, number of blasts at any

one time, magnitude of recorded vibrations etc., a copy of which is to be forwarded

to the Engineer.

v) “The Contractor shall record for the information of the Engineer the spacing and

loading of the charge in each blast. Compliance with this requirement will not relieve

the Contractor of any responsibility as provided for in this sub-clause”.

vi) When blasting to specified profiles, the Contractor shall so arrange the holes and

charges so that the resulting exposed surfaces are as sound as the nature of the

material permits. The Contractor shall make good, at his own expense, any

additional excavation necessitated by the shattering of rock in excess of any over

break allowances specified or given on any Drawing.


Scope of Work


The maximum allowable over break shall be 150 mm.

vii) All blast surfaces are to be covered with mats and/or a suitable thickness of soft

cover material all to the satisfaction of the Engineer.

viii) The Contractor shall include for all costs in complying with the above requirements/

conditions in the tendered rates for excavation.

Notwithstanding any of the requirements of the Specifications the Contractor will be

required to carry out a sufficient number of test blasts (minimum 3), each comprising

of a maximum number of 9 holes charged with small charges, in order to ascertain

the attenuation effects of the in-situ material and to satisfy both himself and the

Engineer that the proposed methods of blasting will not damage any existing

services and/or dwelling sand structures All persons occupying property in the

vicinity shall be informed in writing at least 24 hours before the first blast and shall

be informed of them warning procedures to be employed. In addition, before any

blasting is carried out, the Contractor shall notify the Durban City Police in writing of

proposed operations, the warning procedures to be employed, and the anticipated

duration of the blasting operations. Immediately prior to blasting, all approaches to

the area shall be guarded by personnel carrying red warning flags.

PSD.5.1.4.3 Disposal of Surplus Material (Clause 5.1.4.3 and 5.2.2.3)


“All surplus or unsuitable materials arising from trench excavations shall be spoiled and

neatly spread and levelled along the route of the pipeline so as not to interfere with future

works nor to disrupt the natural overland flow of storm runoff. Rocks, trees, debris and

other unsightly material from trench excavations shall be disposed of at a suitable spoil

site. Where the pipeline is laid within a road reserve the route of the pipeline shall be

finished neatly to be flush with the natural ground level or finished sidewalk level as may

be applicable.

PSD.5.1.6 Accommodation of Traffic (Clause 5.1.6)


The Contractor shall tender a lump sum in the various applicable services Schedule for

accommodating traffic during the duration of the Contract, which sum shall cover all his

obligations in this regard, including but not limited to temporary barricades; the erection and re-

erection of existing and/or temporary traffic signs; lights and flagmen for the guarding and

protection of the Works; and for making all necessary arrangements with the applicable

approving and traffic authorities. Payment shall be made monthly pro-rata to the overall progress

of the Works.


Scope of Work


PSD.5.2.2.1 Working Space beyond Perimeters of Structures (Sub-clause 5.2.2.1b)


Working Space will be restricted, the max allowable working space will be 600mm. The

Contractor shall provide in his tender prices for all restriction on working space. No additional

payment will be made due to this.

All vertical faces for concrete structures shall be shuttered except in the special case of thrust

blocks where no working space shall be excavated and the concrete shall be cast directly

against the undisturbed earth face.

"Material used for backfill behind structures shall generally be the material excavated, subject

to the following conditions:

(a) The material shall not contain an excessive number of stones retained on a 50 mm sieve;

and

(b) The liquid limit of the material shall not exceed 20, neither shall the PI exceed 10."

PSD.5.2.2.2 Borrow Pits (Sub-Clause 5.2.2.2)


The Contractor shall be responsible for making his own arrangement regarding the provision

of material, if required, from commercial borrow pits. The Contractor shall provide in his

tender prices for all royalties payable and for the transport of the material to site.

PSD.5.2.5.1 Free haul and Overhaul (Sub-Clause 5.2.5.1)

All haul shall be considered as free haul and no payment will be made for haul.

Haul and Spoil Roads

The Contractor shall be responsible for the provision of all haul and spoil roads that may be

required for the construction of the works and that the engineer may approve. No additional

payment will be made in this regard.

PSD.7 Testing (Clause 7)

Add the following to the sub clause:

PSD7.2 Taking and Testing of Samples (Clause 7.2)

The Contractor is required to make relative Compaction Tests (Process Control) on every layer in

terms of TMH5 and timeously report these to the Engineer for approval.

Determination of the standard of compaction achieved shall be carried out in accordance with

TMH1.


Scope of Work


PSD.7.3 Subgrade Materials Quality (Clause 7.3)

The subgrade material shall conform to the requirements for a G7 Material as described in TRH

14 with the following Amendments:-

The material shall be free of weathered shale and will be subject to the approval of the

Engineer.

The suitability of the insitu subgrade material should be determined and approved by the

engineer on site before construction.

PSD.8 Measurement and Payment (Clause 8)

Add the following:

PSD.8.2.1 Computation of Quantities and Schedule Items (Clause 8.2.1)


Earthworks will be measured in compacted fill, or cut to spoil. For importation of material for

embankments from borrow pits, earthworks will be measured in compacted fill.

Contractor is to allow for bulking in the nett rates tendered.

Final quantities will be based on final levels and quantities extrapolated from detailed drawings

based on the “End Areas” method of computation.

PSD.8.2.1 Restricted Excavation and Compactive / Backfill Equipment (Clause 8.2.1)

Add the following to the sub clause

The nature of the works is such that a considerable amount of the excavation and compaction

shall be in restricted conditions. No additional payment shall be made for such excavation and

compaction and the Tenderer shall therefore make due allowance in the rates for Bulk

Earthworks for any additional work or hand excavation.

PSD.8.3 Scheduled Items (Clause 8.3)

Add the following:

PSD.8.3.7 Additional Lateral Support (Clause 8.3.7)

Replace Clause 8.3.7 with the following:

In compliance with clause PSD.5.1.1.2, the tendered rate for Excavation and Backfilling shall

include for the provision of temporary lateral support where this is required. All temporary works

to be carried out in accordance to the Occupational Health & Safety Act, 1993 (Act 85 of 1993):


Scope of Work


Construction Regulations 2014 and applicable sections of SANS 1200. The design of any

temporary works including shoring shall be carried out by a registered professional engineer.

Excavations (to a depth of approximately 5m) for the reservoir structure will be in close proximity

to an existing reservoir structures. A minimum distance of 4m from existing reservoir to crest of

excavation slope is to be maintained. Additional temporary lateral support may be required for

excavation of the reinforced concrete wall and this will be determined by the engineer on site.

Additional temporary lateral support will be required for all existing inlet chambers along the

reservoir excavation line.

Contractors are advised that in the case of the proposed pipelines, the depth of trench may

require this temporary lateral support to be provided. Contractors are further advised that in such

cases where the main runs parallel to or across existing services, lateral support will be essential.

Where a pipe is to be laid in a vertically-sided trench with temporary side support, it is necessary

to ensure that the compacted bedding and backfill is hard up against the soil forming the trench

side by withdrawing the temporary supports stage by stage as the backfill rises up the trench.

The unit of measurement shall be in metres (m) measured along the excavation line.

PSD.8.3.11 Maintenance of Grassed Areas (Clause 8.3.11)


Grassed areas, once reinstated by the Contractor will be required to be maintained by the

Contractor for a period of three months. This will include watering and weeding of the planted

areas to the satisfaction of the Engineer. The costs of complying with this requirement are to be

included in the rates for grass planting.


Scope of Work


PSDB EARTHWORKS (PIPE TRENCHES) - SABS 1200 DB


PSDB.3 Materials (Clause 3)

PSDB.3.1 Classes of Excavation (Clause 3.1)

Refer to amended PSD 3.1.

PSDB.5.1.4 Existing Services (Sub-Clauses 5.1.4)

Where any existing service occurs within the specified trench excavation, and the presence of

such service is known before being uncovered, then the protection of the service will be

scheduled and measured as provided for in Clause 8.3.5 of 1200DB. Only known services (as

defined in Clause 5.4 of 1200A) shall be measured for payment.

Where an unknown existing service is damaged during construction, and the Engineer orders

that the Contractor should undertake the repair of such service, then such repair will either be

measured and paid as day works or alternatively as a contractual variation in terms of Clause 36

of the General Conditions of Contract.

No construction activity which may affect the integrity of telephone or electrical poles or stays

may be carried out without the prior written approval of the Engineer, which approval shall only

be given subject to the acceptance of a modus operandi that will ensure the integrity of such

structures during construction.

PSDB.5.2 Trench Widths (Clauses 4.1 and 5.2)

Trenches in general shall not exceed the widths laid down in Sub-Clause 5.2. If trenches exceed

the specified width the Contractor shall be liable for the cost of any thicker pipes or more

expensive bedding which may be required as a result of the additional trench width.

PSDB.5.5 Trench Bottoms (Clause 5.5)

Replace the first paragraph of this sub-clause "Material that .......... compacted as directed" with

the following:-

Where a firm foundation cannot be obtained at the grade indicated due to soft or unsuitable

material, the Engineer may instruct the Contractor to remove such unsuitable material and to

backfill the excess depth with approved selected material or concrete, as directed by the

Engineer in each particular case, at the cost of the Employer. Backfill other than concrete, shall

be placed in layers of 100mm uncompacted thickness, each layer thoroughly compacted to 90%

of modified AASHTO maximum density to be placed on top of it.


Scope of Work


Should the Contractor remove more ground than is required to secure the proper grade of the

pipeline, the Contractor must, at his own cost, backfill the excess excavation with approved

selected material or concrete, as directed by the Engineer in each particular case.

PSDB.5.6.3 Disposal of Excavated Material (Clauses 5.6.3 and 5.6.4)

All surplus or unsuitable materials arising from excavation shall be disposed of in accordance

with Clause PSD3.

PSDB.5.6.8 Freehaul and Overhaul (Clause 5.6.8)

The provisions of Clause PSD 5.2.5.1 shall apply.

PSDB.5.7.2 Areas Subjected to Traffic Loads (Clause 5.7.2)

The requirements of Clause 5.7.2 shall apply only to pipes and sleeves crossing streets or

paved areas and pipes running parallel to the road as described below.

All service trenches running parallel to the road of which the roadside edge of the trench is

located less than 1,4m away from the edge of the travelled way, will be subject to the

requirements for the above mentioned clause.

The measurement and payment will apply to the full trench width. Pipes and sleeves crossing

streets or paved areas will be measured and paid for to a length equal to the width of road or

length of pavement crossed plus 1,4 m either side of the travelled edges.

Compaction of other pipe trenches running parallel to the roadway shall be considered areas

subject to traffic loads only where instructed by the Engineer in writing. The volume will be

computed from the minimum base width determined in accordance with Sub-Clause 5.2 and

the depth from the top of the back fill to the top of the bedding as specified in Sub-Clause

8.3.3.1.

PSDB5.9.4 Reinstatement of Existing Bitumen Surfaced Roads (Clause 3.6 and 5.9.4)

Pipe trenches through the existing bitumen surfaced roads shall be reinstated with a 150 mm

upper selected subgrade layer compacted to 93 % mod AASHTO density, followed by a 150 mm

sub base layer compacted to 95 % mod AASHTO density and a 150 mm graded crushed stone

base compacted to 86 % apparent density. The road shall be provided with a 25 mm thick

asphalt seal.

The upper selected subgrade layer shall have a CBR of at least 15, a grading modulus of at least

0.75 and a maximum PI of 12. The sub base shall conform to SABS 1200 ME and the base to

SABS 1200 MF.


Scope of Work


PSDB.8 Measurement and Payment (Clause 8)

PSDB.8.1 Basic Principles (Clause 8.1)

Add the following to the sub-clause 8.1.2(a):

Payment for the excavation and backfilling of trenches shall be made at the tendered rates and at

the following stages of the construction:

i) upon completion and approval of the trench bottom, prior to bedding : 40 %

ii) upon completion and approval of top of selected backfill: 60% (cumulative)

iii) upon completion and approval of the mainfill: remaining 40 %.


Scope of Work


PSDK GABIONS AND PITCHING - SABS 1200 DK


PSDK.3.1.4 Geotextile (Clause 3.1.4)

The geotextile shall be AG200 or similar approved.

PSDK.3.2.1.2 Pitching (Sub-Clause 3.2.1.2)

Type of pitching shall be grouted Ordinary Stone Pitching, unless otherwise instructed by the

Engineer.


Scope of Work


PSDM EARTHWORKS (Roads, subgrade) - SABS 1200 DM


PSDM. 3.2.1 General - Road Traffic Control (Clause 3.2.1)

In addition to complying with the requirements of Subclause 5.1.1 of SABS 1200 D, the

Contractor shall provide, erect, and maintain all warning and regulatory signs and barricades

that may be necessary to ensure the safe and easy passage of public traffic past roads of

which he has occupation.

Temporary drainage works and temporary deviation of services

a) The relevant requirements of Subclause 5.5 of SABS 1200 A shall apply.

b) The Contractor shall construct the necessary temporary drainage works to deal

adequately with surface run-off by means of side channels, catchwater channels, mitre

channels, culverts, etc.

Where any service, other than provision for stormwater, has to be temporarily deviated the

Contractor shall obtain the written approval of the controlling authority before commencing

the work.

PSDM.5.2.8.2 Disposal of Surplus Material (Clause 5.2.8.2)

All surplus or unsuitable clay and silt material arising from road excavations shall be spoiled

at a suitable spoil site established by the Contractor and approved by the Engineer and

neatly spread and levelled so as not to interfere with future works nor to disrupt the natural

overland flow of stormwater. All other surplus material from the road excavation as well as

rocks, trees debris and other unsightly material shall also be removed and disposed of at a

suitable spoil area noted above. Refer to clause PSD3 for spoil area.

PSDM.5.2.8.2 Overhaul (Clause 5.2.8.2)

No overhaul will be payable on earthworks

PSDM.5.2.4.3 Grass or Other Vegetation (Sub-Clause 5.2.4.3)

The hydroseeding grass seed mix will only contain one or more of the following grass

species:

Cynodon dactylon (Kweek or Couch grass)

Stenotaphrum secundatum (Coastal buffalo grass)

Panicum maximum (Guinea grass)

Erogrostis curvula (Weeping lovegrass)

Details to be submitted for approval by the Engineer, prior to ordering.


Scope of Work


PSDM.7 Testing (Clause 7)

The Contractor is required to make relative Compaction Tests (Process Control) on every layer in

terms of TMH5 and timeously report these to the Engineer for approval.

Determination of the standard of compaction achieved shall be carried out in accordance with

TMH1.


Scope of Work


PSG CONCRETE (Structural) - SABS 1200 G

PSG.2 Interpretations (Clause 2)

PSG.2.1 Supporting Specifications (Clause 2.1)

Add the following:

SANS1491 Part I : Cement-Part 1; Composition, Specifications and conformity criteria

for common cements

SANS 1491 Part II : Pulverised Fly Ash (PFA)

SANS 1491 Part III : Condensed Silica Fume (CSF)

PSG.3 Materials (Clause 3)

PSG.3.1 Approval of Materials (Clause 3.1)

Add the following:

If during the progress of the work, the contractor desires to use materials of proportions other

than those originally approved, or if in the opinion of the engineer or his representative, the

materials from the sources originally approved change in characteristics, he shall provide

evidence satisfactory to the engineer that the new materials and/or new combination of materials

will produce concrete meeting the requirements of the specification and will not bring about

unacceptable changes in the appearance or other characteristics of the structure.

When any changes are made in terms of this sub-clause, they shall be made at the contractor’s

expense, and no extra payment will be allowed by reason of such change.

PSG.3.2 Cement (Clause 3.2)

PSG.3.2.1 Applicable Specifications (Clause 3.2.1)

Add the following:

Ground granulated blast furnace slag (GGBS) used on the Works shall be from a source to be

approved by the Engineer and shall comply with the requirements of SANS 1491 Part I, as

amended.

Pulverised Fly Ash (PFA) used on the Works shall be from a source to be approved by the

Engineer and shall comply with the requirements of SANS 1491 Part II, as amended.

Condensed Silica Fume (CSF) used on the Works shall be from a source to be approved by the

Engineer and shall comply with the requirements of SANS 1491 Part III, as amended.

Cement types to be used under certain specific conditions of environment or geographic location

are given in Table 1 – “Selection of cement type”. A minimum amount of 375 kg/m3 of

cementitious material will be required in the concrete irrespective of the type of cement used.


Scope of Work


Table 1 – Selection of cement type

Location of structure Temperature of

concrete Type of cement

Within 5 km of the sea, or

within 15 km of the sea if

situated in a river valley.

< 20°C CEM II A – S 42.5

CEM II B – S 42.5

CEM II A – M 42.5

20°C - 30°C CEM II A – S 42.5

CEM II B – S 42.5

CEM II A – M 42.5

> 30°C CEM II A – S 42.5*

CEM II B – S 42.5*

CEM II A – M 42.5*

Further than 5 km from the

sea

< 20°C CEM II A – S 42.5

CEM II B – S 42.5

CEM II A – M 42.5

20°C - 30°C CEM II A – S 42.5

CEM II B – S 42.5

CEM II A – M 42.5

CEM II A – V (or W) 32.5

CEM II B – V (or W) 32.5

> 30°C CEM II A – S 42.5*

CEM II B – S 42.5*

CEM II A – M 42.5*

CEM II A – V (or W) 32.5

CEM II B – V (or W) 32.5

*Use with set and hydration retarding admixture.

PSG.3.2.3 Storage of Cement (Clause 3.2.3)

No cement shall be stored on the site for a longer period than 28 days. After this period the

engineer may call for tests to be carried out in accordance with SANS 471, 831 or 626 and if the

cement complies it may be used. Lumpy cement, broken pockets and sweepings shall not be

used. The cement sacks shall be closely stocked, not more than 12 sacks high, and shall not be

stacked against the walls. The arrangements of stacking shall be such as to facilitate the cement

being used in the same order in which it is received.

PSG.3.3 Water (Clause 3.3)

Add the following:

Water shall be obtained from the city water supply where possible and shall be taken from any

other source only on the approval of the engineer. Where there is reason to suspect the

presence of harmful impurities, the engineer may require the contractor to submit the results of

approved tests.


Scope of Work


PSG.3.4 Aggregates (Clause 3.4)

PSG.3.4.1 Applicable Specification (Clause 3.4.1)

Replace the entire contents of the clause with the following:

Grading of fine aggregate. The grading of fine aggregate must comply with the requirements of

Table 2 – “Grading of fine aggregate”. It should be noted that it is unlikely that a single sand with

this grading will be available in the region under the control of eThekwini Water and that two or

more sands will have to be blended.

Table 2 – Grading of fine aggregate

Sieve size Percentage Passing

4 750 µm

2 360 µm

1 180 µm

600 µm

300 µm

150 µm

75 µm

90 – 100

75 – 100

60 – 90

40 – 60

20 – 35

5 – 12

0 – 5

FM 2.03 – 3.00

Grading of coarse aggregate. Coarse aggregate in structural concrete will have a maximum

nominal size of 26.5 mm as specified in SANS 1083 with due cognisance of the spacing of

reinforcing bars.

Water demand of sand. Sand with a water requirement in excess of 200ℓ /m³ when made up into

concrete with the intended mix proportions (including admixtures, if any) will not be allowed.

PSG.3.5 Admixtures (Clause 3.5)

PSG.3.5.1 Approval of Admixtures Required (Clause 3.5.1)

Add the following:

Admixtures may be used with the approval of the Engineer in the design of concrete mixes to

modify the properties of the plastic concrete. The use of admixtures, which have a retarding

effect on the rate of hydration of the cement, may not be used when the concrete temperatures

are below 20°C. When the concrete temperature exceeds 30°C, the use of retarding admixtures

will be mandatory with cements that have a strength class 42.5R or 42.5. Admixtures containing

chlorides shall not be used.

PSG.4 Plant (Clause 4)

PSG.4.1 General (Clause 4.1)

Add the following:


Scope of Work


When considered necessary by the Engineer, stand-by equipment shall be available at short

notice.

PSG.4.2 Batching Plant (Clause 4.2)

Add the following:

The site batching of concrete shall be carried out by mass batching only.

PSG.4.3 Mixing Plant (Clause 4.3)

PSG.4.3.1 General Requirements for Mixing Plant (Clause 4.3.1)

Add the following:

When considered necessary by the Engineer, a spare mixer shall be held in readiness to run on

15 minutes’ notice in case of breakdown of the mixer.

PSG.4.5 Formwork (Clause 4.5)

PSG.4.5.1 Design (Clause 4.5.1)

Add the following:

The design of the formwork and supports shall be the responsibility of the Contractor and shall be

designed and detailed by a registered professional engineer, if required by the special conditions

of contract, and submitted for approval by the engineer. All joints shall be either horizontal or

vertical. Chamfer strips shall be provided on all exposed edges.

The design of all proposed formwork shall be subject to the approval of the Engineer. Such

approval shall in no way relieve the Contractor of his responsibility under the contract.

PSG.4.5.3 Ties (Clause 4.5.3)

Add the following:

The ends of any embedded ties shall have cover equal to that required for reinforcement. The

gap left from the end of the tie to the face of the concrete shall be effectively sealed on both sides

of the structure to ensure water tightness.

PSG.5 Construction (Clause 5)

PSG.5.1 Reinforcement (Clause 5.1)

PSG.5.1.1 Bending (Clause 5.1.1)


Scope of Work


PSG.5.1.1.4 Add the following (Clause 5.1.1.4):

All welding of mild steel, where permitted, shall be in accordance with BS 5135.

PSG.5.1.2 Fixing (Clause 5.1.2)

Add the following:

All reinforcement placed in structures within 5 km of the sea should be washed with clean, fresh

water after placement in the formwork and not longer than 24 hrs. Prior to the casting of concrete.

The placing of bars on fresh layers of concrete, as work progresses will not be permitted. No

concrete shall be placed until the Engineer or his representative has stated that he is satisfied

that the reinforcement is correctly positioned as shown on the drawings.

PSG.5.1.3 Cover (Clause 5.1.3)

Replace clause 5.1.3 with the following:

All concrete cover blocks used shall be of semi-spherical shape. The concrete cover blocks used

shall have the same characteristic 28-day compressive strength as that specified for the

respective structural concrete elements. The reinforcing tie wire used in the manufacture of the

cover blocks shall be hot dip galvanised. A minimum cover of 30mm must be maintained

between the reinforcing tie wire and the conical end of the block.

The minimum clear cover to concrete over all reinforcement shall be as indicated in the following

Table 3 unless otherwise specified on the drawings. Correct cover shall be maintained by

concrete spacers whose strength is not less than that of the concrete specified. Suitable plastic

spacers are permitted if approved by the Engineer.

Type of Construction Min Cover mm

1. Slabs and Walls a) Plastered and un-plastered internal work b) Exposed to water pressure c) External walls 2. Columns 3. Beams a) End cover beyond hooks b) All other surfaces 4. Piles a) Precast piles and on faces poured against

formwork b) On unformed faces poured against ground 5. All structures in sea water or in marine

atmosphere

the greater of 20 or d 50 30

the greater of 40 or d

the greater of 25 or 2d the greater of 25 or d

40

75

50


Scope of Work


6. Structures in contact with backfilling or

corrosive atmosphere 7. Footings a) Members cast on a blinding layer b) Members cast in contact with the ground

40

50 75

Note: In the above table‘d’ refers to the largest reinforcing bar diameter.

PSG.5.2 Formwork (Clause 5.2)

The surface of the blinding layer, the floor, the internal upper surface of the all footings and the

upper surface of the roof and the slabs over the valve chamber shall be finished in accordance

with clause PSG.5.2.1 class 4 - Steel Float Finish.

The internal surfaces of all walls, columns and the underside of the roof and all exposed surfaces

shall be finished in accordance with clause PSG.5.2.1 class 3a - Smooth Finish.

All surfaces in contact with backfill material may be finished in accordance with clause PSG.5.2.1

class 1 - Ordinary Surface Finish.

PSG.5.2.1 Classification of Finishes (Clause 5.2.1)

Replace the entire Clause with the following:

Surface finishes to formed concrete faces shall be classified as hereunder –

Class 1: ordinary finish;

Class 2: rubbed finish;

Class 3: off the form finishes;

(a) smooth finishes,

(b) board marked finishes,

(d) special patterned finishes,

Class 4: exposed aggregate finishes;

(a) brushed and washed finishes,

(b) tooled finishes,

(c) sand blasted finish

(d) aggregate transfer finishes,

Class 5: applied finishes;

(a) rendered finishes,


Scope of Work


(b) painted finishes.

Class 1 – Ordinary Surface Finish

This is the finish left on a concrete surface after the removal of the forms and the filling of all

holes left by shuttering bolts and the repairs of all defects. The surface shall be true and even,

free from stone pockets, depressions and projections.

Class 2 – Rubbed Finish

Immediately after removal of the shuttering all defects shall be made good and the rubbed finish

shall be applied within three days as follows:

Before starting this work the concrete shall be kept thoroughly saturated with water for a

minimum period of 3 hours. Sufficient time shall have elapsed before the wetting down to allow

the mortar used in the pointing of the bolt holes and defects to set properly. Surfaces to be

finished shall be rubbed with a medium coarse carborundum stone, using a small amount of

mortar on its face. The mortar shall consist of cement and fine sand mixed in the proportions

used in the concrete being finished. Rubbing shall be continued until all projections and

irregularities have been removed, all voids filled and a uniform surface has been obtained. The

paste produced by this rubbing shall be left in place for at least five days. The surface shall be

smoothed by being rubbed lightly with a fine carborundum stone.

Class 3 – Off the Form Finishes

Off the form finishes require a very high standard in concrete quality, formwork and technique.

The intention is that no after treatment other than treatment of bolt-holes (which should be placed

with regulatory and precision) should be required. Forms shall be unblemished and panels

regular. Joints shall be a feature of the pattern and shall be handled with care. Reinforcement

cover blocks shall be of semi-spherical shape to minimise their appearance on the finished

surface.

a) Smooth finishes may be obtained from non-absorptive linings to forms, form plywood,

shutterboard, or plastic faced board in new condition.

b) Boardmarked finishes shall be obtained from the use of timber planks, which shall be

dressed and thicknessed unless otherwise specified. When unplanned timber is specified,

boards with a strong grain shall be mixed with boards with a less pronounced grain and not

grouped together. The engineer shall indicate if all boards are not to be horizontal and a

patterned panel effect is required.

c) Special patterned finishes are required to reflect without blemish the surface of patterned

hardboard, rubber, thermoplastic or other lining as specified.

Class 4 – Exposed Aggregate Finishes

The purpose of these finishes is to relieve the uniform colour and texture of the concrete by

exposing the aggregate, which shall be the normal size concrete aggregate except where

otherwise specified. Attention is directed to the necessity for allowing for the material to be

removed and ensuring that the requisite cover to reinforcement is maintained.


Scope of Work


a) Brushed and washed finishes are obtained by stripping and scrubbing the concrete surface

with a stiff wire brush. Unless forms can be stripped at a very early age (approximately 16

hours at 20°C) this method cannot be used unless the formwork has been treated with a

retarding agent. Care shall be taken to ensure that concrete is not deposited against the

face of treated forms, which should be stripped as early as possible. Where scrubbing with

water is not effective, a solution of hydrochloric acid in the proportion of 1 part of acid to 4

parts of water shall be thoroughly and evenly scrubbed into the surface until the desired

texture is obtained. The complete surface shall then be neutralised by washing thoroughly

with water to which a small amount of ammonia has been added. When acid is used,

special precautions shall be taken to protect workmen, underlying materials and persons

passing.

b) Tooled finishes may be carried out by the use of bush-hammers, light mechanical chisels

or other approved tools, preferably mechanically operated. No tooling shall be done until

the concrete has attained an age of at least 14 days after casting when normal Portland

cement has been used and 7 days when rapid hardening cement has been used, or longer

as may be necessary to prevent the aggregate particles from being dislodged.

The final finish shall show a surface of evenly distributed coarse aggregate particles set in

a matrix of mortar, each aggregate particle being in slight relief. After the tooling has been

completed, the surface so treated shall be scrubbed down with a stiff brush and washed

with water.

c) Sand blasted finishes shall be obtained by sand blasting the thoroughly cured concrete

surface of the same ages as given under (b) Tooled Finishes with hard sharp sand to

produce an even, fine, clean surface in which the mortar has been cut away, leaving the

coarse aggregate exposed.

d) Aggregate transfer finishes may be affected by sticking a single layer of selected

aggregate onto ply board or other suitable form liners which have been cut to size and

coated with a layer of water soluble cellulose adhesive mixed with plaster sand. This layer

should be just thinner than half the average least dimension of the aggregate. When the

glue is set the liners are placed in the forms which are then concreted, care being taken to

protect the forms when placing and compacting. Liners shall be stripped after at least 3

days and the adhesive and sand covering the aggregate removed by scrubbing and

washing.

Class 5 – Applied Finishes

It is essential that all surfaces on which applied finishes are to be used shall be sound, clean and

free of mould oil.

Defects shall first be made good.

a) Rendered finishes require a good key. Unless otherwise specified this may be provided by

flicking on to the previously soaked and still moist surface of 1 part cement to 2 parts of

sharp sand. This shall be left untouched apart from curing.


Scope of Work


The render coat shall consist of 1 part Portland cement, or Portland cement 15, ½ part

slaked lime, 4 to 4½ parts of sand by volume and shall not be less than 5mm or more than

16mm in thickness.

If a second coat is required because of the irregularity of the concrete. The surface of the

first coast shall be combed with uniform wavy lines to provide a key after it has begun to

harden. The second coat may be applied the next day. If a scraped finish is specified the

rendering shall be lightly scraped to achieve the desired effect with an old tenon saw blade

or similar implement, after it has attained a biscuit like crispness. It shall then be lightly

brushed and washed to remove loose particles.

All rendered finishes shall be cured.

b) Painted finishes of the type specified shall be applied strictly in accordance with the paint

manufacturer’s instructions. Very smooth surfaces shall be acid washed, lightly sand

blasted or rubbed with abrasive stones before being painted. Painting shall be delayed as

long as possible and two coats applied unless otherwise specified.

Concrete Upper Surface Finishes

Classification

Surface finishes to exposed (non-formed) concrete faces shall be classified as hereunder:

Class 1 – Screeded Finish

Class 2 – Broomed Finish

Class 3 – Wood Float Finish

Class 4 – Steel Trowel Finish

Class 1 – Screeded Finish

Immediately after placing, the concrete shall be screeded with a true edged wooden board

working between forms or other guides set accurately to line and level. No mortar shall be added

and noticeable surface irregularities caused by the displacement of coarse aggregate shall be

made good by re-screeding after removing or tamping down the interfering aggregate.

Class 2 – Broomed Finish

Immediately after placing, the concrete shall be screeded as in Class 1. Thereafter, when the

concrete has begun to dry, the surface shall be broomed with a stiff broom or brush to expose the

aggregate. Dust and loose particles shall be gently washed away once the desired relief has

been obtained.

Class 3 – Wood Float Finish


concrete has begun to dry, the surface shall be brought to a smooth and even finish using a

wood float and including any additional 4:1 sand and cement as necessary.


Scope of Work


Class 4 – Steel Float Finish


concrete has begun to dry, the surface shall be brought to a smooth and even finish using a steel

float and including any additional 4:1 sand and cement as necessary.

PSG.5.2.2 Preparation of Formwork (Clause 5.2.2)

Add the following:

Shutter release oil or any other contaminants will not be permitted on any of the reinforcing steel.

Wedges and clamps shall be used in preference to nails for securing the form components and

wire ties or tie bolts in reinforced concrete must be capable of complete removal after use, except

as otherwise specified. Where oil is used it shall be applied before any reinforcement is placed in

position.

PSG.5.2.5 Removal of Formwork (Clause 5.2.5)

PSG.5.2.5.2 Replace the entire contents with the following (Clause 5.2.5.2):

Where test cubes to determine stripping times are not made, the minimum periods, which shall

elapse between the time of the placing of the concrete and the time of removal of the forms

shall, unless otherwise agreed with the engineer, be in accordance with the table hereunder,

where each day covers a full 24 hour period.

Minimum stripping time in days:

CEM I CEM I

CEM II/A &

CEM II/ B (MAX

29%

EXTENDER)

CEM II/A &

CEM II/ B

(MAX 29%

EXTENDER)

CEMII/B

(30-35%

EXTENDER)

CEMII/B

(30-35%

EXTENDER)

TYPE OF

STRUCTURAL

MEMBER OR

FORMWORK

Normal

weather

(Above

15°C)*

Cold

weather

(Below

5°C)*

Normal weather

(Above

15°C)*

Cold weather

(Below

5°C)*

Normal

weather

(Above

15°C)*

Cold weather

(Below

5°C)*

Beam sides, wall or

unloaded cols 1 2 2 4 2 6

Slabs, with props left

underneath 4 7 5 8 6 10

Beam soffits, props

left under 7 12 8 14 10 17

Removal of slab

props 10 17 10 17 12 21

Removal of beam

props 14 21 14 21 18 28

*Average daily temperature of the atmosphere adjacent to the concrete as measured by a

maximum and minimum thermometer. When the average daily temperature is between 5°C

and 15°C the minimum stripping times shall be interpolated from the table.


Scope of Work


The table assumes that the member concerned is not subjected to any heavy construction

loads and that the total force to be supported is not more than half the design load. Where

heavier loads are to be carried, no stripping of soffits shall be permitted until the concrete has

attained its full strength. Any days during which the average temperature was below 2°C shall

be completely disregarded.

In the case of walls and columns the stripping times shall be determined by means of cube test

results in the first instance, so as to ensure that no damage is caused to the structures by

removing formwork.

PSG.5.2.5.6 Thermal Shock and Thermal Contraction Cracking (Clause 5.2.5.6)

Add the new clause:

When it is possible that a temperature differential of 20oC or more may exist within the concrete

or between the concrete surface and its surroundings, special precautions shall be taken by the

Contractor to avoid thermal shock or thermal contraction cracking. The advice of specialists in

the field of concrete technology will be sought and their recommendations regarding the

peculiar set of circumstances will be implemented

PSG.5.4 Pipes and Conduits (Clause 5.4)

Add the following:

The clear space between pipes of any kind embedded in reinforced concrete and the clear space

between such pipes and reinforcement shall not at any point be less than 40 mm, or 5 mm plus

the maximum size of coarse aggregate, whichever is the greater.

The puddle flanged inlet, outlet, drainage and scour pipes shall be fixed in line and position under

and in the walls by the Contractor as shown on the drawings. All pipework shall be cast into

walls at the time of pouring. The use of “windows” to cast in pipework at a later date shall not be

permitted.

PSG.5.5 Concrete (Clause 5.5)

PSG.5.5.1 Quality (Clause 5.5.1)

PSG.5.5.1.4 Chloride Content (Clause 5.5.1.4)

Replace the entire contents of the clause with:

The chloride content, measured as Cl-, of all concrete in the structure as measured by BS

1881:124:1988 shall not exceed 0.2% mass cement.

The maximum chloride content of fine aggregate shall be 0.2 % by mass as Cl- as measured by

SABS Method 830:1976.


Scope of Work


PSG.5.5.1.7 Strength Concrete (Clause 5.5.1.7)

Add to G 5.5.1.7

The cubes from the trial concrete mix are to be tested at a nominated concrete design

laboratory, and only the results of these tests will be considered for approval.

The minimum content of combined cementitious material shall not be less than 375kg/m³ and

the minimum water/cement ratio shall be 0,5. The Contractor shall also submit for approval the

proposed slumps and the proportions in which he proposes to use the materials for each grade

of concrete in each type of construction. In addition he shall state the minimum cement / water

ratio in terms of total water in the mix for each grade of concrete, and the use of any

admixtures.

No structural concrete shall be placed on the job until the contractor has satisfied the engineer

as to the suitability of the mixes concerned.

The Contractor shall be deemed to have satisfied himself, before tendering, of his ability to

produce concrete of the required quality with available materials conforming to the specification.

PSG.5.5.1.8 Bleeding (Clause 5.5.1.8)

Add the new clause:

Concrete shall be so proportioned and the materials so selected that bleeding is kept below

0.30 mm/cm2 as measured by the ASTM C232 – 99 test.

PSG.5.5.1.9 Shrinkage (Clause 5.5.1.9)

Add the new clause:

Concrete shall be so proportioned by the selection of materials that shrinkage as measured by

the SANS 1085 test is kept below 0.06% when batched at the maximum slump allowed.

PSG.5.5.1.10 Temperature of Concrete (Clause 5.5.1.10)

Add the new clause:

The temperature of the concrete shall be measured when it is delivered to site from a batch

plant or a concrete supplier and shall be within the range 10°C and 30°C. Concrete which has

a temperature outside of that range shall not be placed in the structure.

PSG.5.5.1.11 Rate of Hydration (Clause 5.5.1.11)

Add the new clause:

The rate of hydration of the cement in the concrete shall be such that the concrete can be

placed and properly compacted, 2 hours after the addition of water to the mix even in hot


Scope of Work


weather. Conversely, the initial set of the concrete must not be unduly delayed by low

temperature, inappropriate use of admixtures or cement type, so that bleeding is promoted.

PSG.5.5.2 Batching (Clause 5.5.2)

Add the new clause:

For grade 35/26 concrete, only cement types CEM I (OPC, Duratech), CEM II/A (Eagle Plus) or

CEM II/B (Structcrete, Durastruct, Surecrete) shall be used. No site blending of cement extenders

will be permitted.

PSG.5.5.2.2 Water (Clause 5.5.2.2)

Replace entire contents with the following:

Dependable equipment shall be provided for measuring the mixing water either by mass or by

volume to an accuracy within 3 per cent.

The accuracy of the measuring device provided shall be checked whenever required by the

engineer or his representative by allowing it to discharge into vessels of accurately known

capacity.

The total quantity of water allowed for shall include the free water present in the aggregates.

The moisture content of the fine aggregate shall be determined at the beginning and half way

through each concreting shift, after showers of rain or at such other intervals as may be

required by the engineer.

PSG.5.5.2.3 Aggregates (Clause 5.5.2.3)

Replace entire contents with the following:

Each size of aggregate shall be measured separately by weighing to an accuracy of 5% except

where other methods are authorised or ordered by the engineer.

Where suitable volumetric methods of measuring proportions of aggregates are permitted,

these shall be checked at regular intervals, and shall take full account of bulking of the fine

aggregate as delivered to the mixer. These methods shall be designed in such a manner that

the consistency of the mix shall be as readily controlled as for mechanical batching.

All measuring devices shall be maintained in good order and condition, and no build-up of

material on any part of the equipment shall be permitted.

PSG.5.5.3 Mixing (Clause 5.5.3)

PSG.5.5.3.1 Mixing at Construction Site (Clause 5.5.3.1)

Add the following:


Scope of Work


Mixing shall continue until there is a uniform distribution of the materials and the mixture is

uniform in colour. The minimum period of mixing shall be not less than that recommended by

the manufacturers at the recommended speed and not more than 30 minutes. The entire

contents of the mixer shall be removed from the drum before the materials for the succeeding

batch are loaded.

Where hand mixing is permitted, the quantities of cement used shall be increased by not less

than 10% over those determined for the appropriate mix design. The concrete shall be mixed

on a clean and watertight platform.

PSG.5.5.3.2 Ready Mixed Concrete (Clause 5.5.3.2)

Add the following:

The concrete batching plant is to be inspected by the Engineer for compliance with SANS

tolerances and his approval is to be obtained in writing before commencement of the concrete

works.

A maximum delivery period of 90 minutes from the time water is added to the concrete mix to

the actual discharge of concrete on site shall be permitted. The discharge period (including

placing the concrete) shall not exceed 30 minutes.

The concrete slump of every truck shall be measured on delivery and shall comply with Clause

SABS 1200 G 5.5.1.2 prior to any concrete from that truck is placed.

Where possible, dedicated truck drivers shall be used for the delivery of the concrete to site.

A detailed computer printout of the constituents of the concrete mix from the batching plant is to

be handed over to and retained by the Engineers representative on site on arrival (i.e. truck

registration, mix proportions and the time water was added to the mix). The masses of the

concrete constituents of each truck shall be checked against that of those submitted with the

trial mix, subject to the batching accuracy as specified in SABS 0100-2: 1992. The arrival time

of each truck on site and the time that the concrete discharge is completed shall also be

recorded by the Engineers representative.

Before any ready-mixed concrete is used on the job, the contractor shall furnish the engineer

with a copy of his letter to the suppliers in which he specified –

(i) the type of cement;

(ii) the nominal maximum size of aggregate;

(iii) the cement / water ratio;

(iv) the required compressive strength;

(v) the required slump at the time and place of delivery; and

(vi) the type of additive.

All these properties shall be as specified in the contract documents.

When required the contractor shall satisfy the engineer that acceptable alternative means of

supplying concrete have been arranged to be brought into operation in the event of disruption in

the supply of concrete. In this connection, the engineer may require that the alternative means


Scope of Work


of supply shall commence if the disruption in the supply of ready-mixed concrete has lasted for

an elapsed period in time of 1½ hours.

The use of ready-mixed concretes shall in no way relieve the contractor of any of his

responsibilities for providing concrete complying with the specifications.

For grade 35/26 concrete, a CEM I or CEM II cement may be blended with pulverised fly ash

(PFA) or ground granulated blastfurnace slag (GGBS) and/or condensed silca fume (CSF),

such that the combined cementitious material comprises not less than 65% cement clinker and

a maximum of 35% of extender and/or other additional constituents by mass.

The minimum content of combined cementitious material shall not be less than 375kg/m³ and

the minimum water/cement ratio shall be 0,5.

The concrete mixes for the abovementioned grades of concrete shall be designed by an

approved concrete design laboratory. At least four weeks before placing any structural concrete

on the site, the Contractor shall supply and deliver to the laboratory, at his own cost, samples of

the aggregates and the concrete mix design he proposes to use for the works. The Contractor

shall include in his tender all fees and charges levied as well as all other costs incurred in

designing the required strength concrete mix.

PSG.5.5.4 Transportation (Clause 5.5.4)

Add the following:

Containers for transporting concrete shall be cleaned of all hardened concrete and foreign

material.

During transportation the concrete shall be protected from wind and sun; shall be prevented

from drying out or losing moisture and shall not be subjected to excessive jarring or jolting.

Drying out may be prevented by the provision of covers and / or other protective devices.

PSG.5.5.5 Placing (Clause 5.5.5)

Add the following:

Where plums are permitted they shall be deposited by hand.

Freshly placed concrete shall be protected from rain damage.

No concrete shall be placed if the air temperature in the shade is falling and is below 8°C or is

rising and is below 5°C. Concreting shall not commence if the air temperature in the shade is

above 35°C. The temperature of the concrete at the point of placing shall not exceed 30°C

unless otherwise specified.


Scope of Work


PSG.5.5.5.1 Structural Concrete (Clause 5.5.5.1)

During the whole or any time that the placing of concrete is being carried out, the concreting

operation shall be under the supervision of a suitably experienced person.

The wall footings shall be cast with wall starters to form a horizontal wall construction joint as

shown on the drawings. The construction joint between footing bays shall also be as shown on

the drawings. At least 3 days shall elapse between pouring adjacent wall footings.

After the wall footings have attained a minimum strength of 18 MPa, but not later than 7 days,

each bay of the wall section shall be cast to full height on the same day and vertical

construction joints between bays shall be formed as shown on the drawings.

At least 3 days shall elapse between the pouring of adjacent wall panels.

As soon as possible after the removal of the formwork in vertical joints or after the concrete has

set in horizontal joints the surface laitance of the concrete shall be removed in order to expose

the large aggregate and leave a solid surface.

Openings may be left in the formwork on the outside face only for pouring and vibrating of the

concrete provided they are closed properly and do not impair the concrete finish.

When concreting walls care shall be taken to ensure that there is no loose matter on the

concrete surface and that it is slightly wetted in order to assist the new concrete adhering to the

existing concrete.

The Contractor’s attention is particularly drawn to the fact that the walls form part of a water

retaining structure and that no honeycombing will be tolerated. In order to ensure this, the mix

proportions of the first 250mm depth of concrete placed in contact with the horizontal joint may

be adjusted, with the approval of the Engineer, by reducing the amount of coarse aggregate.

The Engineer’s representative may instruct the use of trunking in placing the concrete to avoid

losses of fines due to adherence to reinforcement and formwork. The concrete shall be placed

evenly over the surface to be covered without reliance on vibration to transport it horizontally.

Special care shall be given in order to ensure full compaction at waterstops.

The floor shall be cast in panels as detailed on the drawings. Consecutively cast panels shall

not adjoin one another. The floor panels shall be cast in a checkerboard pattern with a

minimum of 3 days between the pouring of adjacent panels.

The column and column head shall be cast in one lift. The base of the column may be cast first

provided a centrally placed starter is incorporated.

The Contractor may propose alternative means of construction which shall be subject to the

approval of the Engineer. If the Engineer accepts any alternative means of construction it shall

in no way result in increased costs.

PSG.5.5.6 Compaction (Clause 5.5.6)

Add the following:


Scope of Work


PSG.5.5.6.5 If required by the engineer concrete shall be re-worked by re-vibration 1 to 3 ½ hours after

placing. The time shall be decided by the engineer, taking cognisance of the mix, the ambient

temperature and the workability of the concrete.

PSG.5.5.7 Construction Joints (Clause 5.5.7)

Add the following:

PSG.5.5.7.1 Any additional construction joints required by the contractor shall be approved by the

engineer. Where “off the form” finishes are specified, joints shall be arranged to coincide with

the edges of boards or panels wherever possible.

Only those construction joints shown on the drawings shall be measured and paid for. The

contractor shall allow in his pricing for any additional construction joints that he may require.

PSG.5.5.7.3 (b) Construction Joints when concrete is more than 24 hours but not more than

3 days old (Clause 5.5.7.3)

Delete and replace with the following:

The surface of the concrete shall be sandblasted or chipped to remove all laitance and to

expose stone with a light hammer, swept clean and thoroughly wetted. No Epoxy will be

allowed without the specific approval of the Engineer and submission of a method

statement by the contractor on how he intends doing the work.

PSG.5.5.7.4 Add the following new clause (Clause 5.5.7.4)

a) All horizontal and vertical construction joints shall be cleaned of all dirt and loose

particles and shall be prepared to the satisfaction of the Engineer. Formed keys shall be

provided if shown on the drawings or if instructed by the Engineer. All intersections of

construction joints with concrete surfaces which will be exposed to view shall be made

straight and level or plumb and shall be constructed to the details shown on the

drawings.

b) The Contractor is to provide a compressor (with oil traps) on site for the whole period

during which concreting is in progress, and this must be available for cleaning concrete

faces prior to placing fresh concrete or pouring joints. The cost of this plant and operation

is to be allowed for in the Contractors rate for concrete.

c) “Blowing-off” may generally be carried out on horizontal surfaces but, under special

circumstances approved by the Engineer, it may be carried out on vertical surfaces. The

surface concrete to be prepared shall be between 4h and 8h old after completion of

placing and shall be blown off using a mixture of air and water under a pressure of at

least 500kPa or by using a high pressure water jet until all dirt, laitance, etc is removed

and particles of clean coarse aggregate are exposed sufficiently to produce a rough

surface. Any loose particles of coarse aggregate shall also be removed. The success of

this method of preparation depends on selecting the correct time (dependent on the type


Scope of Work


of cement and atmospheric conditions) so that the concrete has set to just the necessary

degree of hardness. The operation may therefore require to be undertaken outside

normal working hours and at night. When the surfaces are at least 12h old any

remaining loose or fine aggregate particles shall be washed off.

d) The removal of all surface laitance plus roughening the concrete surface with hand tools

in order to expose the coarse aggregate in a uniform pattern, is to be carried out on both

horizontal and vertical surfaces. These areas should then be cleaned with a stiff brush

under running water. The surfaces to be prepared in this manner shall be at least 12

hours old after mixing the concrete. At least 35% of the roughened surface area shall

consist of exposed coarse aggregate.

e) All prepared surfaces shall be kept continuously wet until the next lift of fresh concrete is

to be placed against them; the minimum time being 12 hours.

f) No fresh concrete shall be placed on the top surface of concrete which is laterally

restrained (e.g. by formwork or by in-situ earth) while the bottom layer of concrete is

between 3 hours and 12 hours old after mixing. No fresh concrete shall be placed on top

of the concrete with an unrestrained lateral surface while the bottom layer of concrete is

between 2 hours and 12 hours old after mixing.

