TRANSNET SOC LTD DCT BERTHS 203 TO 205 - National · PDF filetransnet soc ltd dct berths 203...

TRANSNET SOC LTD

DCT BERTHS 203 TO 205 ‐ RECONSTRUCTION, DEEPENING AND

LENGTHENING

PORT OF DURBAN

SPECIFICATION – CONCRETE FOR MARINE CONSTRUCTION

1370‐CO‐000‐C‐SPC‐0001 Rev T‐0A

18 NOVEMBER 2016

TRANSNET SOC LTD DCT BERTHS 203 TO 205 ‐ RECONSTRUCTION, DEEPENING AND LENGTHENING

PORT OF DURBAN


1370‐CO‐000‐C‐SPC‐0001 Rev T‐0A November 2016

REVISIONS

REV DATE DESCRIPTION DESIGNED

BY

CHECKED

BY

APPROVED

BY

T‐00 31 May 2016 Issue for Review MC WvW JZ

T‐0A 18 November 2016 Issue for Tender MC WvW JZ

AUTHORISATION

AUTHORISED BY NAME SIGNATURE DATE

DIRECTOR J ZIETSMAN Pr Eng

18 November 2016

This document, including all design and information therein, is Confidential Intellectual Property of

ZAA Engineering Projects and Naval Architecture (Pty) Ltd.

Copyright and all other rights are reserved by ZAA Engineering.

This document may only be used for its intended purpose.


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CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1

2.0 NORMATIVE REFERENCES ........................................................................................................................ 2

2.1 Reference Documents ..................................................................................................................................... 2 2.2 Standard Specifications ................................................................................................................................... 2 2.3 Employer’s Project Specific Specifications and Standards .............................................................................. 3

3.0 DEFINITIONS ............................................................................................................................................ 4

3.1 Slip‐Forming .................................................................................................................................................... 4 3.2 Method Statements ........................................................................................................................................ 4 3.3 Abbreviations .................................................................................................................................................. 4

4.0 GENERAL REQUIREMENTS APPLICABLE TO ALL CONCRETE WORKS .......................................................... 5

4.1 Trial Mixes, Method Statements and Acceptance .......................................................................................... 5 4.2 Materials ......................................................................................................................................................... 5

4.2.1 Cementitious binders .................................................................................................................... 5 4.2.2 Water for Concrete ....................................................................................................................... 6 4.2.3 Aggregates ..................................................................................................................................... 6 4.2.4 Admixtures .................................................................................................................................... 7 4.2.5 Curing Compound .......................................................................................................................... 7 4.2.6 Grade of Concrete ......................................................................................................................... 7

4.3 Formwork ........................................................................................................................................................ 8

4.3.1 General .......................................................................................................................................... 8 4.3.2 Design and construction of formwork and falsework ................................................................... 8

4.4 Reinforcement ................................................................................................................................................ 8

4.4.1 Bending ......................................................................................................................................... 8 4.4.2 Fixing ............................................................................................................................................. 8 4.4.3 Cover ............................................................................................................................................. 8

4.5 Quality of Concrete ......................................................................................................................................... 8

4.5.1 General .......................................................................................................................................... 8 4.5.2 Workability .................................................................................................................................... 9 4.5.3 Chloride and sulphate content ...................................................................................................... 9 4.5.4 Durability ....................................................................................................................................... 9 4.5.5 Batching ....................................................................................................................................... 10 4.5.6 Mixing .......................................................................................................................................... 10 4.5.7 Potential Heat Generation .......................................................................................................... 10 4.5.8 Transportation of concrete ......................................................................................................... 10 4.5.9 Placing ......................................................................................................................................... 10 4.5.10 Compaction ................................................................................................................................. 11 4.5.11 Joints ........................................................................................................................................... 12 4.5.12 Curing and Protection ................................................................................................................. 12 4.5.13 Concrete Surfaces ........................................................................................................................ 14 4.5.14 Records ........................................................................................................................................ 14


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5.0 ADDITIONAL REQUIREMENTS FOR STEEL FIBRE REINFORCED CONCRETE (SFRC) FOR RIGID INCLUSIONS 15

5.1 General .......................................................................................................................................................... 15 5.2 Materials ....................................................................................................................................................... 15 5.3 Quality of Concrete ....................................................................................................................................... 15

5.3.1 Flexural Strength ......................................................................................................................... 15 5.3.2 Workability and uniformity ......................................................................................................... 15

5.4 Testing ........................................................................................................................................................... 15

5.4.1 Frequency of Testing ................................................................................................................... 15 5.4.2 Acceptance of strength concrete ................................................................................................ 15 5.4.3 Trial mixes ................................................................................................................................... 15

6.0 ADDITIONAL REQUIREMENTS FOR CONCRETE FOR PAVING ................................................................... 16

6.1 Aggregate size ............................................................................................................................................... 16 6.2 Concrete strength requirements................................................................................................................... 16 6.3 Testing and strength monitoring................................................................................................................... 16 6.4 General requirements in respect of placing and compacting concrete ........................................................ 16