The internal surface of joints in the reservoir floor and walls shall be sealed with a surface

mounted “Hypalon” bandage system having an epoxy fixing system, all materials and

procedures conforming to the “Sikadur-Combiflex” surface sealing system as produced by

Sika (Pty) Ltd, or similar approved. The Contractor must ensure that where one Hypalon joint

intersects another (at right angles or otherwise) that the two layers of intersecting hypalon are

not epoxied to each other and thereby restrained from moving. i.e. the Hypalon inside an

intersecting joint must not be restrained by the epoxy adhesive and the full intended width

should be free to move in the intended directions.

A 1mm thick Hypalon bandage is to used on walls less than 6,5m and a 2mm thick bandage is

to be used on walls greater than 6,5m.

The construction joints on the top (and sides where detailed on the drawings) of the reservoir

roof slab are to be sealed with a 75mm wide self-adhesive aluminium foil strip (Bostik “Ditsit”

or similar approved) which shall be installed in accordance with the manufacturer’s

instructions. The “Ditsit” is to be taken over the edge of the roof slab and down the side of the

wall for a distance of 500mm.

The construction joints on the soffit of reservoir roof slab are to be sealed with 2 coats of a

75mm wide application of SikaTop-Seal 107 (or similar approved) applied in accordance with

the manufacturer’s recommendations. The soffit of the reservoir is to be ground down 1.5 to

2mm with an angle grinder and then wire brushed and sprayed clean with water. The slurry is

to be applied to a damp surface.

PSG.5.5.7.5 Water Proofing of Concrete Joints (Clause 5.5.7.5)

Add the following:


Scope of Work


WATERPROOFING OF CONCRETE JOINTS

Three different systems of waterproofing (or construction of systems) exist and the appropriate

system (or combination) will be applied as specified on the drawings: The three systems are:

a) Waterproofing with hypalon bandage system

b) Waterproofing with waterbars

c) Waterproofing with surface sealants

(i) Hypalon system

Hypalon bandage joint sealing system shall be the Sikadur-Combiflex Hypalon bandage

system as supplied by Sika (Pty) Ltd.

The joint shall consist of 2 mm thick Combiflex Hypalon sheeting, 200mm and 250mm

wide, as shown on the drawings. The Hypalon sheeting shall have a tensile strength of

6N/mm² and an elongation at failure of not less than 400%.

The Hypalon sheeting shall be bonded to the concrete with Sikadur 31 two component,

solvent free, moisture intensive, high viscosity, epoxy paste adhesive.

(ii) Waterbars

Except where otherwise specified waterbars shall be manufactured from virgin polyvinyl

chloride complying with BS 2571: latest amendment (Class 3 compounds) and the

Tenderer shall provide full details of the composition and properties of the material in the

relevant annexure where applicable.

Samples of waterbars shall be submitted for approval and all material subsequently

supplied shall be identical in size, shape, colour and quality to the approved sample. The

waterbar shall be of uniform cross-section and size and shall have lugs welded at 1m

centres on both edges of the waterbar to hold it securely in position during concreting

operations.

It shall be possible for all sizes of waterbar to be turned through a 75mm radius without

damage or permanent set to the waterbar.

Joints in waterbars shall be kept to a minimum by the use of the longest possible lengths.

Waterbars shall be held to the required shape, lines, etc, in suitable formwork: site joints

shall be bonded as directed by the manufacturer in such a way as to form a continuous

watertight seal free from pin holes at any point of the length or width of the strip.

Formwork shall be designed to accommodate the waterbars without subsequent bending

and the waterbars shall be adequately supported and protected from damage and sunlight

until finally encased in concrete.

Waterbars shall be tested in accordance with BS 2782 and ISO R527.


Scope of Work


(iii) Waterproofing with surface sealants

a) General

A groove of dimensions specified shall be formed, where indicated, and sealed by

an approved sealant. The sealant shall be non-toxic and shall be either a hand

applied bitumen putty sealant or a polysulphide sealant. The type of sealant to be

specified on the drawings and the product to be used shall be approved by the

Engineer.

b) Bitumen Putty Sealant

All joints shall be clean, dry and free of latance. The concrete shall be at least four

weeks old. The joint surfaces shall then be primed by an ancillary product and the

sealant applied as per the suppliers specification. Special precautionary measures

shall be taken to acquire a neat finish by covering the face edges of the joint with

masking tape before priming. Any excess material will be cut away and finished

flush.

c) Polysulphide Sealant

All joints shall be clean, dry and free of latance. Prime joint face if required –

following the suppliers specification. Apply the sealant and finish off flush with the

concrete surface.

PSG.5.5.8 Curing and Protection (Clause 5.5.8)

Add to G 5.5.8 (d)

Free from rents and tears and lapping by not less than 150 mm, the surface being resprayed

whenever any sign of drying out is evident

Replace entire contents of G 5.5.8e with:

Covering with an inner hessian membrane and an outer plastic membrane. The hessian

membrane is to be kept continuously damp by an independent automatic sprinkler system. The

hessian and plastic membranes are to be firmly secured and kept flush to the concrete surface at

all times.

Add the following:

a) Retaining forms in place.

b) Steam curing may be used on approval as specified by the engineer, provided that the rate

of increase in temperature does not exceed more than 20°C per hour. Steam curing at

higher than atmospheric pressure shall not be permitted if the concrete contains limestone

aggregate. Humidity shall be kept between 90% and 100%.

c) The use of curing compounds will not be permitted.


Scope of Work


Delete the last two sentences of G 5.5.8 and replace with:

The minimum period of curing various types of cement shall be as follows from the date and time

of casting:

a) CEM I - 7 days (168 hours)

b) CEM II (max. 29% extender) - 8 days (192 hours)

c) CEM II (30-35% extender); - 10 days (240 hours)

During periods of extreme temperatures, these periods may be increased at the discretion of the

Engineer. The temperature of concrete shall be retained above 5°C for a period of 3 days after

placement. Should the environment in which the concrete is placed be such that temperatures

drop below 5°C in the concrete, then use shall be made of insulated formwork to retain the heat

generated by cement hydration within the concrete.

Curing methods to be utilised for water retaining structures

Concrete Element Curing Method

Reservoir floor slab G 5.5.8, (a), (b) or (d)

Reservoir walls G 5.5.8. (e)*

Top surface of the reservoir roof slab G 5.5.8 (d)

Soffit of the reservoir roof slab G 5.5.8 (f)

Reservoir columns G 5.5.8 (e)*

* - As amended

The rates for “Curing of Concrete” in the Schedule of Quantities will be paid to the Contractor on

the successful outcome of the durability tests.

PSG.5.5.9 Adverse Weather Conditions (Clause 5.5.9)

PSG.5.5.9.2 Delete Reference to 32° and Replace 30°C (Clause 5.5.9.2)

PSG.5.5.9.4 Weather Station (Clause 5.5.9.4)

The Contractor is to provide equipment to monitor the wind speed, humidity, temperature and

hence calculate evaporation rates at the site. If the rate of evaporation on site exceeds

0,5kg/m2/hour, exposed concrete surfaces shall be protected to prevent plastic cracking. It

should be noted that plastic cracking may occur in cool weather with high wind velocities as well

as in warmer weather conditions. If in the opinion of the Engineer, the weather conditions are

too extreme and run the risk of adversely affecting the concrete, he may instruct the Contractor

not to pour any more structural elements that day. The Engineer may call for protection against

the wind to be provided, or the finished concrete to be covered with a plastic sheet or a fog

spray to be utilised. Similarly, if it appears likely to rain, the Engineer may instruct the

Contractor not to pour any further concrete. An extension of time (without P& G costs) may be

allowed at the Engineers discretion for delays incurred due to inclement weather. Any additional

costs for these delays and/or protective measures are to be allowed for in the Contractors rates

for concrete work.


Scope of Work


PSG.5.5.10 Concrete Surfaces (Clause 5.5.10)

Add the following to G 5.5.10.4:

The Contractor shall make every effort to prevent blowholes from appearing on the off the form

smooth finish. All noticeable defects shall be repaired to the Engineers satisfaction.

PSG.5.5.14 Defects (Clause 5.5.14)

Add the following to G 5.5.14.1:

Water retaining concrete shall be as dense as possible and no honeycombing will be permitted.

If honeycombing is found to be a problem the Contractor shall re-assess the concrete mix

proportions and his concrete placing methods. No additional payment shall be made for using

this mix.

Add the following to G 5.5.14.2

All concrete repair work will be carried out as described below. Repair mortars containing PVA

Latexes shall not be used in any water retaining structures.

1 Honeycombing:-

The area to receive patch material shall be primed with a bonding slurry (e.g. Sika

MonoTop 610 or similar approved). The patch will then be built up while the slurry coat is

still tacky by means of an approved cementitious polymer modified mortar (e.g. Sika

MonoTop 615 HB Prostruct 528 or similar approved).

2 Shrinkage cracks:-

A low viscosity solvent free structural epoxy resin is to be used to fill the cracks (e.g.

Sikadur 52, ABE Epidermix 365/389 or similar approved)

PSG.5.5.14.3 Patching and Repair (Clause 5.5.14.3)

Add the following:

Where defects do not warrant the removal of defective concrete, one or more of the following

procedures shall be required by the engineer:

a) Where the structural strength might be affected and must be restored, repairs may be

effected by the application of either pneumatically-placed mortar or of a mortar made of

silica sand and an approved epoxy formulation mixed and applied in accordance with the

manufacturer’s recommendations.

b) Where there are no fears as to structural strength, all defective material shall be chipped

away until a dense uniform surface of concrete exposing solid coarse aggregate is

obtained. Feathered edges shall be cut away to from surfaces perpendicular to the

concrete face. Seized shutter bolts shall be cut back to at least 35mm into the concrete.

All loose material shall be hosed away and the surface of the cavity shall be saturated


Scope of Work


with water for at least 3 hours, after which a thin layer of neat cement mortar shall be

applied to the surface. The cavity then shall be filled with stiff mortar mixed in the same

proportions of cement to sand as that used in the original concrete. The mortar shall be

thoroughly tamped into place in layers. The use of up to 30% white cement in place of

the normal cement may be required to reduce the darker appearance of a patch. An

interval of thirty minutes shall then elapse before a final surface tamping is given to the

patch, after which the surface shall be treated to resemble the surrounding concrete as

closely as possible. Board marks may be reproduced by striking a suitable piece of

timber held against the plastic concrete. The patch shall be neat and workmanlike in

appearance and after completion it shall be kept wet for a period of at least three days.

The cost of repairing any defective concrete shall be to the Contractors account.

The preparation, application and curing of the above repair materials shall all be in strict

accordance with the Manufacturer’s instructions.

PSG.5.5.16 No-Fines Concrete (Clause 5.5.16)

Add the following:

Only sufficient water shall be added to the mix to produce a smooth grout to completely cover

each and every particle of aggregate.

Proportions may be varied on site with the approval of the Engineer to obtain a more

satisfactory result. The upper surface of the no-fines is to be finished off with a wood float to

provide a smooth working surface while adding just sufficient dry mix cement-sand mortar 1 to 8

ratio to close the upper surface of the voids in order to prevent ingress of foreign matter and

concrete from the blinding/floor concrete into the interstices.

Mixing shall be carried out in a mechanical batching plant and the hopper shall first be charged

with the aggregate to which a small quantity of water has been added to moisten aggregate

particles. The cement shall then be added followed by the remainder of the water.

The no-fines concrete shall be placed within 20 minutes of having been mixed and shall be

rodded and hand tamped into position. The use of vibrators will not be permitted.

No traffic shall be permitted to traverse the surface of the no-fines concrete during the three

days following upon placing and thereafter only over planks or boards placed for that purpose.

No-fines drains shall be measured per metre and shall include for the porous concrete pipe and

the encasement in no-fines concrete.

No-Fines Concrete

General

Unless otherwise specified, no-fines concrete shall only be used for non-structural work.


Scope of Work


Grading of Aggregate

Aggregates for no-fines concrete shall be graded so that not more than 10 per cent (10%) by

mass of aggregate is retained on a sieve having 19mm square openings and not more than 5

per cent (5%) by mass passes a sieve having 9,5mm square openings.

Mix Proportion

No-fines concrete shall be mixed with one part of cement to 9 parts of aggregate.

PSG.6 Tolerances (Clause 6)

PSG.6.2 Permissible Deviations (Clause 6.2)

PSG.6.2.3(a) Replace with the following (Clause 6.2.3):

Description

Permissible Deviation in mm

Degree

III and II I

Spacing between two adjacent bars ± 20 ± 15

Dimensional position of bar ± 20 ± 10

Longitudinal location of bends and ends of bars

± 30 ± 20

Cover to reinforcement - 0 + 10 - 0 + 5

PSG.6.2.3 (h) Specified Add:

Tolerances for bow or camber, twist, squareness and for silos and slip form concrete,

prestressed concrete and precast concrete will be stated in Part Project Specification wherever

applicable.

PSG.7 Tests (Clause 7)

PSG.7.1 Facilities and Frequency of Sampling (Clause 7.1)

PSG.7.1.2 Frequency of Sampling (Clause 7.1.2)

PSG.7.1.2.2 Replace the entire contents of the clause with (Clause 7.1.2.2):

The Contractor shall provide the following number of sets of three standard metric 150mm

metal cube molds for the volume of concrete poured as per the table below:


Scope of Work


Table 4 - Frequency of compressive strength tests

Volume of pour (m3) Number of sets

0 – 25 3

26 – 50 5

51 – 100 7

101 – 200 8

+ 201 10 (or as required by the Engineer)

These sets of concrete cubes will be crushed when they are 7 and 28 days old.

Provide sufficient extra cube molds for 3 days, 7 day, etc., crushing tests to be made as he so

requires for his own purposes i.e. for shutter stripping, post-stressing cables.

Make and cure all cubes on site under the supervision of the engineer, in accordance with

SANS Method 863.

Be represented at the crushing test if he so wishes.

Transport all cubes to the nominated laboratory between 7:30am and 11am on the last working

day prior to the date of test. Only the results from this laboratory will be considered and will be

the sole basis on which concrete is accepted or rejected.

PSG.7.3 Acceptance Criteria for Strength Concrete (Clause 7.3)

Delete the entire contents of G 7.3.1 and G 7.3.2 and replace with:

PSG.7.3.1 Strength Concrete (Clause 7.3.1)

The Contractor is hereby advised that the only basis, on which concrete strength will be accepted

or rejected is on the 28-day cube strength obtained from cubes crushed at the nominated

laboratory. Unless the conditions of sampling, cube manufacture, cube curing and record keeping

are strictly adhered to, the test results will be meaningless. To this end it is emphasised that the

Contractor must strictly comply with all the concrete test methods specified in SANS Method 861.

Table 5 - Acceptance criteria for concrete strength

Acceptance Category

Strength

CS = Average minimum strength for 3 cubes at

28 days (Mpa)

Characteristic strength for water retaining

structures 35

Full acceptance CS ≥ 37

Conditional acceptable 33 ≥ CS > 37

Rejection 33 < CS

The descriptions given in the “Acceptance Categories” column above shall have the following

meanings.


Scope of Work


Full acceptance - Concrete shall be accepted unconditionally, subject to the concrete meeting the

durability and cover criteria.

Conditional acceptance - Concrete shall be accepted with a warning that construction methods

should be examined to improve the strength. A financial penalty of up to R75/m3 will be applied

on a pro rata sliding scale for all concrete poured where the average strength (for 3 cubes at 28

days) test results fall within the conditional acceptable range.

Rejection - At the discretion of the Engineer, the concrete shall be removed and replaced at the

expense of the Contractor.

Core holes - That test cores shall be drilled from the concrete and tested in accordance with the

SANS Method 865 to determine the estimated actual strength and the estimated potential

strength of the concrete.

If the results of the core tests show that the concrete meets the test requirements, the structure

shall be accepted if the cores tests show that the concrete does not meet the strength

requirements, an appropriate full-scale load test, as determined by the engineer, any be applied

on the structure containing the defective concrete.

If load tests are, in the opinion of the engineer, impracticable, or where the portions of the

structure subjected to such test fail to pass the test specified, he shall have the right to require

strengthening or replacement of the portions of the structure concerned.

Upon removal of the core the hole is to be dampened and filled with a stiff mix of an expanding

cementitious grout (Sika Grout G.P. or similar approved). Thereafter, an external slurry coat (0.25

x 0.25m) of a polymer modified cementitious coating (Sika Top-Seal 107 or similar approved) is

to be applied over the exposed surface of the core hole.

PSG.7.3.5. Replacement or Strengthening of Concrete (Clause 7.3.5)

Delete after the words “the Contractor shall”, and insert

“make adjustments in order to meet the specified requirements.”

PSG.7.3.6. Table 8 - Acceptance criteria for concrete cover (Clause 7.3.6)

Add the following:

Acceptance Category Concrete Cover (mm)

(for specified cover of 50mm)

Full acceptance 70 > Cd ≥ 50

Conditional acceptance 45 ≥ Cd > 50

Acceptance with

remedial measures 40 ≥ Cd > 45

Rejection Cd < 40, Cd > 70


Scope of Work



meanings.

Full acceptance - Concrete shall be accepted unconditionally, subject to the concrete meeting the

strength and durability criteria.

Conditional acceptance - Concrete will be accepted with a warning that construction methods

should be examined to improve the cover. A financial penalty of up to R15/m2 will be applied on

a pro rata sliding scale for each structural element where the average test results fall within the

conditional acceptable range.

Acceptance with remedial measures - Concrete will be accepted if the Contractor

undertakes remedial work at his expense, as approved by the Engineer, to improve the

durability of the concrete to the criterion described as “full acceptance”,

Rejection - At the discretion of the Engineer, the concrete shall be removed and replaced at the

expense of the Contractor.

Notwithstanding Clause 29.1 of the General Condition of Contract (Removal of improper work

and materials) and Clause 30 of GCC (Contractor to search), the onus will be on the Contractor

to prove to the Engineer the extent of the concrete for which the durability and cover values fall

below the Specified Values (in the above tables), and the cost of this searching is to be included

in the Contractor’s rates for concrete.

An item has been included in the Schedule of Quantities for the making good of core holes as

directed by the Engineer.

Where the engineer or his representative has reason to doubt whether the concrete cover over

the reinforcement is not in accordance with the requirements of clause PSG.5.1.3, the cover shall

be tested with a cover meter. If necessary, the engineer or his representative shall then indicate

to the contractor where he must expose the reinforcement to prove the depth of cover.

PSG.7.3.7 Costs of Tests (Clause 7.3.7)

Add the following:

The costs of all tests required by the engineer or his representative shall be borne by the

Employer except that costs of tests as set out hereunder shall be borne by the contractor –

(a) preliminary tests on materials and of mix proportions;

(b) all tests as may be made necessary by reason of the provisions of clause SANS 1200 G

7.3.5;

(b) such tests, including concrete coring and load tests, as may in the opinion of the engineer

be made necessary by failure on the part of the contractor to meet the requirements of this

specification.


Scope of Work


PSG.7.3.8 Durability Index Tests (Clause 7.3.8)

Add the following:

To ensure that the concrete has been placed, compacted and cured correctly, a number of tests

will be carried out by a nominated laboratory on the concrete after curing has been completed ie

26 to 30 days after placing of the concrete.

1) A set of four 68mm diameter cores, 75mm in length will be drilled at each test location

through the covercrete (being the concrete layer between the outermost layer of steel

reinforcement and the exposed outer surface of the concrete element) from the

constructed concrete element when the concrete has reached 28 days of age. A slice

(30mm thick) will then be cut from the outer surface of this core such that the slice is

representative of the middle layer of the covercrete (ie the middle layer being a 30mm

thick slice of concrete, 15mm from the exposed outer surface extending in towards the

reinforcement) and tested for: -

1.1) Water sorbtivity,

1.2) Oxygen permeability (tested in the ballim apparatus), and

1.3) Chloride conductivity

The positions at which the cores will be extracted will be indicated by the Engineer.

The oxygen permeability and water sorptivity, and chloride conductivity test procedures shall be

carried out in accordance with the following references:

(1) Guide to the use of durability indexes for achieving durability in concrete structures.

(Research Monograph No. 2)

(2) Concrete durability index testing manual (Research Monograph No. 4)

2) The depth of concrete cover achieved will be measured to ensure that the specified values

have been achieved.

The cost of these tests will be borne by the Employer if the results are equal to or exceed

the specified value. The Contractor will pay for the tests if the results fall below the

conditional acceptance range.

N.B. The Employer will pay for one set of tests per.

Table 7 - Acceptance criteria for durability testing structural element

Acceptance Category

Oxygen permeability

index

(log scale)

Water sorptivity (mm

h) Chloride Conductivity

Full acceptance Op ≥ 9.15 Ws ≤ 8 Cc ≤ 0.75

Conditional acceptance 9.0 ≥ Op > 9.15 6 < Ws ≤ 12 0.75 < Cc ≤ 1.50


Scope of Work


Acceptance with remedial

measures 8.75 ≥ Op > 9.0 12 < Ws ≤ 15 1.50 < Cc ≤ 2.50

Rejection Op < 8.75 Ws > 15 Cc > 2.50


meanings.

Full acceptance - Concrete shall be accepted unconditionally, subject to the

concrete meeting the strength and cover criteria.

Conditional acceptance - Concrete will be accepted with a warning that construction

methods should be examined to improve the durability. A financial

penalty of up to R75/m3 will be applied on a pro rata sliding scale

for each structural element where the average test results fall

within the conditional acceptable range.

Acceptance with remedial - Concrete will be accepted if the Contractor measures undertake

remedial work at his expense, as approved by the Engineer to

improve the durability of the concrete to the criterion described as

“full acceptance”,

Rejection - At the discretion of the Engineer, the concrete shall be removed

and replaced at the expense of the Contractor.

PSG.7.3.9 Water Tightness Testing (Clause 7.3.9)

Add the following:

Each water-retaining structure shall be filled with water at a uniform rate not exceeding 2.0m in

24 hours until the top water level has been reached. The water level will then be carefully noted

and recorded by the Engineer in relation to a fixed bench-mark, and the structure shall be

allowed to remain filled for a period of two weeks to permit complete absorption of water by the

concrete.

Any loss of water which may have occurred shall then be made up by again filling the structure to

the top water level and by allowing the water to remain undisturbed for a period of not less than

four days. The structure shall be considered to be watertight if the drop in level in 96 hours (less

the drop caused by evaporation) does not represent more than 0,06% of the volume of the

reservoir.

The evaporation shall be measured by the mean drop in level caused by the evaporation of the

water in three flat containers floating in the water, being recorded.

The Contractor is free to attend the taking of all measurements by the Engineer.

In the event of an appreciable leakage being evident or visible at any stage of the filling or

testing, or in the event of the final degree of water tightness being unsatisfactory, the Contractor

shall, when so ordered by the Engineer, discontinue such filling or testing and shall, at his own


Scope of Work


expense, take approved steps to rectify the leakage, until a test proves that a sufficient degree of

water tightness has been obtained.

The water tightness of the reservoir roof shall be tested before that of the reservoir itself by water

being continuously sprinkled over the roof in an approved manner so that a film of water is

maintained on the surface of the slab. The roof shall be considered watertight if no damp

patches are visible on the underside after 48 hours of sprinkling.

Before the expiry of the defects notification period, the Engineer shall have the right to retest the

structure for water tightness. Results of such further tests will be made available for the

information of the Contractor. In the event of these tests indicating an unsatisfactory degree of

water-tightness, the Engineer will, before issuing the final certificate, again require the Contractor

to rectify the leakage, at his own expense, in such a manner as will cause the least interruption of

the water supply to consumers and as will ensure the soundness of the work, to the satisfaction

of the Engineer.

The costs of re-testing a water-retaining structure for water tightness shall be borne by the

Contractor.

PSG.8.9 Miscellaneous Work Other Than Metal Work Unit: as Scheduled (Clause 8.9)

Add the following:

Separate items will be scheduled for each type of miscellaneous work.

The tendered rates shall include full compensation for providing all labour, materials and

equipment required to carry out the work, for all preparatory work, for constructing the work

scheduled in a workmanlike manner and for finishing-off and cleaning up when the work has

been completed."


Scope of Work


PSH STRUCTURAL STEELWORK - SABS 1200 H

PSH.1 Scope (Clause 1)

This specification shall apply to the structural steel tank stand and handrails.

PSH.5.2 Drawings and Shop Details (Clause 5.2)

Refer to clauses PHF3.9 and PHF3.10 in this regard.

Certain items are design and construct items, the Contractor will be responsible for the

preparation of both engineering drawings and workshop details. Once submitted, the Engineer

will have one week to comment on the drawings and details prior to the commencement of

fabrication.

PSH.5.7.1 Handrails (Clause 5.7.1)

PSH.5.7.1.1 All handrails shall be of the ball type tubular handrails and shall be manufactured by a reputable

firm specializing in the manufacturing of this type of handrailing.

PSH.5.7.1.2 Tubular handrailing shall be manufactured from mild steel tubing with a minimum yield strength

of 300 Mpa. The tubing shall have a minimum outside diameter of 33 mm and a minimum wall

thickness of 2,5 mm. The knee rail shall have a height of 500 mm above floor level and the top

rail shall have a height of 1 000 mm above floor level.

PSH.5.7.1.3 Stanchions shall be manufactured from mild steel tubing with a minimum yield strength of 300

MPa. The tubing shall have a minimum outside diameter of 42 mm and a minimum wall

thickness of 3,0 mm. The stanchions shall be placed at 1,0 mm centres on stairs and at a

maximum of 1,8 m centres on platform and walkways.

PSH.5.3.4 Welding (Clause 5.3.4)

Welding shall be done in accordance with the relevant requirements of SABS 0162, BS 5135 and

AWS.D.1/18 American Welding Society).

The qualification of welders shall be in accordance with the relevant clauses of the above

standards, and specifically SABS 044 Part III and shall be Grade 1 welders. Grade 2 welders

shall be permitted only with the Engineer=s approval.

The Contractor shall provide evidence, acceptable to the Engineer, that welding procedures and

welders have been tested in accordance with the requirements of AWS D1.1.


Scope of Work


PSL MEDIUM PRESSURE PIPELINES - SABS 1200 L

PSL.2.1.2 Supporting Specifications (Clause 2.1.2)

The latest issues of the following specifications at the time of tender, and as appropriate shall be

deemed to apply to the manufacture of pipes and specials using either submerged arc spiral

welding or longitudinally welded "cans" rolled from low carbon or steel plate and joined by

submerged arc circumferential welding to form suitable pipe lengths. The manufacture of pipe

specials shall also be subject to these requirements:

SANS 62-1&62-2 Steel pipes and pipe fittings up to 150 mm nominal bore, Part 1 and Part 2

SANS 719 Electric welded low carbon steel pipes for aqueous fluids (large bore)

SANS 1431 Weldable structural steels

SANS 1476 Fabricated flanged steel pipework

SANS 1700 Fasteners

SANS 4633 Rubber seals – Joint rings for water supply, drainage and sewerage pipelines

SANS 15589-1 Cathodic protection of pipeline transportation systems – Part 1

BS 534 Steel pipes and specials for water and sewage

BS 970 Wrought steel for mechanical and allied engineering purposes

BS EN 1092 Flanges and their joints

BS 7531 Rubber bonded fibre jointing for industrial and aerospace purposes

API 5L Line pipe

API 1104 Welding of pipelines and related facilities

AWWA M11 Steel pipe - a guide for design and installation (Fourth edition)

AWWA C208 Dimensions for fabricated steel water pipe fittings

PSL.3 Materials (Clause 3)

PSL.3.1 General (Clause 3.1)

The Contractor shall supply and install all pipes and fittings for the works except material which

will be supplied by the Employer.

All mPVC pipes shall be Class 16 in accordance with SANS 966-2:2006.

GRADE OF STEEL (Clauses 3.1 to 3.3)

All steel piping shall be made electric welded low carbon steel pipes in accordance with the

requirements.

Pipes, pipe supports and specials of nominal diameter equal to or less than 150 mm

shall be manufactured of steel in terms of SANS 62 (heavy class pipes) and API 5L for

steel grades up to X52.

Pipes and specials of nominal diameter larger than 150 mm shall be manufactured from

steel grade A, to SANS 719, steel grade 300WA to SANS 1431 and steel grade X42, as

specified.


Scope of Work


Pipes and specials of nominal diameter larger than 150 mm and embedded in soil shall

be manufactured from a steel grade as specified (Grade 300WA steel to SANS 1431,

X42 and X52 or other approved

All flanged pipes and fittings shall have flanges as specified, and shall be supplied complete with

all packings, nuts, bolts and washers. Steel piping shall be made from Grade A steel. The

minimum wall thickness for steel pipes of nominal outside diameter to be as follows.

- for pipes of nominal outside diameter less than 600mm up to 450 mm Dia : 8.0 mm

- for pipes of nominal outside diameter less than 450mm up to 180 mm Dia : 6.0 mm

- for pipes of nominal outside diameter equal and less than 150 mm Dia heavy duty

5.0mm

MARKING

Additionally, all pipes and specials shall be clearly marked/stencilled alongside a longitudinal or

spiral weld on both ends on the inside of the pipe with the following information:

a) Grade and thickness of steel;

b) Serial number of the pipe or special;

c) Nominal diameter (mm);

d) Factory Hydraulic Test Pressure (kPa); and

e) Spool / Coil Number.

PSL.3.4 Steel Pipes, Fittings and Specials (Clause 3.4)

PSL.3.4.1 General (Clause 3.4.1)

Add the following to Clause 3.4.1:

Viking Johnson couplings complete with all seals, bolts, nuts, etc. shall be used where detailed.

Where new installations couple up with existing, the Contractor shall ascertain what the flange

drillings are the same as all existing fittings prior to any placement or order and shall confirm this

information with the Engineer

The pipes to be laid under this contract are 80 to 600 mm in diameter pipes.

PSL.3.4.2 Pipes of Nominal bore up to 150 mm (Clause 3.4.2)

Delete the Sub-Clause.

PSL.3.4.3 Pipes of Nominal Bore over 150 mm (Clause 3.4.3)

Delete the Sub-Clause.

PSL.3.4.4 Fittings and Specials (Clause 3.4.4)

Add the following to Clause 3.4.4:


Scope of Work


The lining and wrapping of specials, which are to be butt-welded, is to be terminated 100 mm

from the end of the pipe. The lining of specials which are to be sleeve welded shall be taken to

the end of the pipe and the wrapping is to be terminated 100 mm from the end. On flanged

specials the wrapping and lining is to be taken to the end of the pipe.

All specials shall be protected in accordance with clauses PSL.3.9.2.3. All electrodes used for

welding of joints shall comply with SABS 455.


All bends shall be minimum radius bends unless otherwise specified or indicated on drawings.

The specials shall comply with the requirements of SANS Specification 719. Where specials have

to be attached by welding the diameters of the specials shall exactly match those of the pipes

supplied.

Segmented bends shall be fabricated in accordance with Table 8 of BS 534 (1990) and the Table 6

below. Cut and shut bends are not permitted. All bends shall be fabricated with ends suitable for

welding.

Table 6 : Fittings and Specials

Deflection of Angle

1° to 5° One pipe ends scarfed on site

5° to 10° Two pipe ends scarfed on site

10º to 30º 2 segment bend



Bends greater than 90º shall be fabricated from combinations of items from the table above, but

at all times adhering to the requirements of BS 534. Shop drawings of these bends shall be

submitted to the Engineer for approval prior to manufacture. Tee pieces for air valve access;

scour off-take etc shall be fabricated in accordance with Table 9 of BS 534 (1990). All other

specials shall be fabricated in accordance with the relevant Clauses of BS 534.

PSL.3.8 Jointing Materials (Clause 3.8)

It is noted that certain special precautions need to be taken to avoid excessive deflections and

over-stressing of the pipeline material during construction. Various physical properties as well as

requirements and recommendations for construction of the pipeline are as follows:

Diameter

(mm)

Length

(m) Grade

Plate

Thickness

(mm)

Mass

kg/m Coating Lining

End

Preparation


Scope of Work


PSL.3.8.3 FLANGES AND ACCESSORIES (Clause 3.8.3)

PSL.3.8.3.1 Bolted Connections (New Sub-Clause) (Clause 3.8.3.1)

Add new Sub – Clause:

Bolted connections shall comply with the following:

All pipes larger than 150mm in diameter, connected to equipment or fittings, or where

specifically indicated, shall be flanged to SABS 1123 – 1600 and 2500 as specified.

All flanges shall be Type 3, plate flanges for welding and blank flanges shall be Type 8.

Matched flanges shall correspond in construction and dimensions to flanges on

equipment. Matched flanges shall be provided with the correct bolts, nuts and packing

rings. All piping shall be clean before connections are made.

Bolts, tie-bolts and nuts shall be galvanised to SABS 763 and shall comply with the

relevant requirements of SABS 135 – 1985 and SABS 136 – 1985.

The length of each bolt shall be such that after the bolt has been tightened, the end of

the bolt shall not project above the nut by more than two threads. Tie-bolts on

restrained couplings shall be fitted with “backing nuts”.

All bolt threads shall be liberally coated with “Copper slip” or similar approved prior to

assembly. Upon completion, bolt heads and nuts shall be coated with “Denso Mastic”.

Satisfactory temporary end covers shall be provided by the Contractor for protection of flanges,

prepared ends of open ended pipes and fittings and screwed ends, to prevent damage to internal

lining during transportation and during handling on site.

Add the following to clause 3.8.2:

Where flexible couplings are called for they shall be the double flanged and sleeve type,

manufactured from rolled steel, and fitted with rubber rings suitable for jointing plain-ended pipes.

They shall be of the slip-on type coupling and couplings comprising bolt over arrangements shall

not be acceptable.

The rubber jointing rings shall be manufactured from first grade natural rubber to B.S. 2494 Class

D. All bolts and nuts shall comply with SABS 135 or SABS. 136. Each sleeve shall be fitted with

a centre register unless stated otherwise in the Project Specification.

Add the following to clause 3.8.3:

Gaskets shall be manufactured from “approved material which complies with the requirements for

Grade B of B.S. 2815.

Maximum Pressure 40 bar @ 0˚C to 20 bar @ 150˚C.


Scope of Work


All gaskets shall be purpose made. Hand cutting and trimming of gaskets on site will not be

acceptable.

Care should be taken to ensure that all gaskets are packed properly and are not damaged by

bending. For larger sizes the gaskets shall be suitably supported by wooden frames during transit

and while in store.

Any item of pipework that is found to have flanges that are incorrectly drilled shall be rejected.

Reaming of bolt holes to oversize dimensions in order to make a particular piece fit shall not be

permitted.

PSL.3.9 Corrosion Protection (Clause 3.9)

PSL.3.9.2.3 Repairs to Coatings and Linings (Clause 3.9.2.3)

Replace the clause with the following:

FBMDPE, fusion-bonded epoxy coated and solvent free liquid epoxy lined or cement-mortar

lined pipe shall be repaired as specified in this clause.

A. External Repairs

1. Detection of Defects in FBMDPE and Epoxy Coating by Holiday Tests

Each pipe length shall first be placed on suitable dunnage adjacent to the trench. The

Contractor shall then arrange for Holiday tests to be undertaken on the accessible portion

of the pipe coating surface by the non-destructive testing firm appointed in terms of this

contract document or the Engineer’s representative, whichever is applicable. It shall be a

requirement of this contract that the Holiday testing device utilised by calibrated and

approved by the Engineer prior to the conducting of any Holiday tests.

2. Surface Preparation

a) Defects in epoxy coating detected by holiday testing

At each pinhole detected by the Holiday test, the surrounding area shall be abraded to 25

mm beyond the defective area. It is noted that any cluster of pinholes within a radius of 25

mm shall be regarded as one defect. The abrasion shall be carried out with clean emery

paper of 80 to 100 mesh so as to provide a suitably rough surface profile without causing

the removal of excessive amounts of coating material.

b) Damage to FBMDPE and epoxy coating caused by welding, damage at joints and bends

and damage at scour and air valve tees, crotch plates and buried valves.

i) All damaged and blistered FBMDPE and epoxy coating caused by welding shall be

removed back to sound epoxy coating by mechanical grinding or other approved

means.


Scope of Work


ii) The exposed steel surface shall be power or hand wire brushed to remove dirt,

scale, rust and other foreign matter to a surface equivalent to a Class 2 finish. Weld

spatter shall be removed by chipping or grinding to a smooth surface flush with the

surrounding steel. Welds shall have a smooth contour free from sharp edges,

protrusions and undercut. Sharp edges and protrusions shall be removed by

grinding to a smooth radius of curvature of not less than 3 mm.

iii) The surrounding sound FBMDPE and epoxy surface shall be abraded to a distance

of 50 mm beyond the defective area. The abrasion shall be carried out with clean

emery paper of profile without causing the removal of excessive amounts of

protective material.

3. Cleaning of Area to be repaired

Grease and oil shall be removed with a non-volatile solvent (eg “Aquasolve”, “Arc Nr.261

Safety Solvent Cleaner” or similar approved). The surface shall then be cleaned with

potable water and allowed to dry completely.

4. Methods of Repair to be Carried Out

a) Defects in epoxy coating detected by Holiday tests

i) The roughened area of coating and the defect shall be repaired by the

application of a two part solventless epoxy repair kit (eg “Copon Hycote 151”,

“Arc 982” or similar approved) to a minimum dry film thickness of 300,

microns. The epoxy repair material shall be applied in accordance with the

manufacturer’s instructions and allowed to dry for 24 hours.

ii) 24 Hours after the application of the epoxy repair material described above,

the pipes may be placed in the trench and rotated so that the underside of the

pipe, which was not Holiday tested at the side of the trench, may be tested.

iii) The pipe coating any defects detected on the now uppermost surface of the

pipe shall be prepared in accordance with the requirements of A.2(a) and A.3

above.

iv) The prepared surface shall then be primed and patched (or wrapped in the

case of the coating reinstatement of joints) with Denso Ultraflex System, or

similar approved. The following criteria shall be strictly in accordance with the

manufacturer’s instructions:

- surface preparation

- application of the primer

- application of the tape

- recommended minimum overlap width (where applicable)

- capping of overlap joints (where applicable).

v) Notwithstanding the above, the tape cover strip shall overlap the sound

FBMDPE and epoxy coating by at least 50 mm (in the case of patches) and


Scope of Work


100 mm (in the case of joint wraps) and shall be applied in layers if necessary

to form a final cover patch or strip at least 2,5 mm thick. The tape repair for

FBMDPE defects shall be continuously, spirally wrapped around the complete

circumference of the pipe with a minimum overlap of 25 mm.

vi) The dielectric resistance of the tape cover strip shall not be less than that of

the FBMDPE (10 000 V) or fusion-bonded epoxy coating (3 500 V)

b) Defects in FBMDPE coating detected by Holiday tests

Where the repair area is less than 650 mm², the application of a hot spatula shall be

used to repair the defect, provided there is a residual layer of polyethylene still

adhering strongly to the steel surface.

c) Defects in FBMDPE coating other than those detected by Holiday tests

Any single repair area less than 0.1m² shall be carried out in accordance with A.4.b

above. The number of repairs shall be limited to three per pipe or fitting. The length

of such repair shall not exceed the nominal pipe diameter in the circumferential

direction, nor twice the nominal pipe diameter in the longitudinal direction.

d) Patch Repairs to Pipes Damaged by Welding

Patch repairs to pipes damaged by welding shall be carried out in accordance with the

requirements of A.4.a(iv), A.4.a(v) and A.4.a(vi) above.

e) Patch Repairs to Pipes that will be Exposed to Ultra-Violet Light

i) Repairs shall be carried out in accordance with the requirements of A.4.a(i)

above with due allowance being made for the 24-hour curing period.

ii) The pipe surface shall then be coated with two coats of “ABE Silvakote” or

similar approved bitumen base aluminium paint applied with brush or roller to

a final minimum dry film thickness of 80 micrometers. The over coating time

shall be as per the manufacturer’s instructions.

f) Joint repairs (including bends) on pipes that are to be buried

i) Repairs shall be carried out in accordance with the requirements of A.4.a(iv),

A.4.a(v) and A.4.a(vi) above.

ii) No air-gap will be permitted between the tape and steel surface and tape

width and application tension shall be such as to ensure that the tape

“dresses down” over steel surface irregularities. This applies particularly on

bell-end pipes.

iii) Gusseted bends requiring two or more welded joints shall be fully externally

wrapped extending 150 mm outside the two outermost welded joints.

g) Scour and air valve tees and crotch plates


Scope of Work


i) Scour and air valve tees and crotch plates that are to be buried shall be

protected in accordance with the requirements of A.4.a(i) above with due

allowance being made for the 24-hour curing period.

ii) Exposed specials in chambers including valves, flanges, crotch plates, flexible

couplings etc shall be protected by the application of “Copon Hycote 151”,

“Arc 982” or similar approved epoxy coating to a minimum dry film thickness

of 300 microns. Surface preparation and application shall be strictly in

accordance with the manufacturer’s instructions.

iii) When coating valves, care shall be taken to prevent the epoxy coating

covering the descriptive name plates and flow direction indicators on the

valves by masking off these plates.

h) Buried Valves

Buried valves or other appurtenances with intricate shapes will be inappropriate for

wrapping with a tape system. Such items shall be protected by the application of a

zinc-rich epoxy primer such as “Berger Master”, “Zinc Anode 304” followed by two

coats of a pitch extended epoxy resin coating such as “Fosroc Nitocote ET550”,

“Epilux 5 Coal Tar Epoxy” or similar approved to a minimum dry film thickness of

250 microns.

Alternatively a petrolatum system “Denso” type or similar approved may be

employed and then wrapped in polythene sheeting to the approval of the Engineer.

B. INTERNAL REPAIRS – EPOXY LINED PIPES

1. Detection of Defects in Epoxy Lining by Holiday tests

Each pipe length shall be first placed in position in the trench, welded to the preceding pipe

and the lining at the joint reinstated (see B.2.b of this Clause). Once all work is complete

in a particular length of pipe, the Contractor shall arrange for the testing of the pipe with a

“wet sponge” detector set at 90 Volts in order to detect any electrical insulation defects.

2. Surface Preparation

a) Defects in epoxy lining detected by holiday testing

At each pinhole detected by the Holiday test, the surrounding area shall be abraded

to 25 mm beyond the defective area. It is to be noted that any cluster of pinholes

within a radius of 25 mm shall be regarded as one defect. The abrasion shall be

carried out with clean emery paper of 80 to 100 mesh so as to provide a suitably

rough surface profile without causing the removal of excessive amounts of coating

material.

b) Epoxy lining damaged by construction operations, joint repairs (including bends),

lining to scour and air valve tees, access openings, stubs and valve bypasses


Scope of Work


i) In order to avoid damage to the pipe lining occurring as a result of construction

activities, all possible care shall be exercised during construction, the following

procedures being required:

Wet sacking or rubber matting shall be placed on the pipe invert at areas where

welding or flame cutting operations are in progress to prevent damage to

coating from weld spatter or molten metal. This requirement shall be strictly

enforced.

Foam shall be provided for the placing of tools etc on the internal pipe surface.

Soft-soled shoes shall be worn by all personnel working inside the pipe.

ii) All damaged and blistered epoxy lining shall be removed back to sound epoxy

by mechanical grinding or other approved means.

iii) The exposed steel surface shall then be prepared in accordance with the

requirements of section A.2.b(ii) and 1.2.b(iii) of the clause.

3. Cleaning of Area to be Repaired

Grease and oil shall be removed with a non-volatile solvent (eg “Aquasolve”, “Arc Nr.261

Safety Solvent Cleaner” or similar approved). The surface shall then be cleaned with

potable water and allowed to dry completely. To this end adequate ventilation shall be

provided.

4. Methods to Repair to be Carried Out

a) Defects in epoxy coating detected by Holiday tests

i) The roughened area of lining and the defect shall then be repaired by the

application of a solvent free epoxy repair material (such as “Copon Hycote

151”, “Arc 982”, “Arc 855”, or similar approved) to a minimum dry thickness of

300 microns.

A “halo” of 1 to 2 mm of the abraded material shall be left uncovered around

the repair.

The patch material shall be of a different colour to the pipe lining material.

ii) In the application of the epoxy the following shall be strictly in compliance with

the manufacturer’s instructions:

Method of application (type of brush or roller.)

Over coating time

Temperature range for application

Mix proportions of activator to base. This shall be strictly enforced, and

splitting of manufacturer-supplied packs shall be allowed only if subsequent

bending is carried out strictly by mass to the correct proportions.


Scope of Work


Method of mixing base and activator.

Number of coats to achieve the specified thickness.

Safety aspects eg eye and hand protection, ventilation, fire precautions, etc.

iii) After the repair has been adequately cured, the repair and the surrounding

250 mm of epoxy lining shall be tested for electrical insulation defects. No

defects will be permitted.

b) Patch Repairs to Pipes Damaged by Construction Operations and Joint Repairs

(including Bends)

i) The roughened area of lining shall be repaired as described in B.4.a (i) above.

ii) The requirements of Clauses B.4.a (ii) and (iii) above shall then be complied

with.

c) Lining to scour and air valve tees, access openings, stubs and valve bypasses

i) The repair procedure shall be as described in B.4.a (i), (ii) and (iii) above.

The epoxy repair material shall be applied to overlap the existing sound

cement mortar lining by 25 mm at access openings, valve bypasses and

scour tees.

C. INTERNAL REPAIRS - CEMENT-MORTAR LINED PIPES

1. The internal surface of the bellmouth is to be power or hand wire brushed from the

pipe end to the cement mortar lining to remove dirt, scale, rust and other foreign

matter.

2. Any grease and oil shall be removed from the pipe surface with a non-volatile

solvent (e.g. “Aquasolve”, “Arc Nr 261 Safety Solvent Cleaner” or similar approved).

The surface shall then be cleaned with water and dried and a 50 mm wide x 20 mm

thick band of “Epidermix 338” or similar approved shall be applied internally on the

uncoated steel adjacent to the cement lining.

3. The plain end of the adjoining pipe shall be pushed into the bellmouth in such a way

that the Epidermix band is compressed and makes contact with the transverse face

of the concrete lining of both pipes. The excess lining material which is squeezed

into the pipe shall be removed by drawing a plug which is 5 mm smaller in diameter

than the bore of the pipe, across the joint. The plug shall be so shaped as to apply a

smooth even surface to the lining material at the joint.

a) Pipes larger than 500 mm diameter

4. The exposed steel surface shall be power or hand wire brushed to remove dirt,

scale, rust and other foreign matter. Burrs, weld spatter etc shall be filed away.


Scope of Work


5. Any grease and oil shall be removed from the pipe surface with a non-volatile

solvent (e.g. “Aquasolve”, “Arc Nr 261 Safety Solvent Cleaner” or similar approved),

flushed with potable water and completely dried.

6. The joint shall then be made good with “Epidermix 338” or similar approved, neatly

formed to meet the adjacent cement mortar.

7. The requirements of Clause C (a).4 shall similarly apply to pipes larger than 500 mm

diameter.

PSL.3.9.2.3.1 Making Good of Field Welded Joints, Repairs & Puddle Pipes (Clause 3.9.2.3.1)

Add new Sub-Clause:

This specification is based on “Denso” products. Alternative products may be accepted at the

discretion of the Employer’s Representative. Once welding is complete and all weld splatter

and burnt coatings have been removed, all welded pipe joints shall be prepared and wrapped

in the following manner:

Surface Preparation

The bare metal shall be cleaned and wire brushed to St.2 standard and, if necessary,

degreased with white spirit. The adjacent coating shall be cleaned to a minimum of 300mm

either side of the joint.

Primer

The pipe barrel at the joint shall be degreased with white spirit and primed with “Denso Primer

D” (or equal approved) extending 200mm onto sound coating. The primer shall cure for 30

minutes prior to the application of a tape system.

Profiling Tape

Apply 1,0mm x 75mm wide “Ultraflex sealing tape (yellow)” to the full circumference of the

weld bead and steel interfaces. Care shall be taken to ensure a smooth profile and to avoid air

bubbles being trapped beneath the tape. The tape shall not be stretched.

Tape System

Tape joint shall be wrapped with “Denso Ultraflex 1250/300 (Blue)” (or equal approved) (55%

overlap) extending 150mm onto sound coating. Even tension shall be applied throughout the

wrapping procedure and care shall be taken to prevent air bubbles from being trapped

beneath the tape.

Repairs

Damaged pipe coating shall be repaired in the same manner with the repair extending at least

150mm either side beyond the edge of the damaged coating. “Spot” tape repairs will not be

acceptable. Damage caused by the Contractor shall be repaired at the Contractor’s expense.


Scope of Work


Damage caused prior to the Contractor accepting responsibility for the pipes shall be repaired

under this contract.

Puddle Pipes

All puddle pipes shall be primed and wrapped in accordance with the above procedure. The

wrapping shall extend from (but shall not include) the puddle flange to 150mm beyond the

concrete surface.