7.0 ADDITIONAL REQUIREMENTS FOR SLIP FORMING/SLIDING FOR CAISSON WALLS ................................. 17

7.1 Formwork ...................................................................................................................................................... 17 7.2 Quality of Concrete ....................................................................................................................................... 17

8.0 ADDITIONAL REQUIREMENTS FOR REAR CRANE RAIL PILES ................................................................... 17

9.0 COMPLIANCE WITH REQUIREMENTS ..................................................................................................... 18

9.1 Testing ........................................................................................................................................................... 18

9.1.1 General ........................................................................................................................................ 18 9.1.2 Acceptance of strength concrete ................................................................................................ 18 9.1.3 Frequency of sampling ................................................................................................................ 18 9.1.4 Beam tests for SFRC .................................................................................................................... 18

9.2 Tolerances ..................................................................................................................................................... 18


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SPECIFICATION –CONCRETE FOR MARINE CONSTRUCTION

1370‐CO‐000‐C‐SPC‐0001 Rev T‐0A

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1.0 SCOPE

1.1 Project

This specification is a project specific technical specification for the DCT Berths 203 to 205 Reconstruction, Deepening

and Lengthening Project in the Port of Durban.

1.2 Scope

The scope of this specification covers the Employer’s requirements for the provision, placing, curing and testing of

concrete in a marine environment, with specific emphasis on durability of concrete in the marine environment. It

covers basic materials, Equipment, quality, manufacture, curing of the concrete, tolerances in workmanship, tests

and acceptance criteria.

The specification covers the concrete requirements for the following works:

a) Caisson manufacturing

b) Precast element manufacturing

c) Steel Fibre Reinforced Concrete (FSRC) for Rigid Inclusions

d) In situ capping beam

e) Service Tunnels

f) Rear crane rail piles

g) Rear crane rail beam

h) Storm water, electrical, sewer and water services

i) Concrete paving

The first section of the specification deals with general requirements which are applicable to all concrete work and subsequent sections deal with specific requirements which are over and above the general requirements and apply only to the specific section of work referenced.


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2.0 NORMATIVE REFERENCES

2.1 Reference Documents

Reference documents to be used by the Contractor shall include:

a) This Specification

b) Industry Codes, Standards and Specifications as listed in Section 2.2

c) Employer’s Project Specific Technical Specifications as listed in Section 2.3

d) Project Drawings:

− 1370‐CO‐030 series of drawings – Ground Improvements – Rigid Inclusions

− 1370‐CO‐060 series of drawings – Caisson Quay Wall

− 1370‐CO‐070 series of drawings – Return Quay

− 1370‐CO‐090 series of drawings – Capping Beam and Service Tunnels

− 1370‐CO‐100 series of drawings – Rear Crane Rail Piles and Beam

− 1370‐CO‐120 series of drawings – Water Supply

− 1370‐CO‐130 series of drawings – Sewer

− 1370‐CO‐140 series of drawings – Electrical and C&I Infrastructure

− 1370‐CO‐150 series of drawings – Storm Water

− 1370‐CO‐160 series of drawings – Paving

e) Method statement prepared by the Contractor, as described in Section 4.1.

2.2 Standard Specifications

The governing standard for this specification shall be:

a) SANS 2001‐CC1:2012 Construction Works – Concrete Works (Structural), which shall apply in its

entirety except for the variations and additions detailed in the specification clauses below.

The following standard specifications and manuals are also referenced in this specification:

a) SANS 50197‐1:2013/EN 197‐1:2011 – Cement – composition, specifications and conformity criteria

‐ Part1: Common cements

b) SANS 55167 – Portland cement extenders – Part 1: Ground granulated blast furnace slag

c) SANS 50450 – Portland cement extenders – Part 2: Fly ash

d) SANS 53263 – Portland cement extenders – Part 3: Condensed Silica Fume

e) SANS 51008:2006/EN 1008:2002 (2012‐11‐23) – Mixing water for concrete, Specification for

sampling, testing and assessing the suitability of water

f) SANS 1083:2014 – Aggregates from natural sources – Aggregates for concrete

g) SANS 5836:2007 (2013‐03‐15) – Drying shrinkage of aggregates

h) SANS 6085:2006 (2012‐04‐20) – Drying shrinkage of concrete

i) Fulton’s Concrete Technology – Ninth Edition

j) ASTM C494/C494M‐15a – Standard specification for Chemical Admixtures for Concrete

k) SANS 50934‐2:2011/EN 934‐2:2009 – Concrete admixtures for concrete, mortar and grout. Part 2:

Concrete admixtures, definitions, requirements, conformity, marketing, labelling

l) SANS 423:2016/ASTM C309‐2011 – Standard Specification for Liquid Membrane‐Forming

Compounds for Curing Concrete

m) ASTM C1152/1152M‐04 (2012) e1 – Standard Test Method for Acid‐Soluble Chloride in Mortar and

Concrete

n) SANS 5026:2015/EN 206:2014 – Concrete – Part 1: Specification, performance, production and

conformity

o) SANS 5863:2006 (2012‐04‐26) – Concrete Tests – Compressive Strength of Hardened Concrete

p) SANS 5864:2006 (2012‐04‐26) – Concrete Tests – Flexural Strength of Hardened Concrete

q) BS EN 14889‐1:2006 Fibres for concrete — Part 1: Steel fibres — Definitions, specifications and

conformity


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r) COLTO Standard Specification for Road and Bridge Works for State Road Authorities

s) ACI 313‐97 – Standard Practices for Design and Construction of Concrete Silos and Stacking Tubes

t) DNV‐03‐C502 – Offshore Standard, Offshore Concrete Structures, 2012

u) BS EN 14651:2005 & A1 2007 Test Method for Metallic Fibre Concrete Measuring the Flexural

Tensile Strength (Limit of Proportionality (LOP) residual)

v) BS EN 14889‐1:2006 – Fibres for Concrete Steel Fibres. Definitions, Specifications and Conformity

w) SANS 5861‐1:2006 (2012‐03‐23) – Concrete Tests – Mixing Fresh Concrete in the Laboratory

x) SANS 5861‐2:2006 (2012‐03‐23) – Concrete Tests – Sampling of Freshly Mixed Concrete

y) SANS 5861‐3:2006 (2012‐03‐23) – Concrete Tests – Making and Using Test Specimens

z) BS EN 12699:2015. Execution of special geotechnical work – Displacement piles

aa) BS EN 206:2013. Concrete. Specification, performance, production and conformity

2.3 Employer’s Project Specific Specifications and Standards

The specifications listed in this section shall, inter alia, be read in conjunction with this specification:

a) 1370‐CO‐000‐C‐SPC‐0002 – Caisson Construction and Placement

b) 1370‐CO‐000‐C‐SPC‐0003 – Cope, Service Tunnels, Quay Furniture and Services

c) 1370‐CO‐000‐C‐SPC‐0007 – Paving

d) 1370‐CO‐000‐C‐SPC‐0010 – Ground Improvement: Rigid Inclusions and Foundation Stone Bed

(Caisson Load Transfer Platform)

e) Environmental Management Plan (EMP)


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3.0 DEFINITIONS

All definitions of responsibilities shall be in accordance with the NEC Engineering and Construction Contract (ECC) for

the construction of the works.

Where the standard specifications referenced in this specification refer to the “Engineer”, replace this term with the

term “Supervisor”.

For the purpose of this specification, the definitions and abbreviations given in SANS 2001‐CC1:2012, together with

the following definitions shall apply:

3.1 Slip‐Forming

The term ‘Slip‐forming’ refers to the process of constructing a vertical structure using a continuously moving form.

Slip‐forming is also referred to as ‘Sliding’ in SANS 2001‐CC1:2012 and all such clauses are applicable to the slip‐

forming operation.

3.2 Method Statements

Method statements shall be compiled by the Contractor for all activities and for all stages of the establishment,

casting, launching, towing and placement work. The method statements shall be submitted to the Supervisor for

acceptance three weeks in advance of the particular activity being undertaken. Full details of all proposed

Equipment (including temporary works) and methods shall be provided for acceptance by the Supervisor. No activity

shall commence until the method statement has been accepted by the Supervisor.

3.3 Abbreviations

ASR Alkali – Silica Reaction

FA Fly Ash

FACT Fine Aggregate Crushing Test

GGBS Ground Granulated Black Furnace Slag

GGGS Ground Granulated Corex Slag

SFRC Steel Fibre Reinforced Concrete

W/C Water Cement Ratio


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4.0 GENERAL REQUIREMENTS APPLICABLE TO ALL CONCRETE WORKS

4.1 Trial Mixes, Method Statements and Acceptance

4.1.1 Prior to casting any concrete included in the permanent works, the Contractor shall:

a) Submit to the Supervisor for acceptance the samples that he proposes to use for the concrete and

shall furnish evidence (test certificates and results) that the aggregates, cement, water, admixtures

and curing compounds comply with the requirements of the material clauses below;

b) Submit to the Supervisor for acceptance details of proposed concrete mix design and program of

trial mix production;

c) Undertake laboratory trial mix designs;

d) Undertake site trials of the specified grades of concrete using the concrete from the trial for site

establishment or temporary works purposes:

− Trial mixes shall be produced under full‐scale production conditions using representative

samples of cement and aggregates.

− Three separate batches shall be produced each on a separate day. The workability of each

batch shall be determined and at least 6 cubes shall be made from each batch. Three shall be

tested at 7 days and the other three tested at 28 days.

− The 28‐day cube results from this site trial confirming that the concrete meets the specified

strength and slump requirements shall be made available to the Supervisor prior to any casting

of concrete in the permanent works.

e) Submit a detailed method statement of the concrete construction method to the Supervisor for

approval 2 weeks prior to commencing any concrete works. The method statement shall include

but not be limited to:

− Method of material storage, concrete batching, transportation, and delivery

− Quality control procedures for batching of concrete

− Details of falsework, formwork and methods of achieving specified finishes

− Details for positioning and securing cast‐in items to specified tolerances

− Details of methods of placement for each structure or type of structure including any proposals

for the use of spouts, chutes or pumps as a means of placing concrete.

− Details of vibration equipment and techniques

− Method and duration of curing

− Quality control procedures for traceability of concrete batches vs. elements cast.