Hot-Dip Galvanizing

Hot-dipped galvanizing shall be done in accordance with the requirements of SANS 763 –

1977, as amended. On site fabrication processes such as welding, drilling, threading, etc. are

to be avoided. All hot-dipped galvanized items shall be passivated immediately after hot

dipping.

PSL.3.9.6 Corrosion Protection to Buried Joints, Couplings and Flanges (Clause 3.9.6)

Delete the contents of the Sub-Clause and replace with the following:

All buried flanges and flexible joints shall, in addition to being epoxy/ thermoplastic powder/Rilsan

coated or fusion bonded epoxy coated, be protected as described below.

This specification is based on a “Denso” system. Alternative products will be subject to the

approval of the Employer’s Representative.

PSL.3.9.6.1 Surface Preparation (Clause 3.9.6.1)

The entire joint area and at least 500mm of pipe either side of the joint shall be cleaned of mud

and other deleterious matter.

PSL.3.9.6.2 Primer (Clause 3.9.6.2)

The cleaned joint and pipe shall be primed with “Denso Priming Solution”, or if moisture is

present, “Denso S105 Paste”. The priming shall extend to at least 400mm beyond either side of

the joint.

PSL.3.9.6.3 Mastic Blankets (Clause 3.9.6.3)

Narrow strips cut from “Denso Mastic Blankets” shall be applied to the joint to achieve a smooth

profile with a 50mm splayed fillet being formed at the joint/pipe interface. Care shall be taken,

particularly at bolts, to avoid the formation of air pockets. Complete “Denso mastic Blankets”

shall then be applied (mastic side down) to the joint until the joint is completely enveloped.

PSL.3.9.6.4 Denso Wrapping (Clause 3.9.6.4)

The ends of the blanket shall be bound to the barrel of the pipe on each end with 100mm wide

“Denso Petrolatum Tape”. “Denso Petrolatum Tape” overlaps shall be 50mm and shall extend


Scope of Work


100mm onto the blanket and 150mm onto the pipe barrel. All exposed bolts on flexible

couplings and flanges adaptors to be wrapped.

PSL 3.9.6.5 Polyethylene Wrapping (Clause 3.9.6.5)

The entire joint shall be wrapped with 350 micron polyethylene sheeting which shall end

400mm beyond the joint. The protective sheeting shall be secured to the pipe barrel and along

the seam with 48mm wide “Denso Adhesive Tape” or similar approved.

PSL.3.9.6.6 Spark Tests on Completed Wrapped Joints (New Sub-Clause) (Clause 3.9.6.6)

Spark tests shall be performed on each and every wrapped joint and the results shall form part

of the required Quality Control sheets. The tendered rates for the laying of the pipeline and the

preparation of Quality Control documentation shall be deemed to include for all spark tests

required.

PSL.3.9.7 Preparation and Cleaning of Pipe (Clause 3.9.7)

Add new Sub-Clause:

PSL.3.9.7.1 Preparation of Pipe (Clause 3.9.7.1)

The following specifies the applicable method for preparation of all exposed steel surfaces for

application of a repair for internal lining and/or external coating. This specification is applicable to

all pipe steel surfaces which have been stripped of its corrosion protection layer, internally or

externally, as a result of the manufacturing of specials, construction activities or pipe laying,

welding and/or damages caused by handling or latent defects in application.

The surfaces of all pipes and specials to be lined and coated, irrespective of the lining and

coating type used, shall be prepared in accordance with the following requirements:

a) All damaged and blistered lining and/ or coating caused by welding shall be removed back

to sound lining or coating by mechanical grinding or other approved means.

b) The exposed steel surface shall be power or hand wire brushed to remove dirt, scale, rust

and other foreign matter.

c) Weld splatter shall have been removed by chipping or grinding to a smooth surface flush

with the surrounding steel.

d) Weld seams shall have a smooth contour, free from sharp edges, protrusions and

undercuts.

e) Sharp edges and protrusions shall have been removed by grinding to a smooth radius of

curvature of not less than 3mm.

f) The surrounding sound coated surface shall be abraded beyond the defective area. The

abrasion shall be carried out with clean emery paper of profile without causing the removal

of excessive amounts of protective material.

g) All pipes for coating shall be in rust condition A to C of Swedish Standard SIS 05 5900.

Pipes in rust condition D will be rejected.


Scope of Work


PSL.3.9.8 Coating and Lining of Fabricated Steel Specials (Clause 3.9.8)

Add new Sub-Clause:

All fabricated bends and specials supplied under this contract shall be coated and lined with an

epoxy coating, thermoplastic powder coating or Rilsan coating for Steel Pipes and Specials.

The mating flange shall then receive one coat of rust inhibitor (Plascon Rustix 84 or equal

approved). The flange profiling shall be clearly visible and no runs or drips will be permitted.

Following the coating and installation of the pipe, the coating is to be free from all electrical

insulation defects.

PSL.3.9.8.1 Thickness of Coating (Clause 3.9.8.1)

The Target Thickness of lining and coating for pipes and pipe specials for solvent free epoxy

lining and coatings shall be 600 microns (minimum 500 microns and maximum thickness 800

microns), and shall be free from sags and runs. Maximum dry film thickness per coat of 125

microns to 250 microns should be achieved.

The Target Thickness of lining and coating for pipes and pipe specials for fusion bonded lining

and coatings shall be 400 microns (minimum 300 microns and maximum thickness 500

microns).

PSL.3.9.8.1.1 Corrosion Protection Coating and Linings for Steel Specials (Clause 3.9.8.1.1)

The following table lists the materials and corrosion protection system to be applied to various

components of the works:


Scope of Work


PSL.3.9.8.1.2 Solvent Free Epoxy and Lining (Clause 3.9.8.1.2)

The requirements for a solvent free epoxy coating system are identical to the requirements for

the solvent free epoxy lining system.

Pipes and fitting to be externally coated and internally lined with a two component cross linked

epoxy that complies with the requirements of SABS 1217.

The cure rate of liquid epoxy coating is very dependent upon temperature, the rate of cure

being very slow below 10ºC and the reaction generally ceased below 5ºC. Contractors

tendering for this type of coating are therefore expected to have a heated shop or warm air

blowers with suitable heat insulating tunnels to enable the temperature of the coating to be

maintained at not less than 15ºC from the time of application until full cure has taken place.

Adverse weather conditions will not be accepted as a reason for delay in the programme or

for solvent retention in multi-coat solvent borne systems.

The two components shall be thoroughly and completely mixed in the proportions specified by

the manufacturer. Application shall be two component hot airless equipment or by single

component airless equipment, as appropriate and as recommended by the material

manufacturer. The coating shall be applied in a uniform manner and, when cured, shall

comply with all the appropriate requirements of the specification.


Scope of Work


When mixing two part epoxies, the base and activator shall be mixed in accordance with the

manufacturer’s specifications.

Mixing in the original container will only be permitted by means of methods that ensure full

integration of different parts of the compound into a homogeneous compound with the

characteristics as intended by the manufacturer.

The different parts of the compound shall not be diluted.

Mixing shall only be allowed with full batches and reduction of volumes from mixing packs by

means of weight or volume measurement, which will result in smaller portions to be mixed, will

not be allowed.

In the application of the epoxy the following shall be strictly in compliance with the

manufacturer's instructions:

Method of application (Type of Brush or roller.)

Over coating time.

Temperature range for application.

Method of mixing base and activator.

Number of coats to achieve the specified thickness.

Safety aspects e.g. Eye and hand protection, ventilation, fire precautions, etc.

Note that roller and brush applicators shall be replaced once the product application

expiry time has been reached on any specific applicator tool.

Only solvent free Epoxy repair kits shall be utilized to repair the internal linings of the pipe line.

The specified thickness shall be achieved in one application for solvent free epoxies. In the

event of the thickness being less than the minimum specified the coating shall be removed

and the pipe length shall be re-blasted and re-coated to comply with the specification.

The Contractor’s tendered rates for the laying of the pipe and fabrication of specials shall be

deemed to include for all the Two Part Epoxy repairs that have to be applied in order to deliver

a serviceable and acceptable pipe line.

PSL.3.9.8.3 Thermoplastic Powder Coating and Lining (Clause 3.9.8.3)

A thermoplastic powder coating and lining is to be used such as “Plascoat PPA 571 Aqua”. The

requirements for the “Plascoat PPA 571 Aqua” thermoplastic powder coating system are

identical to the requirements for the thermoplastic powder lining system.

The preferred means of application of the coating and lining is by either Electrostatic Spray (ES)

or Fluidised Bed Coating (FB) and Flame Spraying (FLS) to be used for field repairs.

Where pipe specials fitted with flanges are to be coated with “Plascoat PPA 571 Aqua” special

methods shall be utilized to ensure that “Plascoat PPA 571 Aqua” is not applied to the flange

face. Under no circumstances shall scraping or grinding of “Plascoat PPA 571 Aqua” on flange

faces be allowed.


Scope of Work


PSL.3.9.8.4 Rilsan Coating and Lining (Clause 3.9.8.4)

The requirements for the “Rilsan” or similar approved fusion bonded powder system are

identical to the requirements for the “Rilsan” lining system. The surface preparation of the

substrate, the application and curing of the product shall be in terms of the supplier’s

specifications and recommendations.

Where pipe specials fitted with flanges are to be coated with Rilsan, special methods shall be

utilized to ensure that Rilsan is not applied to the flange face. Under no circumstances shall

scraping or grinding of Rilsan on flange faces be allowed.

Repair work to Rilsan coated pipes and pipe specials shall be limited to the absolute minimum.

Should Rilsan be affected by welding which in turn requires repairs to be effected, the Rilsan

shall be removed by grinding up to a point where the Rilsan coating is sound and adheres to

the pipe material without traces of disbonding, spalling or flaking.

The 25mm edge of Rilsan, onto which repair epoxy is to be applied, will be abraded with 80 or

100 grit emery paper to ensure adhesion of repair epoxy in the area. The bare metal, where

repair epoxy has to be applied shall be grit blasted to render a surface finish of St2 before the

application of the epoxy.

All steel pipes of nominal bore up to and including DN300, to be used for the manufacture of

pipe specials and fittings, shall be coated and lined with Rilsan or similar approved.

PSL.3.9.8.5 Protective UV Coating and Coating of Permanently Exposed Pipe (Clause 3.9.8.5)

All pipes and specials coated which are to be permanently exposed or above ground shall be

over-coated with three or more coats of “Carboline, Carbothane 134 Clear Coat” or similar

approved light coloured UV protection acrylic polyurethane resistant coating to a total minimum

dry film thickness of 100 microns for UV protection. The pipe surface shall be prepared and the

coating applied in strict accordance with the manufactures instructions or shall be protected

with the “Denso Acrylic Pipeline Tape (Steelcoat 500)” system or similar approved UV Resistant

coating. The pipe surface shall be prepared and the coating applied in strict accordance with

the manufacturer’s instructions.

PSL.4 Plant (Clause 4)

PSL.4.1 Handling and Rigging (Clause 4.1)

Add the following to L4.1:

The Contractor shall supply, operate and maintain an adequate fleet of vehicles including cranes

to be used for the safe conveyance of the pipes, specials and fittings. The pipes and specials

shall be handled with care at all times to avoid damage to them or to the protective coatings. The

equipment for the purpose of loading, transporting, unloading and moving and the manner in

which they are handled shall be subject to the approval of the Engineer.


Scope of Work


During transport, the pipes and specials shall be supported on suitable pipe saddles such that all

pipes and specials shall be separated so as not to bear against each other and shall be handled

with care at all times to avoid damage to them or to the protective coatings. The equipment for

the purpose of loading, transporting, unloading and moving and the manner in which they are

handled shall be subject to the approval of the Engineer.

The use of bare cables, chains, hooks or narrow skids will not be permitted and the

Contractor shall supply canvas slings and padded skids and ramps of a sufficient width to prevent

damage to the protective coating. The dragging or skidding of pipes and specials in contact with

the ground shall not be permitted.

When handling 12m pipe lengths the pipes shall be lifted with band slings (minimum 300 mm

wide) placed centrally around pipe at two points 6 metres apart.

PSL.5 Construction (Clause 5)

PSL.5.1 Laying (Clause 5.1)

PSL.5.1.1 General (Clause 5.1.1)

Add the following to L5.1.1:

It is of paramount importance that the right type and class of pipe be laid as shown on the

longitudinal sections. Invert levels shown on the drawings are the levels of the interior surface of

the pipes at the lowest point of cross section. However, levels at vertical curves shall be

determined when the exact location of pipe joints within the influence of the curve is known.

Pipes and specials shall be lowered gently and carefully into the trench without jarring or

bumping by crane, derrick or other approved lifting tackle and care shall be taken not to damage

the pipe or its sheathing. Pipes and specials with soft sheathing shall be supported in stout wide

canvas slings and no wooden blocks shall be used to support such pipes, either on the side or in

the trench. Any supports required shall be formed with fine sand gravel.

The Contractor shall ensure that all pipe barrels are evenly supported over the whole of their

length and that no weight is taken by the joints. The trench bottom, shall, where necessary, be

accurately trimmed by hand and each pipe shall be firmly bedded down before backfilling is

commenced.

The Contractor's special attention is drawn to the requirements for work in confined spaces and

for shoring of trenches.

It is noted that a through flow of air is required when work is to be carried out inside the pipeline.

The necessary electrical equipment and fittings must be provided to produce this airflow. An Item

in the Schedule of Quantities has been provided for complying with these requirements.

PSL.5.1.2 Damage (Clause 5.1.2)



Scope of Work


Inspection at the Laying Site

All pipes, specials, valves and fittings shall be carefully examined by the Contractor for internal

and external damage at the following stages:

a) on arrival at laying site;

b) prior to laying;

c) after laying;

d) prior to backfilling; and

e) during backfilling.

All damage or defects of any kind shall be repaired by the Contractor in accordance with Clause

3.9.2.3 and to the satisfaction of the Engineer immediately after detection at any of the above

inspections. Where, in the opinion of the Engineer, satisfactory repairs are practicable, the

damaged materials shall be replaced by the Contractor at his own cost.

PSL.5.1.3 Keeping Pipelines Clean (Clause 5.1.3)


Exposed ends of the pipe in the trench shall be tightly closed by a suitable mild steel end cap at

all times when pipelaying is not in progress.

Add the following as L5.1.5:

Stacking of Pipes and Specials

Where a pipeyard is provided, all pipes and specials shall be neatly and methodically arranged

on the ground on delivery, as directed by the Engineer. They shall be segregated according to

diameters and working pressures and the various stacks shall be arranged and separated in such

a way that a pipe of any diameter and working pressure can be located from the stacked position

for transportation to its laying position without necessity of moving other pipes.

PSL.5.2 Jointing Methods (Clause 5.2)

PSL.5.2.2 Flanges (Steel Pipelines) (Clause 5.2.2)


Flanges to fittings or joints will generally be to SABS 1123. It is possible, however, that the

Employer may supply valves with flanges which have not been drilled according to these

standards. The Contractor shall be responsible for checking the flange drilling of all fittings

supplied by the Employer and for supplying flanges drilled to match. No additional payment is to

be made for this work and the Contractor is to allow for such in his rates.

Contractors are to note that generally matching flanges or jointing material to gate and butterfly

valves will be supplied by the Employer.


Scope of Work


Contractors are to allow in the rates for the supply and installation of mild steel pressed washers

(two per bolt) for all flanged fittings. The washers shall have an ID of 2 mm greater than that of

the bolt. Tenderers are to ensure that the length of the bolt includes allowance for the washers.

All bolts, nuts and washers used are to be electro galvanised and yellow passivated.

PSL.5.2.3 Welding (Steel Pipelines of Diameter 200 mm or greater) (Clause 5.2.3)


Welding Procedures

Prior to the commencement of field welding, welding procedures shall be established and

approved by the Engineer and thereafter such welding procedures shall be adhered to during

subsequent construction and shall not be altered unless specifically authorised by the Engineer.

Tenderers shall, if required by the Engineer, provide a detailed description of all aspects of the

welding technique to be employed both in jointing pipes in assemblies above trench level and in

executing in-situ welds whether above or below ground level. The information required shall

include a drawing of the prepared end for sleeve or butt-welding of flanges and pipes and shall

describe the backing rings which must be removed. Records shall be kept by the Contractor to

enable each weld to be subsequently identified with the welder concerned.

Procedure Qualification Tests

Before the Contractor commences routine field welding the procedure tests laid down in API

1104 clause 1.4 shall be carried out.

The minimum number of root bead welds, the minimum number of second bead welders and the

type of clamp used (internal or external) shall be given in the description of the welding technique

as specified above.

The Contractor shall maintain a record of all welders employed on the works giving particulars of

each individual welder’s qualification tests carried out in terms of API 1104, the cost of which

shall be borne by the Contractor. Qualification testing of welders shall be conducted in the

presence of the Engineer or his representative.

Before a welder is employed on tack or root welds, he shall carry out a test tack and root weld on

a pipe of the same materials and under conditions as close as possible to those experienced on

the actual pipeline.

If icicles are present in the bore of the pipes or the weld metal projects more than 5 mm the

welder shall not be permitted to undertake tack or root welding. The completed test weld pieces

shall be visually examined and then radiographed. Should the weld appear sound it shall be

subjected to approved root and face bend tests. Test pieces shall be retained by the Contractor

and marked so that they can be identified with the welder carrying out the test.


Scope of Work


Weather

Field welding shall not be performed when the surfaces to be welded are wet or during periods of

high wind unless the operator and the work are properly protected and sheltered in an approved

manner.

Preparation of Joint

Where scarf cutting of the pipe ends is required in the field the pipe ends shall be prepared by

machining or machine flame cutting. Hand flame cutting shall not be permitted except under the

following circumstances;

Field Welding

Steel pipes may be cut by hand flame as follows:

a) In the case of cement lined steel pipe, the cement lining shall be chipped back 50 mm after

the initial cut and the pipe then re-cut ±10 mm from the original cut in order to remove any

"blow-back".

b) In the case of epoxy lined steel pipe, all damaged lining shall be removed and reinstated in

compliance with the Clause 3.9.2.3.

c) All flame cuts shall be made good by grinding to form the correct gap between steel

sections prior to welding.

d) Bevels may be cut by flame provided they are made good by grinding.

When jointing pieces by butt-welding the number of tack welds applied shall be kept to a

minimum to be effective in holding the pipe ends securely and to maintain the required root gap

prior to welding, but shall in any case be not less than four.

Double ending of pipework shall not be allowed on 12m pipe lengths.

PSL.5.3 Setting of Valves, Specials and Fittings (Clause 5.3)

Add the following to L5.3:

Valves and fittings shall be installed in accordance with the manufacturer’s instructions. Where

valves are supplied by the Employer at Municipal depots they shall be collected by the Contractor

at such depots and transported to the laying site. Valves shall be enclosed in chambers in

accordance with the drawings and specifications and shall be installed with their operating

spindles vertical. The Contractor shall supply the insertions and bolts necessary for the

installation of the valves.

Jet dispersers shall be of the cone and splitter type cast in iron or steel with heavy zinc

galvanising, to the Engineer’s approval. Flanges and bolts shall be sealed in mastic after

installation.

All air valves shall be set level.


Scope of Work


All scour valves shall be installed in such a way that the spindle is vertical.

The Storage, Commissioning and Installation of Butterfly Valves

Butterfly valves shall be stored, installed and commissioned so that the valve blade seal is

protected at all times from oxidation, ozone attack and the ingress of dirt.

Storage

i) It is preferable that the valve is stored in the vertical position.

ii) The valve should be stored in the cracked position (i.e. not shut).

iii) The valve should not be stored in the vicinity of electrical equipment.

iv) The valve should be stored under cover and protected from temperature extremes.

Installation and Commissioning

i) Prior to the installation of the valve, all dust and dirt should be washed off the valve,

particularly the seal, seat and any tapped holes in the valve body.

ii) The seals of all valves shall be checked for complete closure when the valve blade is in the

fully closed position. (See seal adjustment below).

iii) The valve must not be lifted by the hand lever, valve actuator or the handwheel.

iv) The valve must not be used for lining up the pipework.

v) The valve should be left in the fully open position after installation and prior to

commissioning of the system.

Seal Adjustment

To adjust the seal, a 0,004" feeler gauge and an Allen key are required.

With the valve in the fully closed position, it should be possible only with difficulty to introduce the

feeler gauge between the valve blade seal and the seat.

If, due to seal movement during storage the feeler gauge can easily pass between the seal and

seat, then the clamp ring socket head cap screws in the vicinity of the gap should be finger

tightened with the Allen key so as to push the seal out and close the gap.

Payment

All costs incurred for the seal adjustment as stipulated above shall be included in the respective

rates for installation of the valves.


Scope of Work


PSL.6 Tolerances (Clause 6)

Add the following to L 6:

The tolerances for the line and level of pipelines shall be as follows:

Positions of bends: within 150 mm of the locations shown on the drawings or as agreed

with the Engineer;

Level of pipe invert: within 25 mm of the level shown on the drawings;

Location of pipe centre in plan; within 25 mm of the location shown on the drawings

through the sleeves and culverts and elsewhere within 75 mm of position shown on the

drawings.

PSL.7 Testing (Clause 7)

PSL.7.1 General (Clause 7.1)

Add the following to L 7.1:

Inspection

Facilities shall be provided to the Engineer so that he may be able to inspect, during the process

of welding, any layer of weld metal. He may require any defective welds either to be cut out and

rewelded or repaired at his discretion. The Contractor shall clean thoroughly all welds prior to

inspection. The Engineer may require a number of completed joints, selected at random, to be

cut for mechanical tests or to be selected for visual inspection, micro examination or examination

by other means. When the Engineer orders the Contractor in writing to cut out and test joints the

Contractor shall be paid for such work at day work rates.

If as a result of inspection and testing, the work of any welder is found to be unsatisfactory, the

welder shall not be permitted to continue welding under this contract.

Standards of Acceptability

The completed welds shall comply with the requirements of clause 6.0 of API 1104. Work on

which unauthorised repairs have been carried out may be rejected.

Repairs to Minor Faults

Faulty welds shall be rectified in accordance with clause 7.0 of API 1104.

All costs relative to the repair of faulty joints, including removal and replacement of the backfill

and making good the wrapping and lining shall be borne by the Contractor.

PSL.7.2 Initial Tests on Welded Steel Pipes (Clause 7.2)


Scope of Work


PSL.7.2.1 Dye-Penetrant Test (Clause 7.2.1)

Add the following to L 7.2.1:

All fillet welds shall be dye penetrant tested. Any reduction in the percentage of welds to be

tested shall be at the sole discretion of the Engineer.

PSL.7.2.2 Radiographic Examination (Clause 7.2.2)


All butt welds shall be radiographically tested. Any reduction in the percentage of welds to be

tested shall be at the sole discretion of the Engineer.

PSL.7.3 Standard Hydraulic Pipe Test (Clause 7.3)

PSL.7.3.1 Test Pressure and Time of Test (Clause 7.3.1)

Replace L 7.3.1.1, 7.3.1.2, 7.3.1.3 and 7.3.1.4 with the following:

Static Test

When the pipeline is filled with water, all scours and hydrants shall be opened fully for one minute

or until the water emerges clean.

Pressure Test

A suitable pump shall be connected to the pipeline at a mutually agreed point.

The pressure in the pipeline under test shall be raised slowly by means of the pump and

measured by a pressure gauge connected to the pipeline.

The required test pressure for all steel pipework shall be 1600 kPA and for Class 16 mPVC

pipeworks it shall be 1600 KPa measured at the lowest point of the pipeline(s)

The hydraulic testing of the pipelines is to be carried out in two stages:

a) The pressure test as described above is to be carried out with the pipeline fully blanked

and all valves in the open position. All costs relating to this work inclusive of scouring,

supplying and install blank flanges, spade pieces etc are to be included in the rate for

testing. The minimum duration of this test will be 8 hours and 2 hours on non-steel

pipelines.

On successful completion of the pressure test as per (a) above, the Contractor is to remove all

temporary blank flanges, spade pieces, etc. and pressurize the line to maximum working

pressure against closed valves. Should any valve not be drop tight at this pressure the

Contractor is to advise the Engineer in writing of all defects encountered. The duration of this

test shall be 2 hours. (An item has been allowed for this work in the Schedule of Quantities).


Scope of Work


All tests shall be carried out in the presence of the Engineer at such times and in such manner as

he may direct.

The hydraulic testing of pipelines against closed valves shall not be allowed and provision shall

therefore be made by the Contractor for the supply of all necessary bull-noses and blank flanges.

Water for testing shall be made available free of charge in the first instance but for the

subsequent tests shall be charged to the Contractor's account.

A water connection will be provided by eThekwini Water for filling the pipeline for testing

purposes.

The Contractor shall, at his own cost, provide a suitable means of conveying water from this

connection to the mains to be tested, as well as a connection on the new pipeline in order that it

may be filled. This connection shall be capped or removed to the satisfaction of the Engineer

upon completion of the hydraulic test. Payment of this shall be allowed for under the rates for the

hydraulic testing of the pipeline.

After the entire piping system has been laid and all parts thereof have been tested to the

satisfaction of the Engineers or the Engineers Representative and backfilled, the pipe system will

be put into operation and the Contractor shall inspect and commission the same in the presence

of the Engineer/his representative, to ensure that all valves and other equipment are operating

satisfactory and to check that all pipe supports , brackets and the like are capable of

withstanding the loads imposed on them.

Any faults or defects which are detected during this inspection shall be repaired by the

Contractor, or where necessary, the defective parts or materials shall be replaced by the

Contractor, to the satisfaction of the Engineer, all at the Contractors expense.

All items of equipment not specifically mentioned in the Specifications, shall be inspected during

the commissioning period for proper operation and to verify that these items comply with the

requirements of the Specification.

PSL.7.4 Tests on Epoxy Coatings (Clause 7.4)

Add the following to L 7.4:

a) Wet sponge test of SFE lining.

The Employer on submission of the originals of the test results and respective invoices to

the Engineer will reimburse the Contractor for the cost of all successful tests.

Holiday testing of the tape wrapping and epoxy coating of the pipeline shall be carried out

on site by the Contractor. However, at the Engineer's discretion, quotations may be called

for holiday testing of the epoxy coating of the pipeline for quality assurance purposes, from

a reputable non-destructive testing firm. The rate submitted shall be per linear metre.

i) Notwithstanding the requirements of any other specification contained in or referred

to in this document, the holiday testing of the epoxy coating shall be performed with


Scope of Work


the apparatus set at 10 000V for FBMDPE coating and 3500V for FBE and SFE

coating.

ii) The holiday testing of the tape wrap system shall be performed with the apparatus

set at 3 500V.

The non-destructive testing firm approved by the Engineer shall be a nominated sub-contractor to

the main Contractor.

It shall be the responsibility of the Contractor to ensure that all test points along the pipeline are

individually referenced and that this reference be reflected on the reports. Each test point (e.g.

pipeline joints, butt joints in pipe specials, etc.) shall be indelibly marked on the pipe and cross-

referenced to the pipeline chainage.

A DCVG survey will be carried out by the Employer after the issue of the Completion Certificate

and the Contractor will be required to repair all defects discovered by the survey at his own cost.

The cost shall include excavation, repair materials, bedding, backfill and reinstatement to the

satisfaction of the Engineer.

The Contractor shall ensure that the full length of the pipe to be placed in the trench is patched

and holiday-tested prior to the pipe being laid in the trench. Holiday testing of the joints in the

trench shall be carried out on completion of the welding and the required non-destructive testing

by the Contractor.

PSL.8 Measurement and Payment (Clause 8)

PSL.8.2 Scheduled Items (Clause 8.2)

PSL.8.2.1 Supply, Lay and Bed Pipes Complete with Couplings (Clause 8.2.1)


(i) taking delivery of the pipe at the Municipal depot, provision of craneage.

(ii) transporting and lowering pipes into trench, cutting to closures and preparing ends for

jointing, laying true to line and level on prepared trench bed and jointing, including the

supply of joint sleeves where required;

(iii) bonding mechanical joints for electrical continuity;

(iv) completing both internal and external protection at joints and making good any damage to

sheathing or lining, which has occurred after acceptance at the

(v) pipeyard; and

(vi) all other operations necessary to complete laying not separately scheduled.


Scope of Work


PSL.8.2.2 Extra-over 8.2.1 for the Supplying, Laying, and Bedding of Specials Complete with

Couplings (Clause 8.2.2)


The Contractor will only receive payment for a scarfed bend if the pipe is cut to fabricate the scarf

bend.

PSL.8.2.3 Extra-over 8.2.1 for the Supplying, Fixing and Bedding of Valves (Clause 8.2.3)


The unit rate for the installation of scour and air valves when supplied by the Employer shall

include for taking delivery of the valve at the Municipal depot, provision of craneage, transporting

to site and installing the valve as specified and shall allow for the supply of all nuts, bolts and

gaskets as required.

PSL.8.2.11 Anchor blocks/Thrust blocks and pedestals (Clause 8.2.11)

INSERT "concrete" BEFORE "and" IN THE LAST LINE OF THE LAST PARAGRAPH.

Add the following:

"The tendered rates shall also include the wrapping of uPVC pipes and fittings with Densopol 80

or a similar approved material where the pipes and fittings come into contact with concrete."

PSL.8.2.16 Pipeline Marker Posts (Clause 8.2.16)

Payment shall be per cost installed and shall include for the uplifting and transporting to site from

the Municipal depot, handling, excavation, installation, backfilling and painting.

PSL.8.2.17 Cathodic Protection (Clause 8.2.17)

Add the following:

UDI Engineering Services cc was appointed to design a permanent cathodic protection system

for the proposed buried steel pipelines at Adams Mission 5 Reservoir.

The site surveys was carried out on 06 June 2020.

Cathodic protection shall not be required for the short length (6m) of proposed buried steel

pipeline as it is not viable to protect a short length of pipeline.

However, a coating integrity survey shall be carried out during construction once the steel

pipeline is backfilled to ensure no coating defects.

Any coating defects identified must be repaired immediately and the coating integrity survey

redone to ensure ZERO coating defects.


Scope of Work


PSLB BEDDING (PIPES) - SABS 1200 LB

PSLB.3 Material (Clause 3)

PSLB.3.1 Selected Granular Material (Clause 3.1)

Selected granular material shall be regarded as clean river or any other granular, non- cohesive

material of an acceptable nature and a PI less than 6. Stones shall not be in excess of 20mm.

Selected granular material might occur in-situ, be imported or selected from trench excavation

PSLB.3.1.1 Bedding and selected fill material shall be obtained from trench excavation or other necessary

excavations. The Engineer reserves the right to designate alternative sources should the need

arise.

PSLB.3.1.2 Furthermore, bedding material not available from trench excavation, shall be obtained from a

commercial source designated by the Contractor

PSLB.3.2 Selected Fill Material (Clause 3.2)

Selected fill material shall be material that has a PI less than 10 and does not contain vegetation

or stones exceeding 20mm. Selected fill material might occur in-situ, be imported or selected

from trench excavations.

PSLB.3.3 Bedding (Clause 3.3)

PSLB.3.3.1 Rigid Pipes (Clause 3.3.1)

All rigid pipes shall be laid on a class C bedding as shown on Drawing LB-1 of SABS 1200LB.

For the purposes of this contract, the following pipes shall be regarded as rigid:

FC-pipes, vitrified clay, precast concrete, galvanised steel and cast iron pipes.

PSLB.3.3.2 Flexible pipes (Clause 3.3.2)

uPVC, mPVC, GRP (glass reinforced plastic pipe) and polyethylene pipes will be regarded as

being flexible and shall be bedded as per Drawing LB-2 of SABS 1200 LB.

PSLB.3.4.2 Material not Available from Trench Excavation (Clause 3.4.2)

PSLB.3.4.2.1 Ordinary Backfilling (Clause 3.4.2.1)

Ordinary backfilling will consist of material less than 150mm in diameter, excavated and if so

approved by the Engineer, of material imported from other parts of the trench or borrowed

from adjacent to the trench on the downhill side. All material above the selected fill blanket

(drawing SABS LB-1) will be measured as ordinary backfill.


Scope of Work


PSLB.5.2.1 Class A Bedding (Clause 5.2.1)

Concrete to be used in Class A bedding to pipes shall be of grade 25/19.

PSLB.5.4 Concrete Casing to Pipes (Clause 5.4)

Concrete to be used in the casing of pipes shall be of grade 25/19. Pipes shall be encased at the

positions shown on the drawings. Concrete encasing of pipes shall be measured per cubic meter

of concrete irrespective of the size of the pipe in question. Otherwise Item 8.2.4 of 1200LB

remains unchanged.

PSLB.6 Tolerance on Compaction of Bedding Material (Clause 6)

Degree of accuracy II shall prevail.

PSLB.7 Disposal of Displaced Material (Clause 7)

Refer to Clause PSD3 in this regard.

PSLB.8 Overhaul (Clause 8)

Refer to Clause PSD7 in this regard.


Scope of Work


PSLD SEWERS - SABS 1200 D

PSLD.3.1 Pipe Material (Clause 3.1)

Sewers greater than or equal to 250mm nominal diameter shall be constructed with an approved

class 34 solid wall uPVC pipes, complete with coupling (Z-LOK) of diameter as shown on the

layout plans, as manufactured by Main Industries or similar approved.

Sewers less than 250mm nominal diameter shall be constructed with an approved class 34 uPVC

complete with coupling (Z-LOK) pipes of diameter as shown on the layout plans, as manufactured

by Main Industries or similar approved.

All river/channel crossing sewer pipes shall be constructed with an Epoxy coated galvanised steel

pipe complete with galvanised Viking Johnson couplings fully restrained, for diameter as shown on

the layout plans or similarly approved (refer to project specification PSL for Steel Grades, Corrosion

Protection and other relevant specifications).

PSLD.3.5.2 Manholes (Clause 3.5.2)

Manholes shall be constructed of precast concrete sections in accordance with SANS

1294:1981 and the details shown in Plan no. 0523.00.ZA.06D006 to 0523.00.ZA.06D010. Drop

manholes shall conform to the detail shown on Plan no. 0523.04.ZA.06D011 to

0523.04.ZA.06D012.

PSLD.3.6 Marker Posts (Clause 3.6)

End of all house and future connections shall be properly marked with 4mm dia. galvanized wire

tied to the end of the connection and extending to just below ground level. Tie and cast in a

concrete block 250 x 250 x 350 mm in accordance with the details shown in Plan no.

0752.04.ZA.06D020.

PSLD.5.2 Laying Of Pipes (Clause 5.2)

Pipe laying shall proceed in an upstream direction and shall commence in any particular section

of sewer as soon as possible after the excavation has been completed and the trench bottom

inspected and passed by the Engineer. The Contractor shall meet all costs of operations ordered

by the Engineer to remedy defect in the trench caused by lengthy exposure.

Immediately prior to laying, all pipes and fittings shall be carefully examined for cracks and flaws

and shall be lowered into the trench by such means as the Contractor finds most convenient, but

in such a way as not to damage them in any way. Any materials showing defects shall be

rejected and immediately removed from site.

Great care shall be taken to ensure that no soil, sand, stones or other material is allowed to enter

the pipelines, either during laying or subsequently. Suitable caps or plugs shall be provided at all

times to cover the open ends of the pipelines.


Scope of Work


All pipelaying and jointing shall only be carried out by experienced pipelayers who shall, when

requested, produce proof of their capabilities to the satisfaction of the Engineer.

The pipes shall be jointed in accordance with the manufacturer's recommendations and

specifications.

Should trenches be inundated by stormwater there is a risk of flotation of pipes, the Contractor

shall ensure that the trenches are not flooded and that pipes laid in the trench are backfilled as

soon as possible after laying, without disregard, however, of other requirements of this

specification. Should movement of the pipes occur, the Contractor shall remove the pipes from

the trench and thoroughly clean and relay the pipes. Any clay or soil adhering to the inside of the

pipes shall be carefully removed if necessary by scrubbing.

PSLD.5.3 Cleaning the System (Clause 5.3)

When all the sections of the work have been completed or when instructed by the Engineer, the

Contractor shall, at his own cost, remove all foreign matter from the inside of the pipelines and

manholes, leaving them entirely clear and with a smooth bore for unimpaired flow.

All debris must be removed from the system and disposed of as directed by the Engineer and on

no account will the Contractor be permitted to wash debris into downstream pipelines.

PSLD.5.4 Connections to Manholes (Clause 5.4)

In those manholes where sewers to be laid under this Contract will form junctions with future

sewers and in all terminal manholes, one length of piping of the appropriate diameter for each

future sewer or house connection, as the case may be shall be built into the manhole and

suitably orientated. Each such pipe shall be plugged with a stoneware or uPVC stopper sealed

with bitumen. Also all the necessary channelling shall be formed in the floor of the manhole.

PSLD.7.2.6 Watertightness of Manholes (Clause 7.2.6)

All manholes shall be inspected and checked by the Engineer so as to conform with the

Specification. After each manhole has been approved by the Engineer, he may order it to be

tested in the following manner:

All openings are to be closed with expanding plugs, whereafter the manhole is filled with water

up to a level 25mm below the underside of the roof slab.

The water level is to be maintained for not less than one hour or such longer period as may be

necessary to accurately record the rate of leakage. Measurements shall be recorded at frequent

and regular intervals of the variation in the level of the water in the manhole and of the quantity

of water added to that the rate of leakage can be established and this should not exceed one

litre per 5 minutes per metre of depth of manhole.

In the event of any weakness showing or if the manhole leaks excessively, the Engineer shall

order the test to be discontinued and the Contractor shall thereupon rectify such weakness or

defect in the manhole under test. The manhole third-tier shall be refilled with water and re-


Scope of Work


tested in the manner specified. This process shall be repeated until a satisfactory test is

obtained.

The Contractor will be paid for the hydraulic testing of manholes at the rate per manhole to be

quoted by him in the Schedule of Quantities. The Contractor's prices for the hydraulic testing of

manholes shall include for all arrangements of the supply of water for testing, for all work of

rectification, for re-testing and for all labour required to carry out the specified tests and for the

supply and use in testing manholes of all expanding plugs, standpipes, connections, hook and

other gauges, fittings and any other apparatus necessary.

PSLD.8.2.7 Measurement and Payment: Encasing Of Pipes in Concrete (Clause 8.2.7)

Payment for encasing of pipes in concrete will be measured per meter in lieu of per cubic meter

for various pipe diameters. The rate specified in sub-clause 8.2.7 of SABS 1200 LD is not

relevant to this contract.


Scope of Work


PSM ROADS (GENERAL) - SABS 1200 M

PSM.3 Sources of Material (Clause 3)

Materials for the road pavement layerwork (base and sub-base) shall be obtained from a

commercial source designated by the Contractor and approved by the Engineer.

The Engineer may designate alternative sources where required during the construction period.

No overhaul will be payable for materials obtained from commercial sources.

PSM.5.2.2.3 Cut To Spoil (Clause 5.2.2.3) (SABS 1200 DM, Clause 5.2.2.3(b))

Material unsuitable to be used in any part of the works shall be removed and spoiled at a

designated dumping site identified by the Contractor and approved by the Engineer in terms

of PSDM3, where the soil material shall be levelled off in layers not exceeding 200mm

watered down and subjected to the uniformly distributed haul traffic spoiling material.

Under no circumstances will it be allowed to form spoil heaps on the spoil site without the

written approval of the Engineer. Refer to Clause PSDM3 in this regard.

PSM.5.2.4.3 Spreading of Top Soil (Clause 5.2.4.3) (SABS 1200 DM, sub-clause 5.2.2.3(a))

150 mm Top soil shall be stripped over the full width of the road pavement area including the

areas reserved for kerbing and side drains, and be stockpiled and preserved for later use. The

thickness of the spread layer of topsoil shall be at least 75mm between the embankments

formed by the kerb and the fence line of the road reserve after re-spreading.

PSM.5.2.8.2 Overhaul (Clause 5.2.8.2) (SABS 1200 DM)

Refer to Clause PSD7 in this regard. No overhaul will be paid for the cut to spoil on site or at

the designated spoil area as established by the Contractor. No additional payment will be

made for any overhaul in this regard.


Scope of Work


PSME SUBBASE - SABS 1200 ME

PSME.3.2.1 Regional Factor (Clause 3.2.1)

A regional factor of 0.6 is applicable to the area of the Works.

PSME.3.5.1 Source of Subbase Material (Clause 3.5.1)

Refer to clause PSD5 and PSM1 in this regard.

PSME.5.4.1 Thickness of Layers (Clauses 5.4.1 and 6.1.4)

The thickness of the layers shall be as indicated on the Drawings.

PSME.5.7.2 Transport - Overhaul (Clause 5.7.2)

For sub-base material obtained from commercial sources, no overhaul will be applicable to this

payment item and must be included in the overall rate tendered for same.

PSME.5 Testing (Clause 5)

The Contractor shall ensure process control is executed strictly in accordance with the

requirements of the Standardised Specification and that the results are made timeously available

to the Engineer.

PSME.6 Process Subbase Material by Stabilisation (Clause 6)

Additional payment will be made in accordance with subclause 8.3.5 of SABS 1200ME for

stabilising the subbase material where required by the Engineer or shown on the drawings. The

tendered rates for chemical stabilisation shall be paid as an extra over to the rates tendered for

constructing the unstabilised layers. The tendered rates shall therefore include full compensation

for spreading and mixing the stabilising agent, curing the stabilised sections, any extra water

required, and all materials, supervision, labour, plant, equipment, tools and incidentals (extra over

those provided for in the rates tendered for constructing the unstabilised layer) necessary for

completing the specified work, but excluding the cost of supplying the stabilising agent.


Scope of Work


PSMJ SEGMENTED PAVING - SABS 1200 MJ

PSMJ.3.1.2 Class (Clause 3.1.2)

Class 35 blocks are required. Type A, S-A blocks as shown in Figure 17 of UTG2 shall be used.

PSMJ.3 Degree of Accuracy (Clause 3)

Paving shall be constructed to a degree of accuracy I.

PSMJ.5.4 Laying of Units (Clause 5.4)

Units will be laid in the herringbone pattern.


Scope of Work


PSMK KERBING AND CHANNELLING - SABS 1200 MK

PSMK.1 Cast In-Situ Kerbing (Clause 1)

Cast in-situ mountable kerbing type 1 will be placed on top of the finished subbase as shown on

detail. Cast in-situ mountable kerbing type 2 shall be placed on the uppermost pavement layer

after application and curing of the prime. Dimensions are shown on the Drawings. The kerb shall

be adequate protected during the surfacing operation.

PSMK.4.1 Equipment for Machine Placing (Clause 4.1)

Kerb placing machines shall be subject to prior approval by the Engineer. Should a specific

machine fail to obtain the required compaction, tolerances or surface finish the Engineer may

order such machine to be removed from the Site.

PSMK.3.7 Mix Design for Extruded Kerbing (Clause 3.7)

The particular mix design proposed for use in kerbing shall be subject to the approval of the

Engineer.

PSMK.7.2 Testing of Extended Kerbing (Clause 7.2)

Generally transverse strength tests will be required and the requirements for these will be strictly

imposed. The Engineer may order cores drilled and tested should he consider these necessary.

PSMK.5.6 Soilcrete Lining (Clause 5.6)

Soilcrete shall be manufactured as described in clause PSLE4 (New Clause). Soilcrete lining

shall be cast to dimensions, lines, levels and falls shown on the drawings. Soilcrete lining shall

be cast continuously and no jointing will be required. Exposed surfaces shall be given a

woodflow at surface finish and the soilcrete shall be cured as specified in SABS 1200G.


Scope of Work


PSMM ANCILLARY ROADWORKS - SABS 1200 MM

PSMM.1 Scope of the Works: Road Markings (Clause 1)

The intersection shall receive road markings as indicated on the drawings. Typical markings at

these intersections are shown on the specification drawings.

PSMM.4.2.1 Mechanical Equipment for Road Markings (Clause 4.2.1)

The mechanical road-painting machine shall be provided with clearly visible amber warning

flashing lights which shall always be in operation when the machine is on the road.

PSMM.8.3 Scheduled Items for Permanent Road Signs (Clause 8.3)

Road signs will be measured per number which price shall include for signs manufactured from

sheet steel, painting of background, symbols, characters, etc., retro-reflective materials where

applicable, painted sign supports, all bolts, nuts and washers, excavation, backfilling and

concreting, all as specified and detailed, complete.