4.2 Materials

4.2.1 Cementitious binders

4.2.1.1 All cements used for concrete work shall comply with SANS 50197‐1.

4.2.1.2 All cement extenders used for concrete work shall comply with SANS 55167, SANS 50450‐2 or SANS

53263.

4.2.1.3 The cement types given below are acceptable for use in the Works, however the proportion of extender in

factory blended cements shall conform to the requirements of set out in Table 4.1 below.

4.2.1.4 No masonry cements shall be used for concrete work, even if the strength designations are the same as

for common cements.

4.2.1.5 Acceptable cement types are:

a) CEM I 42,5 Portland Cement

b) CEM I 52,5 Portland Cement

c) CEM I 42,5R Portland Cement, rapid hardening

d) CEM I 52.5R Portland Cement, rapid hardening


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e) CEM II/B‐V Portland fly ash cement (Siliceous)

f) CEM II/B‐W Portland fly ash cement (Calcareous)

g) CEM III/A Blast furnace cement

4.2.1.6 All cement shall be fresh and shall be delivered either in unbroken water resistant bags containing

approximately 50 kg cement, or in bulk containers specifically designed for the purpose, bearing the

manufacturer's name and the date of manufacture.

4.2.1.7 Cement shall be stored off the ground in a suitable dry shed or in a self‐clearing silo and shall be protected

against deterioration. Silos shall be provided with a fluidizing facility and shall be of the single

compartment type.

4.2.1.8 During transport and storage cement shall be fully protected from all weather elements.

4.2.1.9 The various types of cement shall be handled, identified, and stored separately.

4.2.2 Water for Concrete

4.2.2.1 Water that is to be used for mixing concrete and curing concrete and any other operation shall at all times

comply with the requirements of BS EN 1008:2002.

4.2.2.2 It shall be fresh, clean, potable and free from injurious amount of acids, alkalis, organic matter and other

substances that may impair the strength or durability of concrete.

4.2.2.3 Requirements for testing of the water including the frequencies for testing are provided in clauses 5 and 6

of BS EN 1008:2002.

4.2.2.4 The pH of water used in concrete work shall be not less than 5.0 and not more than 8.0. Under no

circumstance shall seawater be used for mixing or curing concrete.

4.2.2.5 The chloride and sulphate content of the water shall be included in the assessment of the total chloride

and sulphate content of the proposed concrete mix.

4.2.3 Aggregates

4.2.3.1 All course and fine aggregates shall comply with the requirements of SANS 1083:2014.

4.2.3.2 Under no circumstances and for no portion of the works is the use of plums in concrete permitted.

4.2.3.3 The drying shrinkage of the fine and coarse aggregate, when tested in accordance with SANS 5836, shall

not exceed 175% of that of the reference aggregate for sand and 150% of that of the reference aggregate

for stone.

4.2.3.4 The drying shrinkage of concrete shall not exceed 0.040% when tested in accordance with the

requirements of SANS 6085.

4.2.3.5 The flakiness index of the stone as determined by SANS 1083, shall not exceed 35.

4.2.3.6 The Contractor shall ensure that the total equivalent Na2O content in the concrete mix per m3 is such that

it is below the threshold value, as prescribed in Table 10.1 of Fulton’s Concrete Technology – 9th Edition

[% Na2O equivalent = % Na2O + (0,658 x % K20)].

4.2.3.7 The limits prescribed in Table 10.1 apply only to CEM I cement. For CEM II and CEM III cements or for

blends of CEM I with extenders, the active Na20 equivalent must be calculated depending on the source

and quantity of the major additional constituents and the alkaline content of the clinker in accordance

with section 10.8 of Fulton’s Concrete Technology – 9th edition.

4.2.3.8 The Contractor shall submit, prior to construction, a laboratory report by a certified laboratory confirming

compliance with the requirements for preventing ASR in the concrete.

4.2.3.9 Coarse and fine aggregates shall be delivered to the Site or to the mixing plant by means that prevent


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contamination due to environmental effects, if necessary in covered containers, and shall be stored

separately. Care shall be exercised in the handling and storage of the aggregates to prevent the

segregation of the various particles and to prevent contamination from deleterious materials. The

Contractor shall ensure that aggregates are not located in the vicinity of any ablution facilities.

4.2.3.10 Different aggregates shall be stockpiled separately and dividers provided to prevent mixing.

4.2.4 Admixtures

4.2.4.1 Any admixture used shall comply with the requirements of either SANS 50934‐2:2011 / EN 934‐2:2001 or

ASTM C494/494M‐15a.

4.2.4.2 Admixtures are permitted, provided that the results of trial tests which demonstrate their suitability and

the following are made available:

a) the trade name of the admixture, its source and the manufacturer's recommended method of use;

b) typical dosages and possible detrimental effects of under‐dosages and over‐dosages;

c) whether compounds likely to cause corrosion of the reinforcement or deterioration of the concrete

(such as those containing chloride, in any form, as an active ingredient) are present and, if so, the

chloride content of admixtures, expressed as a mass fraction of chloride ions or expressed as an

equivalent mass; and

d) fraction of anhydrous calcium chloride.

4.2.4.3 Admixtures will only be permitted if the Contractor demonstrates to the satisfaction of the Supervisor that

they do not lead to a reduction in strength, additional shrinkage, bleeding, or any other undesirable

effects. If the use of admixtures is permitted, they shall be used strictly in accordance with the

manufacturer's instructions and any method statement agreed with the Supervisor after site trials have

been carried out.

4.2.4.4 Admixtures containing chlorides will not be permitted in reinforced concrete.

4.2.4.5 Air‐entraining admixtures will not be permitted in reinforced concrete.

4.2.5 Curing Compound

4.2.5.1 In all cases where a concrete curing compound is used, the curing compound shall be grey or white

pigmented membrane forming material complying with SANS 423:2016 / ASTM specification C309‐11,

except that the maximum permissible water loss in the test shall be 0.40 kilograms per square metre.

4.2.5.2 Alternatively, the concrete curing compound shall be acceptable if the treated concrete retains 90% or

more of its mixing water when subject to the test set out in BS 8110: Part 1, Clause 6.6 (c).

4.2.5.3 Note that the application of a curing compound is not a permitted form of curing for steel reinforced

concrete and is only permitted for mass/unreinforced concrete (refer to section 4.5.12 below).

4.2.6 Grade of Concrete

4.2.6.1 Unless shown otherwise on the drawings, the grade of the concrete shall be as follows:

a) Caissons and precast elements – Grade 45

b) Reinforced in‐situ elements – Grade 40

c) Rigid Inclusions – Grade 45

d) Paving – Grade 35


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4.3 Formwork

4.3.1 General

4.3.1.1 The formwork surfaces shall be as follows:

a) All exposed concrete surfaces require a smooth finish to a degree of Accuracy II. The base and outer

walls of the caisson are considered exposed surfaces.

b) All concealed and internal surfaces not exposed to view require a rough finish to a degree of

Accuracy II.

4.3.1.2 The Contractor shall take particular care to ensure that formwork joints are tight enough to prevent

leakage of cement mortar. Shutters that are damaged, or that leave a surface that is unacceptable to the

Supervisor, shall be removed and repaired or discarded. No metal part of any device for securing forms is

to remain within the specified concrete cover.

4.3.2 Design and construction of formwork and falsework

4.3.2.1 The design and drawings for formwork and falsework shall be submitted for review.

4.4 Reinforcement

4.4.1 Bending

4.4.1.1 Bars may be bent hot in accordance with clause 4.4.1.3 and 4.4.1.4 of SANS 2001‐CC1:2012.

4.4.2 Fixing

4.4.2.1 Welding of bars is permitted for fixing in accordance with clause 4.4.2.2 b) of SANS 2001‐CC1:2012.

4.4.3 Cover

4.4.3.1 Minimum concrete cover to all steel reinforcement shall be as shown on the drawings and maintenance of

this minimum cover during casting of concrete shall be strictly enforced. In addition to pre‐pour

inspections, the Supervisor shall use a cover meter to check compliance with the cover requirements.

Concrete, which is cast with insufficient cover to the reinforcement shall be declared a defect and shall be

corrected by the Contractor in accordance with clause 43 of the NEC ECC 3 Core Clauses.

4.4.3.2 Cover blocks used to ensure the cover to reinforcement shall be made of cement mortar using cement

binders in the same proportions as the main concrete mix. They shall be dense and have a minimum 28

day crushing strength of 50 MPa, and shall be cured in water for at least 14 days before being used.

Spacer blocks made of plastic will not be permitted.

4.5 Quality of Concrete

4.5.1 General

4.5.1.1 Before the start of concrete work on site, the Contractor shall submit a quality assurance plan which will

ensure compliance with specification and provide acceptable documentary proof that all specified

operations have been carried out satisfactorily. The quality assurance plan shall make provision for

intervention points, to be agreed with the Supervisor for inspection of the Works.

4.5.1.2 This specification prescribes the strength requirements, maximum and minimum binder contents,

required extender content and maximum water binder ratios. In terms of course and fine aggregate

proportions, this specification is non‐prescriptive.

4.5.1.3 The cementitious binder content for any class of concrete shall not exceed 450 kg/m3 of concrete.


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4.5.2 Workability

4.5.2.1 Pumping of concrete is permitted

4.5.3 Chloride and sulphate content

4.5.3.1 The total chloride content (acid soluble) arising from all ingredients in a mix including cement, water and

admixtures shall not exceed 0.15% chloride ion as a percentage of the mass of cement in the mix.

4.5.3.2 Prior to the use of a concrete mix for the permanent works, a sample of concrete from a trial mix shall be

tested for acid‐soluble (total) chloride ion content in accordance with ASTM C1152. Provided the chloride

content does not exceed the specified limit, no further testing is required unless the mix ingredients are

changed.