Cathodic Protection and AC Mitigation Technical Specification – EWS

Revision: 10 Cover Page 22 April 2016

ETHEKWINI WATER AND SANITATION

TECHNICAL SUPPORT DEPARTMENT – DESIGN BRANCH

CATHODIC PROTECTION AND ALTERNATING CURRENT MITIGATION

TECHNICAL SPECIFICATION

Issued by: Prepared for:

E. MSWELI ETHEKWINI WATER AND SANITATION

HEAD: WATER AND SANITATION TECHNICAL SUPPORT

PRIOR ROAD PRIOR ROAD

DURBAN DURBAN

4001 4001

Tel: (031) 311-8600 Tel: (031 311-8745 Fax: (031) 311-8549 Fax: (031) 311-8549

mailto:[email protected]


Revision: 10 Page 1 of 177 22 April 2016

TABLE OF CONTENTS

1. GENERAL PREAMBLE ........................................................................................... 11

1.1. Scope ................................................................................................................... 11

1.2. Legal Requirements .............................................................................................. 12

1.3. Alternative Materials, Equipment and Work .......................................................... 12

1.4. Guarantee Period ................................................................................................. 13

1.5. Safety and Work Procedures ................................................................................ 14

1.6. Handling and Storage ........................................................................................... 16

1.7. CP Design Requirements ...................................................................................... 16

1.8. Qualified Staff ....................................................................................................... 17

1.8.1. CP Design Engineer ...................................................................................... 17

1.8.2. CP Engineer .................................................................................................. 17

1.8.3. AC Mitigation Engineer .................................................................................. 17

1.8.4. Senior CP Technician .................................................................................... 18

1.8.5. CP Field Technician ....................................................................................... 18

1.8.6. Pipe Coatings Inspector ................................................................................. 18

1.8.7. CP Field Assistant ......................................................................................... 18

1.8.8. Semi-skilled CP Hands (Labourer) ................................................................. 19

1.9. Quality Assurance ................................................................................................. 19

1.9.1. Contractor Qualification ................................................................................. 19

1.9.2. Quality Control ............................................................................................... 19

1.9.3. Quality Surveillance ....................................................................................... 20

2. RELEVANT SPECIFICATIONS ............................................................................... 21

2.1. American Society for the Testing Of Materials (ASTM) ......................................... 21

2.2. British Standards Institution (BS) Specifications .................................................... 21

2.3. International Electrotechnical Commission (IEC) Publications .............................. 21

2.4. National Association of Corrosion Engineers (NACE) ........................................... 22

2.5. South African National Standards (SANS) ............................................................ 23



3. GLOSSARY OF TERMS / DEFINITIONS ................................................................ 26

4. CABLING FOR CATHODIC PROTECTION ............................................................. 33

4.1. General Properties of Isolating Compounds .......................................................... 33

4.2. Cable and Cable Insulation Compliance ............................................................... 34

4.3. Cathodic Protection Cable Requirements ............................................................ 34

4.4. Cable Identification ............................................................................................... 36

4.5. Cable Weld Attachments....................................................................................... 36

4.5.1. General .......................................................................................................... 36

4.5.2. Surface Preparation ....................................................................................... 37

4.5.3. Exothermic Welding (Thermit Welding) .......................................................... 37

4.5.4. Stud Welding/Pin Brazing .............................................................................. 38

4.5.5. Testing ........................................................................................................... 39

4.5.6. Safety Precautions ......................................................................................... 39

4.6. Coating Make-Good .............................................................................................. 39

5. CONTINUITY AND CROSS BONDING ................................................................... 41

5.1. Cross bonding ....................................................................................................... 41

5.2. Continuity Bonding of Buried Joints ...................................................................... 42

5.3. Continuity Bonding of Buried/Below Grade Bolted Flanges (Alternative System) .. 42

5.4. Continuity Bonding Inside Valve Chambers .......................................................... 43

5.5. Continuity Bonding Outside Valve Chambers ........................................................ 43

6. TERMINAL BLOCKS ............................................................................................... 44

7. ELECTRICAL ISOLATION OF CATHODICALLY PROTECTED PIPELINES ........... 45

7.1. Isolating Flanges ................................................................................................... 46

7.2. Isolating Gasket .................................................................................................... 47

7.3. Isolating Bolt/Stud Sleeves ................................................................................... 48

7.4. Isolating Washers ................................................................................................. 48

7.5. Steel Washers ...................................................................................................... 49

7.6. Studs, Nuts And Bolts ........................................................................................... 49

7.7. Surge Protection ................................................................................................... 50

7.8. Identification and Protection of Isolating Flange .................................................... 50



7.8.1. Protection of IF Installations ........................................................................... 51

7.8.2. Wrapping of the IF Installation ....................................................................... 51

7.8.3. Visual Identification of IF Installations ............................................................ 52

7.9. Electrical Insulation Testing Of Isolating Flanges .................................................. 52

7.10. IF Installation Guidelines ................................................................................... 53

8. CATHODIC PROTECTION TEST STATIONS ......................................................... 54

8.1. Potential Criteria for Cathodic Protection .............................................................. 54

8.2. Locations .............................................................................................................. 54

8.3. Test Station Installation Options ............................................................................ 55

8.4. Types Of Test Stations ......................................................................................... 56

8.4.1. Pipe-to-soil Potential Monitoring Test Station (MTS) (Type A) ....................... 56

8.4.2. IR-Free Test Station (Type B) ........................................................................ 56

8.4.3. Cross Bonding Test Station (Type C) ............................................................. 57

8.4.4. CP Test Stations with Temporary CP ............................................................. 57

8.4.5. 4-Wire Current Span Test Station (Type E) .................................................... 58

8.4.6. Test Station with AC Mitigation Hardware (Type F) ........................................ 58

8.5. Coupons ............................................................................................................... 58

8.6. Stationary Reference Electrodes (SRE) ................................................................ 59

8.6.1. SRE Manufacture Specifications .................................................................... 60

9. ICCP ANODE GROUNDBEDS ................................................................................ 61

9.1. General Description .............................................................................................. 61

9.2. Groundbed Components ....................................................................................... 62

9.2.1. Watering System ........................................................................................... 62

9.2.2. Anode Cabling ............................................................................................... 62

9.2.3. Anode Junction Box ....................................................................................... 63

9.2.4. Anode Canisters ............................................................................................ 63

9.2.5. Cable Warning Tape ...................................................................................... 64

9.3. Anodes ................................................................................................................. 64

9.3.1. Mixed Metal Oxide Anodes (MMO) ................................................................ 64



9.3.2. Chemical and Performance Testing of Anodes .............................................. 65

9.3.3. Carbonaceous Backfill ................................................................................... 65

9.4. Groundbed Installation Types ............................................................................... 67

9.4.1. Shallow Horizontal Anode Ground Beds ........................................................ 67

9.4.2. Vertical Anode Ground Beds .......................................................................... 68

9.4.3. Vertical AGB Anode Installation ..................................................................... 68

10. SACRIFICIAL ANODES .......................................................................................... 70

10.1. Magnesium Anodes ........................................................................................... 70

10.2. Typical Installation Details ................................................................................. 71

10.3. Chemical and Performance Testing of Anodes .................................................. 72

11. TRANSFORMER RECTIFIER UNITS (TRUs) ......................................................... 73

11.1. Introduction ....................................................................................................... 73

11.2. Housing ............................................................................................................. 73

11.3. Power Supply .................................................................................................... 73

11.4. Control .............................................................................................................. 74

11.5. Test Switch Facility ............................................................................................ 74

11.6. Rectification ....................................................................................................... 75

11.7. Transformers and Chokes ................................................................................. 75

11.8. Instrumentation.................................................................................................. 76

11.8.1. Multifunction Digital Display ........................................................................ 76

11.8.2. Additional Displays ..................................................................................... 76

11.9. Alarm Indication ................................................................................................. 77

11.10. Testing Probes .................................................................................................. 77

11.11. Protection .......................................................................................................... 77

11.11.1. Surge Protection ........................................................................................ 77

11.11.2. Electrical Protection .................................................................................... 77

11.11.3. Radio Frequency Protection ....................................................................... 78

11.12. Smoothing ......................................................................................................... 78

11.13. Cabinets ............................................................................................................ 79



11.13.1. Powder Coating for Chassis Plates ............................................................ 79

11.13.2. Electronic PCB ........................................................................................... 79

11.14. Wiring ................................................................................................................ 79

11.15. Power Point ....................................................................................................... 81

11.16. Drawings ........................................................................................................... 81

11.17. Spares ............................................................................................................... 81

11.18. Labelling ............................................................................................................ 81

11.19. Inspection .......................................................................................................... 82

11.19.1. Pre Power-up Testing ................................................................................. 82

11.19.2. Power On Testing....................................................................................... 82

11.19.3. Constant Current Tests .............................................................................. 83

11.19.4. Constant Voltage Tests .............................................................................. 83

11.19.5. Constant Potential Tests ............................................................................ 83

11.20. Telemetry and Remote Monitoring..................................................................... 83

12. NATURAL DRAINAGE UNITS (NDUs) .................................................................... 85

12.1. General ............................................................................................................. 85

12.2. Surge Protection ................................................................................................ 86

12.3. Housing ............................................................................................................. 87

12.4. Powder Coating for Chassis Plates ................................................................... 87

13. FORCED DRAINAGE UNITS (FDUs) ...................................................................... 88

14. POWER FACTOR SWITCH MODE UNITS (SMUs) ................................................ 89

14.1. Scope ................................................................................................................ 89

14.2. Compliance ....................................................................................................... 89

14.3. Information to be Submitted by Tenderers ......................................................... 89

14.4. Operating and Maintenance Manuals ................................................................ 90

14.5. General Specification for SMU Enclosure Construction ..................................... 90

14.6. General Specification for Coating Systems ........................................................ 90

14.6.1. Enclosure Coating System ......................................................................... 90

14.6.2. Chassis Plates Coating System .................................................................. 91



14.7. Electronic PCB .................................................................................................. 91

14.8. General Specification for Electrical Wiring ......................................................... 91

14.9. Terminals .......................................................................................................... 93

14.10. Colour Coding and Labelling of Conductors, Equipment and Components ........ 93

14.11. Electrical Construction ....................................................................................... 94

14.11.1. General ...................................................................................................... 94

14.11.2. Test Switch Facility ..................................................................................... 94

14.11.3. Earthing /Grounding ................................................................................... 95

14.11.4. Auxiliary Power Socket Outlet .................................................................... 96

14.11.5. Output Control ............................................................................................ 96

14.11.6. Control Mode 1: Constant Output Current .................................................. 98

14.11.7. Control Mode 2: Constant Output Voltage .................................................. 98

14.11.8. Control Mode 3: Potential Control ............................................................... 98

14.11.9. Meters and Monitors ................................................................................... 98

14.11.10. Surge Protection ................................................................................... 100

14.11.11. Radio Frequency Protection .................................................................. 101

14.11.12. Component Layout and List .................................................................. 101

14.12. Inspection and Testing .................................................................................... 101

14.12.1. Pre Power-up Testing ............................................................................... 102

14.12.2. Power On Testing..................................................................................... 102

14.12.3. Constant Current Tests ............................................................................ 103

14.12.4. Constant Voltage Tests ............................................................................ 103

14.12.5. Constant Potential Tests .......................................................................... 103

14.13. Telemetry and Remote Monitoring Systems .................................................... 103

14.14. Documentation ................................................................................................ 104

14.15. Generic SMU Data Sheet and Electrical Circuit Diagram ................................. 104

15. STEEL CABINET ................................................................................................... 105

15.1. General Cabinet Construction ......................................................................... 105

15.2. Coating of Steel Cabinets ................................................................................ 107



15.2.1. Method No 1a: Wet Spray Coating ........................................................... 107

15.2.2. Method No 1b: Powder Coating ................................................................ 108

15.2.3. Method No.1c: Alternative Coating ........................................................... 108

16. CONSTRUCTION OF TEST POSTS, CONCRETE BUNKERS AND CONCRETE

ENCLOSURES ................................................................................................................. 109

16.1. Galvanized Steel Test Posts (TP) .................................................................... 109

16.2. Monitoring Test Posts ...................................................................................... 109

16.3. Large/ Mushroom Head Concrete Test Post .................................................... 110

16.4. Bonding Test Posts (BTP) ............................................................................... 110

16.5. Concrete Bunkers ............................................................................................ 110

16.6. Identification .................................................................................................... 112

16.7. Concrete Enclosure ......................................................................................... 112

17. TESTING AND MONITORING............................................................................... 114

17.1. Pipe-to-Soil Potential Logging ......................................................................... 114

17.2. Testing of Isolating Devices ............................................................................. 114

17.3. Digital Volt Meters and CP Analyser ................................................................ 114

17.4. Coating Performance Testing .......................................................................... 114

18. TEMPORARY CP .................................................................................................. 115

18.1. Temporary CP Criteria ..................................................................................... 115

18.2. Installation of Temporary Cathodic Protection ................................................. 115

18.2.1. Installation of Hi-Potential Magnesium Anodes for Temporary CP ............ 115

18.3. Installation of temporary ICCP systems ........................................................... 116

18.4. Temporary Cathodic Protection Monitoring Procedure .................................... 117

19. OPERATION AND MAINTENANCE MANUALS AND INSTALLATION DATA

PACKS ............................................................................................................................. 119

19.1. OMM Requirements ........................................................................................ 119

19.2. Installation Data Packs .................................................................................... 120

20. AC MITIGATION .................................................................................................... 122

20.1. Gradient Control Wires .................................................................................... 123

20.2. Valve Chamber Earth Mats.............................................................................. 123



20.3. Cable connections ........................................................................................... 124

20.4. Solid State Decoupling Device (SS - DCD) ...................................................... 124

20.4.1. Performance Specification for AC Mitigation Decoupling Device .............. 125

20.4.2. Performance Specification for Transient Voltage Protection Device ......... 126

20.4.3. Enclosure Construction ............................................................................ 126

20.4.4. Inspection and Testing ............................................................................. 126

20.5. Cathodic Protection Monitoring Points ............................................................. 127

20.6. Safe Working Procedures In Power Line Servitudes ....................................... 127

20.6.1. Appointment of Electrical Safety Officer (ESO) ......................................... 127

20.6.2. General Safe Working Procedures ........................................................... 128

20.6.3. Daily Measurements ................................................................................. 129

20.6.4. Temporary Earthing .................................................................................. 130

20.6.5. Bonding Of Isolating Flanges, Joints And Couplings ................................ 131

20.6.6. Precautions During Coating And Lowering-In Operations ......................... 131

20.6.7. Work Stoppage ........................................................................................ 131

20.6.8. Inspection And Testing And Of Pipeline A.C. Mitigation Components Prior To

Commissioning .......................................................................................................... 131

20.6.9. Long Term Maintenance Requirements Of Pipeline And Power Line A.C.

Mitigation Components .............................................................................................. 132

21. CATHODIC PROTECTION REMOTE MONITORING UNIT (CPRMU) .................. 133

21.1. CPRMU Packaging ......................................................................................... 133

21.2. CPRMU General Specification ........................................................................ 133

21.2.1. CPRMU Type 1 ........................................................................................ 133

21.2.2. CPRMU Type 2 ........................................................................................ 134

21.2.3. Data Processor ........................................................................................ 135

21.2.4. Display Unit .............................................................................................. 136

21.2.5. Communicator .......................................................................................... 136

21.2.6. Power Supply ........................................................................................... 136

21.2.7. Lightning Protection .................................................................................. 137



21.2.8. Documentation to Be Provided With the Tender ....................................... 137

21.2.9. Site Regulations ....................................................................................... 137

21.2.10. Installation ................................................................................................ 138

21.3. Typical CPRMU Variables ............................................................................... 139

21.4. Data Inputs ...................................................................................................... 139

21.5. Suggested Transducers .................................................................................. 140

21.6. Communication Options .................................................................................. 140

21.7. Channels ......................................................................................................... 140

21.7.1. CPRMU Type 1 ........................................................................................ 140

21.7.2. CPRMU Type 2 ........................................................................................ 141

21.8. Data Transfer, Storage and Management........................................................ 141

21.9. Maintenance, Servicing and Call Outs ............................................................. 142

21.9.1. Maintenance and Servicing ...................................................................... 142

21.9.2. Call Outs .................................................................................................. 143

21.10. CPRMU Guarantee and Defects Warranty ...................................................... 143

21.11. Vandalism ....................................................................................................... 144

21.12. Airtime Agreement ........................................................................................... 144

21.12.1. Direct with Cellular Service Provider......................................................... 144

21.12.2. Direct with Supplier / Distributor / Agent of CPRMU ................................. 144

21.12.3. Prepaid Data Card Option ........................................................................ 144

22. NAMING CONVENTION FOR EQUIPMENT AND MATERIALS ............................ 145

22.1. TRUs, SMUs, NDUs and FDUs ....................................................................... 145

22.2. Test Stations, Monitoring Points, Bunkers and Other Monitoring Facilities ...... 145

23. CONTRACTOR REQUIREMENTS ........................................................................ 147

23.1. Construction, Testing and Inspection ............................................................... 147

23.1.1. TRUs , SMUs, FDUs and NDUs ............................................................... 147

23.2. Work to be Supervised by a Qualified Representative ..................................... 148

23.3. Supplier to Submit Full Details ......................................................................... 148

23.4. Commissioning, As-Built Drawings and Records ............................................. 148



23.4.1. Commissioning ......................................................................................... 148

23.4.2. Drawings .................................................................................................. 148

23.4.3. Records .................................................................................................... 149

23.4.4. Spare Parts .............................................................................................. 149

23.5. Installation ....................................................................................................... 149

23.5.1. Supply / Installation Obligations ................................................................ 149

23.5.2. Guarantee of Equipment .......................................................................... 150

23.6. Operation and Maintenance of the CP System ................................................ 150

23.7. CP System Acceptance Criteria ...................................................................... 150

23.7.1. Operational Acceptance Period ................................................................ 150

23.7.2. Certificate of Completion .......................................................................... 151

24. ANNEXURES ........................................................................................................ 152

24.1. Annexure A: TRU/SMU/FDU/NDU Compliance Test Certificate ...................... 153

24.2. Annexure B: TRU/SMU/FDU/NDU Factory Acceptance Testing ...................... 163

24.3. Annexure C: Isolating Flange Guidelines ......................................................... 168

24.4. Annexure D: Drawing Register ........................................................................ 175



1. GENERAL PREAMBLE

1.1. Scope

This Specification defines the minimum and mandatory requirements governing the design,

application, installation and commissioning of both Sacrificial Anode Cathodic Protection

(SACP) and Impressed Current Cathodic Protection (ICCP) and AC mitigation (ACM) systems

for the following:

Pipelines, fire water and utility piping, as well as pipes located inside chambers;

Pipeline casings (cased crossings);

The internal surface of water storage tanks

Any buried or submerged steel structure

Unless otherwise agreed by the purchaser's Engineer in writing, the materials and

specifications used shall strictly follow the clauses of this specification.

The requirements of this specification may not necessarily be repeated in the bill of quantities

or typical drawings issued. Thus this specification must be strictly adhered to.

The “Client” shall refer to the asset owner’s Corrosion Engineer or his designated

representative.

The “Engineer” shall refer to the CP design engineer or his designated representative.

The “Contractor” shall refer to the supply and/or installation contractor.

The “Corrosion Engineer” be appointed by The Client and shall have discretion and

authority in the following:

Agreeing corrosion protection system and specification

Approval of Protection System and procedures

Specific Materials for both corrosion protection and materials of construction

Quality Control systems

Approval of qualifications

In the event of any detail that is not fully addressed in this specification and that is warranted

to be carried out by The Contractor, the work shall be performed in accordance with the

relevant applicable codes and best recognised engineering practices in the cathodic protection

(CP/Corrosion) industry. The Consultant shall develop detailed specifications, procedures and

method statements required to perform the CP design and/or corrosion engineering during



The Engineering phase of work and this shall be submitted to The Client for review and

approval prior to construction, supply and/or installation work by an appointed Contractor.

AC interference mitigation may be achieved through the use of pipeline-earth grounding

systems, in conjunction with solid state DC decoupling devices. It must not adversely affect or

interfere with the CP system, or others.

The details and extent of the plant or structure equipment required to be cathodically

protected, the site / locality and the meteorological data shall be both specified and supplied

by The Client.

1.2. Legal Requirements

All works shall be conducted in compliance with the relevant sections of the OHS Act. The

Consultant / Contractor is responsible for ensuring that all personnel are equipped with

appropriate PPE.

All materials, plant and equipment shall be the best of their respective kinds and spare parts,

replacements and servicing facilities shall be readily available from local sources.

The following sections represent general specifications that shall be adhered to. Specific sizes

and descriptions are detailed in the Bill of Quantities.

All work shall be carried out by qualified personnel and correctly supervised.

The Contractor shall be required to backfill and compact all excavations and ensure that all

waste products and materials are removed from site and safely disposed of. All civil works are

to be accepted/rejected by an approved competent civil professional.

Should any requirement of the project specification conflict with any requirements of the

standardised or particular specifications listed in the list of specifications, the requirement of

the project specification shall prevail.

1.3. Alternative Materials, Equipment and Work

If alternatives pertaining to materials, equipment and work method are submitted, the Supplier

/ Contractor shall supply with their quotation/proposal all detailed specifications, designs,

calculations, drawings and a fully priced Bill of Quantities as per the original quotation and/or

any alterations and any further information that may be required by The Client for the proper

evaluation of the offer.



The attention of the Supplier / Contractor is particularly drawn to the high standard of materials,

workmanship, testing and performance applicable to the Contract as a whole.

The Client reserves the right to carry out a factory inspection at their discretion.

Should any requirement or provision of the Project Specification conflict with any requirement

of any standardized (SANS 1200) specifications or any drawings, the order of precedence,

unless otherwise specified, are:

Project Specification

Drawings

SANS 1200

Bill of Quantities

Any discrepancies will be brought to the attention of the Corrosion Engineer or designated

representative.

When all tests have been successfully completed to the satisfaction of The Client, an

Operational Acceptance Period shall commence and shall consist of a continuous period of

operation of 12 months free from trouble.

During the operational acceptance period The Contractor shall carry out all necessary

servicing and any adjustments required at their expense.

1.4. Guarantee Period

* The Contractor is required to supply a written guarantee on the items supplied by them for a

period of 2 years from date of site acceptance testing under continuous working conditions

after the successful completion of the abovementioned Operational Acceptance Period.

* NOTE: Where the CP and AC Mitigation Contractor is employed as a sub-contractor

to the main construction contractor, the guarantee period for all manufactured,

supplied and installed equipment shall reflect the main construction

contractor’s guarantee and performance bond durations.

The only exceptions shall be for damages arising from vandalism, mechanical damage, and

external fire and/or flooding.

Any faults as may be certified by The Client due to poor materials, workmanship or The

Contractor’s design (where applicable), shall be remedied and faulty goods replaced entirely

at the Installation Contractor’s cost.



The Contractor is responsible for the guarantee of all items under the terms of the tender and

for the safe delivery and installation of the equipment and materials, as called for in the Bill of

Quantities, unless otherwise instructed in writing by The Client.

Where the Contractor is required to manufacture, supply and deliver materials and/or

equipment to The Client’s stores, or a suitably designated depot, the guarantee period shall

commence from the time of delivery and sign off at the stores, by the Client, that the materials

and/or equipment was received in good order. The guarantee for manufacture, supply and

delivery type contracts shall be issued in writing for 2 years from the delivery date.

All materials and/or equipment delivered to The Client’s stores, or a designated depot, (only

under a manufacture, supply and delivery type contract) shall be delivered in a rugged crate

with suitable solid impact resistant walls, unless otherwise specified. The enclosure shall be

marked with black 50mm high lettering stating the purchase order number (PO No. XYZ) and

a single line description of the contents ie. TRU, Anodes,

1.5. Safety and Work Procedures

The Contractor shall ensure that a competent person is assigned to the works at all times in

terms of OHS Act. The Contractor shall ensure that he complies with all statutory regulations,

municipal by-laws, etc. concerning pollution and the health and safety of his personnel and

members of the public who may be affected by his work. The Contractor shall provide for all

necessary safety precautions and risk assessments and the loss control or safety officer shall

prepare a safety plan for the area to be worked in. The Contractor shall advise The Engineer

of all hazardous materials to be brought on site.

All electrical commissioning works and tie in to Eskom or the relevant power supplier shall be

carried out by a qualified Electrician registered with the Electrical Contracting Board of South

Africa. All excavation and construction work shall be carried out strictly in accordance with the

relevant Health and Safety regulations of local authorities or relevant departments within the

Relevant Metropolitan Area.

Oily or solvent rags shall be kept segregated in closed containers and in minimum quantity.

Any spillage of volatile material shall be wiped up immediately. Solvents and volatile materials

shall be stored in designated areas. The Contractor shall provide and erect such scaffolds and

rigging as may be required. All scaffolds and rigging shall comply with the requirements of the

OHSA. Temporary welded support elements are not permitted except where written approval

has been granted by The Engineer.



The Contractor shall ensure that the relevant electrical, civil, roads, rail or other departments

are timeously informed of proposed project works. The necessary wayleave approval for each

aspect of the work shall be kept on file for inspection during the project.

On completion of the works, The Contractor shall include the wayleave forms with the

documentation to be handed over to The Client.

Furthermore, The Contractor shall ensure that the relevant departments are approached to

determine:

• Specific requirements according to the SAECC

• Specific department safety regulations.

• Specific construction restrictions and timing.

• Notification of work requirements.

• Procedures for work approval.

• Location of services that may be affected during construction.

• Public notification requirements to inform residents or business owners of potential

disruptions.

The Contractor shall inform The Client of the requirements and ensure that the relevant

minutes of meetings with departments are kept of record for the duration of the works. The

relevant project information and minutes of meetings with third parties shall be copied to The

Client at the end of the project. The Contractor shall prepare typical Hazard Identification and

Risk Assessment forms for each of the major aspects of a construction project namely:

• Working near or under High Voltage Power Lines.

• Step and touch potential mitigation measures when approaching, working under or

exiting High Voltage Power Line areas.

• Handling, storage and installation of anodes, cables, TRU/SMU/NDU and other

electrical equipment to minimize theft and vandalism.

• Excavation, backfilling and compaction.

• Lifting and moving of heavy equipment on site.

• Operation of machinery on site.

• Road traffic management.

• Working in trenches deeper than 1.5m.

• Managing pedestrian traffic nears construction works.

• Electrical testing, connections and commissioning.



• Locking out and securing of sensitive areas during normal work hours and after hours.

• Entry into pipes of 800mm diameter or less.

1.6. Handling and Storage

The following precautions shall be taken for the site storage and handling of supplied items:

All coated components shall be handled using soft slings and/or acceptable methods

that will not cause damage.

All components to be transported shall be loaded with support blocks, packaging and

packing between pieces and tight lashing to avoid chafing.

Off-loading at site shall be conducted using the same care and precautions for on-

loading. Components shall not be tipped off the transportation.

Coated corrosion protection items shall be stored under cover where possible.

Items not stored under cover shall be stored in such a manner as to avoid retention of

water and allow good air circulation.

Items shall be stored on baulks of timber to raise the lowest level above the rain splash

zone.

Items shall be stacked using timber packing or other approved means to avoid item-

to-item contact. Sufficient bearing area of packing shall be used to avoid damage to

items.

Storage of anodes, cables, TRU / SMU / NDU and other related electrical equipment

shall be in a secure location that is fenced off, inside a locked/secure building or

enclosure and adequate security measures should be in place for 24 hour guarding

and armed response.

Handling of all anodes, cables, TRU / SMU / NDU and other related electrical

equipment up to the point of installation and backfilling shall be managed in such a

manner that the maximum security is in place to minimize theft and vandalism before

the equipment is tested, commissioned and handed over.

1.7. CP Design Requirements

The CP system requirements i.e. design life, type, materials, supply and installation method

shall be as specified by The Engineer. The buried / immersed steel components should be

designed to be accessible for the purposes of supplying, installing, applying, inspecting and

maintaining the CP system.



The guidelines to ensure accessibility and suitability for maintenance and upkeep of the

complete CP system shall be drawn from SANS 15589 “Cathodic Protection of Pipeline

Transportation systems: Part 1 On-Land pipelines”.

1.8. Qualified Staff

The Contractor/Consultant shall ensure that there are at all times sufficient suitably qualified,

experienced and skilled staff to carry out and supervise all activities.

1.8.1. CP Design Engineer

The CP Design Engineer must:

Hold an engineering degree or a technical diploma.

Have a NACE CP Specialist Certification with a minimum 8 years corrosion

related work experience or a NACE CP Specialist with a Professional

Engineer’s License and 4 years CP related work experience.

Alternatively, hold an engineering degree or a technical diploma and have a

minimum of 20 years post qualification engineering work experience, of which

15 years are CP design related with verifiable references.

1.8.2. CP Engineer

The CP Engineer must:

Hold an engineering degree or technical diploma.

Have a minimum of 15 years corrosion related experience or hold a NACE CP

Level 3 Certification with a minimum 6 years corrosion related experience.

Alternatively, hold an engineering degree or a technical diploma and have a

minimum of 15 years post qualification engineering work experience, of which

10 years are CP trouble shooting, construction and design related with

verifiable references.

1.8.3. AC Mitigation Engineer

The AC Engineer must:

Hold an engineering degree or technical diploma and have a minimum of 5

years post qualification Cathodic Protection experience

Have a minimum of 10 years corrosion related experience or hold a NACE CP

Level 3 Certification with a minimum of 3 years corrosion related experience.



Have a minimum of 5 years AC Mitigation experience and have suitably been

trained on AC mitigation modelling software (Certificates to be provided) or be

able to demonstrate sound engineering practice in the design development with

detailed calculations and estimations.

Have a Professional Engineer’s License.

1.8.4. Senior CP Technician

The Technician must:

Hold a minimum of a 3 year diploma or be a trade tested electrician.

Have a minimum of 8 years Cathodic Protection experience or hold a NACE

CP Level 2 Certification with 8 years corrosion related experience.

Have the ability to sign off and verify all maintenance records that the system

is safe for operation.

1.8.5. CP Field Technician

The CP Field Technician must:

Hold a minimum of a 3 year diploma.

Have a minimum of 3 years Cathodic Protection experience or hold a NACE

CP Level 2 Certification with 3 years corrosion related experience.

1.8.6. Pipe Coatings Inspector

The Inspector must:

Hold a N3 Technical with English or Grade 12 certificate.

Hold a minimum NACE CIP 1 Certification with two year post qualification

experience or a SAQCC (Corrosion) Inspector certification with a two year post

qualification experience or have a minimum of 7 years’ experience in Inspecting

Coating Systems.

The inspector’s CV should reflect all experience relevant to the job.

Have the ability to sign off and verify all maintenance records that the system

is safe for operation.

1.8.7. CP Field Assistant

The CP Field Assistant must:

Have 3 years electrical or electronics practical experience.

Have a NACE CP Level 1 Certification or 5 years CP related field experience.



Be a permanent employee of the company.

Be properly trained for the work that needs to be executed.

1.8.8. Semi-skilled CP Hands (Labourer)

The Labourer must:

Have relevant experience in the discipline of Cathodic Protection of Pipelines.

Be a permanent employee of the company.

Be properly trained for the work that needs to be executed.

1.9. Quality Assurance

1.9.1. Contractor Qualification

All material, certification and records of the Contractor will be subject to examination by the

Engineer. This shall include the checking and testing of the equipment. If any deviation to the

approved QCP or product quality is found, the Contractor may be instructed to perform

additional testing and quality surveillance, at no additional cost to the Client. The Engineer

may, at his discretion, require a Quality Audit of The Contractor’s facility to ensure that he has

the management, facilities and skilled staff to carry out the work in accordance with the

specification.

The Contractor shall accept full responsibility for the quality of his work and of materials used,

irrespective of any quality surveillance that may be carried out by The Engineer.

1.9.2. Quality Control

The Contractor shall have the necessary equipment and qualified staff to carry out the quality

control required to ensure compliance with the specification.

Quality control shall be carried out by a qualified inspector who is independent of the

application activities. Quality control cannot be carried out by the site supervisor or any

member of staff involved in production and programming.

The Contractor shall keep at least the following records:

Material batch records

Site Data Sheets

Records

Records of specific tests as required by The Engineer



These records shall be kept in a format that meets the approval of The Engineer.

The cost of quality control shall be included in The Contractor’s tender price.

Before the commencement of the contract, The Contractor shall prepare a Quality Plan

detailing each activity to be carried out during the execution of the works. Each activity shall

be supported by a detailed Works Procedure for that activity. The Quality Plan will also detail

the inspection requirements of each specific activity, listing whether it be a review, witness or

hold point, and define the responsibilities of the various parties at each stage of the works.

The Contractor shall provide the necessary documentation to be used during these

inspections. Such documentation shall be reviewed and approved by The Engineer

beforehand.

1.9.3. Quality Surveillance

A third party specialist corrosion consultant may be appointed by The Client to perform

independent quality assurance inspections.

For the purpose of carrying out quality surveillance, the Specialist shall be granted access to

any part of The Contractor’s premises relevant to the work being carried out, at any reasonable

time. The Contractor shall provide, at his own cost, any equipment or labour necessary to gain

access to the works that are in progress.

The Specialist may remove any reasonable samples of materials to be used in the application.

Rejection of the samples will place a hold on the use of material of the same batch number

and may lead to rejection of all that batch of material and the reworking of any components

that have already been worked on with rejected material.

The Specialist may carry out reasonable destructive tests to ascertain compliance with the

specification. Areas thus damaged shall be repaired by The Contractor to the satisfaction of

The Engineer at no additional cost.

A report shall be compiled by the Specialist for each visit. A copy of the report will be given to

The Contractor on completion of each surveillance visit.



2. RELEVANT SPECIFICATIONS

Below is a list of typical relevant specifications that may be used in the execution of a project.

Where applicable, items specified in this document shall comply with the latest revision of the

stated specifications and other specifications quoted or referred to within these documents:

NOTE: Where there is a contradiction, the project specification takes preference. The exact

specifications to be used will be specified by The Corrosion Engineer at the Pre-Job

Conference (“kick-off” meeting).

2.1. American Society for the Testing Of Materials (ASTM)

ASTM B265 Standard specification for titanium and titanium alloy strip, sheet and

plate

ASTM B338 Titanium Alloy for Heat Exchangers

ASTM A518 Specification for corrosion resistant high silicon iron castings

ASTM G57 Method for field measurement of soil resistivity using the Wenner Four

Electrode method

ASTM G95-87 Standard Test Method for Cathodic Disbondment Test of the Pipeline

Coatings

ASTM 3418 Method of measuring transition temperatures by Differential Scanning

Calorimetry (DSC)

ASTM D293 Standard Test Method for the Sieve Analysis of Coke

ASTM B418 Standard Specification for Cast and Wrought Galvanic Zinc Anodes

2.2. British Standards Institution (BS) Specifications

BS 171 Specification for power transformers

BS 1016 Method for analysing and testing of coal and coke

BS 1872 Specification of electroplated coatings on tin

BS 6001 Sampling Procedures for Inspection by Attributes

2.3. International Electrotechnical Commission (IEC) Publications

IEC 60038 Standard voltages

IEC 60028 Copper wire.

IEC 60051 Direct Acting Indicating Analogue Electrical Measuring Instruments and

their Accessories.

IEC 60071 Co-ordination of insulation.



IEC 60076 Parts 1-5 Power Transformers.

IEC 60144 Degree of protection of enclosures for low voltage switchgear and

control gear

IEC 60146 Semiconductor Converters.

IEC 60189 PVC Insulation and PVC Sheath.

IEC 60269 Low voltage fuses – Fuses mainly for Industrial applications.

IEC 60445 Identification of equipment terminals and of Terminations of certain

designated Conductors, including general rules for Alphanumeric

system.

IEC 60616 Terminal and tapping markings for power transformers.

2.4. National Association of Corrosion Engineers (NACE)

NACE SP0169 Control of External Corrosion on Underground or Submerged, Metallic

Piping Systems

NACE SP0177 Mitigation of Alternating Current and Lightning Effects on Metallic

Structures and Corrosion Control Systems

NACE SP0188 Discontinuity (Holiday) Testing of New Protective Coatings on

Conductive Substrates.

NACE SP 0207 Performing close-interval DC pipe-to-electrolyte potential surveys on

buried or submerged metallic pipelines

NACE SP0286 Electrical Isolation of Cathodically Protected Pipelines

NACE SP0502 Pipeline External Corrosion Direct Assessment Methodology

NACE SP0572 Design, Installation, Operation and Maintenance of Impressed Current

Deep Groundbeds

NACE RP 0104 The Use of Coupons for Cathodic Protection Monitoring Applications

NACE TM 0102 Measurement of protective coating electrical conductance for

underground pipeline

NACE TM 0109 Techniques for aboveground evaluation of the coating condition of

underground metallic pipelines

NACE TM 0497 Measurement Techniques Related to Criteria for Cathodic Protection

on Underground or Submerged Metallic Piping Systems

NACE Pub Measurement Techniques Related to Criteria for 10A190 Cathodic

Protection of Underground or Submerged Steel Piping Systems

NACE Pub Impressed Current Anodes for Underground 10A196 Cathodic Protection

Systems



2.5. South African National Standards (SANS)

SANS 10142-1 The wiring of premises Part 1: Low-voltage installations

SANS 1091 National colour standards for paint

SANS 10129 Plastic tape wrapping of steel pipelines.

SANS 10140 Parts 1 to 3: Identification - Colour Marking.

SANS 10064 Preparation of steel surfaces for coating.

SANS 121 Hot dip galvanised coatings on fabricated iron and steel articles.

SANS 1700 SET/

ISO 1461 Fasteners

SANS 122-1975 Pressure-sensitive adhesive tapes for electrical purposes (Metric Units)

SANS 10199 The design and installation of an earth electrode specifications

SANS 10313 Protection against lightning – Physical damage to structures and life

hazard

SANS 1063 Earth rods, couplers and connection

SANS 1411-1 Materials of insulated electric cables and flexible cords Part 1:

Conductors

SANS 1411-2 Materials of insulated electric cables and flexible cords Part 2: Poly-

Vinyl- Chloride (PVC)

SANS 1411-3 Materials of insulated electric cables and flexible cords Part 3:

Elastomers

SANS 1411-4 Materials of insulated electric cables and flexible cords Part 4: Cross-

linked Polyethylene (XLPE)

SANS 1411-5 Materials of insulated electric cables and flexible cords Part 5: Halogen

free, flame-retardant materials

SANS 1411-6 Materials of insulated electric cables and flexible cords Part 6: Armour

SANS 1507-1 Electric cables with extruded solid dielectric insulation for fixed

installations (300 / 500 V to 1900 / 3300 V) Part 1: General


installations (300 / 500 V to 1900 / 3300 V) Part 2: Wiring cables


installations (300 / 500 V to 1900 / 3300 V) Part 3: PVC distribution

cables


installations (300 / 500 V to 1900 / 3300 V) Part 4: XLPE distribution

cables




installations (300 / 500 V to 1900 / 3300 V) Part 6: Service cables

SANS 15589 Part 1 Petroleum and natural gas Industries – Cathodic Protection of pipeline

transportation systems. Part 1: On-land pipelines.

SANS 50162 Protection against corrosion by stray current from direct current

systems.

SANS 53509 Cathodic Protection measurement techniques

SABS 10142 Wiring of Premises - LV Installations

SANS/IEC 79&10108 The classification of hazardous locations and the selection of apparatus

for use in such locations

SANS 1222` Enclosures for electrical equipment classified by IP code

SANS 121/ISO1461 Hot dip galvanized coatings on fabricated iron and steel articles:

specifications and test methods.

SANS 1091 H40 national colour standard

SANS 15589 Petroleum And Natural Gas Industries - Cathodic Protection of Pipeline

Transportation System.

SANS 089 The installation of underground storage tanks, pumps/dispensers and

pipework at service stations and consumer installations

SANS 086 Code of practice for the installation and maintenance of electrical

equipment used in explosive atmospheres

The relevant SANS Standardised Specifications for Civil Construction shall apply.

It shall be the responsibility of The Contractor to obtain at his own expense, copies of the

relevant editions of the documents referred to above. Subsequent amendments or revisions

to these documents that have direct bearing on the project specification shall be clarified in

writing with The Engineer before construction commences.

In addition to this all elements of the Contract Documents shall be available for inspection on

Site at all times.

SANS 1200 A General

SANS 1200 AB Clients Office

SANS 1200 C Site Clearance

SANS 1200 D Earthworks

SANS 1200 DB Earthworks small works

SANS 1200 GA Concrete – small works



SANS 1200 H Corrosion Protection of structural steelwork

SANS 1200 M Roads – General

SANS 1200 MF Base

SANS 1200 MH Asphalt base and surfacing

SANS 1200 MK Kerbing and Channelling



3. GLOSSARY OF TERMS / DEFINITIONS

AC: Alternating Current

ACM: Alternating Current Mitigation

Anode: The electrode of an electrochemical cell at which

oxidation occurs. Electrons flow away from the anode

in the external circuit. Corrosion usually occurs and

metal ions enter the solution at the anode.

Anode Backfill: Carbonaceous material placed in a hole to fill the

space around the anodes, vent pipe and buried

components of an anode groundbed.

Anode Groundbed: One or more anodes installed below the Earth’s

surface for the purpose of providing a long-lasting,

corrosion-resistant, positive connection to earth in a

cathodic protection system, that enables the required

current to pass into and through the electrolyte to the

steel surface to be protected. A sacrificial anode

groundbed sacrifices itself in favour of the steel

structure being protected.

Anode Groundbed Survey: This survey involves the measurement of soil

resistance values at regular spacing intervals of 2m up

to a spacing of 50m or more. Results are analysed to

determine the suitability of a location to install a low

resistance anode groundbed.

Bill of Quantities (BOQ): The pricing instructions that are in the tender

document that contains the quantities to be supplied or

installed.

Bonding: A method of connecting metal surfaces to each other

by cable using exothermic or pin brazing techniques;

often used to establish electrical continuity along

pipelines coupled with mechanical joints.



Bonding Cabinet: A cabinet used to house cable that establishes a

connection between metal structures.

Bonding Stations: A station used to facilitate connection of metal

structures to each other.

Cathode: An electrode of an electrochemical cell at which

reduction (gain of electrons) is the principal reaction.

Electrons flow toward the cathode in the external

circuit.

Cathodic Protection: The process to reduce or prevent corrosion of metal

structures in contact with an electrolyte by the flow of

direct current from the electrolyte into the structure

surface.

Cathodic Protection Station: A combination of equipment installed to provide

cathodic protection to the pipeline.

Chamber Bonding: Continuity bonding of all pipe work within a chamber.

Client: The “Client” shall refer to the asset owner’s Corrosion

Engineer or his designated representative.

Continuity Bonding: A suitable electrical connection, usually metal, that

provides electrical continuity between structures that

can conduct electricity.

Copper Sulphate

Reference Electrode: See reference electrode

CandI: Control and Instrumentation

Contractor: The supply and/or installation contractor.

Corrosion Engineer: The individual appointed by the Water Authority

Current Drainage Survey: Survey aimed at determining the amount of DC current

required to render a particular structure cathodic to

accepted criteria.



Data Logger: A digital instrument used to measure the potential of a

structure over a period of time. This data is then

downloaded on to a computer, processed and

graphed.

DC: Direct Current

Digital Multi Meter: Digital instrument used to measure current, voltage

and resistance. For example: a "Fluke™" meter.

Drain Point: The point on the pipeline where the connection of the

negative terminal of the cathodic protection voltage

source is made to conduct (drain) the returning current

from the pipeline to the foreign voltage source.

Electrolyte: A conductive liquid or material such as soil or water in

which an electric current can flow.

Earth Spike: 16 mm diameter, threaded type, 1.5 m long

electroplated SANS 1063.

Earth Cable: 70 mm2 bare stranded copper

Engineer: The CP design engineer or his designated

representative.

Exothermic Welding: An exothermic welding process that makes use of

copper oxide and aluminium powder to weld copper

cables to a pipe or other steel structure.

Flange: A mechanical joint comprising two flush steel faces,

usually at pipe ends, used to join pipe lengths.

Forced Drainage Unit (FDU): A unit comprising of a TRU and a bypass diode

connected between pipe and rail.

Foreign Structures/Pipelines: Metal structures or pipelines other than that under

consideration in contact with the same electrolyte as

the structure/pipeline and which are or may become

under the influence of the structure/pipeline’s cathodic



protection system. Foreign structures /pipelines may

be owned by The Client and/or other companies and

may or may not be equipped with cathodic protection.

Impressed Current: A DC electric current supplied by a device employing

a power source that is external to the electrode

system. Current that flows as a result of an impressed

voltage between anode and cathode components of a

cathodic protection system.

Isolation Flange: An isolation flange typically comprises a gasket of

phenol resin with isolating sleeves over high tensile

bolts fitted with isolating washers .The purpose of the

isolating flange is to stop current flow between a pipe

and structural steel or earthing systems.

“IR Free” potential: The pipe-to-soil potential measured immediately after

the cathodic protection system is switched off and the

applied electrical current stops flowing to the pipeline

surface, but before polarisation of the pipeline has

decreased.

Marker Stations: Typical stations of concrete construction to mark out

cable and pipe routes.

Megger: A meter used to measure resistance values.

Midpoint: The point on a pipeline between two cathodic

protection stations where the influence of the two

cathodic protection stations is expected to be equal

and the protection levels are usually expected to be at

their lowest depending on the design overlap that has

been included.

Monitoring Cabinet: A metal cabinet designed to house recording

equipment for monitoring purposes.

Natural Drainage Unit (NDU): An electrical device comprising a diode and surge

protection units linked between pipe and rail to allow



the flow of current back to the rail under certain

conditions.

Natural Potential: The pipe-to-soil potential measured shortly after

installation of the pipe when the soil has been

backfilled and compacted. No cathodic protection is

applied, polarisation caused by cathodic protection is

absent and no significant stray current is present.

OEM: Original Equipment Manufacturer

“OFF” Potential: The pipe-to-soil potential measured immediately after

the cathodic protection system is switched off and the

applied cathodic protection electrical current stops

flowing to the pipeline surface, but may still include

stray current or foreign service interference in the

measured value.

“ON” potential: The pipe-to-soil potential measured while the cathodic

protection system is continuously operating.

O and M: Operations and Maintenance Manual (also OMM)

Pipe-to-Soil Potential: The difference in electrochemical potential between a

pipeline or foreign structure/pipeline and a specified

reference electrode in contact with the electrolyte.

Similar terms such as structure-to-soil potential, pipe

to electrolyte potential are sometimes used as

applicable in the particular context.

Polarisation: The change of the pipe-to-soil potential caused by the

flow of DC current between an electrolyte and a steel

surface.

PRE: See SRE

Reference Electrode: An electrode with an open circuit potential that is

constant under similar conditions of measurement,

which is used for measuring the relative potential of



other electrodes or metals under varying electrolyte

environments.

Sacrificial Anode System: Anodes manufactured from materials that are

sacrificed preferentially when placed in a galvanic

couple with another metal i.e. Magnesium coupled to

steel in soil.

SCADA: Supervisory Control and Data Aquisition

Sealer: Mastic putty, rubber tape and PVC insulation tape.

Soil Resistivity: An indication of the soil resistance at a certain depth

measured using a Megger and the Wenner four-pin

technique.

SRE: Stationary Reference electrode

Stray Current: Current that flows through paths other than an

intended circuit i.e. current flow though the soil that

originated from a DC traction railway line. The current

may cause interaction with the cathodic protection

system and often acts upon foreign structures and/or

pipelines.

Test Station: A point, often of concrete or steel construction, where

regular measurements of structure-to-soil potentials

may be taken. Test cables are connected directly to

the structure being monitored. This term can be used

interchangeable with Test Post, Test Point, Test

Chamber, Test Cubicle etc.

There are several types of Test Station namely:

Type A – monitoring station

Type B – SRE monitoring station

Type C – Cross bonding test station

Type E – 4 wire current span test station

Type F – Test station with ACM



Each test station type (A, B, C, E or F) may have

optional temporary CP in the form of a suitable

galvanic anode that may be disconnected.

Transformer Rectifier Unit (TRU): An electrical device designed with the purpose of

stepping down either single or three phase power to a

suitable voltage and then rectifying the power supply

to provide a suitable DC output.

Viking-Johnson Type Coupling: A coupling that uses a rubber seal on both sides of the

coupling barrel, allowing flexibility of the joint, but also

electrically isolating one length of pipe from another.



4. CABLING FOR CATHODIC PROTECTION

4.1. General Properties of Isolating Compounds

Cable insulation properties are based on environmental, physical and performance

requirements. All three requirements are key factors to consider for CP design purposes,

however the cables insulation performance with respect to the environmental conditions is

more critical. Cable insulation properties should be based on the environmental requirement

and the best isolating material for this requirement should be selected. These insulation

materials can generally be split into thermoplastic and thermoset materials.

Thermoplastic materials soften and flow when heated and usually possess a definitive melting

point. The material will become firm again upon cooling. These materials can be moulded and

shaped with a heating and cooling process and the process can be repeated.

Thermoset materials are soft and pliable during one stage of the processing, can be moulded

and extruded at this state after which they are set or cured, usually at a higher temperature.

After the setting or curing process (cross linking) is complete, they cannot be softened by

reheating.

Some of the insulation compounds available include, but are also not limited to:

Polyvinyl Chloride (PVC)

Polyolefins

Polyethylene (low (LMPE), medium (MMPE) and high density (HMWPE)) (PE)

Polypropylene

Cellular Polyolefins

Non-Halogen compounds

Fluorocarbons (PTFE, PVDF (KynarTM), ECTFE (HalarTM), ETFE (TefzelTM))

The primary insulation material (i.e. outer cable insulation) is the most important of the cable

material for overall performance reasons. The key requirements that should also be

considered include, but are not limited to:

Voltage dielectric properties for higher voltage charge at the conductor surface.

Low loss material for high frequency signal cables,

Heat resistance in high temperature environments,

Low temperature flexibility,



Toughness for cut-through, abrasion and burial (crush) resistance.

Fire resistance

Ultra violet (UV) resistance (weatherability)

Chemical resistance (i.e. acids and alkalis, pH resistance)

4.2. Cable and Cable Insulation Compliance

Cathodic Protection cables shall be insulated and rated for voltages up to 600V/1000V and

shall have stranded copper conductors in accordance with SABS 1507 or ASTM Specification

B-8. The cable conductor and cable voltage drop shall be calculated in accordance with SANS

10142.

All cable suppliers are to ensure that they are familiar and possess the latest SABS

specifications herein referred to (refer to section 1.3). Alternative cabling solutions are to

adhere to the requirements as stipulated Preamble “Alternative CP Materials”.

4.3. Cathodic Protection Cable Requirements

The following table shall be used when selecting DC cables for Cathodic Protection. The

insulation layers are specified as inner/outer layer. All cables are to be embossed or otherwise

identified on the outer insulation.

The specific labelling requirements are outlined in Section 4.4. The material certification will

be available upon inspection and/or delivery.



Cathodic Protection Single Core Cable Insulation Requirements

Cable Detail Installation Environment Insulation Layers*

and Type

Insulation

Colour

Positive DC Direct Sun HMWPE/PVC Red

Partial Sunlight PVC/PVC Red

Soil (Non Polluted) PVC/PVC Red

Soil (Polluted) PVDF/ HMWPE/PVC Red

Negative DC

Direct Sun HMWPE/ PVC Black

Partial Sunlight PVC/PVC Black

Soil (Non Polluted) PVC/PVC Black

Soil (Polluted) PVD/ HMWPE/PVC Black

Continuity / Cross

Bonding DC

Direct Sun HMWPE/PVC Black

Partial Sunlight PVC/PVC Black


Soil (Polluted) PVDF/HMWPE/PVC Black

Earthing Direct Sun PVC Green-Yellow

Partial Sunlight PVC Green-Yellow

Soil (Non Polluted) PVC Green-Yellow

Soil (Polluted) PVC Green-Yellow

Sacrificial Anodes Soil (Non Polluted) PVC/PVC Red / Blue

Soil (Polluted) PVDF/HMWPE/PVC Red / Blue

Pipe Monitor Soil (Non Polluted) PVC/PVC Black


Reference

Electrode

Soil (Non Polluted) PVC/PVC Red

Soil (Polluted) PVDF/HMWPE/PVC Red

Corrosion

Coupons



AC Mitigation

Grounding

Soil (Non Polluted) PVC Green-Yellow

Soil (Polluted) PVC Green-Yellow

*Insulation layers are defined inside layer to outer layer.

In exceptionally corrosive environments, fluorocarbon insulation shall be provided, as

detailed by The Client. The cable and associated cable warning tape burial depth will be

specified in the Bill of Quantities. No chevron or bunting tape will be allowed. Warning tape

is to stipulate live electrical cables and/or CP cables.

Furthermore, negative cables to pipe and positive cables to the anode groundbed may



require additional protection against vandalism i.e. concrete encasement.

In certain instances, multi-core power cabling might be required, such as: 4 Core

PVCI/PVCS/SWA/PVCS, as per the Bill of Quantities.

4.4. Cable Identification

Cables are to be labelled by means of permanently marked plastic ferrules with black lettering

on a white background. Ferrules shall be the slip-on type and matched to the size of the

cable.The ferrules are to be fastened to the cable with cable ties. Ferrules shall be situated

so as to read the right way up on horizontal cables and from lug to insulation on vertical

cables. All labels of this type shall be supplied in “made-up” condition ready for fixing.

4.5. Cable Weld Attachments

4.5.1. General

The cable weld attachment method to be used shall ensure that metallurgical contact is

achieved between the cable and the pipe substrate surface.

The Contractor shall submit detailed QCP’s of the preferred system for approval listing the

equipment and staff. In addition a detailed QCP for the coating repair and re-instatement

thereof is to be submitted for approval.

Unless otherwise specified, all cable connections to the pipe are to be by means of thermit

(exothermic) welding. This applies equally to the cable for the following CP installations:

Main negative cable,

Continuity cables,

Cross Bonding Cables,

Test station Monitoring cables,

DC Decoupling device cables, etc.

Where cables are attached to the overt of the pipe, these attachments should be made at field

joints to minimise the number of repairs required. The minimum amount of pipe coating shall

be removed in preparation for the weld. Where ever possible, cable connections should be

made onto the pipe outside of chambers as vandalism and theft in many instances renders

the chambers accessible and the connections are removed.



Thermit welding may not be used on the barrel of epoxy lined pipes unless weld pads have

been provided. Solder pads many be use subject to satisfactory prequalification trial. Charge

size, cleanliness and fluxing are critical aspects of solder pad use.

All welding on epoxy lined pipes must be preceded by a trial on spare pipe or reference pipe

piece and the epoxy subjected to visual and holiday detection testing after welding.

Exothermic welding is not permitted on a pipeline where the wall thickness is less than 3.0mm

or severe corrosion i.e. metal loss has occurred and the pipe wall thickness is unknown.

In these instances, cables shall be connected by means of pin brazing / Stud welding /

Capacitive Discharge Welding. The proposed method of attachment shall be detailed with

adequate substantiation to address the relevant concerns set out previously, thereby allowing

The Engineer to make an informed decision.

4.5.2. Surface Preparation

The area where the welding is to take place shall be thoroughly cleaned to provide an area

slightly larger than that of a typical graphite mould (approximately 75 x 75mm). The welding

surface area must be brushed with a steel wire brush and all traces of petroleum mastic,

concrete, bitumen coating, primer material or any other matter shall be removed.

Prior to making the weld the area shall be roughened using a coarse file or an angle grinder

fitted with a flapper disc.

Always ensure that the steel surface is dry prior to welding.

4.5.3. Exothermic Welding (Thermit Welding)

A detailed QCP procedure is to be submitted by the contractor for approval. A guideline

procedure for thermit welding is as follows:

Bare the end of the insulated cable for a distance of 25mm.

Select the correct size and type of mould for the weld application.

Place the supplied retaining cap in the bottom of the mould and pour the correctly sized

weld metal powder into the mould.

Pour the starting/igniter powder over the weld metal, close the lid and sprinkle some

on the lip of the mould.

Place the cable on the pipe and the mould squarely over the cable, pressing down

firmly. Ensure that the mouth of the mould is turned away from the welding operator.



Ignite the starting powder with a flint gun and allow the weld to solidify, the mould is to

be kept still during the entire procedure.

Remove the mould and clean out the residue in preparation for the next weld.

The cables and charges as well as types of joins will be suitably matched as follows (the list

below is not considered exhaustive and the manufacturer’s guidelines should be adhered to):

Cable

(mm2) No. of Welds Entry

Charge Size

(g)

10 One Single 15

16 One Single 15

35 Two Single 15

70 Four Single 15

For multicore cables, each core will require its own thermit weld as per the table above.

A ferrule is required on any 10mm2 cable.

4.5.4. Stud Welding/Pin Brazing

A detailed QCP procedure is to be submitted by the contractor for approval. Equipment and

rating thereof to be identified, ensuring that the welding unit is suitable for the studs and pipe

to be welded. After successful trials and reference samples have been signed, all works will

be performed in strict accordance with this QCP and adhered to for all further work.

A guideline procedure to be followed when stud welding is as follows:

Bare the end of the double insulated cable and crimp into the appropriate sized lug

using an approved OEM crimping tool. Insert the stud in the welding mechanism (gun)

i.e. Mandrel and place against the cleaned steel surface. Ensure all pins have pipe

contact.

Select the appropriate power setting and press the trigger of the stud welding gun,

pressing down firmly. Ensure that the correct setting, stud welding consumables, studs,

and lugs have been selected prior to welding.

Remove the stud welding from the cable connection and clean any residue from the

brazed connection.



Stud welded connections shall be tested as above, but the stud will be protected using a

nut in order to prevent damage to the thread. Should any movement occur the cable shall

be re-welded and re-tested.

4.5.5. Testing

After the above procedure(s) have been carried out, a number of welds shall be tested by an

approved inspector as appointed by The Client. The test will be performed by striking the weld

with a 2kg hammer. Should any movement occur the cable shall be re-welded and re-tested.

4.5.6. Safety Precautions

In addition to all OSH Act requirements and relevant safety procedures, the following

precautions should be exercised when welding (stud or exothermic):

a. Ensure that the weld-metal and starting powders, mould and surface to be welded is

perfectly dry.

b. Do not attempt to weld in areas where the water level is close to the area to be welded

on.

c. Ensure that the correct mould and consumables are used. Do not use moulds past

their design life or force a cable into an incorrect mould.

d. Use correct PPE and safety shoes which may be readily removed or shoe spats are to

be used.

e. Wear appropriate eye protection, welding gloves and protective clothing. Always

ensure that the mouth of the mould face away from the body of the operator. Centre

the mould over the pipe, holding it steady during welding. Use special exothermic putty

on small bore pipes, in order to prevent the hot liquid weld-metal from escaping

between the base and the pipe damaging the coating system and/or possibly cause

harm to the operator.

f. Use only a pistol type flint igniter, matches and/or cigarette lighters are not permitted.

g. Follow all permit conditions required by the pipeline owner prior to and during the

exothermic and/or stud welding operation.

4.6. Coating Make-Good

All coating repairs associated with CP connections shall be made in accordance with the repair

procedures relevant to the coating system applied to the pipe. The Contractor is to submit

detailed QCP for the coating repair and re-instatement thereof is to be submitted for approval.



After connecting the cable the entire exposed area shall be encapsulated. Remaining coating

to at least 50mm beyond the final repair limits shall be removed and the outer edges suitably

feathered.

All cable to pipe connection and coating repairs shall be witnessed by The Engineer or The

Client’s nominated representative.

Any buried attachments to the exterior of the pipe will require repair using circumferential

wrapping. Patch repairs may not be used in buried applications.

Cable connections to epoxy coated specials in valve chambers will require a different coating

make good application. A surface tolerant high-build epoxy shall be applied adequately

covering the weld and cable area and overlap onto the existing pipe coating by at least 25mm.

Epoxy is to be given time to fully cure.



5. CONTINUITY AND CROSS BONDING

Continuity and cross bonding shall include excavation, cable connections, make-good of the

coating system, QA/QC test and back filling.

Make good of the coating system where necessary is to be carried out in accordance with the

relevant specifications.

5.1. Cross bonding

Cross bonding facilities are to accommodate cable facilities that will enable the following:

Bonding if a common cathode approach is required

Current bond is required

Interference bond is required

Facilitate breaking of the bond to allow for fault finding and pipe utility tracing

Each cross bond cable shall be clearly identified and labelled, indicating to which pipe it is

connected.

Cables shall be identified in accordance with Section 4.4 above.

Cross bonding facilities will be required where buried pipeline systems run parallel to each

other or to other foreign services.

Where sections of buried piping of varying diameter run parallel for some distance, frequent

cross bonding facilities are required.

Bonding is required from one pipeline to another, i.e. upstream feed and downstream supply

of a pump station, or a current carrying bond is required from one system to another that cross

or run parallel to each other.

All cross bonding will be done through approved cross bonding facilities i.e. galvanised test

posts, concrete bunkers adjacent to valve chambers using bonding links mounted in the

enclosure.

One 4-core 16mm² SWA cable shall be installed between foreign pipeline and the bunker.



5.2. Continuity Bonding of Buried Joints

Examples of buried pipe joints are as follows:

Flanged joint

Bolted flanges

Viking Johnson type Type Couplings

Victaulic pipe joints

Spiggot and socket

Piping within valve chambers

Flexible couplings

Buried pipe joints shall be continuity bonded by means of two double insulated single core

copper cable connected to either side of the joint on the pipe using either of the approved CP

connection methods as described in Section 4.5. Cable insulation and compliance is to be in

accordance with the requirements as stipulated in Section 4.2.

Guidelines on the cable size to pipe diameter for continuity bonding is given as follows:

Buried pipes Ø < 700mm → 2 x 16mm²

Buried pipes Ø ≥ 700mm → 2 x 35mm²

In the case of Viking Johnson type couplings, at least one cable shall be bonded to the body

of the coupling.

5.3. Continuity Bonding of Buried/Below Grade Bolted Flanges

(Alternative System)

Continuity bonding will be required on all buried/below grade bolted flanges, preferably at the

pipe overt.

Continuity bonding by means 25mm x 6mm steel flat bar is to be welded across the flanges

(flange centre to flange centre).

Flat bar to have a minimum thickness of 6mm.

Guidelines on the number of flat bars size to pipe diameter for continuity bonding is given as

follows:



Buried pipes with Ø < 700mm → 2 x flat bar

Buried pipes with Ø ≥ 700mm → 3 x flat bar

The weld shall be a full depth fillet weld across the end of the flat bar.

Weld approval will be in accordance with the weld test as given in Section 4.5.

Coating make good of the flat bar is to be in accordance with one of the options referred to

section 4.6.

5.4. Continuity Bonding Inside Valve Chambers

This method of establishing electrical continuity along a pipeline is not the first choice solution

and every effort should be made to establish electrical continuity by installing a continuity bond

outside the chamber. The reason behind this is vandalism and theft. Only under exceptional

circumstances will an internal continuity bond be considered by the Engineer and approval

must be in writing.

Valve chambers shall be continuity bonded by means of insulated copper cable connected to

either side of the valve chamber. Cable shall be run through a 20mm diameter PVC conduit

mounted with saddles 200mm above the top of pipeline along inside wall of the chamber.

Where there are aboveground sections of piping on a buried pipeline network that section of

aboveground piping is also to be electrically continuous. Continuity bonding will be required

on all above ground dismantling flanges or couplings (i.e. Viking Johnson type Couplings).

Continuity bonding is by way of double insulated single core copper cable. The cable size to

pipe diameter relationship for continuity bonding is given as follows:

Pipes with Ø < 700mm → 1 x 16mm²

Pipes with Ø ≥ 700mm → 1 x 35mm²

5.5. Continuity Bonding Outside Valve Chambers

Continuity bonding will be required around all valve chambers where bolted flanges,

dismantling flanges or couplings are found. Bonding cables will be attached to the pipe(s),

each side of the valve chamber wall. Weld should be placed approximately 300mm from the

valve chamber wall to accommodate ease of coating make-good. The cables are to be laid

around the outside of the valve chamber walls at a nominal depth of 2000mm below final grade



level. All cabling to be concrete encased to a thickness of 300mm x 300mm for the full length

of cable.

Continuity bonding by means of 2 off black single core, double insulated copper cables which

are to be welded on the pipe overt on either side of the valve chamber.

The bonding cable is to be independent from any monitoring cables.

The cable size to pipe diameter relationship for continuity bonding is given as follows:

Pipes with Ø < 700mm -> = 1 x 16mm²

Pipes with Ø > 700mm -> = 1 x 35mm²

The bonding cables are to be independent from any monitoring cables.

6. TERMINAL BLOCKS

Din rail mount bolt connection terminal blocks for cable lugs up to 35 mm2 in accordance

with DIN 46234 and DIN 46237 shall be supplied.

The type of modular terminal block will be specified on the drawing as follows.

1. The terminal block shall be either:

1.1. CLIPLINE™ RT Bolt connection terminal blocks, 35mm2, 125A, feed-through type.

Type RTO- 8-TC, Order No. 305002 as supplied by Phoenix Contact or approved

equivalent OR

1.2. CLIPLINE™ RT Bolt connection terminal blocks, 50mm2, 150A, bolt connection

terminal blocks. Type HV M8/2, Order No. 3049550 as supplied by Phoenix Contact

or approved equivalent.

2. Tenderers to price for whichever terminal block module type costs more as The Engineer

shall specify either type at the time of placing an order to the successful tenderer and it

will be accepted that the Tenderer made adequate provision while pricing the tender to

accommodate either type of connector block.

The Bill of Quantities shall specify the minimum number of terminals blocks to be supplied

on a particular length of DIN rail. The manufacturer / supplier shall inform The Engineer at

the time of tender whether or not the specified DIN rail length shall be adequate to hold the



specified number of terminal blocks and recommend an alternative DIN rail length if so

required.

The terminal blocks shall be rated for 125A continuous use and a maximum voltage of

1000V. The minimum terminal bolt size shall be M8. The manufacturer / supplier shall

ensure that the terminal blocks fit securely onto the DIN rail and that the end terminal blocks

prevent sliding off the DIN rail. At the time of tender full details of proposed DIN rail mount

type terminal blocks shall be provided.

7. ELECTRICAL ISOLATION OF CATHODICALLY PROTECTED PIPELINES

Cathodic Protection (CP) is most effectively, efficiently and uniformly applied when the primary

structure requiring CP is electrically isolated from those structures not requiring CP.

Electrical isolation implies that all metallic/electrical contacts with foreign metallic structures

are completely eliminated.

Electrical isolation provides three major benefits:

Restriction of the required protective current to the surface of the primary structure to

produce a uniform polarised level of protection.

Minimising stray current influence (AC and/or DC).

Prevention of unwanted galvanic current flowing between metallic structures.

Best practice guidelines are to be followed here, and Isolating joints are to be installed as

above ground and housed in a well-drained and ventilated chamber with inspection access.

IF are typically required at:

Pump stations

Reservoirs

Pressure break tanks

Electromagnetic flow meters

Valve actuators

At points of dissimilar metal contact

Any earthed instrumentation

Any other place indicated by the Corrosion Engineer



7.1. Isolating Flanges

Pipeline electrical Isolating Flange (IF) materials shall be selected with consideration given to

quality and standard material availability.

The chosen material shall be suitable for the following pipe conditions:

Gasket material must be drinking water approved

Flange type

Flange face

Dielectric properties

Line temperature maximum and minimum

Surrounding Temperature maximum and minimum

Pressure

Medium

Cyclic loading

Predicted line movement

Installation of IF’s is to be conducted by accredited and competent joint integrity bolting

practitioners.

IF materials shall be cross referenced to the manufacturer’s specifications to ensure

compatibility between materials, service and the environment.

The materials required per IF, shall be supplied as one complete set.

The IF kit shall consist of an isolating non-metallic central gasket, non-metallic bolt sleeves

and non-metallic washers and steel thrust washers, as well as the associated studs, nut and

bolts.

A detailed QCP procedure is to be submitted by the contractor for approval.

Equipment and rating thereof to be identified, ensuring that the IF kit and surge protection

device used is acceptable.

Type of gasket, thickness and whether the gasket is raised face or full face must be specified,

together with material certification and approvals.



7.2. Isolating Gasket

The contractor shall provide full details of the manufacturer’s specifications and recommended

application procedures for approval and sign off by the engineer.

The isolating gasket between flanges is to be in accordance with following table based on pipe

diameter and pressure rating.

The internal diameter of the pipe and gasket shall be equal in all instances.

Field Test

Pressure MPa

Nominal Pipe

Dia. (mm) Isolating Gasket Material

Lower or equal

to 2.5

All diameters 3.2mm Thick High Density Polyethylene to PEH

Hostalen GM5010 Specification, full face gasket

in one piece.

Lower or equal

to 4.6

Smaller or equal

to 1200

3.2mm Thick Fabric Reinforced Phenolic (BS

EN 60893-3-4) full faced gasket in one piece

with neoprene or nitrile rubber faces 0.8mm

thick.

Greater than 4.6 Smaller or equal

to 1200

3.2mm Thick Fabric Reinforced Phenolic (BS

EN 60893-3-4) full faced gasket in one piece

with neoprene or nitrile rubber faces 0.8mm

thick with a composite gasket.

Isolating gasket shall be tested to BS5102 Appendices A-M: type III, with not more than 3

factory made lap joints and with Neoprene or Nitrile faces 0.8mm thick. The gasket’s internal

diameter (ID) is to be 6mm smaller than the pipe ID.

The non-metallic central gasket and non-metallic washers shall conform to the following

materials specification:



Material Property ASTM Test Method SI Value Imperial Value

Dielectric Strength (Min.) D149 21 kV/mm 540V/mil

Compressive Strength (Min.) D625 340 MPA 49,000 psi

Water Absorption (Max) D229 0.1% 0.1%

Operating Temp (Min) ---- -17°C 0°F

Operating Temp (Max) ---- +93°C 200°F

Hardness, Rockwell M (Min) D785 115 115

Shear Strength (Min) D732 150 MPA 22,000 psi

7.3. Isolating Bolt/Stud Sleeves

The insulating sleeve shall be made-up of a glass reinforced epoxy (GRE) material with high

resistance to damages associated with thread pinch, cracking, breaking and crushing. The

total length of sleeves is to be 2-3mm less than the length between the inside faces of IF

washers. The insulating sleeves shall fit completely inside the insulating washers and extend

partially within the IF washers.

A lead free, non-metallic, non-conductive and lubricating heavy-duty anti seize compound

shall be applied as a lubricant on the bolt within the sleeve. It must contain a blend of water-

resistant properties, corrosion inhibitors in high extreme (environmental and pressure)

conditions to provide protection to in excess of 1000ºC. It shall have no hazardous ingredients,

complete with reduced torque capabilities and low friction effects.


application procedures for approval and sign off by The Engineer.

7.4. Isolating Washers

Isolating Flange (IF) - washers shall be machined with diameter and thickness to SABS 1149,

Table 3, and be either:



o 3.2mm thick Glass Reinforced Epoxy * (GRE) or,

o 3.2mm thick Hardened Coated Steel (Coated with resin bonded modified PTFE).

* Note: the preferred washer type shall be specified by The Client.

Double Washer set IF kits are preferred and shall include the following components for each

Bolt:

Two (2) – 3.2mm thick hardened steel washers.

Two (2) – Isolating washers.

One (1) – Full length isolating sleeve.

Double washer configuration is highly recommended as an additional protection against the

potential electrical ‘shorting out’ of nuts and bolts. Furthermore, the double washer sets acts

as an electrical isolator of both nuts and bolts from the main metal flanges.

The inner diameter of the isolating washer shall be a sliding fit over the OD of isolating sleeves.


application procedures for approval and sign off by The Engineer. The manufacturer shall

provide recommended torque values to ensure that the washers are not damaged during the

tightening process.

7.5. Steel Washers

Steel washers shall be machined with diameter and thickness to SANS6149:1989. Stud bolts

shall be to SANS 1700 and nuts to SANS 1700.

7.6. Studs, Nuts And Bolts

All studs, nuts and bolts supplied are to be of the same material grade as the pipe flange to

mitigate any galvanic effect, unless otherwise stated.

Stud bolts and studs shall be grade 8.8 and nuts grade 8 to SANS 1700.

Stud bolt diameters shall be selected to the next smaller size for installation in standard drilled

flanges. Stud bodies shall be machined down to the next smaller standard size and suitable

smaller nut to be used.



Stepped stud bolts shall be sized on the one end to fit the tapped blind bolt holes in the valve

flanges, the other end shall be of the same diameter as the normal stud bolt.

7.7. Surge Protection

The Contractor is to ensure that compliance with electrical surge requirements is maintained

and that approval and sign off by a professional electrical engineer is obtained. The following

are best practice guidelines that the contractor can follow providing the mechanical

compliance of the joint is maintained:

The explosion-proof Spark Gap Type ExFS (minimum acceptable shall be according to

EN62561-3 or IEC 62561-3) shall be installed across the flange faces complete with hot-dip

galvanized mild steel mounting brackets to suit the flange bolt. The width of the holding bracket

of the explosion-proof spark gap shall be the same as the steel insulating washers and the

bottom end be rounded off to fit into the spot faced area of the valve and/or steel flange.

If required for AC mitigation, a steady-state DC decoupler (SS-DCD) device or technically

compliant equivalent shall be installed across the flange faces complete with surge rated non-

corroding metal mounting brackets to suit the flange bolt. The DCD shall be located in a

suitably rated enclosure as stipulated in SANS/IEC 79 and SANS 0108.

In the absence of a DCD, a spark gap device (as specified above) or technically compliant

equivalent shall be installed across the flange faces complete with hot-dip galvanising mild

steel mounting brackets to suit the flange bolt.

Installation of the brackets is to be in strict requirements with the OEM requirements ensuring

that there is adequate mechanical, metal, electrical contact to the metal surface with minimal

coating damage to the surface.

7.8. Identification and Protection of Isolating Flange

Visual, physical and insulation testing is required at IF installations. Positive visual

identification in the form of an approved paint system, aluminium punched tag (minimum

12mm punch die) (and ID) is required for traceability and routine testing requirements. The

identification of IF installations using paints, tags or labels shall be submitted to the engineer

for approval.



7.8.1. Protection of IF Installations

All IF testing is to be completed and signed off together with the installed surge protection

device before protection of the IF can be supplied and installed.

No painting over the studs, nuts, bolts and washers.

Protection of the IF installation is to be installed to cover the gap between the flange faces

only. If possible an opaque covering should be used to allow for visual inspection of the

sleeves and/or gap.

Flange protection devices and/or tape wrap systems approved by the engineer shall be

installed.

Nuts are to be protected against corrosion and rust, nut protection covers are to be

installed.

7.8.2. Wrapping of the IF Installation

The engineer shall specify whether or not the IF installation shall be wrapped and will be

determined by the following environmental considerations:

Likelihood of flooding.

Likelihood of conductive material build up on the exposed surface of the flanges.

The entire isolating flange shall be wrapped circumferentially with a 1.5 to 2.0mm thick white

plastic backed polymer modified bituminous tape, or similar approved. The latter shall have a

minimum overlap of 25mm. In the case of surface irregularities, i.e. stepped flanges, etc. A

CLIENT approved Petrolatum mastic material shall be used to provide a smooth contour for

subsequent tape application.

The isolating flange shall be wrapped circumferentially with a 1.5 to 2.0mm thick white plastic

backed polymer bituminous tape, or similar approved. The latter shall have a minimum overlap

of 25%. In the case of surface irregularities, an approved Petrolatum mastic material shall be

used to provide a smooth contour for subsequent tape application.

The entire isolating flange should be wrapped circumferentially with a white plastic backed

polymer modified bituminous tape, or similar approved, 1.5 to 2.0mm thick with a minimum

25mm overlap.

In case of surface irregularities, i.e. stepped flanges, etc., an approved mastic material shall

be used to provide a smooth contour for subsequent tape application.



The entire isolating flange should be wrapped circumferentially with a white plastic backed

polymer modified bituminous tape, or similar approved, 1.5 to 2.0mm thick with a minimum

25mm overlap.

In case of surface irregularities, i.e. stepped flanges, etc., an approved mastic material shall

be used to provide a smooth contour for subsequent tape application.

7.8.3. Visual Identification of IF Installations

For coding, a red colour band of 30mm width shall be applied in the centre on the horizontal

surface. The tape shall be a plastic backed electrical tape to SANS 1222. A 2mm thick

aluminium plate shall be fixed to the isolating flange with stainless steel strapping. The

following shall be stamped thereon in 20mm high characters filled with black indelible ink:

“OPERATING ISOLATING FLANGE”

“NO ATTACHMENT TO PIPEWORK PERMITTED”

“VALVE CHAMBER TO BE KEPT DRY”

“DO NOT PAINT”

7.9. Electrical Insulation Testing Of Isolating Flanges

Electrical insulation testing of the joint (IF and surge protection) must be conducted after

installation confirming that the isolating joints are in compliance with the specifications and

drawings.

The Contractor is to submit a detailed QCP of their IF insulation testing procedure together

with test report formats for approval by the engineer. Once joint integrity has been confirmed

a data book for each IF must be prepared for sign off once:

All material certifications for the IF kit and surge protection device are on hand and

signed off

Joint integrity has been tested and confirmed including torque tightness and pressure

tests

Visual inspection has confirmed that all isolating sleeves, washers, steel washers etc.

are in place

Surge protection device has been installed.



The IF inspection shall be witnessed by The Client, the CP Design Engineer and the IF

installation contractor.

The procedures for the electrical insulation tests on the IFs to be performed as a minimum are

detailed below:

OPTION 1

Switch off Transformer Rectifier.

A free-floating compass shall be placed on top of the isolating flange. The needle

normally aligns itself along the pipeline axis. If strong stray currents are present the

needle may align at an angle to the pipeline.

A 12 Volt heavy-duty car battery or DC welding generator should then be used to bridge

this isolating flange. If the isolating flange is functioning correctly, no significant

deflection of the needle will be observed. If the isolating flange is not functioning, the

compass needle will deflect to a position orthogonal to the pipeline.

The current drawn from the battery is an additional indicator of flange integrity. A short

circuited IF will typically draw in excess of 200A.

Before changing a faulty isolating flange assembly, a bolt by bolt continuity check should

be carried out to determine if the problem is not a faulty bolt, isolating sleeve or isolating

washer.

Re-testing must be carried out upon replacing faulty components.

OPTION 2

Short wave radio frequency testing device such as the Tinker and Rasor IFTM tester or

equivalent shall be used.

Testing across the flange face and across the stud to flange interface of each stud is to

be tested, recorded and verified.

7.10. IF Installation Guidelines

Guidelines pertaining to ordering, installation, torqueing and electrical protection of IF

installations is given under Annexure E: Isolating Flange Guidelines.



8. CATHODIC PROTECTION TEST STATIONS

8.1. Potential Criteria for Cathodic Protection

There are several techniques used to verify the levels of efficacy of the Cathodic Protection

(CP) system to ensure that the minimum specification guidelines are adhered to. For buried

steel coated pipelines, the pipe-to-soil potential measured with respect to a calibrated copper

to copper sulphate reference electrode (CSE) will be used as the criterion for corrosion

protection.

In general, the natural potential of steel (i.e. iron) in soil with respect to CSE is in the region of

-0.4 to -0.5 Volts (DC).

The buried water pipeline shall be regarded as being under effective CP when a negative

(Cathodic) potential of at least -0.95V (with reference to a CSE) with the Cathodic Protection

applied is measured. Voltage drops across the structure-to-electrolyte boundary must be

considered for valid interpretation of the voltage measurement. This additional negative

potential i.e. more negative than -0.85V is required for mitigation against microbe induced

corrosion and effects.

A 100mV (0.1V) minimum polarisation obtained between the carbon steel surface of the

pipeline and a stable reference electrode contacting the electrolyte can be used as an

alternative measure. The formation or decay of polarisation may be measured to satisfy this

criterion.

8.2. Locations

The test station location and positioning shall be selected based on a number of

considerations, such as:

On the pipeline servitude and pipeline right of way (ROW),

Risk of vandalism, theft and/or general damage;

Access relating to operation, maintenance and monitoring;

Possible damage by agricultural vehicles, plant vehicles, etc.

Test stations are to be constructed over the pipeline within the servitude. Locations where test

Stations are to be installed are listed as follows:



Pipeline crossings (Client and foreign) which are cathodically protected and

major pipeline (> 200mm OD) crossings which are not cathodically protected.

Other utility crossings which are cathodically protected and major pipeline

(>200mm OD) crossings which are not cathodically protected.

Sacrificial anode locations, unless otherwise specified by the Pipeline owner.

Either side of electrified and non-electrified railway lines.

AC power line utility corridors as a minimum at the crossing point, parallel

sections at the start middle and end of these parallelisms.

Either side of all national, provincial and major roads.

At all cased, directional drilled and/or pipe jacked crossings.

On one side of all frequently used (greater than 50 vehicles per day) roads

and/or heavy haul sand / dirt roads.

AC mitigation stations.

Major water crossings (on both sides) where water flows for at least 6 months

of the year on a continuous basis and the river crossing exceeds 3m in length.

Reservoirs.

In stray current environments, TP are to include IR-Free reference electrodes

as and where The Client specifies.

Every 1 km (maximum separation between any two TPs).

Other locations The Client considers important.

8.3. Test Station Installation Options

Test stations will fulfil various roles as follows and can be located as follows:

Free standing test stations (concrete, galvanised construction or material specified by

The Client).

Valve chambers.

Buried test stations are test station facilities designed with burial or below ground

construction in mind.



8.4. Types Of Test Stations

Type Description With AC

A Monitoring Test Station FA

B IR Free Station (SRE installed) FB

C Cross Bonding Station FC

E 4 Wire Current Span Station FE

F AC mitigation installed F

Note: Temporary CP test posts will be variations of

the A, B, C, E and F type test posts with the addition

of sacrificial anode/s as set out in the Bill of

Quantities or as directed on site by the Engineer.

8.4.1. Pipe-to-soil Potential Monitoring Test Station (MTS) (Type A)

These are to be located nominally every 1000m over a given pipeline route or as specified by

The Client.

Preferably MTS are to be installed adjacent to valve chambers and/or at other significant

locations as detailed in the MTS listing and installation schedule.

This standard monitoring test station comprises two single core 16 mm² black double insulated

cables exothermically welded to the pipe.

MTSs will have a DC coupon installed. Refer to Section 8.5 for details.

8.4.2. IR-Free Test Station (Type B)

These test stations will be used to measure “IR-free” potential readings. They will be located

as specified or at minimum every 5 km. These test stations will contain two 16 mm² black

double insulated cables exothermically welded to the pipe.

In addition, a separate buried stationary reference electrode (SRE) and a separate steel

coupon are to be installed. The SRE will be connected to the test station with 6 mm² yellow

cable and the coupon will have one 2-core 2.5mm² blue PVC/PVC cable. The construction of

the IR-Free Test Station shall be specified by The Engineer.

Each coupon shall be connected via a reed switch or a fuse link (10A slow-blow).



8.4.3. Cross Bonding Test Station (Type C)

Cross bonding test stations allow current to pass from one buried structure to another. Caution

should be exercised when testing or maintaining the system at these stations due to the

current flowing. The pipe shall be cross bonded as follows:

To other “foreign” pipelines,

To other foreign utility structures

To parallel pipelines where a common cathode is required,

Current bond required for Cathodic Protection requirements

Bonding cables from the foreign pipe to the test station shall be one 2-core 16mm² SWA cable

or as specified by The Engineer.

Bonding test stations are to be constructed of reinforced concrete, galvanized steel or material

specified by The Client.

The Test stations are to be installed over the pipeline.

The contractor shall supply and install a ceramic wire wound resistor with the resistance range

and wattage as specified in the Bill of Quanitites. If not specified in the Bill of Quantities the

minimum ceramic wire wound resistor shall be adjustable from 0 to 5 Ohms and rated at 500

Watts. These resistors shall be wound in such a manner so that they can fit comfortably into

a standard galvanised test post of concrete type bunker.

8.4.4. CP Test Stations with Temporary CP

Temporary CP may be specified during upfront pipeline construction or at times when there

are prolonged outages on impressed current CP (ICCP) systems. This will be provided using

sacrificial anodes.

For upfront pipeline construction, this will be used for short lengths of pipeline. However, once

the pipeline sections reach a longer length and start becoming subjected to stray currents, the

temporary protection will be provided with impressed current systems.

The temporary CP station will comprise a standard MTS with facilities to connect and dis-

connect the associated sacrificial anodes as and when required. The MTS will be connected

to bagged magnesium anodes (as the need arises). Once the sacrificial protection is no longer

required, the magnesium anodes will be disconnected from the test station and the test station



will therefore function as a MTS. The type of test post to which the magnesium anode is

temporarily attached will be specified in the Bill of Quanities or the Engineer will direct the

Contractor on site to install anodes where deemed necessary.

8.4.5. 4-Wire Current Span Test Station (Type E)

These test stations will be used to measure the magnitude and direction of current flow at

selected locations along the route to monitor stray current activity.

One 2-core 16 mm² SWA PVC/PVC cable (upstream) and two single core 16 mm² SWA

PVC/PVC cables (downstream) will be used for each test station. The first cable will be

connected to the pipeline 1m downstream of the test station (yellow), the second cable will be

located 1m away from the first cable (blue), in the upstream direction, the third cable will be

located between 90 -125 m away from the second cable (black), in the upstream direction and

the last cable (red) will be 1m away from the third, in the upstream direction.

One test station will be located within 1km from each cathodic protection rectifier.

8.4.6. Test Station with AC Mitigation Hardware (Type F)

Any test station that has AC mitigation hardware and/or gradient control installed.

8.5. Coupons

The design life of the coupon should be such that it will be able to operate continuously for 20

years under conditions of full cathodic protection. The coupons shall be used in conjunction

with either Copper Sulphate or Silver Chloride reference electrodes to achieve essentially IR-

free or instant “off” potentials in terms of NACE RP0169, NACE RP0104 and BS EN 13509.

The coupon shall be designed to operate in a temperature range between 0°C and 50°C. Each

coupon shall have a unique identification number and sizing certificate to suit.

The Engineer shall specify the construction layout of the coupon, particularly if this is to form

part of the IR-Free test station.

Coupon suppliers/manufacturers shall provide the following information with their QCP for

approval by The Client:

Record of manufacturing coupons with a 10 year, or longer, intended design life.

QA/QC documentation of coupons previously supplied to industry with verifiable

track record i.e. contact persons and names.



Coupons previously supplied should have a service life of more than 10 years with

traceable records.

Substantial evidence of product performance comprising a mixture of local and/or

international customers that may be verified by The Client.

The coupon shall comprise a round steel elements that is flush mounted into a suitable acid,

alkali and chemically resistant epoxy. The coupon material shall be similar to the pipe material.

Details of the proposed coupon material shall be approved in writing by The Engineer before

manufacturing commences. The coupon shall be connected to a standard 2 core 2.5mm2

cabtyre cable with all the connections encapsulated in epoxy. The cabtyre shall exit the

coupon assembly via a suitably sized cable gland. The cabtyre cable length i.e. tail, shall be

specified by The Engineer.

For AC measurements the coupon shall be machined from an 11 mm diameter steel rod. Each

AC coupon shall be connected via a resistor only if specifically requested in the Bill of

Quantities.

For DC measurements the coupon shall be machined from a 36 mm diameter steel rod.

Random testing will be carried out on 10% of the coupons manufactured and supplied. The

random testing shall be carried out as follows:

Select coupons.

Check coupon dimensions.

Check assembly and physical appearance for compliance in terms of the specification.

Sign off.

8.6. Stationary Reference Electrodes (SRE)

The SRE design life should exceed 15 years’ active use and will be used in conjunction with

bare steel coupons to allow for “IR-free” potential measurement in terms of NACE RP0169,

NACE RP0104 and BS EN 13509.

The SRE installation position (3 or 9 o’clock) shall be determined by The Engineer on site and

shall be placed in the same soil as the pipeline adjacent to the coupon station or independent

coupon at a distance from the pipe as specififed in the approved typical construction drawings

or as directed by the Engineer on site.



SRE suppliers/manufacturers shall provide the following information with their QCP for

approval:

i. Record of manufacturing SRE with a 20 year intended design life.

ii. QA/QC documentation of reference electrodes previously supplied to industry

with verifiable track record i.e. contact persons and names.

iii. SRE previously supplied should have a service life of more than 10 years with

traceable records.

iv. Substantial evidence of product performance comprising a mixture of local

and/or international customers that may be verified by The Engineer.

The SRE should be commercially available from a reputable supplier with a proven track

record. The Contractor must supply full details of the intended manufacturer.

The Client shall determine whether or not the SRE shall be used to monitor coupons complete

with and approved PC Board. The shunt shall be rated at 20W and 0.1Ω as a minimum and a

Reed Switch shall be used to interrupt the coupon during testing. Push button and toggle

switches are not permissible.

Note: The Contractor shall price for a PC Board that allows for simultaneous

monitoring of two coupon feeds, whether or not the BoQ states the specific

details of a PC board being used at test stations that have coupons installed.

The permanent burial type SRE shall consist of an encapsulated ceramic tube with protective

end caps.

Stability to be <10 milli-volts (mV) with 3 micro-amp load in a temperature range of 0oC to

57.2oC.

8.6.1. SRE Manufacture Specifications

Full data packs of the design detail of the proposed reference cell must be submitted. Failure

to do so may disqualify the bid. A standard drawing detailing the reference cell is included in

this technical specification.

The SRE shall display high stability under conditions of continuous measurement and when

inactive or not attached to an external measuring circuit.



The reference cell stability shall be tested before shipping and shall comply with the following

limits:

• 2mV potential shift after application of 0.1μA for 30 seconds,

• 12mV potential shift after application of 1.0μA for 30 seconds.

The SRE shall be designed to operate in a temperature range between 0°C and 50°C. Full

details pertaining to the chemical composition, calibration procedures, manufacture process

and drawings of the SRE shall be submitted at the time of tender. Each SRE shall have a

unique identification number and calibration certificate to suit.

Random testing will be carried out on up to 10% of the reference cells manufactured and

supplied.

9. ICCP ANODE GROUNDBEDS

9.1. General Description

The actual length of each groundbed is presented in the CP design report. However, each

groundbed has the following common features:

Anodes.

Canisters.

Spacer canisters.

Coke breeze backfill.

Sand fill.

Bentonite.

Positive header or ring main cable.

Watering system.

Cable warning tape.

The watering system will be installed during the groundbed construction.

Cable warning tape (yellow on black) will be installed at a depth of 600 mm below

surface along the entire length of the groundbed.

Anode junction box and concrete markers (markers to be installed only if so specified

in the Bill of Quantities).



The Contractor shall await The Client’s instruction to proceed with groundbed construction.

The Contractor is to supply detailed QCP for approval. All materials are to be pre-inspected

and signed off with the material certification data book.

9.2. Groundbed Components

9.2.1. Watering System

Watering systems shall be provided to enable groundbed hydration during dry seasonal

periods.

The watering system shall consist of a ribbed and slotted, double walled PVC drainex pipe,

110mm in diameter, typically 6m in length. The pipes should be coupled together suitably and

the end of the pipe must be closed with an end cap. The pipe along its full length is to be

covered by one layer of flow net and then by one layer of Bidim cloth A2.

Note: The Contractor shall ascertain at the time of tender which of the following options The

Client wishes to implement:

The pipe shall be fed using a 50mm HDPE pipe from the closest valve chamber.

The pipe shall be laid in the same trench as the groundbed header cable.

Terminate the pipe in small manhole at ground level (at highest point) and charge

pipe via water tanker when required.

9.2.2. Anode Cabling

No cable joints are permitted in these systems. The outer insulation of the anode cables shall

be fluorocarbon based e.g. PTFE, PVDF (KynarTM), ECTFE (HalarTM), ETFE (TefzelTM). The

anodes will be supplied with certification to this effect.

The cable size to be used for the anode positive cable connection shall be stipulated by The

Client. All positive anode cable insulation shall be PVC / HMWPE / PVDF or PVC / PVC /

Halar insulation. The minimum thickness of each layer of the insulation shall be 2mm. No

cable joints will be permitted under any circumstances in the buried or submerged portions of

the positive anode cable. The minimum cable to anode breaking strength shall be greater than

the cable breaking strength.

The anode tails shall be sufficiently long to terminate directly into a suitably rated DC

distribution cabinet / enclosure, cognisance shall be taken of the area classification,

environment, type (concrete, galvanised steel or as specified) and rating of enclosure required.



Anodes may be connected in pairs.

Cable warning tape will be inserted above the groundbed, at a depth of 600 mm below grade.

The positive cable from the groundbed to the TRU shall be encased in concrete as shall the

power supply cable.

Cable warning tape (yellow skull and bones with associated wording) shall be placed along

the entire length of the horizontal anode bed at typically 500mm below grade.

9.2.3. Anode Junction Box

A concrete bunker shall be installed on top of the anode groundbed in the case of a deep well

and at a position indicated by The Engineer in the case of shallow vertical groundbeds. The

anode tails as well as positive cables from the TRU shall enter the anode junction box via an

HDPE conduit.

The anode tails and the TRU positive cables shall be terminated in the standard terminal

blocks.

9.2.4. Anode Canisters

Anodes shall be pre-packed in spirally welded galvanised steel canisters that are thick enough

such that each canister is self-supporting, as per Bill of Quantities. Both ends are to be sealed

off with galvanised steel end caps and have a side gland conduit for the exit of the anode

cable. The anodes will be centrally located within the canister and the annular space between

the anode and the canister will be filled with coke breeze.

Care shall be taken in the storage of these anode canisters to ensure they are stored in

controlled areas.

Anode canisters filled with coke breeze shall be used as spacer anodes, in order to ensure

that the correct anode separation is achieved, in horizontal anode beds. This is not required

in vertical distributive systems.

Each anode shall be centralised inside its canister and encapsulated in coke breeze. Cable

glands are to be used for exit of the tail cable as to avoid damage that can be caused by the

sheet metal.



9.2.5. Cable Warning Tape

Cable warning tape shall be placed along the entire length of the horizontal anode bed at the

required depth below grade at 600mm.

9.3. Anodes

9.3.1. Mixed Metal Oxide Anodes (MMO)

The MMO and PMO (precious metal oxide) anode operating voltage shall not exceed 50V for

soil and 9V for sea water and halogen polluted applications. The latter assumes that no Halide

pollutants are present such as Fluorine (F) or Bromine (Br). Where deleterious pollutants are

to be expected, the precise soil and ground water chemistry shall be determined, prior to the

use of any MMO/PMO anodes. The anode manufacturers maximum current output for the

various anode configurations and dimensions shall not be exceeded under any circumstances.

The anode current output and other parameters shall be submitted during the quotation or

proposal stage.

In addition to the certification provided by the manufacturer, two anodes from each batch will

be subjected to the following range of destructive tests at an independent laboratory:

Test Minimum requirements/Test Method

Test solution 10% by volume sulphuric acid

Test temperature Less than 50 ºC for duration of test

Test Current Density 20 kA/m2 min

Test Duration Minimum 35 days at the specified current density

Coating adhesion test ASTM B 571

X-Ray/NDT The tubular anode shall be X-Ray’ed in order to ensure that

bubbles are not contained within the epoxy sealant

Metallurgical and SEM

analysis

Anodes will be sectioned and the MMO/PMO coating

verified

The anode tails will be 10 mm² PVDF/ HMWPE/ PVC.

All anodes, regardless of type shall be rated for at least 2A, 60Ayr and 25y life.

Anode dimensions and loading parameters shall be specified in the CP design document and

the Bill of Quantities.



9.3.2. Chemical and Performance Testing of Anodes

A specified number of anodes will be randomly selected from the batch to be supplied and

tested as detailed below. The anodes for testing will be selected as per BS 6001/ISO 2859-

“Specification for sampling plans indexed by acceptable quality level (AQL) for lot-by-lot

inspection”.

The anodes will be tested by an accredited third party laboratory, such as MINTEK, in order

to confirm compliance with the specification. Details of the third party laboratory must be

approved by The Client prior to testing.

The maximum cable to anode resistance shall be 10 m. The cable shall be pulled or tugged

initially as a test after making the cable to anode connection.

9.3.3. Carbonaceous Backfill

Carbonaceous backfills include various coke products produced from coal, tar (pitch cokes)

and bitumen (petroleum cokes) and graphite granules. The coke is in essence the solid

residue left from coal after its volatile constituents have been driven off by heating in the

absence of air and as such, coke is amorphous. This also implies that any metallurgical coke,

contains significant amounts of sulphur, ash and volatiles. The ash also generally entraps the

heavy metals, such as lead, cadmium, mercury, copper, zinc, etc, which would not be

environmentally acceptable.

The effective resistivity of the soil surrounding an electrode (anode) is confined to the

immediate region of the anode, it is therefore common practice to reduce the local resistance

by using these so-called backfill materials. The backfill being a conductor, “carries” a measure

of the current, reducing to some extent, the consumption rate of the anode. Therefore, the

essential purpose of the carbonaceous backfill, is to lower the anode/soil interface resistance,

increase the current capacity by increasing the effective anode area and thus prolonging the

anode’s life. The backfill must also allow for the egress of anodic gases during its normal

operation and be as environmentally safe and friendly, as possible.

Preference shall be given to pitch coke, however, calcined petroleum cokes may be permitted,

providing that it is fully compliant with the technical specification. The supplier must be an ISO

9002 or equivalent accredited organisation. Alternatives will only be permitted to be used upon

written approval from The Client.

Coke breeze with the following chemical composition shall be used:



Element/Compound Specification Test Method

Fixed Carbon 99.5% min By calculation – 100% minus (%ash

+ VCM)

Sulphur 0.25% max ASTM D 4239

Ash and volatiles 0.50% max Ash – ASTM D 4422

Volatiles – BS 1016: Part 4

Moisture 0.15% max ASTM D 3173

Bulk density 1000 kg/m3 max ASTM D 527

Resistivity 55 Ωm max Alusuisse C-109

The particle size distribution (PSD) of the impressed current anode backfill material is a very

important variable and shall vary according to the anode material and burial depth. The PSD

shall be determined in accordance with the following specifications ASTM D293-69, BS.

Anode Type Environment Burial Depth Max. PSD Min. PSD

MMO/PMO Soil / Brackish < 15m 100% < 1.0mm 5% < 0.5mm

MMO/PMO Soil / Brackish > 15m 100% < 1.5mm 5% < 0.5mm

MMO/PMO Soil / Brackish > 50m 100% < 2.0mm 5% < 0.5mm

Silicon Iron Anode All All 100% < 3mm 5% < 0.5mm

Technical motivations for the use of other PSD will be considered by The Client, should the

above values not suffice.

The particle size distribution shall be a maximum of 100% < 1.0 mm and a min of 5% < 0.5

mm.

The backfill material shall be supplied in 25kg polypropylene bags, or suitable size that may

be available, that are to be packed on palettes to a safe height and weight.



The Contractor shall make provision in the quotation for adequate testing by an approved third

part laboratory. At the time of quotation the Contractor shall nominate a suitable laboratory

capable of carrying out the tests required to assess compliance with the standards of this

section of the quotation document.

2 weeks prior to delivery 10 randomly selected 500g samples drawn by the Engineer from the

materials at the Contractor’s premises will be sent to the nominated laboratory for testing to

confirm compliance with the standards set in this section of the quotation document. Should

any of the randomly selected samples fail to comply with the said standards the Contractor

shall then conduct further tests at his own expense to verify the compliance of the remaining

materials. Should compliance not be achieved the materials shall be rejected by the Engineer.

The rejected materials shall be replaced at the Contractor’s expense.

9.4. Groundbed Installation Types

9.4.1. Shallow Horizontal Anode Ground Beds

The contractors shall supply Anodes as specified in the bill of quantities. Shallow horizontal

groundbeds will contain mixed metal oxide (MMO), encased in galvanised steel canisters, with

each canister spliced alternatively to the positive ring main cable. The anode canisters will be

2 m in length, 200 mm diameter, while the spacer canisters will be 1 m long, 200 mm diameter.

The groundbed shall consist of a number of anodes installed horizontally at a specified

distance away from the pipeline and shall have a spacing of 1 x anode or anode canister

length between them .

The depth of the anode trench shall be at depths as specified but care should be taken when

exceeding 2 meters below natural grade level.

The bottom part or third of the groundbed shall be filled with calcined petroleum coke covering

the anodes with at least 300mm of coke.

The second third with selected backfill and the last third with backfill to grade level.

All depths are to be verified and signed off by The Contractor and The Engineer.

Watering systems will be provided to enable the groundbed hydration during dry seasonal

periods and to prevent groundbeds from drying out.



9.4.2. Vertical Anode Ground Beds

Anode centralisers shall be employed in order to locate the anodes in the centre of the coke

column / groundbed. Centralisers shall be designed as such that they do not cause bridging

of the coke backfill. Coke is then to be poured/pumped into the borehole in order to ensure

that the anode is surrounded by pitch coke. The coke must be pumped as a wet mixture when

MMO / PMO anodes are used.

The Groundbed shall consist of a number of shallow vertical holes drilled or augured to a

maximum depth and diameter as specified with a minimum spacing of 3m at positions as

indicated by the Engineer and a 165mm nominal diameter steel casing shall be installed where

the stability of the hole above is doubtful. The exact numbers of holes, spacing and dimensions

as well as quantities of coke are given in the Bill of Quantities.