4.5.4 Durability

4.5.4.1 In order to enhance durability and notwithstanding strength considerations, the concrete mixes shall be in

accordance with Table 4.1, noting the following:

a) Total binder content is the sum of the Portland cement and any extenders used.

b) GGBS – Ground Granulated Blast Furnace Slag.

c) GGCS – Ground Granulated Corex Slag.

d) FA – Fly Ash.

e) W/C ratio is the free water divided by the cementitious binder content.

f) Water‐reducing admixtures may be used to improve workability (See also Clause 4.2.4 above). The

water cement ratio shall include the water content of admixtures.

g) Factory blended cements (CEM II/B‐V, CEM II/B‐W or CEM III/A) will be accepted provided that they

conform to one of the blends specified in the table. The Contractor shall supply certification thereof.

h) Blends of CEM I and Condensed Silica Fume (CSF) are not acceptable for steel reinforced concrete.

Table 4.1 – Concrete Mixes

Concrete Type/

Structural

Element

Exposure

Class (EN

206‐1:2013

28 Day

Characterist

ic Strength

(MPa)

Total Binder

Content

kg/m3

Required extender content

% of total binder content

Max Water/

Binder Ratio

Min Max FA

(Min/Max)

GGBS / GGCS

(Min/Max) Max

Reinforced

Concrete

(Precast)

XS3 45 340 450 30% / 30% 50% / 50% 0.45

Reinforced

Concrete (In‐

situ)

XS3 40 340 450 30% / 30% 50% / 50% 0.45

Cast In situ piles XS3 40 340 450 30% / 30% 50% / 50% 0.45

Rigid Inclusion

Concrete XS3 45 340 450 30% / 30% 50% / 50% 0.45

Mass Concrete

Paving X0 35 320 420 0% / 15% 0% / 15% 0.53


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4.5.5 Batching

4.5.5.1 All aggregates shall be precisely measured by mass using approved and certified precision weigh‐batching

equipment.

4.5.6 Mixing

4.5.6.1 The use of ready‐mixed concrete is permissible.

4.5.6.2 No water shall be added to the mix after it has left the ready mixed concrete plant. Each delivery shall be

tested at the site for workability. (Concrete not complying with the Specification must be removed from

site and may not be tampered with and returned).

4.5.7 Potential Heat Generation

4.5.7.1 Measures, subject to the acceptance of the Supervisor, shall be applied to reduce heat development in

concrete of which the minimum dimension to be placed during a single pour is larger than 600 mm, and

the cement content exceeds the values given in Table 4.2

Table 4.2: Heat Generation Limiting Cement Contents

Structural Element Cement Types I and III/A

(kg/m3)

Cement Types II/B‐V and II/B‐W

(kg/m3)

Reinforced Concrete 400 450

Prestressed Concrete 500 550

4.5.8 Transportation of concrete

4.5.8.1 The Contractor is made aware of possible traffic congestion en route to site and shall plan the delivery of

concrete to site accordingly. No compensation shall be entertained for delays resulting from traffic

congestion.

4.5.9 Placing

4.5.9.1 Pre‐pour Inspections and Approvals

4.5.9.1.1 No concreting shall commence in any portion of the Works until the preparations have been accepted by

the Supervisor. Sufficient notice shall be given to the Supervisor to inspect and accept the work prior to

concrete manufacture. No manufacture is to commence until written acceptance has been given to

proceed.

4.5.9.1.2 Concrete shall not be placed in the Works unless the Supervisor’s Representative is present and the fixing

of all formwork and reinforcement has been completed and accepted by the Supervisor.

4.5.9.1.3 All surfaces shall be free of dust and standing water.

4.5.9.2 Underwater concrete

4.5.9.2.1 All pours of concrete between tide levels shall be carried out in the dry and the top surface blanketed

before being covered by the rising tide. Placing of concrete shall commence on a falling tide after the tide

level has fallen below the base of the pour.

4.5.9.2.2 Casting concrete underwater is subject to the approval of the Supervisor with respect to the methods,

equipment and materials that the Contractor intends to use. Use of a concrete admixture such as Sika

UCS‐01 ZA or other similar approved proprietary admixture to minimise the washout of cement paste

shall be used in accordance with the Suppliers specification.

4.5.9.2.3 Unless otherwise permitted, the technique adopted for placing of concrete underwater and any

dewatering shall be designed to prevent the washing out of cement from the concrete mixture, minimise

the segregation of materials and the formation of laitance, and prevent the flow of water through or over

new concrete less than 24 hours old.


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4.5.9.2.4 After commencement, the placing of concrete underwater shall be continuous until completion, unless

otherwise permitted.

4.5.9.2.5 No vibration shall be carried out until the top of the concrete is above water or tide level. For concrete

totally cast below water level, no vibration will be allowed.

4.5.9.2.6 The maximum size of aggregate shall be 38 mm and the aggregates shall be well graded.

4.5.9.2.7 The bed shall be cleaned of silt and loose material, and must be passed by the Supervisor before concrete

is placed.

4.5.9.3 Depositing Concrete by Tremie

4.5.9.3.1 The top section of the Tremie shall consist of a hopper of greater capacity than the pipe. The tremie shall

be sturdily constructed of steel, and be not less than 200 mm in diameter. It shall be strong enough to

withstand the full hydrostatic pressure, even if a partial vacuum develops in the pipe, and shall be

completely watertight.

4.5.9.3.2 The lower end of the Tremie shall be equipped with an approved automatic check valve which shall be

watertight.