Anode strings shall be installed centrally inside the coke bed with individual tails being brought

to the level of the positive cable trench from where they shall be run to the position of the

anode junction box.

The vertical position of the anodes in each hole shall be given in the Bill of Quantities.

The Engineer shall witness the entire anode Groundbed installation.

9.4.3. Vertical AGB Anode Installation

The bore holes shall be drilled by an approved professional drilling contractor registered with

the Borehole Water Association. Contractors are to submit details of the company they intend

to use for this activity.

Relevant deep soil resistivity tests shall be carried out as directed by The Engineer.

The main borehole shall be drilled as follows (unless stated otherwise in the Bill of Quantities):

The Engineer shall specify the dimensions of the AGB and may vary from those

provided in this specification.

A 36cm diameter hole shall be drilled to the depth of the inactive zone.

A hole of 25cm diameter shall be drilled to accommodate the active zone.

A 25cm diameter steel casing (schedule 20) with a closed bottom (welded closed)

shall be inserted for the full borehole length.

A 30cm diameter PVC casing shall then be installed on the outside of the steel

casing for the length of the inactive zone.



Drilling depths as well as quantities of coke and river sand are given in the Bill of

Quantities and/or drawing.

The Engineer shall witness the entire anode Groundbed installation.

Graded washed river sand with a particle size distribution of 0.5 mm to 3.5 mm shall be poured

into the anode bed to a depth of 1.5 m below grade level. The remaining 1.5 m to grade level

shall be sealed with Bentonite.

Note: The Bill of Quantities may state different dimensions, quantities and types of materials

and shall be read in conjunction with the specification. The BoQ shall be used as the

measure for pricing and installation purposes. Where a significant conflict arises the

details should be presented to the Engineer in writing for a final determination.

The anode tails shall be terminated into a suitably rated DC distribution cabinet / enclosure.

Inside process plant areas, cognisance shall be taken of the area classification, environment,

type and rating of enclosure required.



10. SACRIFICIAL ANODES

10.1. Magnesium Anodes

The performance characteristics of the 1.75V high potential magnesium alloy, is detailed

below. The high potential alloy is specially formulated from pure virgin magnesium and other

elements to produce a higher voltage. The advantages of the high potential anode versus its

1.55 V counterpart, is as follows:

The higher driving potential permits fewer anodes in this specific application;

The capacity of a high potential anode is some 4 % greater than that of the other anodes,

improving the overall life of the anode;

The anodes shall be manufactured in accordance with ISO 9002. The contractor shall submit

written confirmation from the relevant standards authority, confirming complete registration in

this regard.

The anode shall be free of blow holes, cold laps, porosity seams and any other imperfection

which may impair its performance. Extruded anodes shall be used and cast anodes may be

used if approved by The Client.

A 5mm diameter pre-galvanised steel threaded stud or rod shall be centrally located within the

anode. The latter shall extend for at least 95% of the anode length and shall be extruded or

cast into it. The pre-galvanised threaded steel stud or rod shall be suitable for the electrical

connection of the anode to anode cable, which shall terminate in a recess at the one end. The

connection shall be suitable for 20 years under submerged conditions.

In all instances a suitable hole will be drilled into the end of the thread or rod and the cable

shall be brazed / soldered into the hole.

The insulation of the cable shall be removed for a length such that at least 25mm of the copper

is inserted into the drilled galvanised steel rod hole.

The cable shall then be brazed / soldered into the hole. At least 25mm of insulation shall

extend into the anode recess.

Mechanical connections between the anode cable and the pre-galvanised steel rod or thread

shall not be permitted under any circumstances.



The anode recess shall be completely flooded with hydrochloric acid (10% solution) resistant

epoxy. All proposed epoxies shall be submitted to The Client for review, prior to their use. The

epoxy shall completely fill the recess without spilling over onto the external surface of the

anode.

No bare copper cable shall extend outside the epoxy; the insulation shall extend at least

25 mm into the epoxy as stipulated above.

The maximum cable to anode resistance shall be 10 m. The cable shall be pulled or tugged

initially as a test after making the cable to anode connection.

Magnesium anode locations will be designated by The Engineer. The hi-potential anodes,

manufactured from virgin material, shall have the following composition:

The anodes will be pre-packaged in a cotton bag with a backfill containing 70% gypsum, 25%

bentonite and 5% sodium sulphate. The volume of the backfill shall be such that there is a

minimum of 35mm surrounding each anode.

The anodes will contain a steel core, onto which the anode cable connection will be soldered

and the connection will be covered in an appropriate epoxy. No mechanical connections

between the cable and the steel core are allowed.

10.2. Typical Installation Details

All anodes shall be installed at a minimum depth of 2.5m or pipe invert depth, whichever is the

deeper. The anodes shall be located a minimum of 3.5m from the pipe or as determined by

Element Composition (%)

Al 0.01 max

Mn 0.5 – 1.3

Cu 0.02 max

Ni 0.001 max

Fe 0.03 max

Zn -

Other 0.05 max each or 0.3 total

Mg Balance

Potential (V) -1.7

Capacity (Ahrs/kg) 1100



the CP Design. The anode / pipe separation distance shall be stipulated in the bill of quantities

of the RFQ document.

The distribution of the anodes shall also be stipulated in the in the bill of quantities of the RFQ

document.

The cable connection, installation and backfilling / reinstatement shall be witnessed by The

Client.

10.3. Chemical and Performance Testing of Anodes

A complete set of both chemical and metallurgical tests shall be conducted on a number of

randomly selected anodes, as determined in accordance with BS 6001, Part 1, prior to

installation of the anodes. All of these costs shall be borne by the supplier/installation

contractor Anodes may only be installed subsequent to testing and review from The Client.

Complete chemical and metallurgical compliance shall be ensured prior to their installation

and a detailed report shall be submitted to The Client for review. Testing shall be carried out

at the contractor’s expense.

The anodes will be tested by an accredited third party laboratory, such as MINTEK, in order

to confirm compliance with the specification. Details of the third party laboratory must be

approved by The Client prior to testing.

The solution potential of the anode when fully submerged in the test chamber, shall be more

negative than -1,65 V with respect to a saturated copper / copper sulphate reference electrode.

The anode shall maintain this potential at a 100 mA output and shall possess a capacity of

1200 A.hrs/kg.

The natural anode potential and current drawn shall be measured prior to permanently

connecting the anode to the pipe / structure. This data shall be submitted with the

commissioning report.



11. TRANSFORMER RECTIFIER UNITS (TRUs)

11.1. Introduction

All powered units (TRU or FDU) will be standard / modular construction in order to minimise

the carrying of spares.

The general details of the sites are as follows:

Ambient Temperature: 10° to 40° C

Relative Humidity: 30% to 90%

Lightning risk: severe

The TRU’s may be used in environments where metallic dust, soot and grit may be present.

All structure bolts, washers and nuts shall be stainless steel. Bolts with spring washers are

preferred and “Nylock” nuts are permissible where devices being secured remain at ambient

temperature.

Where no TRU/FDU cabinet is specified the components shall be mounted on one free-

standing frame and access to all components, especially in regard to replacement of diodes

shall be possible without excessive dismantling. The frame shall be capable of being located

inside a reinforced concrete / brick or other specified enclosure.

Suitable lifting lugs (capable of carrying the total mass of the frame and all its components)

shall be incorporated onto the frame (or cabinet if specified) to allow safe handling and

installation on site.

11.2. Housing

The TRU’s are to be installed in reinforced concrete, coated steel, reinforced brick structures

or other structure types as specified. All components must be treated so as to provide

satisfactory service under the corrosive conditions of the proposed installation sites.

11.3. Power Supply

Input

400V, 3 phase, 50Hz or

230V, 1 phase, 50Hz



Typical Outputs (refer to Bill of Quanities)

0 - 50V DC

0 - 50A

11.4. Control

Selection of constant pipeline potential, constant current and manual voltage control for over

line surveys. Each selection must be controllable from zero to full output.

Facilities are required on rectifiers for switching in order to undertake over line surveying and

site commissioning testing.

11.5. Test Switch Facility

The rectifier must have a facility to plug in a switch on the output circuit for over line testing on

the protected pipelines. This requirement is irrespective of any built in timer which may be

provided.

Manual output voltage and current adjustment facility:

Over line surveying testing requires a "manual mode" to adjust to a constant voltage range

from zero to full output voltage, similarly the current depending on load resistance. This is to

enable over line testing at a pre-set output current.

Ideally the thyristor firing circuit of the rectifier can be switched with a switch through a

timer socket.

Firing cards must provide 100% balanced firing over all phases.

The adjustment of the firing card must be such that the rectifier attains full set output

current within 100ms of switching.

Irrespective of control mode, the TRU control equipment must be capable of output voltage,

output current and potential pre-set limits.

When the control equipment is changed from one control mode to another control mode, all

user programmable parameters must be automatically restored to minimum values to prevent

an instantaneous application of output voltage or output current to the load.



Note: Should the electronic PCB, automatic control or LCD display fail, the “manual mode”

shall allow the user to switch over to this mode and manually adjust the output voltage

and current to pre-set limits within the operating range of the TRU.

11.6. Rectification

The rectifier shall provide single phase bridge or 3 phase full wave six pulse (minimum)

rectification.

Control shall be provided by one of the following techniques, as set out in the Bill of Quantities:

matched thyristors in the primary circuit of the main transformer

control of the saturation current in a magnetic amplifier incorporated in the primary

circuit of the main transformer

fully controlled secondary thyristor bridge

switch mode

All semiconductors shall be rated at twice full load current and 1600V PIV. Forced cooling of

thyristors and semiconductor devices is not permitted. The efficiency of the transformer

rectifier unit must be not less than 85% at maximum rating.

Control stability must be within 3% of set point over the whole range, irrespective of control

mode selected.

11.7. Transformers and Chokes

Transformers must be continuously rated, double wound air cooled.

The transformer must have suitable windings on the secondary of the transformer to facilitate

coarse selection of the voltage. The windings must be so wound to provide coarse adjustment

of 33%, 66% and 100% of the step down voltage.

All transformers and chokes shall be earth screened.

Aluminium wound chokes are not permitted.

The Contractor shall comply with Annexure F: Local Content Requirements for Transformers

and submit the necessary contractual documentation to demonstrate compliance with this

tender requirement.



11.8. Instrumentation

11.8.1. Multifunction Digital Display

Note: Output indication may be by means of a multifunction digital display.

DC Output current (Analogue millivoltmeter with shunt located on load side of smoothing

devices)

Pipeline reference potential (Cu/CuSO4) (high impedance digital meter) Note: the input

impedance of the monitoring/feedback control circuit shall be a minimum of 10 megohms

in order to prevent polarisation of the stationary reference electrode.

Mains on indication

DC fuse fail indication

AC fuse fail indication

kWh meter

11.8.2. Additional Displays

The TRU will include high quality stand-alone analogue and digital display elements to indicate

the following;

i. Output Voltage – Analog, (display min. 75mm x 75mm).

ii. Output Current – Analog, (display min. 75mm x 75mm).

iii. Reference Potential DC – Digital, (display height minimum 12mm to 15mm readable

in sunlight).

iv. kWhr Meter – Digital, measuring and displaying SMU power only and no other auxiliary

TRU attachments.

The Output Voltage, Output Current and Reference Potential Meters shall be mounted in a

suitable location to facilitate easy reading and measurements.

The meters shall be arranged in such a way that the Voltmeter is to the left, the Potential

Display meter in the centre and the Current meter to the right of the resin board.



All digital meters must be either LCD or TFT display types and the display must be legible in

direct sunlight and from distance away of from the display of 2 meters. All of the Additional

Displays shall be mounted on the detachable display panel.

Captive (banana) sockets must be incorporated below the meters mentioned above and must

be continuously connected to the measurement points mentioned above. The captive sockets

connected to the output current measurement point must be labelled with the shunt rating i.e

50mV = (Maximum Rated current as held in the Bill of Quantities).

11.9. Alarm Indication

Mains fail indication by means of under voltage and phase failure (if applicable) relay (voltage

free contact)

AC/DC fuse fail (voltage free contact)

11.10. Testing Probes

Standard insulated banana socket points at 20mm centres for external measurement /

calibration.

Pipe-to-soil potential (Cu/CuSO4 reference electrode)

Rectifier output voltage.

Rectifier output current (from shunt – shunt rating to be indicated on label)

11.11. Protection

11.11.1. Surge Protection

Necessary surge protection must be installed to protect the rectifier and control circuits, both

input and output, against power surges and lightning. This shall incorporate a “pi” filter in the

negative leg of the TRU.

11.11.2. Electrical Protection

Necessary fuse and overload protection must be provided to protect the equipment. The

grading must be in a way to limit unnecessary trips. Phase rotation protection must be

installed.

DC Output fuses must be capable of carrying the full load current of the unit.



The input circuit breaker must be of the magnetic type to carry inrush currents after a power

failure in order to prevent nuisance tripping.

All protection devices, semiconductors, power devices and wiring must be matched to prevent

overheating and component failure due to overload.

All metal components shall be connected to the common earth and to the AC supply earth.

All electrical circuits shall be floating with respect to earth.

All earth connections within the enclosure must be as short as possible and rated at possible

fault current.

Earth buss bar mounting studs must be adequately sized to accommodate collective fault

current.

A separate earthing system will be provided for the TRU consisting of suitable earth rods and

bare earthing cable which will have a resistance below 10 Ω in compliance with SANS 10142.

See typical drawing showing grounding / earthing layout for TRU, which is applicable to FDU

and SMU applications.

The Contractor shall provide detailed drawings at the time of tender showing the earthing

arrangement for the unit, the layout, location and means of connection to earth from the

various components to demonstrate the principle of building the unit with the shortest distance

to earth, thereby minimizing resistance.

11.11.3. Radio Frequency Protection

The rectifier must be radio frequency protected.

11.12. Smoothing

Necessary smoothing of the output must be provided to prevent interference with telephone,

radio and other services.

Smoothing shall be such that the peak – trough amplitude of the output waveform shall be

less than 10% of the mean DC output voltage across the entire range of the rectifier unit. The

output ripple shall be measured using an oscilloscope with the rectifier connected to a pure

resistive load.



11.13. Cabinets

The rectifier and control must be mounted on a stainless steel skeleton frame suitable for

installation in a concrete enclosure where a cabinet is not specified. When a cabinet is

specified The Contractor shall provide detailed construction drawings showing the proposed

layout of all components.

11.13.1. Powder Coating for Chassis Plates

Coating shall comply with Type 5 of SANS 1274:2013 including the use of a wet primer.

Degrease, pickle and phosphate in accordance with powder manufacturer’s requirements.

Apply powder by means of electrostatic spray to ensure a final DFT of 120 micron.

Finish colour: white

11.13.2. Electronic PCB

All electronic printed circuit boards shall be coated with a proprietary military specification

conformal coating designed to prevent corrosion to the exposed component leads. All PCB’s

shall have a primary solder mask and legend.

11.14. Wiring

All current carrying conductors shall be insulated to withstand a minimum voltage of 1000V.

All wiring shall comply with the provisions of the Wiring Code of Practice; SANS 10142 (latest

edition).

All current-carrying conductors shall be multi-stranded, flexible and sized to adequately carry

the design current without a rise in temperature.

Thyristor gate leads (if fitted) shall be screened or twisted pair.

All conductors shall be terminated at each end with suitably-sized, pre-insulated lugs or pre-

insulated ferrules. No trimming of conductor strands will be permitted. All ferrules and lugs

shall be crimped with appropriately sized crimping equipment.

All primary and secondary power cables and control wiring must be marked to ease installation

and maintenance of rectifiers. Both ends of each cable shall be uniquely numbered in

accordance with the wiring diagram.



Cable markers must be colour coded as well as have their number embossed indelibly on the

marker. i.e.

0- Black

1- Brown

2- Red

3- Orange

4- Yellow

5- Green

6- Blue

7- Violet

8- Grey

9- White

Cable markers must be appropriately sized to suit the insulation size of the cable.

Cable markers shall read from cable to lug on all conductors.

All AC supply conductors shall be colour coded according to the incoming phase and retain

the colour nominated throughout the cabinet.

Positive and negative power cables shall have colour coded shrouds/shrink sleeve over the

lugs.

All conductors excluding busbars shall be routed in trunking or harnessed using polyethylene

spiral wrapping.

AC carrying conductors must be routed separately from DC carrying conductors.

Grounding cables connected to surge diversion devices must be kept as short as possible and

may not be routed with either AC or DC carrying conductors.

No more than two cables may be terminated at any one point.

All bolt on terminals shall be independently mounted with locknuts such that cables may be

removed without having to hold the terminal.

The positive and negative output terminals must be marked Pipe, Anode, Reference etc. to

prevent incorrect connections.

All terminals shall be completely accessible after completion of wiring.



All terminations made to buss bars shall be provided with spring washers.

All supply power terminations shall be enclosed and be highlighted with a warning label.

Transformer and inductor or smoothing capacitor terminations shall be covered with a

transparent cover prohibiting accidental contact.

Output terminals shall be fully insulated from any metal of the housing or chassis.

All terminals shall be clearly marked and sized according to the current the terminal will carry.

11.15. Power Point

A 230V AC power point with separate earth leakage must be provided for use of small

electrical hand tools and instruments inside the rectifier panel.

11.16. Drawings

Relevant drawings and manuals must be supplied with the rectifier.

A laminated schematic drawing of the rectifier must be installed in the rectifier.

11.17. Spares

A recommended spares list must be supplied.

Necessary breakdown spares must be installed in each rectifier comprising:

3 sets of fuses

1 set of semiconductors

1 set indicator lamps (if used)

1 set transient protection devices (other than chokes and capacitors)

11.18. Labelling

Terminals within a TRU/FDU/NDU shall be labelled as follows:

+ GROUNDBED or RAIL (depending on application)

- PIPE

PIPE MON

REF CELL

COUPON

EARTH



TELEMETRY

AC 400V or 240V (whichever is applicable)

SHUNT ??mV:??A (rating to be inserted for each unit type)

Labels shall be fixed by means stainless steel pop rivets such that they shall not become

dislodged during the life of the unit. Component and other labelling/marking shall be engraved

or fixed on fixed chassis and not on loose chassis or trunkings.

Labels shall be engraved trafolyte or other hard stamped equivalent. Labels shall be fixed to

the panels with screws. Adhesive labels are not permitted.

11.19. Inspection

All rectifiers will be inspected and tests witnessed by The Client’s representative prior to

despatch. All material, test and compliance certificates must be incorporated into the O and M

Manual.

The following tests must be carried out at the manufacturer’s works, after successful

completion of the tests a certificate will be issued by the manufacturer and signed by the

Engineer or his nominated representative. All testing and damaged components resulting from

the testing will be at the manufacturer’s expense and carried out at the manufacturers

premises. Adequate adjustable load resistances, adjustable power supplies and testing

equipment will be made available to the engineer by the manufacturer to verify specified

operational characteristics of the TRU under test.

11.19.1. Pre Power-up Testing

The various earth points, cabinet body, chassis plates and all exposed metal surfaces shall

be measured for continuity to the main earth terminal.

The cabinet and AC inputs, the DC outputs shall withstand a 1 kV insulation test. The insulation

testing shall be conducted with all circuit breaker and fuses in their normal operating position

without power or load connected.

11.19.2. Power On Testing

The TRU shall operate for a period of 6 hours continuously at maximum current and at full

rated voltage with all doors closed or until the temperature of the Rectifier heat sink is stable

for a period of one hour. Where the temperature continues to rise after a period of 7 hours the

equipment will be rejected. The ambient, cabinet compartment internal temperature, heat sink



temperature and transformer winding temperatures must be recorded during the heat run and

plotted upon conclusion of the heat run. K type thermocouples shall be used for the continuous

recording of the all the various temperatures.

Immediately after the heat run, the aforementioned insulation check will be carried out without

the power or load applied. A maximum heat sink temperature of 80 °C is permissible at the

highest vertical point of the heat sink.

Control mode testing shall be carried out after the conclusion of the heat run.

11.19.3. Constant Current Tests

The manufacturer will demonstrate the TRU’s ability to control the output current to within 5 %

of the pre-determined set point. The load resistance is to be manually adjusted to ensure that

the output current remains constant irrespective of the load resistance. Four specific current

set points are to be set 25%, 50% 75% and 100% of maximum rated output current. Voltage

at the given pre-determined set points will be recorded and noted in the O and M Manual.

11.19.4. Constant Voltage Tests

The manufacturer will demonstrate the TRU’s ability to control the output voltage within 5% of

the pre-determined set point. The load resistance is to be adjusted to ensure that the output

voltage remains constant irrespective of the Load resistance. Four specific voltage set points

are to be set 25%, 50% 75% and 100% of maximum rated output voltage. Current at the given

pre-determined set points will be recorded and noted in the O and M Manual.

11.19.5. Constant Potential Tests

The manufacturer will demonstrate the TRU’s ability to control the electrolyte to structure

potential within 50 mV of the pre-determined set point. Current limit and voltage limit features

are to be tested and verified whilst carrying out potential mode testing. Dynamic feedback is

required to demonstrate the control mode. That is, a simulated Cathodic Protection system

must be used to demonstrate the control mode. In the potential mode verification a variable

power supply may not be used to simulate the Reference Electrode.

11.20. Telemetry and Remote Monitoring

The rectifier shall be provided with outputs suitable for connection to a SCADA or remote

monitoring system. The outputs shall be potential free contacts for alarm and status signals,



and 4 – 20mA, 0 – 5V, or actual value for analogue signals. A comprehensive Ethernet Modbus

signal may be provided as an alternative.

Power consumption and quality monitoring:

Mains failure

Fuse failure

Output current

Output voltage

Pipe/soil potential

Detailed requirements for telemetry or remote monitoring will be determined by the project

requirements.



12. NATURAL DRAINAGE UNITS (NDUs)

12.1. General

Typically an NDU is a device connected between a pipeline and the return rail of a DC traction

system. The NDU allows current to pass through in a unidirectional manner i.e. when the

Pipeline becomes more positive than the rail, then current will pass through the NDU from the

pipe to the rail. When the rail is positive with respect to the pipeline no current will flow through

the NDU.

It is critical that the diode within the NDU be adequately sized and protected by a series fuse

which is selected to meet both the forward current and I2t rating of the Diode as well as the

cables. All field cable terminations will be made directly to sections of copper buss bar

designed for cable termination.

All current carrying conductors shall be suitably rated buss bars fabricated from copper. The

buss bars shall be capable of carrying a continuous current of 600 A. The temperature of the

buss bar shall not increase by more than 6°C above ambient at 600 A.

Joints and connections in the buss bars must be kept to a minimum. Suitably sized brass

bolts, flat washers and spring washers shall be used to secure the joint. The brass securing

bolt or bolts must have the same cross sectional area as the buss bar. The jointing faces must

be liberally coated prior to jointing to ensure oxygen exclusion at the joint face with a suitable

proprietary compound. Excess compound shall be cleaned from the joint after the joint has

been finally tightened at correct torque setting.

Copper buss bars must be tinned or white zinc plated irrespective of whether the buss bar is

sleeved with a heat shrink or plastic sleeve.

Diodes shall be of the silicon type. The Diode shall be a suitably rated hockey puck type and

shall be mounted between two aluminium heat sinks and clamped to manufacturers torque

settings. No parallel diodes will be permitted. Care must be taken when mounting the diodes

between the heat sinks to ensure that the faces to which the diode contact are absolutely

parallel.

The diode selected is to be rated at a minimum of 4 000 V peak inverse voltage and be capable

of a peak forward current of 2800 A. Stud mount diodes will not be permitted.

The resistor and capacitor used in the snubber network must be suitably rated to cope with

transients from both pipe and rail caused by lightning or switching surges.



The snubber devices are to be mounted separately, be easily accessible and must be as close

as possible to the diode, without being mounted to the heat sink. Connections to the snubber

devices must be kept completely separate from any other wiring in the NDU.

A 50mV shunt must be installed in series with the cathode leg of the diode immediately after

the diode. The sensing terminals of the shunt must be brought out to captive insulated test

stations (Banana Sockets) to accommodate banana plugs. A 72 x 72mm panel mount moving

coil milli-volt meter must be installed. Full Scale Deflection of the meter must be 600 A and

graduated in minor divisions of 20 A with major graduations of 100 A. The banana sockets

must be mounted below the moving coil meter. The accuracy of the panel meter must be better

than 1.5%.

A substitute shunt rated at 60A with the same physical stud spacing as the 600A shunt must

be provided with the unit.

Fuses shall be of the DIN 3 indicating fuse type. Fuse holders shall be knife action type with

adequate spring tension. A fuse puller must be left attached to the fuse within the NDU. A DIN

3 fuse base must be installed into the cathode leg as well as the anode leg of the NDU as

close to the cable connections as possible. Only one fuse will be fitted into the cathode leg

and the fuse base mounted in the Anode leg of the NDU must be fitted with a suitably rated

removable link equipped with similar removal fixtures as the fuse. Fuses shall be rated to

protect both the current and I2t rating of the diode.

A 100A fuse of the same dimensions as the 600A fuse must be provided with the unit.

The Bill of Quantities may set out different specifications and will be used at the basis for

pricing, manufacture and supply when read in conjunction with the technical specification.

Should there be a significant conflict between the Bill of Quantities, Technical Specification or

drawings the matter shall be referred to the Engineer for a final determination.

12.2. Surge Protection

Surge protection shall be incorporated so as to protect the NDU from surges from both the

pipe (lightning) and the rail (switching). Note that the rail being a live load places severe

demands on the quenching capabilities of any spark gaps used in the NDU. The surge

diversion devices are to be connected to the field side of the fuse holders. The surge protection

shall be in the form of “pi” filters in both positive and negative legs with air-cored inductors.

The brass terminating studs utilized for rail connections must differ in diameter to those utilized

for terminating the pipe connections. The rail termination studs must be M16 and the pipe



termination studs M10. Only one termination is permissible per stud. Termination lugs used

for field cable termination must be of the distribution lug type, adequately rated and

hexagonally crimped. Dimple crimping of the cable lug to cable core is not permissible. Colour

coded heat shrink or plastic sleeves must be installed to identify the rail and pipe conductors.

Rail conductor is to be marked with a red sleeve 40mm in length and the pipe conductor with

a black sleeve 40mm in length as close to the lug body as possible. The sleeves must be tight

fitting and not able to slide easily along the length of the conductor after fitment.

12.3. Housing

The NDU’s are to be installed in reinforced concrete, coated steel, reinforced brick structures

or other structure types as specified. A suitable frame may be specified as a replacement for

a cabinet, in which case the NDU shall be mounted onto a chassis plate that shall be attached

to the frame. All components must be treated so as to provide satisfactory service under the

corrosive conditions of the proposed installation sites.

12.4. Powder Coating for Chassis Plates




Finish colour: white.



13. FORCED DRAINAGE UNITS (FDUs)

The FDU comprises a TRU/SMU and NDU mounted on a common chassis.

The FDU will typically operate in constant pipeline potential mode, unless otherwise specified

by The Engineer.

Provision must be made to decouple the TRU / SMU from the NDU with a series resistor in

the event that it is necessary to limit the output of the unit under natural drainage conditions.

Note: The Engineer shall specify the resistor requirements should the need arise for this.

The FDU shall be designed and constructed in accordance with the specifications for

TRU/SMU and NDU.

The rating of the TRU/SMU component of the FDU will typically be 100V 100A DC, unless

otherwise specified in the Bill of Quantities or by The Engineer.

The unit shall be so designed that the transition from forced to natural drainage and vice versa

will be seamless. Under natural drainage conditions, no current should flow through the

TRU/SMU power circuit.

The Client may call for the upgrade of existing FDU installations to TRU/SMU and NDU

installations which has the following implications:

The NDU portion of the DC electrical circuit is routed to have the pipe common with

the TRU negative output circuit and the DC traction railway line is a separate circuit

from the TRU positive output circuit.

The TRU portion of the DC electrical circuit comprises a common pipe connection

shared with the NDU, but the positive output of the TRU is connected to an anode

groundbed.

The new circuit arrangement allows stray current emanating from the DC Railway

Traction system to return to its source via the NDU circuit, while allowing impressed

current to flow via the anode groundbed to the pipe in the TRU circuit.

Typical installations shall include a chassis mounted TRU in the front with an NDU

mounted on the back.

See typical drawing showing grounding / earthing layout for TRU, which is applicable

to FDU and SMU applications.



14. POWER FACTOR SWITCH MODE UNITS (SMUs)

14.1. Scope

This specification is for the supply and delivery of Power Factor Switch Mode AC to DC

Conversion Units. SMU’s will be powered by single phase AC to an upper limit of 240 volts

AC power or three phase 380 – 400 Volts plus neutral AC power.

The SMUs may be connected to a variety of anode groundbed installations and metallic

structures as specified by the Design Engineer. The anode groundbed resistance and the total

circuit resistance will determine the voltage and current output requirements of the SMU and

will be specified as such.

The supplier data sheet will specify the typical input voltage range that the device can handle.

14.2. Compliance

The tenderer shall indicate, paragraph by paragraph, either that this tender complies in every

respect with this specification, or if not, precisely how it differs from the specification. A broad

statement that the equipment is in accordance with the specification is not acceptable. Failure

to comply with this clause may preclude a tender from consideration.

14.3. Information to be Submitted by Tenderers

A comprehensive technical description of the equipment offered shall be submitted in

duplicate. The tenderer shall submit, with his tender, electrical schematic diagrams and

drawings, which show constructional details of the equipment offered.

Red-lined equipment datasheet.

Tenderers shall detail the numbers and dates of the relevant standards specifications to which

the equipment conforms.

The following information (datasheet to be completed) must be provided by the tenderer, prior

to the start of manufacture of the Power Factor Switch Mode AC to DC Conversion Units

(SMU):

• Type and Make of Unit.

• AC Input Rating.

• DC Output Rating.



• Voltage Control Range.

• Current Control Range.

• Voltage Output Limit.

• Current Output Limit.

• Ripple Magnitude and frequency.

• Surge Protection Layout including the use of Chokes.

• Identify the need for additional ripple smoothing on the DC Output by means of

capacitor.

14.4. Operating and Maintenance Manuals

The successful tenderer shall be required to submit four complete sets of operating and

maintenance manuals, the cost of which should be included in the prices quoted.

14.5. General Specification for SMU Enclosure Construction

The SMU may be mounted on a chassis plate for installation in a concrete bunker type

installation or on stainless steel skeleton frame suitable for installation in a larger concrete

enclosure. The Engineer shall specify the enclosure requirements and the Contractor shall

submit details at the time of tender of the proposed layout for construction.

14.6. General Specification for Coating Systems

14.6.1. Enclosure Coating System

Surface Preparation

Ensure surface of the area to be coated is free from dust, moisture and oil. Coat with a

proprietary bonding liquid as per coverage specified by supplier.

Coating System

After surface preparation is completely dry coat with a proprietary exterior grade PVA

compatible with the surface preparation and preferable from the same manufacturer as the

surface preparation. Concrete enclosures internal as well as external surfaces shall be coated

as follows:

Exterior colours : to be specified by the Design Engineer

Interior colours : White, unless otherwise specified by the Design Engineer



14.6.2. Chassis Plates Coating System




Finish colour: white.

14.7. Electronic PCB

All electronic printed circuit boards shall be coated with a proprietary conformal military spec.

coating designed to prevent corrosion to the exposed component leads. All Printed Circuit

Boards (PCB’s) shall have a primary solder mask and legend.

14.8. General Specification for Electrical Wiring

All current carrying conductors shall be insulated to withstand a minimum voltage of 1000V.

All wiring shall comply with the provisions of the Wiring Code of Practice; SANS 10142 (latest

edition), PL 631 and 771, SANS 10089-2.

Wherever possible flexible, multi-strand cable is to be used.

Where possible, and as much as possible, flexible conductors shall be routed in slotted

trunking. Where it is not possible or practical for the conductors to be routed in slotted trunking,

then the conductors shall be bundled together and strapped neatly with cable ties or correctly

sized polyethylene spiral wrapping.

All current carrying conductors shall be multi stranded, flexible and sized to adequately carry

the design current without rise in temperature.

All conductors shall be terminated at each end with fit for purpose, pre insulated lug or pre

insulated ferrule. No trimming of conductor strands will be permitted. All ferrules and lugs shall

be crimped with appropriately sized crimping equipment.

Where crimping cables of ≥ 10mm2, dimple crimping of lugs and ferrules is not permissible,

only hydraulic hexagonal crimping dies may be utilized and must be adequately sized and

include the cable size marking in the die. Power wiring minimum 2.5mm2 and Control wiring

0.5mm2.



Where elevated temperatures are expected beyond the operating range of PVC insulated

conductors then the conductors in the heat affected area must be insulated with materials

capable of withstanding the elevated temperature environment.

Cable markers must be colour coded as well as have their number embossed indelibly on the

marker. i.e.

0- Black

1- Brown

2- Red

3- Orange

4- Yellow

5- Green

6- Blue

7- Violet

8- Grey

9- White

Cable markers must be appropriately sized to suit the insulation size of the cable.

Cable markers shall read from the right on horizontal conductors and from cable to lug on

vertical conductors.

All AC supply conductors shall be colour coded according to the incoming phase and retain

the colour nominated throughout the unit.

AC carrying conductors must be separated and not be routed with DC carrying conductors.

Grounding cables connected to Surge diversion devices must be kept as short as possible

and may not be routed or combined in the same trunking or loom with either AC or DC carrying

conductors. Ground cables should not run over conduit, devices or components to earth as

the chassis plate of the cabinet shall be used as the connection to earth.

Joints or splices in any wiring will not be permitted. No more than two conductors shall be

connected to any one terminal.

All conductors shall be numbered at both ends with reference to the Schematic Wiring

Diagram supplied with the unit.



Buss bar conductors must be used on the output side of the Power factor type switch mode

unit where the rating of the unit exceeds 100Ampere.

Buss bars shall be Aluminium and rated and sized according to the current that it will carry.

Minimum size of buss bar will be no less than 25 x 3mm.

Buss bar joints shall be bolted or welded.

When a buss bar is bolted, the mating surfaces must be coated with conductive water repellent

paste prior to assembly.

Spring washers and nuts shall be used when bolting Buss bar joints.

14.9. Terminals

In accordance with SANS 1433.

All terminals shall be completely accessible after completion of wiring.

All terminations made to buss bars shall be provided with spring washers.

All supply power terminations shall be enclosed and be highlighted with a warning label.

The SMU, inductors and capacitor (when specified) terminations shall be covered with a

transparent cover prohibiting accidental contact.

Output terminals shall be fully insulated from any metal of the housing or chassis.

All terminals shall be clearly marked and sized according to the current the terminal will carry.

Entrilec terminals to be used, rail mounted and ATEX Approved.

Cable lugs to be sandwiched between flat washers and spring washers when fastened to stud

type terminals, similarly where fastened to buss bars flat washers and spring washers are to

be used.

14.10. Colour Coding and Labelling of Conductors, Equipment and

Components

Positive electrical conductors : Red

Negative electrical conductors : Black

Earth cables : Green with yellow stripe



AC Supply cables

Phase 1 : Red or Brown

Phase 2 : Yellow or White

Phase 3 : Blue

Neutral : Black

Reference Electrode cable : Yellow

Electrical warning signs : Black on yellow background

Monitor cable : Blue

Component Labels : Black on a white back ground.

All labels shall be engraved sandwich type Gravoply labels. All labels to be mounted with

screws or blind rivets only. Silk screen labels or Aluminium anodized labels shall not be

utilized.

14.11. Electrical Construction

14.11.1. General

The SMU is to comprise a 3 phase or single phase power factor controlled switch mode AC to

DC convertor with a maximum ripple on the DC of 200mV. The maximum output voltage and

output current will be reflected in the Bill of Quantities.

The output of the unit will be automatically controlled in one of three control modes unless

specified otherwise by the Design Engineer:

• Constant output current.

• Constant output voltage.

• Constant Structure to Electrolyte potential.

14.11.2. Test Switch Facility

The SMU must have a facility to plug in a switch on the output circuit for over line testing on

the protected pipelines. This requirement is irrespective of any built in timer which may be

provided.

Manual output voltage and current adjustment facility:



Over line surveying testing requires a "manual mode" to adjust to a constant voltage range

from zero to full output voltage, similarly the current depending on load resistance. This is to

enable over line testing at a pre-set output current.

Ideally the SMU can be switched with a switch through a timer socket.

Switching of the SMU should be instantaneous without significant lag and should be

such that the full set output current is achieved within 100ms of switching.

Irrespective of control mode, the SMU control equipment must be capable of output voltage,

output current and potential pre-set limits. When the control equipment is changed from one

control mode to another control mode, all user programmable parameters must be

automatically restored to minimum values to prevent an instantaneous application of output

voltage or output current to the load.

Note: Should the electronic PCB, automatic control or LCD display fail, the “manual mode”

shall allow the user to switch over to this mode and manually adjust the output voltage

and current to pre-set limits within the operating range of the SMU.

14.11.3. Earthing /Grounding

All metal components shall be connected to the common enclosure earth and to the AC supply

earth. All electrical circuits shall be floating with respect to earth. All earth connections within

the enclosure must be as short as possible and rated at possible fault current.

No earth connection cabling is permitted to run over conduit, equipment or components as the

chassis plate shall be used as the return path to earth. Earth buss bar mounting studs must

be adequately sized to accommodate collective fault current.

Surge protection devices attached to the earthing/grounding system and/or chassis plate shall

be of modular construction and positioned in such a manner as to facilitate ease of removal

and replacement, without the need to strip out the chassis plate and associated component

removal.

A separate earthing system will be provided for the SMU consisting of suitable earth rods and

bare earthing cable which will have a resistance below 10 Ω in compliance with SANS 10142.

See typical drawing showing grounding / earthing layout for TRU, which is applicable to FDU

and SMU applications.



The Contractor shall provide detailed drawings at the time of tender showing the earthing

arrangement for the unit, the layout, location and means of connection to earth from the

various components to demonstrate the principle of building the unit with the shortest distance

to earth, thereby minimizing resistance.

14.11.4. Auxiliary Power Socket Outlet

The unit shall be provided with a surface mount industrial switched 15A power socket

adequately inspected according to the Occupation health and safety act and regulations Act

85 of 1993 as amended.

The auxiliary power socket shall be fitted with a suitably rated earth leakage device and be

compliant with SANS 10142.

14.11.5. Output Control

The adjustment and control of the output shall be achieved automatically in one of the above

control modes through power factor switch mode AC to DC conversion. The control signal to

the power factor switch mode AC to DC conversion will be 0-5VDC from an adequately rated

controller capable of control in one of the aforementioned control modes. The power factor

switch mode AC to DC conversion unit must have an AC input range of 90-264VAC and

tolerate a frequency range of 47-63Hz.

Efficiency of the power factor switch mode AC to DC conversion unit is to be typically 90%

and a typical power factor of 0.95/230VAC. The output of the power factor switch mode AC to

DC conversion unit must be constant current limiting; recovering automatically after fault

condition is removed. The must power factor switch mode AC to DC conversion unit must

shut the output off when its main control elements reach 105 degrees Celsius and recover

automatically when their temperature normalizes.

The power factor switch mode AC to DC conversion unit must further be able to be paralleled

to increase the current output and enjoy current sharing technology to ensure each unit in the

parallel assembly shares the current without any unit in the parallel assembly carrying more

than another. No more than 4 power factor switch mode AC to DC conversion units may be

stacked in parallel. When units are paralleled the wire and buss bar sizes must be adjusted to

meet the current carrying capacity under the new configuration.



Each power factor switch mode AC to DC conversion unit must comply to EMC standards

EN55022(CISPR22), EN55024, light industry level criteria A and have a noise immunity

compliance with EN61000-4-2,3,4,5,6,8,11, EN 55024. Light industry level criteria A.

The power factor switch mode AC to DC conversion unit must be able to operate in a relative

humidity level of 20-90% NON-CONDENSING and between -20 to +70 Degrees Celsius.

The entire power factor switch mode AC to DC conversion unit must be housed in its own

easily removable housing with the input termination and output termination clearly marked and

accessible from the front of the overall enclosure. No more than four fixing screws per power

factor switch mode AC to DC conversion unit may be used and each fixing screw must be

easily accessible. Lock nuts are to be used and at no point should the threaded fixing stud be

able to rotate or work loose during the fastening or loosening process.

The power factor switch mode AC to DC conversion unit must have a built in external remote

on / off control (POTENTIAL FREE CONTACT) as well as a remote sense function. The power

factor switch mode AC to DC conversion unit must also have an output trim function capable

of trimming the output of the power factor switch mode AC to DC conversion unit from 10V

through to 24VDC, or a voltage range otherwise specified by the Design Engineer.

Selection of a control mode, as well as adjustment of the limits and control set points must be

user programmable and the control equipment must be capable of both local as well as remote

selection. Remote selection of the control mode is to be accomplished via the RS 232 port

utilizing modbus protocol.

The control equipment must be capable of controlling the application of power to the load in

either a pre programmable incremental percentage of maximum output stepped manner or in

a linear incremental manner in addition to the aforementioned control modes the selection

must be user programmable.

The input impedance of the reference electrode input to the control equipment must be no

less than 500 meg ohm and must not adversely load the reference electrode thereby distorting

the potential measurement.

Precise control is required and local adjustment of set points and control modes must be via

sealed tactile push buttons, unless specified otherwise by the Design Engineer, and not

through the use of adjustable potentiometers as these deteriorate with time especially in

corrosive atmospheres.



14.11.6. Control Mode 1: Constant Output Current

Within restrictions of load circuit resistance the output current of the SMU shall be maintained

constant.

14.11.7. Control Mode 2: Constant Output Voltage

Within restrictions of load circuit resistance and the current limiting settings of the controller,

the output voltage of the SMU shall be maintained constant.

14.11.8. Control Mode 3: Potential Control

The output of the SMU must be automatically varied to maintain the potential between a

permanently installed reference electrode and the structure, constant. This mode of control

shall be subject to restrictions associated with load resistance and current limits set by the

controller.

14.11.9. Meters and Monitors

a. Controller Display

The SMU will include high quality Liquid Crystal Display (LCD) back lit type or TFT tactile

display elements to indicate the following;

Output Voltage

Output current

Reference Potential AC and DC

Heat sink temperature

Cabinet Ambient Temperature

Control mode selected

Level of control signal.

No DC output current- hour totalizer.

The input impedance of the reference potential digital volt meter must exceed 500 meg ohms

and must not adversely load the reference electrode or the control circuitry. The accuracy of

the reference potential meter must be less than + or – 20mV.

All meters must be either LCD or TFT display types and the display must be legible in direct

sunlight and from distance away of from the display of 2 meters.





connected to the output current measurement point must be labeled with the shunt rating i.e

50mV = (Maximum Rated current as held in the Bill of materials (BOM))

b. Additional Displays

The SMU will include high quality stand-alone analogue and digital display elements to

indicate the following;

v. Output Voltage – Analog, (display min. 75mm x 75mm)

vi. Output Current – Analog, (display min. 75mm x 75mm)

vii. Reference Potential DC – Digital, (display height minimum 12mm to 15mm readable

in sunlight)

viii. kWhr Meter – Digital, measuring and displaying SMU power only and no other auxiliary

SMU attachments

The Design Engineer will specify whether or not a detachable display is required. In this

specification provision is made for a detachable display when the SMU is installed in a

concrete vandal proof enclosure. In instances where the Design Engineer specifies a metal

cabinet enclosure the manufacturer shall adapt the requirements set out in this specification

to suit a metallic door panel with the same layout, umbilical cable connections and meter types.

Similarly, if the SMU is to be installed using a metal frame then the additional displays shall

be mounted in a suitable location to facilitate easy reading and measurements.

The Output Voltage, Output Current and Reference Potential Meters shall be mounted on a

detachable display panel that is positioned directly behind the door of the concrete bunker

with a suitable clearance. The detachable display panel shall be fitted with an umbilical cable,

or suitably rated cable loom, that feeds the meters from a central point on the main chassis

plate.

The detachable display panel should be manufactured from a suitable panel resin board, or

suitably powder coated metal base plate, that will retain its shape and support the meters and

related components while holding it in position. The meters shall be arranged in such a way

that the Voltmeter is to the left, the Potential Display meter in the centre and the Current meter

to the right of the resin board.



All digital meters must be either LCD or TFT display types and the display must be legible in

direct sunlight and from distance away of from the display of 2 meters. All of the Additional

Displays shall be mounted on the detachable display panel.



connected to the output current measurement point must be labelled with the shunt rating i.e

50mV = (Maximum Rated current as held in the Bill of Quantities).

14.11.10. Surge Protection

Surge protection devices attached to the earthing/grounding system and/or chassis plate shall

be of modular construction and positioned in such a manner as to facilitate ease of removal

and replacement, without the need to strip out the chassis plate and associated component

removal.

The input circuitry of the unit will be protected via a C curve 10 kA circuit breaker adequately

rated so as to avoid nuisance tripping. The circuit breaker must dis-engage all phases and

neutral of SMU when tripping and must be capable of isolating the supply (live and neutral)

from the unit.

The SMU is to be protected with thermal fuses incorporated into the positive and negative

legs. The fuses are to be adequately rated to allow for maximum rated current to be maintained

for one hour without rupturing. With a 20% increase in output current one of the DC fuses must

rupture within twenty minutes.

All thermal fuses are to be of the mechanical indicating type whereby an irreparable form of

mechanical indication occurs when a fuse is ruptured.

Each unit shall be supplied with a fuse puller, per fuse size, that is suitably affixed to the device

plate using an insulated, strong yet flexible lead to prevent removal.

a. Mains Surge Protection

Surge protection devices must be installed in the incoming mains circuit immediately

electrically downstream of the isolating mains circuit breaker. The Surge protection devices

must be rated at a discharge current of 50kA and the maximum permitted operating voltage

to be 25% above the RMS value of the applied voltage. The response time of the over voltage

device is to be less than 25ns.



Where Single phase units are implemented the surge protection devices must be connected

between live and earth and neutral and earth.

b. Output Circuit Surge Protection

Output Voltage ≤ 50V DC or as otherwise specified by the Design Engineer.

Surge protection devices must be installed after the DC fuses situated in the positive and

negative legs of the SMU. Each unit shall be supplied with a fuse puller, per fuse size, that is

suitably affixed to the inside of the device using an insulated, strong yet flexible lead.

The Surge protection devices must be rated at a discharge current of 40kA and the maximum

permitted operating voltage to be 25% above the RMS value of the maximum output voltage.

The response time of the over voltage device is to be less than 25ns.

The equipment must have coarse and fine surge protection and the coarse protection must

be a minimum of 100kA and consist of both Metal Oxide Varistor (MOV) and Gas discharge

devices and must not follow on at the rated output voltage. Gas discharge devices must be

hermetically sealed.

14.11.11. Radio Frequency Protection

The SMU must be radio frequency protected.

14.11.12. Component Layout and List

Where capacitors and inductances are used in the construction of an SMU these are to be

mounted in such a way that they are easily accessible for testing and removal. Trunking and

any other heat sensitive devices must be kept well away from the heat bearing heatsinks.

The manufacturer shall supply a proposed construction layout diagram showing front view,

side view and top view of the respective components installed inside the specified enclosure.

The manufacturer shall supply a complete component list for the SMU, with detailed

specifications for each component to facilitate repair or exchange should the need arise.

14.12. Inspection and Testing

The complete Inspection and Test Plan (ITP) pack shall be presented to the client before

undertaking the Factory Acceptance Test (FAT). The Engineering Package would typically

include, but not be limited to the following:



• all OEM data sheets

• material, test and compliance certificates for all original components

• test and compliance certificates for assembled equipment

• the O and M Manual

• full list of components and recommended spares.

The following tests must be carried out at the manufacturer’s works, after successful

completion of the tests a certificate will be issued by the manufacturer and signed by the

Engineer or his nominated representative. All testing and damaged components resulting from

the testing will be at the manufacturer’s expense and carried out at the manufacturers

premises. Adequate adjustable load resistances, adjustable power supplies and testing

equipment will be made available to the engineer by the manufacturer to verify specified

operational characteristics of the SMU under test.

14.12.1. Pre Power-up Testing

The various earth points, cabinet body, chassis plates and all exposed metal surfaces shall

be measured for continuity to the main earth terminal.

The cabinet and AC inputs, the DC outputs shall withstand a 1 kV insulation test. The insulation

testing shall be conducted with all circuit breaker and fuses in their normal operating position

without power or load connected.