4.5.9.3.3 For initial filling the Tremie shall have the automatic check valve closed and filling shall take place in such

a manner as to prevent air locks. An initial ‘Slush’ mix is to be used in order to lubricate the pipe. This mix

which will be less dense than the balance of the concrete will rise to the surface and be discarded.

4.5.9.3.4 When concrete is deposited the Tremie shall penetrate the concrete bed and shall be slowly raised to

discharge a uniform flow of concrete. The end of the Tremie shall be under concrete during the whole

operation.

4.5.9.3.5 Concreting shall continue to such a point that laitance can be removed and a sound surface left at the

final finished level.

4.5.9.4 Depositing concrete by pumping

4.5.9.4.1 Placing of concrete by pumping is permitted.

4.5.9.4.2 The same conditions and criteria as for depositing by Tremie as described in 4.5.9.3 apply.

4.5.10 Compaction

4.5.10.1 The concrete shall be compacted into a dense impermeable mass without segregation, bleeding or plastic

cracking. Subsequently, the concrete shall be durable and cracks in hardened concrete shall not exceed

0.15 mm in width. Surface crazing or other types of surface pattern cracking will not be accepted.

4.5.10.2 The concrete shall be compacted with immersion vibrators used by properly trained and supervised

operators. Vibrators shall penetrate the full depth of the layer of concrete and where the underlying

layer is of fresh concrete shall enter and re‐vibrate that layer to achieve effective knitting together.

4.5.10.3 Vibrators shall not be allowed to remain in contact with the reinforcement or formwork. Over and under

vibration shall be avoided and vibrators shall be withdrawn slowly to prevent void formation.

4.5.10.4 Care shall be taken to compact the concrete fully around reinforcement but without causing displacement

of the bars.

4.5.10.5 Hand compaction will not be permitted.

4.5.10.6 Sufficient vibrators shall be provided at each pour location to ensure that the concrete is fully compacted

without delay. At least one reserve vibrator and power source shall be provided on site and not less than

one reserve for every three in use at one time.

4.5.10.7 Immediately before the mixing and pouring of concrete each day the necessary vibrators shall be started


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and tested to the satisfaction of the Supervisor. Undue difficulty in starting a vibrator shall be sufficient

grounds for rejection. External vibrators shall not be used without written approval.

4.5.10.8 Care shall be taken to prevent men engaged in placing concrete from introducing foreign matter into the

concrete from their footwear or in any other way and, where concrete is placed directly against the

surfaces of excavations, any softened material shall first be removed.

4.5.10.9 In‐situ concrete shall be well compacted to a minimum of 98% of the density of the relevant cubes.

4.5.11 Joints

4.5.11.1 No construction joints are permitted in the caisson slip form/sliding operation.

4.5.11.2 Construction joints are required in the in situ capping beam and service tunnels.

4.5.11.3 It is essential that a good bond is achieved between casts at construction joints. The joint surface of the

concrete is to be roughened while still green by means of brush and water spray to expose the coarse

aggregate. Retarders may be used on stop‐ends, which should be removed after 12 hours for green

cutting. Mechanical roughening of hardened concrete using power tools will not be permitted as it may

break or dislodge the coarse aggregate.

4.5.11.4 All surfaces must be cleaned and kept continuously wet for 24 hours before pouring of the adjoining cast.

Unless otherwise shown on the drawings, the exact position of horizontal construction joints shall be

marked on the formwork by means of grout checks in order to obtain truly horizontal joints.

4.5.11.5 Stub columns, stub walls and stays on footings shall be cast integrally with the footings and not

afterwards, even where another class of concrete is being used.

4.5.11.6 Joint lines shall be so arranged that they coincide with features of the finished work.

4.5.11.7 At contraction joints (joints having no reinforcement passing through the joint), no bond is required

between casts. Contraction joints shall be smooth, and shall be coated with an approved bond‐breaker

applied to the older surface prior to casting the newer concrete.

4.5.11.8 The Supervisor's prior written acceptance must be obtained before the adjoining concrete is cast.

4.5.11.9 Proprietary bonding compounds between old and new concrete may be used.

4.5.12 Curing and Protection

4.5.12.1 In order to enhance the long term durability of the concrete in the marine environment it is

essential that it is correctly cured so that adequate hydration of the cement and extenders may take

place.

4.5.12.2 All water for curing shall be clean, fresh water and under no circumstances will seawater be permissible.

4.5.12.3 The curing period for concrete containing CEM I only shall be 7 days. The curing period for concrete's

containing CEM I plus cement extenders (GGBS, FA) shall be 10 days. The period will start on completion

of the concrete pour and for formed surfaces shall include the time for which forms are still in place after

the pour.

4.5.12.4 The Supervisor's prior written acceptance of the curing method to be used must be obtained before

any concrete is cast.

4.5.12.5 Concrete, of which the adequacy of the curing is not in compliance with this specification, shall be

declared a defect and shall be corrected by the Contractor in accordance with clause 43 of the NEC ECC

core clauses.

4.5.12.6 After formwork has been removed and as soon as it is practicable all concrete shall, subject to provisions

of the adverse weather conditions, be protected from contamination and loss of moisture.