14.12.2. Power On Testing

The SMU shall operate for a period of 6 hours continuously at maximum current and at full

rated voltage in a suitable enclosure (agreed beforehand with the Design Engineer) or until

the temperature of the SMU heat sink is stable for a period of one hour. Where the temperature

continues to rise after a period of 7 hours the equipment will be rejected. The ambient, cabinet

compartment internal temperature and heat sink temperature must be recorded during the

heat run and plotted upon conclusion of the heat run. K type thermocouples shall be used for

the continuous recording of the all the various temperatures.

Immediately after the heat run, the aforementioned insulation check will be carried out without

the power or load applied. A maximum heat sink temperature of 80 °C is permissible at the

highest vertical point of the heat sink.



Control mode testing shall be carried out after the conclusion of the heat run.

14.12.3. Constant Current Tests

The manufacturer will demonstrate the SMUs ability to control the output current to within 5 %

of the pre-determined set point. The load resistance is to be manually adjusted to ensure that

the output current remains constant irrespective of the load resistance. Four specific current

set points are to be set 25%, 50% 75% and 100% of maximum rated output current. Voltage

at the given pre-determined set points will be recorded and noted in the O and M Manual.

14.12.4. Constant Voltage Tests

The manufacturer will demonstrate the SMUs ability to control the output voltage within 5% of

the pre-determined set point. The load resistance is to be adjusted to ensure that the output

voltage remains constant irrespective of the Load resistance. Four specific voltage set points

are to be set 25%, 50% 75% and 100% of maximum rated output voltage. Current at the given

pre-determined set points will be recorded and noted in the O and M Manual.

14.12.5. Constant Potential Tests

The manufacturer will demonstrate the SMUs ability to control the electrolyte to structure

potential within 50 mV of the pre-determined set point. Current limit and voltage limit features

are to be tested and verified whilst carrying out potential mode testing. Dynamic feedback is

required to demonstrate the control mode. That is, a simulated Cathodic Protection system

must be used to demonstrate the control mode. In the potential mode verification a variable

power supply may not be used to simulate the Reference Electrode.

14.13. Telemetry and Remote Monitoring Systems

The SMU shall be provided with outputs suitable for connection to a SCADA or remote

monitoring system. The outputs shall be potential free contacts for alarm and status signals,

and 4 – 20mA, 0 – 5V, or actual value for analogue signals. A comprehensive Ethernet Modbus

signal may be provided as an alternative.

Power consumption and quality monitoring:

Mains failure

Fuse failure

Output current

Output voltage



Pipe/soil potential

Detailed requirements for telemetry or remote monitoring will be determined by the project

requirements.

14.14. Documentation

The SMU shall be supplied with the following documentation:

Databook as per datasheet.

A removable clear laminated schematic diagram and the laminated schematic diagram

shall be located inside the SMU enclosure.

SMU operation and maintenance manual (O and M) complete with schematic, parts list,

fault finding flow chart, operating instructions, original certificates and recommended

spare.

Three copies of the O and M shall be supplied to the Engineer prior to commencement of

the manufacturing of the equipment.

The complete Inspection and Test Plan (ITP) Pack.

14.15. Generic SMU Data Sheet and Electrical Circuit Diagram

Note: At the time of tender generic data sheets and electrical circuit diagrams are provided.

The tenderer shall provide project and application specific SMU data sheets and

electrical circuit diagrams and these shall form an addendum to the specification of the

accepted Tender. All the relevant information shall form part of the engineering data

pack that will be present at the time of FAT at the manufacturer.



15. STEEL CABINET

15.1. General Cabinet Construction

The electrical equipment is to be housed in a weather-proof steel cabinet which is to be

constructed in accordance with the tender specific drawings.

Cabinets shall be of sufficient size to allow for easy access for servicing and maintenance.

The cabinet must be so designed that there are no inherent moisture traps.

Cabinets to be manufactured from 3Cr12 with No.1 Mill finish. Two coating systems are

described in this technical specification.

Cabinets shall be manufactured from minimum 2,5mm thick steel and all individual panels

are to be visibly hard stamped with “3Cr12" prior to the application of paint.

All external welds should be continuous seam welds. Tack welding is not permitted. Stitch

welding is only permitted on the inside of the cabinet.

Cabinet doors shall be provided with suitable robust door stays to hold the door open during

servicing and maintenance.

The cabinet doors must be provided with 304L stainless steel lockable handles designed to

accept padlocks.

The cabinet shall be provided with a bottom plate which shall incorporate a removable gland

plate. The gland plate shall be manufactured from 304L stainless steel. All holes punched

into the gland plate shall be true round and suitably sized for steel gland use.

Cabinets shall be provided with channel section bases and lifting lugs suitably designed to

prevent distortion during transport, handling and installation. The cabinet lifting lugs shall be

of the same material as the cabinet or be hot dipped galvanised.

Note: Each cabinet should be provided with stainless steel bolts and washers to

replace the lifting lugs once the cabinet has been installed on site. These

bolts should be secured in the transformer compartment of the cabinet and

marked LIFTING LUG REPLACEMENT BOLTS.



The cabinet channel base shall be 3Cr12 steel. All cabinet channel base material must be a

minimum of 3mm in thickness.

All the channel bases must be pre-drilled with M16 holes to facilitate mounting on concrete

plinths. It is important to adhere to the dimensions provided in the drawings as to ensure

proper and correct mounting on plinths and pallets.

The housing shall be suitably designed to prevent ingress of dust and rain.

The housing shall allow for adequate ventilation of the heatsinks and power elements.

Note: No heatsink or power element shall be installed within 75mm of any cabinet wall.

It shall also have a cooling duct around the two (Instrument and Control) top compartments.

Refer to drawings. Alternatives will be considered provided extra volume is then designed

into each cabinet with adequate venting to suit.

Note: A set of louvres shall be pressed into the bottom of the Instrument and Control

compartment floors and another set on the vertical, inner back panel of the same

compartments, in order to permit convection cooling. The louvres shall be pressed

into the cooling duct.

Stainless steel filter elements to provide insect proofing and dust prevention shall be bolted

to the inside of the cabinet to cover the louvres.

Cabinet doors shall be sealed by means of Closed Cell Expanded Rubber such as NEO25

or approved equivalent material.

All laps, crevices and internal non-continuous welds after coating must be caulked using

oleo-resinous mastic applied by gun. A rubber strip of closed cell expanded rubber such as

NE24 or approved equivalent must be installed between the roof and cabinet body and

channel basis. Alternative materials must be specified by the supplier with their tender

submission.

An enclosure for the O&MM and facilities to attach drawings shall be located at a suitable

point inside the cabinet. Rails (Z-Rails) instead of studs shall be used to fix enclosures and

facilities to the doors.



All studs and wing nuts for wiring diagram holders and spare component rack to be brass.

The following information is to be hard stamped or engraved onto the manufacturer's

nameplate attached to the instrument panel of the cabinet:

AC rating:

DC rating:

Max. operating temperature:

Type of equipment offered: (e.g. Manual Transformer Rectifier Unit).

Serial No:

Owner:

Date of Manufacture: (Month & Year)

Contract No.:

Manufacturer:

All structural bolts, nuts and washers shall be stainless steel. Bolts with spring washers or

ny-lock nuts shall be used. All studs shall be brass or stainless steel and cut to size.

15.2. Coating of Steel Cabinets

SUBSTRATE - 3Cr12 (No.1 Mill Finish)

15.2.1. Method No 1a: Wet Spray Coating

SURFACE PREPARATION

Degrease, rinse, acid pickle, phosphate and passivate, all after welding. Pickling and

passivating in accordance with steel manufacturer's specifications.

COATING SYSTEM

Primer Coat : Plascon Epilyte 325/661 or equivalent.

1 Coat D.F.T. 30 Microns

Final Coat : Plascon recoatable PU Code CPC Enamel or equivalent. One Coat.

D.F.T. 30 Microns



Total D.F.T. : 60 Microns.

Colour : Orange.

Preferred application by means of electrostatic spray. Equivalent Coating Material may only

be used with the approval of the Engineer. Coating system to be from one supplier only.

15.2.2. Method No 1b: Powder Coating

SURFACE PREPARATION

Degrease, rinse, acid pickle, phosphate and passivate, all after welding. Pickling and

passivating in accordance with steel manufacturer's specifications.

COATING SYSTEM

Apply two coats of Chemstop Polyurethane Enamel or equivalent with light sanding between

coats.

D.F.T. : 35 Microns per coat

(2 x coats)

Total D.F.T. : 70 Microns.

Colour : Orange.

Application by means of electrostatic spray. Equivalent Coating Materials may only be used

with the approval of the Engineer. Coating system to be from one supplier only.

15.2.3. Method No.1c: Alternative Coating

Alternatively, Tenderers may submit their own specification for surface preparation and

painting. This must be accompanied with full details, records of past performance and a two

year guarantee. The successful Tenderer may only use his system with the approval of the

Engineer.



16. CONSTRUCTION OF TEST POSTS, CONCRETE BUNKERS AND

CONCRETE ENCLOSURES

16.1. Galvanized Steel Test Posts (TP)

TP are to be constructed of galvanized steel as per standard drawing.

The TP dimensions shall be as per standard drawings. The base shall be cast in a concrete

in the ground.

The door shall be lockable as per the latest revision of the drawings.

16.2. Monitoring Test Posts

Monitoring test posts are to be constructed of reinforced concrete or as specified by The

Engineer. The reinforced concrete type test posts are to be monolithic construction, containing

no part that operate or close, nor any that have a cover with lock. The test post should be

nominally 1.4m in length with approximately the bottom 0.5m concreted into the ground. The

cross section should be minimum 130mmx130mm square. The test post will be constructed

with a mild steel flat bar 6mm thick by 30mm wide and 40mm long protruding from it halfway

down. The flat bar is to have a 15mm diameter hole to which a recording instrument may be

chained.

Where The Engineer specifies that concrete enclosures or test stations are to be painted,

the following shall apply:

The concrete stations and/or points will be sealed and painted with an undercoat. Test

stations, bonding test stations and/or bunker test stations will then be painted with PVA

paint. With exception of the test stations which will be painted white, all concrete

structures will be painted as per Client requirements according to SABS 1091 H40.

A 50mmm diameter orange circle will be painted around the potential test station

banana jack test point.



16.3. Large/ Mushroom Head Concrete Test Post

The large / mushroom head concrete test post will contain a cavity with minimum dimensions

450x390x200mm. Must be cast with a minimum of four (4) off cable conduits and each with

a draw wire. A paper base phenolic board, (Tufnol) 3mm thick will be fitted to the inside the

recess. The board will contain either:

Four (4) off link busbars. A horizontal busbar will in turn connect the top of each link

busbar and extend to include a terminal for external monitoring point. The eight

terminals/bolts are to be M6 brass and supplied with relevant washers and nuts.

DIN Rail mounted terminal blocks as specified elsewhere. The number of terminal

blocks and their cross connection will be set out in the Bill of Quantities.

The large / mushroom head concrete test post cavity shall be fitted with a suitable vandal-

proof 5mm thick galvanised steel door, complete with a robust locking mechanism.

Dimensions may vary based on the application and the Contractor / Manufacturer shall

provide construction details of the proposed concrete bunker at the time of tender as part of

the compulsory quality documentation to be returned.

16.4. Bonding Test Posts (BTP)

Bonding Test Posts (BTP) is to be constructed of galvanized steel or reinforced concrete

depending on the project specification.

The BTP will contain cavity with minimum dimensions 245x250x135mm with a recess. The

recess will be nominally 200x110x30mm. The standard EWS drawings shall apply or be

modified to suit each project specification.

The door shall be lockable as per the latest revision of the drawings. The overall dimensions

of the BTP shall be specified for each project.

16.5. Concrete Bunkers

A concrete bunker shall comprise of 25MPa concrete in a ratio of 1:4:4 (Portland cement:

13mm stone: river sand) placed on at least a 350mm thick complete steel reinforced 25MPa

1250mm x 1250mm x 75mm thick surround. Dimensions may vary based on the application

and the Contractor / Manufacturer shall provide construction details of the proposed concrete

bunker at the time of tender as part of the compulsory quality documentation to be returned.

The concrete shall be agitated while wet and cured for 48 hours prior to moving. All surfaces



are to be smooth and free of spalling, cracking and honeycombing. The minimum concrete

wall thickness shall be 150mm. All reinforcing steel (mesh and rods) shall be 10mm in

diameter and shall be hot dip galvanised to SANS 121/ISO 1461.

The door shall be manufactured from 5mm thick hot dip galvanised steel plate. The door

locking mechanism shall be deadbolt locks (keyed alike to The Client’s requirements) and the

door shall be hung on internal concealed hinges.

400 Grade Stainless Steel 40mm rod, with an M12 internal threaded hole shall be installed at

least 100mm into the concrete. The stainless steel rod shall welded onto a stainless steel base

plate (50mm x 50mm x 3mm) in order to ensure that the bunker may be suitably moved on

site.

Each bunker shall have a portable reference electrode drop tube which shall comprise of

110mm PVC drain pipe and shall extend from 150mm above the pipe into the bunker. At the

time of tender The Contractor shall ascertain from The Client what the separation distance

shall be between the pipe and test station as the drop tube shall be installed vertically

The overall dimensions shall be no less than 1050mm high, 950mm wide and 770mm deep.

The structure is to contain a recess of no less than 470mm deep and 400mm wide. The

minimum distance from any outer sidewall shall be 150mm. The recess to be painted with a

white PVA based paint, a suitable primer shall be used prior to application of paint.

A 5mm galvanised (SABS ISO 1461) vandal proof door shall be mounted in a recessed sill,

min 75mm deep, and shall contain a vandal proof locking mechanism. The door shall also be

fitted with a dummy mechanism to distract potential vandals.

The structure to contain two lifting lugs mounted on the top. 16mm eyebolt threads cast into

the concrete is preferred so that the lugs can be removed after lifting.

The structure shall contain a cable duct of sufficient size (300mm x 150mm min.).

A 3CR12 backplane is to be fitted inside the recess for component mounting purposes.

A typical Bunker drawing is included in this technical specification.



16.6. Identification

The galvanised steel test posts shall not be marked unless specified as such in the project

specification.

The concrete will be sealed and painted with an undercoat. The Test post will then be

painted with PVA paint, colour to be specified by The Client.

Labelling characters are to be 20mm high with black paint (unless otherwise specified).

If the labelling procedure is not specified in the Bill of Quantities the Contractor shall

ascertain project specific requirements from The Client at the time of tender.

16.7. Concrete Enclosure

This specification is for the construction of a precast reinforced concrete structure with a

secure safe door. The structure is intended for the housing of electronic equipment at sites

where theft and/or vandalism is prevalent. This specification is to be read in conjunction with

the relevant standard drawing.

a. Concrete thickness to the walls /roof shall be a minimum of 90mm and the floor a

minimum of 100mm.

b. Minimum concrete strength shall be 35 MPa at 7days.

c. Walls/roof/floor shall be double reinforced with the inner reinforcing comprising of

6.3mm bars at a maximum spacing of 75mm centres and the outer reinforcing

comprising of 8mm bars at a maximum spacing of 75mm centres.

d. Internal dimensions shall be a minimum of 1850mm x 1850mm x 2050mm in height.

e. Two number 50mm diameter ventilation holes (approximately 1000mm c/c) shall be

provided on each of the two walls adjacent to the door and be set approximately

200mm below the soffit and shall be approximately centred on each of the walls.

f. Internal corners shall be chamfered.

g. Two 300mm square “box out’s” (for cables) shall be provided through the floor slab:

- one in the centre, and

- one at the back left hand corner.

h. Access shall be provided centrally into the front face of the structure.



i. A secure steel door (type Mutual Zinga or similar approved) shall be fixed at multiple

points to the precast concrete structure in a manner approved / recommended by the

supplier of the door.



17. TESTING AND MONITORING

17.1. Pipe-to-Soil Potential Logging

Pipe-to-soil potential measurements will be complimented by measuring the stray current

fluctuations over periods of twenty four hours, using data loggers.

17.2. Testing of Isolating Devices

The status of isolation devices such as isolating flanges and monolithic joints will be tested

using a radio frequency tester, such as the Tinker and RasorTM RF IT Tester (or equivalent

approved) and not by measuring the potential difference on either side of the joint with a

conventional digital voltmeter.

17.3. Digital Volt Meters and CP Analyser

All digital voltmeters used for potential measurements and logging will need to be calibrated.

The use of cathodic protection analysers, based on waveform analysis is encouraged.

17.4. Coating Performance Testing

The pipeline itself must be electrically continuous and all other civil structures and extraneous

earths shall be electrically isolated from the pipeline at pump stations, off-takes, chambers,

scour valves, air valves, non-return valves, etc. by means of isolating flange kits, etc. The

pipeline shall not be bonded to Foreign Service pipelines unless designed accordingly and

subsequent to interference testing.

Current draining testing shall be conducted in accordance with NACE TM0102. Not more than

5,000 m of pipeline may be tested at any given time during construction.

The Contractor shall submit a written Method Statement regarding the current draining testing

for approval, prior to commencing with the Works.

The Electrical Coating Conductance shall be normalised to the 10 Ω.m soil.

The Electrical Coating Conductance shall be <100 µS/m² for the pipeline.

All coating defects shall then be located using the Direct Current Voltage Gradient (DCVG)

technique, as approved by the Engineer. The Contractor shall then carry out excavations and

coating defect repairs, until the coating complies with the <100 µS/m² criteria.



18. TEMPORARY CP

Temporary cathodic protection during construction of the pipeline is a vitally important activity.

Significant external corrosion can occur on pipelines during construction if this is not done

correctly.

Temporary cathodic protection under stray current conditions is time consuming as the stray

current patterns change on a daily basis, as the pipeline segments increase in length. The

temporary protection is provided by a number of different systems, both sacrificial and

impressed current and these also change depending on the level of stray current activity on

the pipeline. In addition, there are many temporary bonds, using copper cable to tie-in

segments of pipeline in order to make them electrically continuous. These need to be checked

and monitored on a daily basis.

It is therefore necessary to take frequent potential measurements on the pipeline segments

during construction and make daily adjustments to the temporary CP systems. The procedures

and methodologies for doing this are described in this section.

18.1. Temporary CP Criteria

The criteria for temporary protection during monitoring of temporary CP shall be in accordance

with SANS 15589 as follows:

During temporary protection where temporary ICCP is in use, a minimum ON potential of

-2500mV (excluding spiking) vs. Cu/CuSO4 reference electrode shall be utilised.

The percentage time within the specified protection criteria shall be determined and ensure

that a minimum of 95% of the potential recording is within the specified protection criteria.

Where temporary SACP is in use, and there is no stray current activity, a minimum ON

potential of –1000mV vs. Cu/CuSO4 reference electrode shall be utilised.

18.2. Installation of Temporary Cathodic Protection

18.2.1. Installation of Hi-Potential Magnesium Anodes for Temporary CP

For temporary protection using bagged Hi Potential Magnesium Anodes the following

procedure will apply:



The anodes shall be installed vertically such that the top of the anode is 1.5m below the natural

ground level.

The anodes shall be installed where required in conjunction with the available Type A, B, C,

E or F test stations.

The distance between the anode/s and the pipe to be protected shall be 3-5m depending on

available space and shall be installed on the spoil side of the pipe.

The anode tail of each anode shall be terminated on the pipeline by means of a thermit weld

or stud weld onto:

The access tee flange*, or

Onto the barrel of the pipeline*.

The Engineer shall specify which method is to be used at the time of tender.

The anode excavations shall be backfilled with native soils.

The GPS co-ordinates of the exact location of the Hi-potential Magnesium anode/s shall be

recorded for entry into the The Client’s GIS, and the test post through which they are

connected to the pipe, to ensure that the magnesium anode/s is disconnected once the

permanent CP system is installed and energized.

18.3. Installation of temporary ICCP systems

Under stray current conditions experienced during the construction phase, it may be

necessary to implement temporary ICCP system. The following procedure is recommended

for the implementation of temporary ICCP systems in order to provide protection.

The temporary ICCP systems shall comprise constant current portable TRU’s when DC

railway lines are being used as temporary groundbeds, or potential-controlled battery systems

with temporary anodes.

The location of the ICCP stations shall depend on the following:

Construction progress.

Stray current levels measured on the pipeline.

Progress in the installation of the permanent ICCP Stations.

Appropriate soil resistivity in the area where temporary protection is required.



The extent and frequency of ICCP systems shall be at the discretion of the cathodic protection

site engineer and as a rule shall be applied to provide protection wherever the integrity of the

pipeline may be compromised by stray current activity.

18.4. Temporary Cathodic Protection Monitoring Procedure

The temporary protection monitoring procedure shall be classified for SACP and ICCP

segments as follows:

SACP segments:

Spot ON potentials shall be taken once per week for 15 minute intervals during which

the minimum, maximum and mean potentials shall be determined.

The ON potential measurements shall be carried out at the following locations:

Start of segment

One third of length of segment

Two thirds of length of segment

End of segment

Each segment shall not exceed 5km in length. Once a section exceeds 5km then the

ON potential measurements shall be carried out at every 1 to 1.5km along the pipeline

section.

The mean potential value shall comply with the minimum ON potential of -1000mV vs.

Cu/CuSO4 reference electrode.

Where spot potentials do not comply at any location, the situation shall be rectified by

the installation of additional discreet bagged magnesium anodes. The exact location

of these anodes shall be the subject of interpretation by the cathodic protection

engineer. The location and GPS coordinates shall be recorded for future reference.

Results of monitoring and non-compliance interventions shall be reported on a monthly

basis.

Should the difference between minimum and maximum potential recorded exceed

800mV the relevant pipeline section shall be classified as a stray current affected

pipeline section (ICCP segment).

ICCP segments:

24 hour stray current ON potential recordings shall be carried out once per week on all

pipeline segments classified as stray current affected pipeline sections.

The recordings shall be carried out at the following locations:

Start of segment



One third of length of segment

Two thirds of length of segment

End of segment

Each segment shall not exceed 5km in length. Once a section exceeds 5km then the

24 hour stray current ON potential recordings shall be carried out at every 1 to 1.5km

along the pipeline section.

The ON potential recordings shall be graphically presented and the maximum,

minimum and mean values determined.

The minimum potential shall comply with the specified temporary protection criteria,

i.e. a minimum ON potential of –2500mV (excluding spiking) vs. Cu/CuSO4 reference

electrode.

The percentage time within the specified protection criteria shall be determined and

ensure that a minimum of 95% of the potential recording is within the specified

protection criteria.

Where stray current ON potential recordings do not comply due to stray current activity

the situation shall be addressed by the installation of temporary portable transformer

rectifier units and groundbeds (SiFe or MMO). The exact location of these units shall

be the subject of interpretation by the cathodic protection engineer.

Results of monitoring and non-compliance interventions shall be reported on a monthly

basis.

Only once a particular pipeline segment has an energized permanent ICCP system at

either end shall monitoring be reduced to 24hr ON potential recordings fortnightly, until

the commissioning of that particular pipeline segment is completed. Subsequent to this

and upon approval from the owner, the 24hr ON potential recordings may be reduced

to once every 2-3 months.



19. OPERATION AND MAINTENANCE MANUALS AND INSTALLATION DATA

PACKS

The contractor will refer to The Client’s specification regarding number of copies, format,

binding etc. of submitted documents.

The CP System Operation and Maintenance Manual (OMM) will provide the owner and

technical staff with knowledge on the operation of the CP system and the subsequent

maintenance thereof.

19.1. OMM Requirements

In general an OMM shall include the following:

Manual Update / Revision Register: Page where any alterations, after the final manual

distributed, can be noted.

General Description: This is aimed at Artisans and Operating personnel and should be

presented in simple terms with little technical detail.

Operating Instruction: These should be clear, concise, easy to follow and must include

all necessary checks.

Routine Maintenance: This shall include charts covering the complete installation, i.e.

if a manufacturer’s manual is included to cover a “brought-in” item, then the relevant

maintenance instructions must be extracted and included on a master chart so that the

Operator has only one check-list of periodic servicing to cover the whole installation.

Fault Diagnosis (Flow chart could also be used) and Repair Procedures: Shall include

details of all servicing replacement and repairs which Artisans or Operating personnel

would be expected to carry out on site. In this section the reader may be referred to

supplier’s brochures elsewhere in the manual for specific detail.

Full details of calibration and adjustment for the meters, monitors and electronic

circuitry including all control and power supply cards shall be provided.

Components

o Component Names.

o Component Values and/or Rating.

o Spares Lists: where possible, drawings shall be positioned opposite to the

appropriate text.

o Component values, description and Supplier’s name and contact details shall

be included in the Maintenance Manual.

Certificates: The following certificates must be included:



o Competence test certificate.

o Heat run test certificate (Generation Graph).

o Handover certificate.

o Delivery checklist complete Guarantee.

o Coating certificate.

o Output load test certificate – Maximum Output.

o Overload test certificate

o Insulation Test Certificate (1kV)

Electrical schematic, component layout drawings and cabinet construction and layout

drawing must be included with the maintenance manual.

Telemetry: Details of Remote Monitoring operation, service, testing and repairs.

Specification: Brief summary of the equipment specifications must be given

Special and Safety instructions: Any special instructions regarding the equipment

which is important to know.

Subcontractors / Supplier’s brochures and instructional literature.

19.2. Installation Data Packs

All drawings are to be to scale and presented in suitable AutoCAD format as agreed to with

The Client. Prior to finalising drawings it shall be submitted to The Client for his/her perusal

and approval.

Records of the installation, problems, and site meetings shall be kept and handed to The Client

upon handover.

Minutes shall be kept at every meeting held with The Client or third parties affected by the

contract. Copies of these minutes approved / accepted by all parties concerned shall be

distributed and kept on record as the project proceeds.

Approved minutes of meetings will be used as the basis of assessing additional work, claims

and extensions of time. Should The Contractor fail to keep such minutes The Client reserves

the right to assess claims, additional work and extensions of time based on fair assessment

of the site conditions and requirements to complete the project successfully.

The Contractor shall keep thorough records for the duration of the contract with a duplicate

file for presentation to The Client on successful completion of the project. Documentation

should typically include, but not be limited to:



• Quality Control Plans.

• Hazard Identification and Risk Assessment Plans.

• Test certificates.

• Certificate of Compliance for electrical works.

• Site inspection certificates.

• Minutes.

• Variation orders.

• Correspondence with The Client.

• Correspondence with third parties.

• Rainfall on site.

• Site notes reflecting working conditions, difficulties and progress on a daily basis.



20. AC MITIGATION

The use of Solid State DC Decoupling (SS-DCD) devices is the most superior form of ensuring

electrical isolation. This equipment must not only ensure that it meets the safety standards

enforced relating to effective earthing / grounding of a structure, but it must also ensure

adequate electrical isolation for the Cathodic Protection (CP) system. The SS-DCD shall

protect personnel and equipment during all types of electrical disturbances by providing an

effective grounding / earthing path which will instantaneously conduct:

AC fault currents

Lightning

Induced AC

Power switching surge currents

Applications include but are not limited to:

AC fault current protection across IFs and other devices

Mitigation of induced AC on pipelines and other structures.

Lightning protection for equipment including Transformer Rectifier Units (TRU),

pipelines, cathodically protected tanks and other structures.

Decoupling between primary structures and general earthing systems.

A CP engineer will conduct AC interference investigations and there-after compile a report

containing findings and mitigation recommendations to be discussed with The Client’s

Engineer. Investigations and reports shall be conducted as per NACE SP0177 and ESKOM

guidelines. Mitigation measures will be designed to maintain the following conditions on the

pipelines and appurtenances.

Steady state touch potentials at above-ground appurtenances will be below 15 VAC.

Maximum steady state touch potentials at buried and normally inaccessible portions of

the pipelines will be below 50 VAC unless specified otherwise by The Engineer.

Maximum coating stress voltages will be below 5 000 V.

Short term transients will be in accordance with IEC voltage/time constraints.

Where mitigation is required to maintain the above criteria, gradient control wires, zinc

grounding electrodes and gradient control mats will be designed.



20.1. Gradient Control Wires

Zinc ribbon shall be installed (where necessary, depending on the detailed AC mitigation

design) within the pipeline trench at strategic locations as gradient control wires to ground any

steady state AC and reduce the potential difference between the pipelines and local earth

during AC power system fault conditions.

The composition of the zinc will be as per ASTM B418, and suitable independent

compositional testing will be carried as directed by The Client, in addition to the quality control

information presented by the supplier of the zinc ribbon.

The zinc ribbon geometry will be of the “standard” dimensions as follows:

Cross section (D1 x D2) 12.7 mm x 14.3 mm

Radii (R1 x R2) 2 mm x 5 mm

Zinc weight 0.89 kg/m

Steel core diameter 3.3 mm

Potential -1.1 V vs CSE

Capacity 780 Amp hrs/kg

Ribbon is to be installed at pipe invert depth in the pipe trench during construction or for retrofit

installations the depth shall be specified by The Engineer and where necessary, spaced at

equidistant apart either side of the pipe centre-line as specified by The Engineer.

Gradient control wires will not be connected directly to the pipelines, but through low voltage

solid-state decoupling devices (SS-DCD), see below. These wires should not be installed in

length in excess of 400m for the given rating of the SS-DCD, unless otherwise specified by

The Engineer.

The length of zinc ribbon required at each location has been detailed in the BoQ or as directed

by the Engineer on site.

20.2. Valve Chamber Earth Mats

Gradient control mats (equipotential mats) and/or isolating surface layers shall be installed at

valve chambers and bunkers for step and touch protection. The mats will comprise 200 x 200

x 8mm galvanised weldmesh encased in a minimum of 250mm thick 20MPa concrete. A

connection point must be provided for attachment of the 25 mm² insulated copper cables. An

alternative to the galvanised weldmesh is the used of zinc ribbon anode in a spiral formation



buried at 600mm, covered with 200mm of compacted soil, then having a 200mm thick concrete

slab cast and the top 200mm layer filled with compacted soil.

External mats shall be buried at a depth specified by The Engineer (this will be determined by

the valve design and location) and extend 1.2m beyond the valve chamber in all directions.

Alternatively, an external “skirt” or surround of asphalt 150mm thick with an underlying

impermeable 1mm thick polymeric membrane shall be placed around the chamber extending

1,2m in all directions.

Internal mats shall be placed below the stone layer of the floor of the valve chamber, or cast

into a conductive screed in place of the normal cement screed as appropriate.

Continuity bonding of chamber reinforcing may be utilised subject to the approval of the

Engineer in place of the gradient control mats provided the reinforcing is welded to create a

continuous cage.

The internal grid (rebar or weldmesh) must be connected via two separate insulated copper

tails.

The groundmats (internal and external) must be separately connected to the pipeline through

suitably rated SS-DCD’s unless otherwise specified.

20.3. Cable connections

All cable connections from either zinc ribbons, gradient control mats or valve chamber

reinforcing shall be 25mm2 stranded copper with green/yellow insulation.

2 cables are required for ground mat and rebar connections. Copper to steel connections shall

be crimped and encapsulated to prevent water ingress

20.4. Solid State Decoupling Device (SS - DCD)

The SS-DCD shall be non-electrolytic, fail safe and maintenance free.

Fail safe shall imply that the failure of any SS-DCD component, shall result in an open circuit

system and not a short circuit system. That is, the pipeline or structure shall never be directly

connected to the earthing or grounded system.

SS DCD will be installed inside an enclosure at locations along the AC-affected portions of the

pipelines, through which the gradient control wires will be connected to the pipelines.



Two types of decoupling devices are used. The first type will be used to decouple the zinc

ribbon from the pipeline and the second to decouple the gradient control mats from the test

station connection.

Details are as follows:

20.4.1. Performance Specification for AC Mitigation Decoupling Device

Steady state AC current: 45A

AC fault current rating: 3.7kA for 500ms

50Hz AC impedance: 0.04Ω

Lightning current rating (10/350μs)) 100kA

DC blocking voltage: -12/+1V

Diode PIV 1500V

Diode forward surge current 1200A

DC steady state current (15 min): 60A

DC sparkover voltage: 1.0kV

Lightning impulse voltage: 2.2kV

The decoupling device shall comprise a suitably rate diode stack capable of blocking direct

current in both directions at the specified voltages.

Once the blocking voltage is exceeded, the diode stack shall be capable of conducting the

steady state DC up to 60A (15 minute rating) without overheating.

The device shall exhibit a progressive, smooth transition from blocking to conduction and vice

versa without commutating.

A bypass capacitor (network) shall be connected in parallel with the diode stack to conduct

50Hz AC up to the blocking voltage of the diode stack.

The capacitor and diode network shall be protected by a suitably rated spark gap for high

voltage and lightning induced transients. This will include the appropriate inductance required

to decouple the spark gap from the diode stack in terms of lightning protection zone standard

practice.

Note: If DC blocking voltage higher than 12V is required, a thyristor based SS-DCD may be

utilised. Details of the design and performance characteristics shall be submitted to

the Engineer for approval.



The decoupling device shall preferably be of open frame construction to permit maintenance

/ replacement of component parts. The frame shall be sized to fit on a standard 800 X 600mm

chassis plate. The unit will be mounted inside an IP65 rated enclosure.

Component parts shall be of reputable manufacture with proven performance record and

certificated test data.

The decoupling device shall be provided with two M10 terminals at each pole for the

connection of 25mm² single core cables.

20.4.2. Performance Specification for Transient Voltage Protection Device

AC fault current rating: 50kA

DC blocking voltage: 100V

Lightning current rating 8/20: 40kA

Lightning impulse clamping voltage: <500V

Response time: 25ns

The test station ground mats are provided for personnel safety during short term (transient)

voltage spikes which may occur due to powerline faults or lightning. They are not required for

steady state AC mitigation.

20.4.3. Enclosure Construction

The SS-DCD device shall be enclosed in a suitably rated enclosure as required by SABS

0108, SABS 089 and SABS 086. The enclosure shall also be rated according to the

environmental conditions prevailing. This includes but is not limited to vandal resistant

concrete reinforced structures where required on transmission and distribution pipelines. Solid

State DC Decoupling Devices (SS-DCD)

20.4.4. Inspection and Testing

The testing of the SS-DCD shall be carried out at the Supply Contractor’s works or at the third

party inspector’s laboratory/works. A sample of the SS-DCD to be supplied shall be selected

in accordance with BS 6001: Part 1 for testing purposes. All of the SS-DCD device

components shall pass the tests and the testing shall be carried out in the presence of The

Client. The Supply Contractor will issue a Test Certificate upon completion of the tests and it

shall be signed by The Client. All of the testing shall be carried out at the Supply Contractor’s

expense.



The SS-DCD shall be supplied with the following items :-

A removable clear-polyester laminated circuit diagram, which shall be located inside

the enclosure.

Operation and Maintenance Manual (OMM).

Recognised third party testing certificate that sets out the test conditions and test

results confirming compliance with the performance specification of the SSDCD.

The equipment shall carry an unconditional two year guarantee. The only exceptions shall be

for damages arising from vandalism, mechanical damage, external fire and flooding.

20.5. Cathodic Protection Monitoring Points

All cathodic protection monitoring points along the section of the pipeline subject to AC

interference are to be of dead front construction unless the appropriate gradient control mats

have been installed.

A dead front test point shall be constructed in such a way as to ensure that no metallic parts

are exposed to a person on the operating side of the equipment. Contact should only be

possible with insulated measuring probes. Appropriate operating instructions and a warning

of the hazard shall be printed adjacent to the measurement points. Access to the live side

should only be available to trained personnel. The test station is to be installed inside a

galvanised steel or reinforced concrete bunker enclosure.

20.6. Safe Working Procedures In Power Line Servitudes

20.6.1. Appointment of Electrical Safety Officer (ESO)

Prior to any work commencing an Electrical Safety Officer (ESO) shall be appointed by the

Contractor or the Contractor’s agent. This person shall:

a) be the designated safety officer for the project,

b) have completed a recognised and accredited responsible person training course,

c) be authorised by a authorised person (GMR2.1) to work without constant supervision in

a power line servitude

d) have completed the SAECC Electrical Safety Officer training course,



e) have experience in the supervision and management of temporary mitigation measures

during pipeline construction, and

f) be furnished with the authority and equipment required to implement and maintain safe

working conditions, keep a record of any non-compliance and advise the construction

manager and the project safety officer.

20.6.2. General Safe Working Procedures

a) No person, equipment or machinery shall enter the HV/EHV servitude without the approval

of the ESO. All affected areas shall be suitably demarcated and access restricted to those

personnel who have been advised of the hazards and requirements when working

underneath or adjacent to HV/EHV power lines.

b) All personnel shall be made aware of and be able to recognize the potential shock hazards

and be trained in the approved safety procedures.

c) Pipeline construction personnel shall avoid contact with HV/EHV structures and supports.

No mechanical equipment shall come closer than 5 m from any power line tower.

d) Direct connections to the power line tower structures or buried counterpoise earthing

system are not permitted under any circumstances. The earthing systems of the power

line and the pipeline must be kept separate.

e) Temporary construction sheds, trailers, living quarters, pipe sections, storage areas or

vehicle fuelling facilities are not permitted in the HV/EHV servitude.

f) No mechanical equipment, including mechanical excavators or high lifting machinery, shall

be used in the vicinity of eThekwini Electricity’s apparatus and/or services, without prior

written permission having been granted by eThekwini Electricity. If such permission is

granted the applicant must give at least seven working days prior notice of the

commencement of work. This allows time for arrangements to be made for supervision

and/or precautionary instructions to be issued. The internal assessor must provide the

applicant with the details of an eThekwini Electricity person to be contacted in this regard.

g) All rubber tyre construction vehicles used in the HV/EHV servitude shall be equipped with

a steel chain secured to the chassis at one end and freely dragging on the earth at the

other, to discharge any electrostatic build-up.

h) The minimum vertical clearance between construction equipment and overhead

conductors shall be in accordance with Table 1. The actual height of the conductors at

their lowest point shall be measured by means of optical measuring equipment to ensure

that this minimum clearance is achieved.



Table 1: Minimum vertical clearance underneath power line conductors

(from Regulation 15 of the Electrical Machinery Regulations of the OHS Act (Act 85

of 1993))

i) Vehicles such as mobile cranes with extendable members that can potentially exceed this

minimum vertical clearance height shall be identified and the operators issued with specific

instructions with regard to the maximum permissible extension, prior to doing any work in

the HV/EHV servitude.

j) If for any unforeseen reason, the life-threatening situation occurs where a construction

vehicle comes into contact with a live HV/EHV conductor or a flash-over occurs, the

operator(s) shall remain inside the vehicle and attempt to get it out of the contact situation

using ONLY the vehicle’s own power. On NO account shall the operator(s) leave the

vehicle and on NO account shall any person approach the vehicle, until the contact

situation has been reversed, or until the ESO has received confirmation from the electricity

utility that the power line has been de-energized. Arcing may temporarily stop due to the

action of the protection, however this in itself shall NOT be taken as an indication that the

line is safe, since the line may automatically attempt to re-energize. Effective assistance

in this situation entails ensuring that all persons present maintain a safe distance from the

vehicle (>10 m) and alarming the electricity utility’s operational centre.

k) Any foreign metal structures exposed during trenching inside or alongside HV/EHV

servitudes shall be treated as a live electrical conductor, until measurement proves

otherwise. The pipeline shall not be bonded any foreign structures without an assessment

by a qualified engineer and written permission from the owner.

l) The use, storage, disposal, treatment or generation of any hazardous substances shall not

be permitted in the power line servitude.

20.6.3. Daily Measurements

a) Qualified personnel shall measure and record the pipeline voltage to earth to verify that

conditions are safe to work (a.c. < 15V r.m.s.), on all sections and on each day prior to the

commencement of any construction or other activity involving contact with the pipeline.

Nominal r.m.s. voltage (kV)

66 88 132 220 275 400 533 d.c.

765

Minimum vertical clearance (m)

3.2 3.4 3.8 4.5 4.9 5.6 6.1 8.5



b) For pipeline voltage measurements, a voltmeter of suitable range and impedance shall be

used. Low resistance earth connections shall be used to avoid induction or capacitive

pickup on test leads and related items that could result in erroneous readings on a high

impedance instrument. A suitable reference is a metal rod driven into the earth.

c) Test leads shall be attached to the instrument first and then to the pipeline. After

measurement, the leads shall be removed from the pipeline first and from the instrument

last.

d) Each time a voltage measurement is made, the following data shall be recorded:

i. location,

ii. time,

iii. date, and

iv. pipe-to-earth voltage.

20.6.4. Temporary Earthing

a) Pipelines exhibiting voltages greater than 15 V r.m.s. shall be earthed with temporary

driven earth rods. Pipelines parallel to a.c. power systems shall be earthed opposite the

midpoint of each span, maximising the distance to the nearest HV/EHV structure.

b) The temporary connections to the pipeline shall be made with earthing clamps that apply

firm pressure at the contact point with a mechanically sound connection, and with the

coating at the contact point removed down to the bare metal. The connection between the

earthing clamp and the earth rod shall be made with 25 mm² stranded copper cable, green

PVC insulated.

c) To prevent the risk of personal injury or arc burns, the connection and disconnection of

temporary earths shall be carried out in the following order:

connection:

i. the earthing clamp is connected to the pipeline,

ii. the earthing cable is connected to the earth rod,

iii. the earthing cable is connected to the earthing clamp.

disconnection:

i. the earthing cable is disconnected from the earthing clamp,

ii. the earthing cable is disconnected from the earth rod,

iii. the earthing clamp is removed from the pipeline.

d) Temporary earths shall be left in place until immediately prior to backfilling. Sufficient

temporary earths shall be maintained on each section until adequate permanent grounding

connections have been made.



e) When the pipeline voltage remains above 15 V r.m.s. in spite of the temporary earth rods,

temporary earth mats that extend a minimum of 1 m outside the work area shall be used.

The connection between the pipeline earthing clamp and the temporary earth mat shall be

made with 16 mm2 or larger stranded copper cable. There shall be no contact between

persons over the earth mat and those not over the mat, including the handing over of tools

or materials.

20.6.5. Bonding Of Isolating Flanges, Joints And Couplings

a) Work on isolating flanges, joints, or couplings shall only proceed after the AC status has

been verified. A temporary bond across the flange or the use of a properly sized temporary

earth mat shall be used to protect personnel while they work on the pipe.

b) When cutting a pipeline, adequate bonding across the point to be cut shall be used,

irrespective of the AC voltage measured between the pipeline and earth. When this voltage

exceeds 15 V r.m.s, additional earthing shall be installed BEFORE cutting commences.

20.6.6. Precautions During Coating And Lowering-In Operations

a) Where coating is to be applied at field joints, precautions shall be taken to ensure that

equipment contacting the bare pipe is adequately bonded and earthed. For the lowering-

in operation, the coated pipeline shall be handled with nonconductive slings.

b) Because the coated pipeline may not be effectively earthed during part of this operation,

contact with the bare portion of the pipeline shall be avoided when the support slings are

removed from the end of the pipeline.

20.6.7. Work Stoppage

a) The ESO shall have liaison with the electrical utility to determine planned switching,

outages, and load changes that may affect pipeline voltage. Work involving contact with

the pipeline shall be stopped during scheduled switching of the electric power system.

b) WORK SHALL BE STOPPED WHEN ANY LIGHTNING ACTIVITY IS PRESENT.

20.6.8. Inspection And Testing And Of Pipeline A.C. Mitigation Components Prior

To Commissioning

a) When the A.C. mitigation measures agreed upon by the eThekwini Electricity and the

Pipeline Operator have been installed, an eThekwini Electricity representative shall be

permitted to inspect all the components of this installation and to perform necessary

measurements to prove the effectiveness of the A.C. mitigation system.



b) Final approval of the A.C. mitigation installation is subject to the outcome of this

inspection.

20.6.9. Long Term Maintenance Requirements Of Pipeline And Power Line A.C.

Mitigation Components

a) The A.C. mitigation measures shall be maintained by regular inspection and

measurement of the effectiveness of the measures. The interval between inspections

shall not exceed 6 months.

b) Maintenance personnel shall be provided with special training to acquaint them with the

A.C. mitigation components, measurements and safety requirements.

c) Clear and detailed maintenance records shall be kept available for inspection by an

eThekwini Electricity representative for the full operational lifetime of the pipeline.



21. CATHODIC PROTECTION REMOTE MONITORING UNIT (CPRMU)

21.1. CPRMU Packaging

Each CPRMU should include the following basic components, but not limited to:

- Instruction manual for CPRMU.

- Basic CPRMU unit.

- CPRMU mounting bracket for installation inside units to be monitored.

- Backup battery and charging circuit.

- Data management and storage capabilities.

- Installation software (CD ROM), 1 original and 1 copy required.

- Base station security access codes for historic data accessibility.

21.2. CPRMU General Specification

The CPRMU must be a self-contained unit, housed in a suitably rated enclosure that collects

and stores the information from field variables in a suitable digital format. Two types of

CPRMU are to be developed / supplied, namely:

21.2.1. CPRMU Type 1

This Type of CPRMU is to be used where external power supply is available typically at

Transformer Rectifier (TRU’s) and Forced Drainage Units (FDU’s).

Variables to be measured as minimum requirement:

Rectifier Condition. (On or Off).

Pipe -to-Soil Potential, complete with input capacity range of ±50 Volts auto ranging.

Coupon Potential, complete with input capacity range of ±2.4 Volts.

Rectifier Output Current. (0mVdc to + 100mVdc) converted to Amps at base station or as

determined by the unit shunt rating.

Drain / diode Current (FDU, NDU, Cross bonds). (0mVdc to ±100mVdc) converted to Amps

at base station or as determined by the unit shunt rating. Note: Drain current at cross

bonds requires positive and negative range as current direction changes in the field.

Rectifier Output Voltage, complete with input capacity range of ±100 Volts auto ranging.

AC Ripple, complete with input capacity range of 20Vac RMS.



Intruder Alarm.

CPRMU actual unit backup power supply capacity.

AC Mains Power Failure Alarm.

The CPRMU Type 1 internal building blocks consist of:

Applicable Microprocessor unit – with data processing and data logging capabilities.

Communicator – GSM or GPRS or direct RS232.

Power Supply Unit to work off 220V mains with AC ±10%.

Data capture modes to be adjustable between the following selections:

Logging at set intervals starting from 1 reading per second to one reading every 30

seconds, similarly once per minute up to once per 30 minutes, similarly once per hour

every day.

Logging only if exception conditions are met i.e. Upper and / or Lower boundaries are

breached.

Mode adjustment to be available via remote signal or RS232 connection.

Storage capacity to be minimum of 1 000 000 readings per channel.


This Type of CPRMU is to be used where no external power supply is available, typically at

Natural Drainage Units (NDU’s), Cross Bonds and Cathodic Protection Test Points.

Variables to be measured as minimum requirement:

Pipe -to-Soil Potential, complete with input capacity range of ±50 Volts auto ranging.

Coupon Potential, complete with input capacity range of ±2.4 Volts.

Cross Bond (across shunt) or Drain Current (0mVdc to ± 100mVdc) converted to Amps at

base station. Note: Drain current at cross bonds requires positive and negative range as

current direction changes in the field

AC Ripple, complete with input capacity range of 20Vac RMS.

Intruder Alarm.

CPRMU actual unit backup power supply capacity.



The CPRMU Type 2 internal building blocks consist of:

Applicable Microprocessor unit – with data processing and data logging capabilities.

Communicator – GSM or GPRS or direct RS232.

Optional:

RF Communicator – GSM. The unit may be used strictly as a data logger with RS 232

download capabilities, alternatively, the CPRMU Type 2 should allow for GSM Module to be

integrated that will enable GSM transmission form the unit to a predefined base station. This

option has been defined as GSM module and suppliers are encouraged to make this a

separate module to the logger component so as to reduce the cost of the logger component

as much as possible.

Note:

Power Supply Unit to work off replaceable and rechargeable battery backup. Data capture

modes to be adjustable between the following selections:

Logging only if exception conditions are met i.e. Upper and / or Lower boundaries are

breached.

Data transmission to be adjustable in daily increments to once per month, if the GSM

module is in use.

CPRMU Type 2 to power down unless programmed to transmit data regularly. Applicable

only if the GSM module is in use.

Storage capacity to be for 1000000 readings per channel.

Mode adjustment to be available via remote signal, if the GSM module is in use, or RS232

connection.

21.2.3. Data Processor

All data processing factors shall adhere to the following minimum technical guidelines:

Fixed Time Logging suppliers to provide the ranges and conditions of data capture.

Logging by Exception to be based on the activation of the logging sequence only if the

calculated average of an input valve changes by a pre-set percentage value. This pre-



set percentage value (∆ Value) must be user adjustable to activate logging for ∆ Value

in a minimum range between 5% and 30% of a set point.

Data Transmission to be via GSM Network using scheduled communication from a

central base station or from the field unit back to base station when predefined

exception or security conditions are met. For the CPRMU Type 1 and 2 data

transmission must be enabled via RS 232 protocol or other suitable data transmission

method such as Bluetooth.

21.2.4. Display Unit

The CPRMU must have an LCD (Liquid Crystal Display) screen.

This display has a dual function, firstly to monitor set-up values during CPRMU Type 1 and

Type 2 configuration and secondly to monitor the measured variables during normal operation

for comparison with external meter measurements.

The LCD must be able to display various selectable configuration menus as values using an

external programming unit, during configuration of the CPRMU where applicable.

During normal operation the LCD must display input values by scrolling at suitable intervals.

21.2.5. Communicator

The GSM Communicator must comply with the requirements and specifications of Vodacom,

MTN and Cell C. The Communicator must be capable of transmitting all data collected by the

logger unit via the GSM network. For the CPRMU Type 1 and 2 the transmission of data must

be permitted using a standard RS232 connection or other suitable data transmission method

such as Bluetooth.

21.2.6. Power Supply

The Power supply module mounted in the CPRMU Type 1 should be capable of accepting

both AC and DC supply voltages such as: 110-240VAC and 12 Vdc respectively. Typically the

12 Vdc supply will be supplied by an external battery.

CPRMU Type 1 and Type 2 shall have battery supply only. Assurance is required that during

all operating modes the battery life will not be less than 5 years, with a minimum of 5



continuous logging sessions per year comprising duration of 5 days each. The balance of the

period will be for periods of 1 reading every hour and one transmission per week.

The supplier shall specify how this will be achieved for CPRMU Type 2 at the same time of

submitting the tender. Alternatives and different combinations will be considered on an

individual basis and the merit of each offering.

21.2.7. Lightning Protection

The CPRMU will be equipped with suitable lightning protection lending itself to easy

replacement and capable of offering protection to each of the input channels.

21.2.8. Documentation to Be Provided With the Tender

a. CPRMU front end capability to display historic field data from 1 to 120 days for multiple

units.

b. Typical report (in graphical representation) of the CPRMU type 1 and type 2 layout– Data

Logger type showing multiple data series.

c. Internal battery backup should have a 5 year maintenance free capacity for both CPRMU

type 1 and type 2. The supplier is to state the maximum backup duration and expected

battery life with the tender submission.

d. Software calibration details of the CPRMU and turnaround calibration time.

e. Details of technical backup that will be provided by the supplier.

f. CPRMU units used elsewhere and details of the clients that can be contacted for

reference.

g. Operations Maintenance Manual (OMM) of the CPRMU.

h. Installation team experience details.

21.2.9. Site Regulations

The contractor shall comply with the site regulations of the relevant eThekwini Municipal

Authorities and is required to complete the necessary indemnity forms for work conducted on

the site. The responsible authorities shall be kept informed of all works conducted on their

sites.



21.2.10. Installation

The installation specifications on which this contract is based are the South African Bureau of

Standards Standardized Specifications for SANS 10142-1_2009 Edition 1.7 the Wiring of

Premises - LV Installations.

Although not bound in, nor issued with this document, all the relevant sections of the

Standardised Specifications of SANS 10142-1_2009 Edition (Latest Revision) shall form part

of this Contract.

The Contractor should note that the following minimum requirements should be noted and

implemented on site when installing CPRMU, aerials, surge/lightning protection, power

supplies and other project related works:

1. Suitably sized and rated cable glands shall be used where cable pass through, into or out

of an enclosure.

2. All cabling shall be numbered using appropriate sized labels that are legible.

3. Trunking or conduit shall be used to neatly route cables inside TRU, FDU and other

permanent installations.

4. A legible circuit diagram shall be provided for each permanent CPRMU installation

showing the correct cable numbering and routing to the terminals being monitored. The

circuit diagram shall be provided in hard copy and on a CD in PDF format, with each PDF

file named in accordance with the equipment number or name it is installed in.

5. Good workmanship is expected.

6. No loose cables will be accepted.

7. Each CPRMU installed in a permanent location must be mounted using a suitable bracket

or enclosure that is fixed either on the inside of the equipment being monitored or the

structure housing the equipment being monitored.

8. Aerials must be vandal proof and installed in the most inconspicuous manner possible.

9. The Contractor must make provision for tracing and locating the appropriate terminals to

monitor. Should any uncertainty arise in this regard the matter must be raised with the

Engineer, but it does not absolve the Contractor from completing the works.

10. The intruder alarm on powered, fixed installations shall have a minimum allowance of 1

contact switch for a ROCLA, or Brick Kiosk Door and a maximum of 6 contact switches,

wired in series, for TRU/FDU equipment with multiple doors. The Contractor’s price in the

Bill of Quantities is deemed to include these minimum requirements.



21.3. Typical CPRMU Variables

Typical input variables, operating environment and dimensions of the CPRMU are given below

as guideline only. Each supplier shall provide detailed information of the proposed solution

with their tender documents; failure to do so may prejudice the evaluation of the tender and

lead to its rejection.

Logger interval : user adjustable range. (Sec, min, hr).

Logger Averaging : User adjustable range. (Sec, min, hr).

Power Supply : 12V DC/110-2040VAC, OR (Type 2)

Battery only.

Supply Load : 20mA at 12V and 1% transmit duty Cycle.

(Depending on the communication media).

Operating Temperature Range : - 20°C to + 70°C.

Humidity Limit : 95% at 40°C (May Condense).

Maximum Dimensions : 370mmmx140mmx80mm for CPRMU Type 1.

100mmx240mmx100mm for CPRMU Type 2.

Approximate Weight : Supplier to provide information.

Download : GSM Network or RS 232 (Bluetooth protocol

Optional) .Contractor / Supplier to provide with

submission of Tender document.

Dimensions of the unit should be such that it will fit into the existing cathodic protection units

or into select test posts. The Contractor / Supplier shall provide the dimensions of the

proposed CPRMU with the tender submission and if there are any deviations from the

maximum dimensions listed above these shall be recorded as a deviation from the tender

requirements.

21.4. Data Inputs

i. Output Voltage (0Vdc to + 100Vdc into 20M-ohm).

ii. Output Current (0mVdc to + 100mVdc into 33k-ohm).

iii. Drain / Diode Current (0mVdc to ±100mVdc into 33k-omh).

iv. Reference Cell, Voltage (± 50Vdc into 20M-ohm)

v. Digital alarm input (from galvanic isolated contact).

vi. Power failure. (Contractor / Supplier to specify).

vii. AC Ripple, complete with input capacity range of 20Vac RMS.



Input selection to be predefined for the CPRMU Type 2 most likely to be same as for item ii

and iv above. Items iii and iv require positive AND negative range.

Note: Drain current at cross bonds requires positive and negative range as current direction

changes in the field

21.5. Suggested Transducers

Each contractor to provide details of transducers that will be used to convert signals from direct

measurements to acceptable inputs to the CPRMU. Information pertaining to the transducers

to be submitted with the tender document detailing source of supply, technical support and

offices capable of carrying out repair.

21.6. Communication Options

Due to the rather varied and remote nature of present and future sites that require monitoring

THE CLIENT requires that the CPRMU have the capacity to transit all field data, with SMS

capability for exceptions, intruder alarms and specific fault conditions programmed into the

field CPRMU.

21.7. Channels


Channels are to be configured as follows, as minimum guidelines:

1=Output Current (in millivolts across the shunt). Software to display Ampere (A).

2=Diode Current (in millivolts across shunt). Software to display Ampere (A).

3=Mains Voltage Monitor. Software to display Voltage (V).

4=Pipe-to-soil Potential. Software to display Voltage (V).

5=Coupon Potential. Software to display Voltage (V).

6=AC Ripple.

7=Intruder Alarm.

Note 1: The use of galvanic isolation and a dedicated input lightning protection device

are a prerequisite for each CPRMU. Supplier to provide full details of the input

isolation technique that will be applied to the proposed CPRMU solution at the

time of tender.




Only channels 1 or 2, 3, 4 and 6 of the CPRMU Type 1 unit will be applicable:

1 or 2= Drain Current (in millivolts across the shunt). Software to display Ampere (A).

4=Pipe-to-soil Potential. Software to display Voltage (V).

5=Coupon Potential. Software to display Voltage (V).

6=AC Ripple.

7=Intruder Alarm.

Note 1: Drain current at cross bonds requires positive and negative range as current

direction changes in the field.

Note 2: The use of galvanic isolation and a dedicated input lightning protection device

are a prerequisite for each CPRMU. Supplier to provide full details of the input

isolation technique that will be applied to the proposed CPRMU solution at the

time of tender.

21.8. Data Transfer, Storage and Management

Each Contractor/Supplier must provide the following with their tender submission:

a. A flow diagram setting out the data transfer path from the CPRMU Type 1 and 2 to end

users. A full description of the data transfer process to be set out in writing.

b. A flow diagram indicating how the data from the CPRMU Type 1 and 2 can be integrated

with a dedicated base station. A full description to be provided of the software, hardware

and development requirements to be set out in the tender document cover letter.

c. Demonstration software to be stipulated in the tender submission. Examples of output

graphs for the respective variables to be provided in A4 format with the tender document.

d. Computer hardware and software requirements to be stated clearly with the tender

submission setting out what the minimum system requirements will be to run proprietary

software.

e. Contractors to provide details of configurations available for data transfer on the proposed

CPRMU Type 1 and 2 and the requirements for reconfiguration on site. Data destinations

transmission durations and ability to back up data in the event of a failed transmission.



i. Contractors to provide the costs associated with the data transfer on a monthly

basis for typical GSM options.

ii. Contractors to provide costs associated with data transfer once a day, once a

week and the amount of data transferred per session.

f. For purposes of The Client’s CPRMU application the following basic data transfer, storage

and management option or combinations thereof are a prerequisite:

i. CPRMU Type 1 and 2 direct to several cell numbers, Data to include most recent

input channel values and alarm status. Daily logged readings not required.

ii. CPRMU Type 1 and 2 direct to several email addresses. Data to include most

recent input channel values and alarm status. Daily logged readings not required.

iii. CPRMU Type1 and 2 direct to a Base Station. Data to include daily logged channel

values and alarm status as per the configuration of the CPRMU. The Base Station

should keep full records of the respective CPRMU variables, with suitable

identifiers for each CPRMU. Base station features to include data backup every

month to CD Rom with a library facility. The Base station should essentially provide

one site (at end user), secure and stable back up of CPRMU data. This is the

chosen delivery configuration option for this tender document.

21.9. Maintenance, Servicing and Call Outs

The following section of the technical specification sets out the basic requirements in the event

of maintenance, servicing or call-outs being initiated by the end user. Contractors are to

provide detailed flow diagrams and written submission, with their tender, on how they intend

to provide the services as and when they may be required in future.

21.9.1. Maintenance and Servicing

Each Contractor must submit with their tender a plan for dealing with maintenance and

servicing related requirements that may arise over time with the installed CPRMU. The plan

must include contact names, procedures to follow and how repair requirements will be

reported to the end user before work is carried out.

THE CLIENT will not authorize work, maintenance and servicing of any CPRMU without

proper procedures that identify the cause and nature of damage that may occur to CPRMU

field installation.



21.9.2. Call Outs

Call out rates to be provided in the cover letter to this submission. The following basic criteria

would constitute a call out:

End user is unable to retrieve data from the CPRMU via the specified medium. Contractor

to visit the end user / site within the eThekwini Municipal area.

Calls out costs are to be calculated on the basis that the supplier is locally based.

End user identifies a physical fault on the CPRMU on site and notifies the contractor

accordingly. Contractor to visit the end user / site within the eThekwini Municipal area.

End user identifies calibration errors that occur after successful commissioning of the

respective CPRMU. Contractor to visit the end user / site within the eThekwini Municipal

area.

A call out will compromise the time and transport of a suitable skilled technician. The

transport costs per call out are any site within the eThekwini Municipal area, with the

restriction of one call out per site. Time to from and on site to be three (3) hours per hours

per call out. Contractors to provide information on the structuring of costs and the

personnel that will carry out the proposed visits. Should the call out period be exceeded

the client will have to be informed of standard hourly rates that will apply.

21.10. CPRMU Guarantee and Defects Warranty

A guarantee of one (1) year is required on each CPRMU supplied and installed. In addition to

the general guarantee a 24 months defects warranty is required. The guarantee and warranty

must commence from the date that the CPRMU is installed and handed over to the end user.

Contractors to provide detailed guarantee and warranty information setting out the following:

Guarantee / Defects Warranty period.

Components covered by the Guarantee / Defects warranty.

Exclusions.

Guarantee / Defects Warranty claim procedure.

Contact details for responsible person who will deal with guarantee and defect warranty

claims.

Failure to provide the above information in writing with the tender document may prejudice the

tender and it may be rejected as a result.



21.11. Vandalism

Each contractor must provide details of vandal proofing that will be implemented to secure the

GSM aerials required for communication purposes. Each contractor should note that the final

installation sites may not all be within secure environments necessitating the need for secure

aerial enclosure.

21.12. Airtime Agreement

For purpose of this tender contractors are to provide the following airtime options at the time

of tender submission.

Note: The Contractor must provide pricing for ALL options clauses listed under this part of

the specifications as failure to do so will invalidate the offer and the Client reserves the

right not to reject the pricing and associated offer.

21.12.1. Direct with Cellular Service Provider

Contractors should provide requirements for an airtime agreement to be signed directly

with the cellular service provider (MTN, VODACOM, or Cell C). THE CLIENT requires

sufficient information to support this option with respect to the following. Assurance of

continuity of data.

Contingency in the event of the supplier ceasing to exist ie. Data routing, use of CPRMU.

Access to configuration software to make adjustments to the CPRMU.

21.12.2. Direct with Supplier / Distributor / Agent of CPRMU

Contractors to provide requirements for an airtime agreement to be signed directly with the

supplier of the CPRMU. THE CLIENT requires sufficient information to support this option with

respect to the following:

Assurance of continuity of data

Contingency in the event of the supplier ceasing to exist ie. Data routing, use of CPRMU.

Access to configuration software to make adjustments to the CPRMU.

21.12.3. Prepaid Data Card Option

Contractor to provide existing options and recommendations based on different data

transmission rates.



22. NAMING CONVENTION FOR EQUIPMENT AND MATERIALS

The labelling technique for each item will be specified by The Client. If a technique is not

specified the labelling shall comprise the use of stencils with a compatible paint system

approved by The Client before application.

The naming convention for all equipment shall following the following convention:

22.1. TRUs, SMUs, NDUs and FDUs

TRU, SMU, NDU and FDU shall have engraved name plates labelled with the following:

Location name

Reference number comprising: Client abbreviation, Unit Type first letter,

supplier abbreviation, supply date month and year ie. XYZ/T/CPSA/0105

Supplier serial number

Date of Supply

Client Name

Font size to be no less than 6mm high

The Client shall specify external and internal labelling requirements for TRU, SMU, FDU and

NDU for ease of identification. Typically these units will have the following external labels:

Unit name

Location

Contact number

Font size to be no less than 30mm high or as specified

Black lettering on white background

22.2. Test Stations, Monitoring Points, Bunkers and Other Monitoring

Facilities

Test stations, monitoring points, bunker type stations and other monitoring facilities shall have

a sequential number system relative to the pipeline or pipe network. The monitoring facilities

system shall be labelled as follows and/or in accordance with The Client’s specifications:

Monitoring test station :Type A

IR free test station :Type B

Recording stations :Type C

Bunker stations :Type D



Cross Bond stations :Type E

Test station where ACM is installed :Type F*

* = any letter from A-E depending on the type of installation within the ACM

test station.

Unique number supplied by The Client to follow above abbreviation.

Client abbreviation will prefix the stations label. Example: XYZ/TP10013.

Font size to be no less than 20mm high.

Monitoring stations that have lockable doors / facilities shall include internal

labelling comprising:

Date of manufacture.

Station number.

Pipeline route.

Label and print size will be determined by the space available in the

enclosure.

Labelling to be on a white Trafolyte board with black lettering.



23. CONTRACTOR REQUIREMENTS

23.1. Construction, Testing and Inspection

The Contractor shall not commit any act of trespass or commit any nuisance and must confine

all installation personnel to the servitude widths, access roads, etc., as approved by The Client

so as to avoid any damage to adjacent crops, structures, fences, livestock, etc.

The Contractor shall provide and maintain at all stages of the work adequate drainage pipes

at all contour drainage channels, existing furrows, subsoil drains, subsoil irrigation pipes, etc.,

which are cut by the works and the cost of this work shall be to The Contractors account.

The Contractor shall not permit any operation which may constitute a fire hazard.

The Contractor shall bear the cost of damage caused by fire started during the Contract or

maintenance periods due to any negligence on the part of The Contractor or his workmen.

23.1.1. TRUs , SMUs, FDUs and NDUs

The Client or his representative shall at all times have the right to inspect and test all

equipment, materials and workmanship as work progresses and to reject material and/or

workmanship which is defective, does not comply with best Engineering practice or otherwise

not in accordance with the Contract.

The Contractor shall manufacture one of each type of equipment for inspection and notify The

Client of its completion.

Any rejected work or material shall be satisfactorily corrected and/or replaced, the cost to be

borne by The Contractor.

On written instructions of The Client, The Contractor may be called upon to leave the pipeline

exposed for inspection for any particular part of the works that they consider necessary. Such

written notice can be given at any time during the installation of the works.

On completion of all works and prior to the commissioning, The Contractor shall avail himself

for a final site inspection. This shall comprise of a thorough inspection of all works carried out

and a punch / snag list shall be issued for any remedial works.



23.2. Work to be Supervised by a Qualified Representative

The carrying out of all works included in the contract shall be supervised throughout the

duration of the Contract by an approved representative of The Contractor.

23.3. Supplier to Submit Full Details

The Contractor shall submit full data and particulars to enable a decision on the conformity of

the equipment, etc., offered to the Specification and to enable a comparison with the other

quotations / proposals received.

The data and particulars required which shall be submitted in duplicate, shall include full

technical, descriptive and dimensional particulars and drawings of:-

Transformer Rectifier Units,

Switch Mode Units,

Natural Drainage Units,

Resistive Bonding Units,

Mixed Metal Oxide Anodes and

Any other equipment as specified in the Bill of Quantities.

No proposal / quotation will be considered which is not accompanied by sufficient data and

particulars as described above. Unless specifically stated, it will be assumed that all equipment

complies in full with the Specification.

23.4. Commissioning, As-Built Drawings and Records

23.4.1. Commissioning

The CP System will be commissioned by the appointed Specialist Consultant to ensure that

the installation was performed to standard and that all respective equipment operates

satisfactorily.

23.4.2. Drawings

All drawings are to be to scale and presented in AutoCAD 2000 format. Prior to finalising

drawings it shall be submitted to The Client for their perusal and approval.



23.4.3. Records

Records of the installation, problems and site meetings shall be kept and handed to The Client

upon handover.

23.4.4. Spare Parts

Spares (2 off) shall be supplied as specified and either attached to a panel affixed inside the

equipment cabinet or separately in a spares box. Listing of all spares detailing their

specifications, locations and sizes shall be attached to the equipment.

The component manufacturer (supplier) list and contact details shall be provided with all

spares complete with current price list – fuses, MOVs, diodes, Thyristors, spark gaps and

control cards.

23.5. Installation

23.5.1. Supply / Installation Obligations

The Contractor shall warrant and guarantee that the materials and workmanship provided

shall be in accordance with the Contract Specification and documentation.

The Contractor shall furnish to The Client, on completion of all works and before Contractor’s

handover, As-Built Drawings of:

Equipment.

Cable routes to pipe.

Cable routes to anodes.

Power supply cables.

Cabinets.

Enclosures.

Test posts

All significant installations included in the Bill of Quantities or Technical Specification.

The purpose of the As-Built Drawings is to provide The Client with a correct record of all works

carried out. The Contractor shall confirm at the time of tender:

GPS sub-centimetre accuracy.

Format for presenting captured data.

Detailed sketches required to explain the captured data.



The Client’s contact person/s to verify As-Built Data with.

It shall be the responsibility of The Contractor to ensure that all items are available for

inspection prior to delivery.

All materials, plant and equipment shall be the best of their respective kinds and spare parts,

replacements and servicing facilities shall be readily available from local sources.

All work shall be carried out by qualified personnel and shall be correctly supervised.

23.5.2. Guarantee of Equipment

The Contractor is required to supply a written guarantee on the items supplied by him for a

period of 2 years (this is in addition to the standard defects liability period of 1 year) from date

of commissioning under continuous working conditions. In the event that the CP and AC

Mitigation Contractor is appointed as a sub-contractor to the main construction contractor the

guarantee terms shall, as a minimum, be the same as those of the main contractor.

Any faults as may be certified by The Client due to poor materials, workmanship or The

Contractor’s design (where applicable), shall be remedied and faulty goods replaced entirely

at The Contractor’s cost.

The Contractor is responsible for the guarantee of all items under the terms of this tender and

for the safe delivery and installation of the equipment and materials, as called for in the Bill of

Quantities, unless otherwise instructed in writing by The Client

23.6. Operation and Maintenance of the CP System

The CP System Operation and Maintenance Manual (OMM) will provide the owner and

technical staff with knowledge on the operation of the CP system and the subsequent

maintenance thereof.

23.7. CP System Acceptance Criteria

23.7.1. Operational Acceptance Period

When all tests have been successfully completed to the satisfaction of The Client, an

operational acceptance period shall start and shall consist of a continuous period of operation

of two weeks free from trouble. During the operational acceptance period The Contractor shall

carry out all necessary servicing and any adjustments required.



23.7.2. Certificate of Completion

A certificate of completion will be issued in line with the conditions of contract applicable to the

specific project in question.



24. ANNEXURES

Annexure A: TRU/SMU/FDU/NDU Compliance Test Certificate

Annexure B: TRU/SMU/FDU/NDU Factory Acceptance Testing

Annexure C: Isolating Flange Guidelines

Annexure D: Drawing Register



24.1. Annexure A: TRU/SMU/FDU/NDU Compliance Test Certificate



Compliance Test Certificate

1. Visual Inspection (TRU/SMU/FDU/NDU)

Using an approved circuit diagram conduct the following inspections:

1.1. Correct Component Connections

Check through the unit and confirm that the wire connections made on the

specific components are correct. Yes/No

Check that all the components in the unit are compliant with the original

specifications and correspond with the circuit diagram. Yes/No

Are fuses installed in compliance with the design? Yes/No

2. Insulation Test (TRU/SMU/FDU/NDU)

Carry out a 1 kV insulation test as follows:

Temporarily disconnect the MOV’s mounted in the primary and secondary circuits.

2.1. Transformer (TRU and FDU where an SMU is not used. Not for NDU)

AC Input to Frame…………………………………………… Meg Ohm at 1 kV

Primary Winding to Secondary Winding………….……….. Meg Ohm at 1 kV

2.2. Output (All Units)

DC Positive to Frame………………………………...……….. Meg Ohm at 1 kV

DC Negative to Frame………………………………………… Meg Ohm at 1 kV

2.3. Earth (All Units)

Earth bar / stud to any non-insulated Mounting Stud ……………………...Ohm

Does the earth bar / stud meet Technical Specification / Drawing

Requirements of only 2 terminations per bolt/stud?.............................. Yes/No

Reinstate the connections to the surge devices (Not for NDU) ............ Yes/No



3. Display / Meter Tests (TRU/SMU/FDU)

Monitor the voltage, current and reference potentials as displayed on the analogue meters

and the Reference Meters LCD display. Also record direct measurement of these

parameters with a handheld multi-meter.

Measurement errors must not exceed 5% using the handheld multi-meter as the standard.

List the following results as follows:

LCD / Panel

Meter Display

Digital Multi-

meter (DMM)

Error (V) Error (%)

DC Output

Voltage (V)

DC Output

Current (A)

Reference

Potential (V)

Reference Set

Point (V)

Measurement errors are calculated from comparisons between the Controller LCD/Panel

meter and the DMM. PASS / FAIL

4. Efficiency Test (TRU/SMU/FDU)

4.1. No Load

Input Voltage……………………….. Volts. Input

Current…………………Ampere.

4.2. 25% Load

Output current at 25% of maximum Ampere; Output Voltage…………...V

Input Voltage……………………….. Volts

Input Current………………..……… Ampere



4.3. 60% Load

Output current at 60% of maximum Ampere; Output Voltage……………...V


Input Current………………………. Ampere

4.4. 100% Load

Output current at 100% of maximum Ampere; Output Voltage…………….V


Input Current………………..……… Ampere

4.5. Efficiency Calculation

Output Voltage x Output Current = Eo

Average of the three Input Voltages x Average of the three Input Currents x 1.73205

= Ep

Eo / Ep x 100 = % Efficiency.

25% Load ……………………….. % Efficiency



5. Output Voltage (Manual TRU/FDU)

Lowest Tap Setting…………………………………………...Volts

Highest Tap Setting…………………………………………..Volts

Step Increments of…………………………………………...Volts



6. Output Load Test Certificate (One per Unit: TRU/SMU/FDU)

6.1. Connect a load to the unit that will permit a current output of

approximately 15% more than the rated unit current for a

period of 10 minutes.

Output Voltage……………………………… Volts

Output Current………………………………. Ampere

DC fuses must not rupture at this load.

6.2. Connect a load to the unit that will permit a current output of approximately 20%

more than the rated unit current for a period of 10 minutes.


Output Current………………………………. Ampere

DC fuses must not rupture at this load.

6.3. Connect a load to the unit that will permit a current output of approximately 25%

more than the rated unit current for a period of 10 minutes.


Output current………………………………. Ampere

Time delay to fuse rupture………………………………………… minutes

7. AC Overload Tests (TRU/SMU/FDU)

Replace the DC fuse links with link bars. Increase the current output to 20% above the

rated unit output current.

Time the duration it takes for the AC Fuse to rupture....................................... minutes

Should the AC fuses not rupture within 30 minutes the TRU fuse selection is deemed to

be incorrect.

Check all wiring for signs of discolouration after completion of the test. PASS / FAIL



8. DC Output Overload Tests (TRU/SMU/FDU)

Replace the AC fuse links with link bars. Increase the current output to 20% above the

rated unit output current.

Time the duration it takes for the DC Fuse to rupture.......................................... minutes

Should the DC fuses not rupture within 30 minutes the TRU fuse selection is deemed to

be incorrect.

Check all wiring for signs of discolouration after completion of the test. PASS / FAIL

9. Fault Indication and Reset Testing (TRU/SMU/FDU)

Where a unit specification requires built in fault indication, with associated relay switching,

this testing shall be carried out.

Operate the following fault indicators manually and observe whether or not the indication

is correct on the instrument cabinet. When the fault is manually activated, the LED

indication should change from Green to Red where applicable and if an intelligent control

card is installed this too shall indicate the fault condition correctly.

9.1. AC Fuse Fail PASS/FAIL

9.2. DC Fuse Fail PASS/FAIL

9.3. Remove one of leads to the Thermal Switch on the heat sink and verify that the

condition registers and indicates correctly. PASS/FAIL

9.4. With a Load connected to the TRU check that when the load is decreased to the point

where the current falls below 50mA the No Current Hour meter begins to totalize up.

PASS/FAIL

9.5. Depress the No Current Hour Meter reset push button and check that the totalized

value resets to zero. PASS/FAIL

9.6. Swap any two mains input phases feeding the TRU and check that the Phase rotation

output relay changes state and that the indication on the instrument cabinet changes

from Green to Red. PASS/FAIL



10. Tap Settings (Manual TRU/FDU)

10.1. Change connecting links in each of the settings below and record the open circuit

voltage measured at the output buss bars where the field connections will be

made with no load. Adjust the table for test results to suit the number of tap

settings on the specified unit.

Fine /

Coarse

Fine 1 Fine 2 Fine 3 Fine 4

Coarse 1

Course 2

Coarse 3

Coarse 4

10.2. Change the connecting links in each of the settings below and record the voltage

measured at the output buss bars where the field connections will be made with

a load calculated to achieve 100% of the rated unit current output for each

voltage setting.

Fine /

Coarse

Fine 1 Fine 2 Fine 3 Fine 4

Coarse 1

Course 2

Coarse 3

Coarse 4



11. Output Wave form (TRU/SMU/FDU)

Use an oscilloscope with a built in recording function to record the output wave form with

the tap settings set to maximum voltage and maximum current. Save the wave form in the

relevant job file and present a hard copy with the hand over documentation.

Measure the ripple and capture the wave form in the following two modes (where a

smoothing capacitor has been specified):

11.1. Capacitor installed.......................................................... Volts AC

11.2. Capacitor not installed…………………………..………… Volts AC

11.3. Measure current flowing in the capacitor circuit……….. Ampere AC

(Use a clamp on ammeter to measure 11.3)

12. Heat Run (One test per Unit Type) (TRU/SMU/FDU)

12.1. Using a Temperature logger connect the TRU up to a 100% Load and run the

TRU until not further Temperatures increase is noted.

12.2. Maximum Rectifier Stack temperature…………………………………… (oC)

12.3. Maximum Transformer Coil temperature (Not for SMU)...……………… (oC)

12.4. Maximum Cabinet Internal ambient bottom of cabinet………………….. (oC)

12.5. Maximum cabinet internal ambient top of cabinet………….……………. (oC)

12.6. External Ambient…………………………………….………………………. (oC)

13. Control Mode Tests (Automatic Control TRU/SMU/FDU)

13.1. Constant Current

Current Set Point: ……………………………….. (Amps)

Vary the load resistance to simulate voltage changes through the full rated

voltage range of the unit and observe whether or not the current set point is

maintained. PASS/FAIL



13.2. Constant Voltage

Voltage Set Point: ……………………………….. (Volts)

Vary the load resistance to simulate current changes through the full rated

current range of the unit and observe whether or not the voltage set point is

maintained. PASS/FAIL

13.3. Constant Potential

Structure-to-Electrolyte Set Point: ……………………………….. (VCSE)

Vary the load resistance to simulate current /voltage changes on the unit and

observe whether or not the structure-to-electrolyte set point is maintained.

PASS/FAIL

14. Diode Test (FDU/NDU)

Disconnect the diode from any parallel or connected circuits. Using a variable DC power

supply apply a voltage across the diode in the forward direction until current passes and

then steadily increase the current to 20% of the unit rating. Record the following:

Unit Ampere Rating ……………… (Ampere)

Unit Fuse Rating ……………………. (Ampere) Fuse Type / Make………………………….

Voltage across diode at which current first passes …………………………….… (Volts)

Current flow measured across shunt at 20% of unit rating ……….…................. (Ampere)

Current displayed on panel meter at 20% of unit rating …………………....…… (Ampere)

Using a diode tester. Test the diode in the forward bias ……………….............. (Volts)

Using a diode tester. Test the diode in the reverse bias ………………………… (Volts)

Shunt Rating ………………………………………………………………………….. (A/mv)

Does the shunt and panel meter rating suit the unit current rating?................... Yes/No

Does the unit pass or fail the requirements of the Technical Specification and Drawings?

PASS/FAIL



For The Client :

I…………………………………………………………………………. hereby acknowledge that

the above test results were obtained from tests carried out in full accordance with the

Technical Specification. Further, I acknowledge that the guarantee period, as contained in

the aforesaid contract document, commences from date given therein.

Signed this………….day of ……………………20................. at ………………………………...

Name: ………………………………………………. Signature: …………………………………..

For the Contractor/Supplier/Manufacturer:

I ……………………………………………………………………………………. hereby

acknowledge that the above test results were obtained from tests carried out in full

accordance with the Technical Specification. Further, I acknowledge that the guarantee

period, as contained in the aforesaid contract document, commences from date given

therein.

Signed this………….day of ……………………20................. at ………………………………...

Name: ………………………………………………. Signature: …………………………………..



24.2. Annexure B: TRU/SMU/FDU/NDU Factory Acceptance Testing



FACTORY ACCEPTANCE TESTING

Date / /20 Place

Present

Unit Information

Supply

1Ph 3Ph

Rectifier Construction Frame Cabinet

Rectifier Manufacturer _________________________________ Rectifier Rating / Size _________________________________ Type of DC Output Control _________________________________ Serial No. _________________________________ Tag No. _________________________________

Visual Inspection

Cabinet / Frame

Workmanship & Painting YES NO N/A

Frame completely coated with Galvanizing YES NO N/A

Cabinet Paint no missed spots No Dents / Scratches on cabinet YES NO N/A

Dimensions match general arrangement. YES NO N/A

Final Coat DFT

Electrical

Compliance to Data Sheet YES NO N/A

Surge Protection installed AC - Make:______________________ YES NO N/A

Surge Protection installed DC - Make:______________________ YES NO N/A

RMU Fitted - Make:______________________ YES NO N/A

Covers Over AC Terminals YES NO N/A

All Labels Fitted YES NO N/A

Bus bar Labels Fitted YES NO N/A

DC Isolator / links Fitted YES NO N/A

kWhr Meter Fitted YES NO N/A

Door Switch Fitted YES NO N/A

Main AC Isolator YES NO N/A

ELR Fitted YES NO N/A

15A Socket Outlet Fitted YES NO N/A

MCB For Socket Outlet YES NO N/A

Type of Diode (SKR, 16mm Stud, 1600 PIV) YES NO N/A

Fast Blow Fuse YES NO N/A



Fuse Current Rating Bridge Amp

Fuse Current Rating NDU Amp

Type of Panel Meters Digital Analogue N/A

Rectifier Output Voltage Meter Yes Yes N/A

Rectifier Output Current Meter Yes Yes N/A

Rectifier Output Bypass Current Meter Yes Yes N/A

Correct Shunt Rating for Unit Yes Yes N/A

Correct Bypass Shunt Rating for Unit Yes Yes N/A

Wiring Sizes and Selection Yes Yes N/A

Barriers and Shrouds on Power Connections Yes Yes N/A

Wiring Point to Point According to Wiring Diagrams Yes Yes N/A

Tagging Yes Yes N/A

Labelling Yes Yes N/A

Constant Current

Setting

AC Voltage Volts AC Current Ampere

DC Voltage Volts DC Current Ampere

Percentage AC Ripple: _____________________________________________________

Remarks: ________________________________________________________________

________________________________________________________________________

________________________________________________________________________



Constant Voltage

Rectifier Setting

AC Voltage Volts AC Current Amp

DC Voltage Volts DC Current Amp

Percentage AC Ripple

Remarks:

Constant Potential

Rectifier Setting




Remarks:

Control Manual Variable Transformer

Rectifier Setting




Remarks:



Auto Control

Rectifier Setting




Remarks:

Acceptance of Tests

Test Results Accepted

Yes No

Manufacturer’s Representative

Name Date / /20

Designation

Signature

The Engineer

Name Date / /20

Designation

Signature

The Client

Name Date / /20

Designation

Signature



24.3. Annexure C: Isolating Flange Guidelines



Insulating Flange (IF) - ENQ. Guideline Form: Order/ Enquiry

Insulating Flange information:

Item Description - Insulating

Flange (IF) Special Selection

Bolt - Dimension

(ND/INCH

PCS.[m]/[piece

(length)]

IF - Facing

IF - Internal diameter(ID)

IF - Outside diameter(OD)

IF - Thickness

Number of Studs/Bolts

Stud/Bolt diameter

Stud/Bolt Hole diameter

Stud/Bolt Circle diameter

Internal Lining

External Coating

Pipeline Product carried

Pipeline ID

IF - Sleeve Length

Nominal Bolt diameter

AWWA Class & Table ref.

IF - Specifications

Other Information:

Representative Signature

Date: _____________________________________

Name & Surname: ____________________________



Without flange information

Isolation washers Special Selection Bolt - Dimension PCS.[m]/[piece (ND/INCH (length)]

Carbon steel

Hardened Coating Steel

Glass-Reinforced Epoxy

Zinc-Plated Steel (ZPS)

Stainless steel (SS)

Isolating screws/ - bolts:

Dimensions (Metric)

Quality class

Pcs.

Operating temperature

Special Electrical isolation required:

Other General Notes:

Requesting Company:

Contact:

Address:

Country:

Cell:

Tel.:

Fax:

E-mail:

Representative Signature

Date: _______________________________________ Name & Surname: ____________________________



Insulating Flange (IF) - Practical Installation Guideline

Item Instruction

HOW TO TIGHTEN THE INSULATING FLANGE (IF) BOLTS

1 Clean flanges, wipe all the dirt and make check for cracks/damages.

2 Insert full faced IF gasket between actual metal flange faces.

3 Insert isolating bolt sleeves in bolt holes.

Calculation for Isolating sleeve length: 2 x flange thickness including raised face + 1 x thickness of the flange isolation + 2 x thickness of the isolation washer.

4 ( If using stud bolts run one nut on one end until end of nut is flush with stud bolt ).Place one steel bolt washer and one

isolating washer over bolt and insert in bolt hole .

5 Fit one isolating washer and one steel washer on protruding bolt end. Nuts must be hand tightened nuts.

6 In order to achieve an even distribution of pressure at the flange sealing ring, we recommend to tighten the bolts as

required and stipulated by the IF kit supplier, until the flange faces and the sealing ring are in contact .

7 Tighten bolts alternately across the diameter of the flange.

8 Always use torque wrench to ensure even tightening and follow the tightening torque guidelines provided.

9 Do not over tighten or leakage may occur.

10 Ensure that bolts are well lubricated .No grease on sealing surfaces.

Notes: With flanges having a different number of bolts, you should generally follow the same procedure as per above instruction table guide. In order to achieve an even distribution of pressure at the flange sealing ring we recommend tightening the bolts as shown above until the flange faces and the sealing ring are in good contact. Please ensure that the bolts are greased/lubricated sufficiently so as to avoid damage to the threads by friction. In water pipelines applications, it is advisable to use a based grease/lubricate to ensure IF's durability & effectiveness. As a guideline, the maximum tightening torque are calculated at 85 % of the apparent yield point with coefficient to friction from μ = 0.140, slightly lubricated. If relatively soft and flexible gasket are used and tightened in a cold condition, the sealing material may relax when the system is put into operation , and the bolts may turn loose .We therefore recommend retightening the bolts after the operating temperature has been reached if possible without the operating pressure and at ambient temperature. Bolts should be checked and re-tightened, if required, after the initial operation and before bringing the system back from ambient temperature to the operating temperature.



Isolating Flange - Tightening Torque (Nm): Technical

Guidelines

Rev.1

(05/06/2015)

Tightening

torque (Nm)

Metric

Size

5.6 Ck

35 8,8 10,9 12,9 A2 - 70

42 CrMo 4 A

320 L7M 40

CrMoV 47

INCH Size

Tightening

torque (Nm)

A193 B7

M4 1 3 4 5 2 2

M5 3 6 8 10 4 4

M6 5 10 15 17 7 6

M8 10 24 36 42 17 15

M10 21 50 70 85 34 30

M12 37 85 120 145 59 52 1/2 - 13 UNC 80

M16 90 210 300 350 145 128 5/8 -11 UNC 160

M20 180 410 570 690 280 264 3/4 -10 UNC 320

M22 240 550 780 940 380 360 7/8 - 9 UNC 480

M24 310 700 1000 1200 480 456 1 - 8 UNC 750

M27 450 1050 1480 1775 - 672 1 -1/8 - 7 UNC 1050

M30 610 1400 2000 2400 - 912 1 -1/4 - 7 UNC 1450

M33 830 1900 2700 3250 - 1240 1 - 3/8 - 6 UNC 1900

M36 1060 2500 3450 4200 - 1600 1 - 1/2 - 6 UNC 2500

M39 1380 3200 4500 5400 - 2080 1 - 3/4 - 8 UNC 4600

M42 1700 4000 5600 6700 - 2560 2-8 UNC 8400

M45 2120 5000 7000 8400 - 3200 2-1/4 - 8 UNC 9800

M48 2570 6000 8450 10150 - 3840

M52 3310 7750 10800 13000 - 4960

M56 4120 9600 13500 16200 - 6200

M60 5130 12000 16800 20200 - 7680

Warning!

The fastening of the bolt shall be 8.8 with the maximum tightening torque on DIN. If not adhered to,

this could result in deforming the flanges face. We advise and recommend the use of 80 % of the

maximum tightening torque for the bolts .



Rev.1(05/06/2015)

EXFS 100 / EXFS 100 KU (or equivalent part)

Purpose - For indirect connection / earthing of functionally isolated parts

installations under lightning conditions. Use - Device for lightning

equipotential bonding according to IEC 62305 in hazardous areas.

Ref. Doc. - Approval according to ATEX Directive 94/9/EC and IECEx.

Isolating spark gap for use with IF kit and in hazardous areas with plastic sheath and M10 threaded bolts.

TYPE PART NO. (or equivalent) EXFS 100 923 100

(or equivalent)

Isolating spark gap according to EN 62561 - 3/IEC 62561-3 Yes

Lightning impulse current (10/350 Ns) (limp) 100kA

Class (lightning current carrying capability H

Rated power - frequency withstand voltage (50 Hz)(UwaC) 250 V

Rated impulse spark over voltage (Ur imp) 1.25 Kv

Operating temperature range (Tu) - 20°C... + 60°C

Degree of protection IP 67

ATEX approvals DEKRA 11ATEX0178 X

Ex marking according to EN 60079 - 0 and EN 60079 - 1:gas II 2 G Ex d iic T6 Gb

Ex marking according to EN 60079 - 0 and EN 60079 -31 : dust Ex tb IIIC T80 ° C Db IP 66/67

Enclosure length 100 mm

Enclosure diameter 45.5 mm

Enclosure material plastic sheath

Connection of enclosure M10 threaded bushing , 2x M10 x 25 mm,2x spring washer

Extended technical data:

Rated discharge current (50 Hz)(Imax) 500 A / 0.2 sec

Nominal discharge current (8/20ps) (In) 100kA

Power frequency spark over voltage (50Hz) (Uaw) 0.5 Kv



Angled Connection Brackets - IF 1 - Flat Connection Brackets - IF 3 -

Angled connection bracket for EXFS….,diameter corresponds to the bolt diameter of the bolted flange joint; material : St/Zn

Flat connection bracket for EXFS….,diameter corresponds to the bolt diameter of the bolted flange joint; material : St/Zn

Type AB EXFS…. IF1 W 11 IF1 W 14 IF1 W 18 Type AB EXFS…. IF3 G 11 IF3 G 14 IF3 G 18

Part No. 923 311 923 314 923 318 Part No. 923 311 923 314

923

318

Max.borehole diameter d1 11 mm 14 mm 18 mm Max.borehole diameter d1 11 mm 14 mm 18 mm

Type AB EXFS…. IF1 W 22 IF1 W 26 IF1 W 30 Type AB EXFS…. IF3 G 22 IF3 G 26 IF3 G 30

Part No. 923 322 923 326 923 330 Part No. 923 322 923 326 923 330

Max.borehole diameter d1 22 mm 26 mm 30 mm Max.borehole diameter d1 22 mm 26 mm 30 mm

Type AB EXFS…. IF1 W 33 IF1 W 36 IF1 W 39 Type AB EXFS…. IF3 G 33 IF3 G 36

Part No. 923 333 923 336 923 339 Part No. 923 333 923 336

Max.borehole diameter d1 33 mm 36 mm 39 mm Max.borehole diameter d1 33 mm 36 mm

Type AB EXFS…. IF1 W 42 IF1 W 48 Type AB EXFS…. IF3 G 39 IF3 G 42

Part No. 923 342 923 348 Part No. 923 339 923 342

Max.borehole diameter d1

42 mm 48

mm Max.borehole diameter d1 39 mm 42 mm

Type AB EXFS…. IF1 W 56 IF1 W 62

Part No. 923 356 923 362

Max.borehole diameter d1 56 mm 62mm

EXFS 100: Connecting Cable, Cu 25 mm²

Connecting cable for EXFS 100; two cable lugs ( Ø10.5 mm) made of Cu/gal Sn,screw,nuts and spring washer .

Type AL EXFS … L100 KS L200 KS L300 KS

Part No. 923 025 923 035 923 045

Cable length 100 mm 200 mm 300 mm



24.4. Annexure D: Drawing Register



DRAWING REGISTER

EWS Drawing Number

Drawing Description

72019/1 TYPICAL DURA-SAFE GA CONSTRUCTION

72019/2 TYPICAL TRANSFORMER RECTIFIER FRAME CHASSIS FOR DURA-SAFE INSTALLATION

72020/1 STANDARD DRAWING FOR BONDING AND MONITORING FACILITY DETAILS

72020/2 STANDARD DRAWING FOR BONDING LINK PANEL

72020/3 STANDARD DRAWING FOR VALVE CHAMBER TEST POINTS

72020/4 STANDARD DRAWING FOR CONTINUITY BONDING ACROSS FLANGES

72020/5 STANDARD DRAWING FOR PIN BRAZE / STUD WELDING DETAILS

72020/6 STANDARD DRAWING FOR CONTINUITY BONDING INSIDE VALVE CHAMBER

72019/3 STANDARD DRAWING FOR CONCRETE CABINET

72019/4 STANDARD DRAWING FOR CONCRETE CABINET BASE

72019/5 STANDARD DRAWING FOR TYPICAL CONCRETE DISTRIBUTION / MONITORING / BONDING CABINET II

72021/1 TRU CABINET TYPE 1 MECHANICAL LAYOUT



72022/1 TYPICAL CIRCUIT DIAGRAM FOR 3-PHASE AUTOMATIC CONTROLLED TRU

72022/2 TYPICAL CIRCUIT DIAGRAM FOR 3-PHASE TRU

72022/3 TYPICAL CIRCUIT DIAGRAM FOR 3-PHASE FDU

72022/4 TYPICAL CIRCUIT DIAGRAM FOR SINGLE PHASE AUTO CONTROL TRU

72022/5 TYPICAL CIRCUIT DIAGRAM FOR SINGLE PHASE MANUAL CONTROL TRU

72022/6 TYPICAL CIRCUIT DIAGRAM FOR RESISTIVE BONDING UNIT

72022/7 TYPICAL CIRCUIT DIAGRAM FOR NATURAL DRAINAGE UNIT

56735/1 INSTALLATION DETAILS POTENTIAL MONITORING TEST POST TYPE "A"

56735/2 INSTALLATION DETAILS POTENTIAL MONITORING TEST POST TYPE "B"

56735/3 INSTALLATION DETAILS POTENTIAL MONITORING TEST POST TYPE "C"

56735/4 INSTALLATION DETAILS POTENTIAL MONITORING TEST POST TYPE "E"

56735/5 TYPICAL TEST POST SHOWING SACRIFICIAL ANODE

56735/6 TYPICAL TERMINATION DETAILS TYPE "A"

56735/7 TYPICAL TERMINATION DETAILS TYPE "B"

56735/8 TYPICAL TERMINATION DETAILS TYPE "C"

56735/9 TYPICAL TERMINATION DETAILS TYPE "E"

56735/10 TYPICAL TERMINATION DETAILS ANODE JUNCTION BOX

56735/11 GALVANISED TEST POST EQUIPOTENTIAL MAT AND AGGREGATE FILL

56735/12 CONCRETE BUNKER EQUIPOTENTIAL MAT AND AGGREGATE FILL

56735/13 AC MITIGATION LAYOUT

56735/14 TYPICAL TERMINATION DETAILS TYPE "A-F"

56735/15 TYPICAL TERMINATION DETAILS TYPE "B-F"

56735/16 TYPICAL TERMINATION DETAILS TYPE "C-F"

56735/17 TYPICAL TERMINATION DETAILS TYPE "E-F"

56735/18 HORIZONTAL ANODE GROUNDBED INSTALLATION DETAILS



EWS Drawing Number

Drawing Description

56735/19 VERTICAL ANODE GROUNDBED INSTALLATION DETAILS

56735/20 TYPICAL AC AND DC COUPON LAYOUT WITH UPVC TUBE AND CABLE DETAIL

56735/21 SOLID STATE DC DECOUPLER WIRING SCHEMATIC FOR AC MITIGATION

56735/22 TYPICAL INDEPENDENT DC AND AC COUPON ASSEMBLY DETAILS

56735/23 TYPICAL VALVE CHAMBER EQUIPOTENTIAL GRADIENT CONTROL MAT

56735/24 TYPICAL SMU SINGLE PHASE AUTO CONTROL

56735/25 TYPICAL TERMINAL BLOCK LAYOUT

56735/26 INSTALLATION DETAILS TYPICAL CABLE TRENCH

56735/27 INSTALLATION DETAILS TRU ENCLOSURE

56735/28 INSTALLATION DETAILS TRU ELECTRICAL LAYOUT

56735/29 INSTALLATION DETAILS TRU EARTHING/ GROUNDING LAYOUT

NOTE: The drawing register is updated regularly by The Client and

will change. It is the contractor’s responsibility to ensure that

they are in possession of the most recent revision of the

relevant project drawings.