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4.5.12.7 When the wind velocity exceeds 5 m/s and/or the ambient temperature is above 25°C and/or the relative

humidity is below 60%, the initial 24 hour curing of concrete surfaces not covered by formwork shall be

carried out by ponding, covering with constantly wetted sand or mats, or continuous spraying as detailed

below.

4.5.12.8 The following curing methods are permissible for plain/unreinforced Concrete:

a) Retaining forms in place on vertical surfaces provided they are made with non‐absorbent facing

materials. The forms shall be not more than 10°C cooler than the concrete and not more than the

concrete curing temperature.

b) Ponding of water on horizontal surfaces. Curing water shall be fresh and not be more than 10°C

cooler than the concrete on which it is to be applied in order to avoid surface cracking.

c) Covering with sand, earth, straw, sawdust, cotton, jute, burlap or hessian or similar moisture

retaining materials. The materials shall be kept continually moist and shall not be allowed to dry out

as alternate wetting and drying is detrimental to the curing process. The material shall be free of

injurious amounts or substances such as sugar or fertiliser that may harm the concrete or cause

discoloration.

d) Sprinkle or spraying with water. This may be done at frequent intervals provided that the concrete

surface remains continuously moist and is not allowed to dry out between wetting. Erosion of the

fresh concrete surface must be avoided.

e) Covering with plastic sheeting, waterproof or other curing paper. The covering material shall be

firmly and continuously held in place along its edges such that the concrete surface is not allowed to

dry out. Care must be taken not to tear, puncture or otherwise disrupt the continuity of the curing

film. Plastic film shall not be black, white or clear.

f) Liquid membrane‐forming curing compounds, which comply with the requirements of 4.2.5 may be

used. Only resin type compounds will be permitted. The formulation must be such as to form a

moisture retentive film shortly after being applied and must not be injurious to Portland cement

paste. White or grey pigments or dyes must be incorporated to enable the compound to be visible on

the surface for inspection purposes.

g) For unformed surfaces the compound shall be applied after finishing and as soon as the free water on

the surface has disappeared and no water sheen is visible, but not so late that the liquid curing

compound will be absorbed into the concrete.

h) For formed surfaces, when forms are removed, the exposed concrete surface shall be wet with water

immediately and kept moist until the curing compound is applied. Immediately prior to application,

the concrete shall be allowed to reach a uniformly damp appearance with no free water on the

surface. Application of the compound should then begin at once. The compound should be applied at

a uniform rate with two applications at right angles to each other to ensure complete coverage, and

may be applied by hand or power sprayer. Pigmented compounds must be adequately stirred to

assure even distribution of the pigment during application, unless the formulation contains a

thixotropic agent which prevents settlement.

i) The compound manufacturer must supply a certificate confirming compliance with 4.2.5 and the

manufacturer’s directions with respect to preparation and application. The manufacturer’s

preparation and application directions for the compound must be strictly adhered to.

j) The total application rate shall be as specified by the Manufacturer, or 0,30 litres per square metre,

whichever is the greater.

k) In the case of concrete surfaces with run‐off problems, it may be necessary to apply more than one

coat of membrane forming curing compound to obtain the specified total or cumulative application

rate.


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4.5.12.9 The following curing methods are permissible for steel reinforced concrete:

a) Covering with burlap or hessian or similar moisture retaining materials. Requirements as given above

for plain concrete.

b) Sprinkling or spraying with water. Requirements as given above.

c) Releasing the forms slightly and allowing a flow of water between the form and the concrete.

d) Curing methods using sealing materials such as plastic or liquid membrane forming compounds is

NOT permitted for steel reinforced concrete structures due to the low W/C ratio of the concrete mix.

The water provided by the moist curing is required for completion of the hydration of the concrete in

the cover layer.

4.5.13 Concrete Surfaces

4.5.13.1 All exposed concrete surfaces shall have a neat, smooth, even and uniform finish, free from any

honeycombing and blow holes.

4.5.14 Records

4.5.14.1 The Contractor shall maintain the following daily records for every part of the concrete work and make

these available at all times during the progress of the work for inspection by the Supervisor:

a) Date and times during which concrete was placed

b) Identification of the part of structure in which the concrete was placed

c) Mix proportions and specified strength

d) Type and brand of cement

e) Slump of the concrete

f) Identifying marks of test cubes made

g) Curing procedure applied to concrete placed

h) Times when shuttering was stripped and props were removed

i) Date of dispatch of the cubes to the testing laboratory

j) Cube test results


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5.0 ADDITIONAL REQUIREMENTS FOR STEEL FIBRE REINFORCED CONCRETE (SFRC) FOR RIGID INCLUSIONS

5.1 General

5.1.1 Notwithstanding the clauses below, the Contractor shall be responsible for the design of the fibre

reinforced concrete mix in terms of determining the type of fibre and dosage required to achieve the

required performance.

5.2 Materials

5.2.1 The fibres shall be cold drawn, hooked end, high strength steel fibres conforming to the requirements of BS

EN 14889‐1.

5.2.2 The length, diameter, aspect ratio, tensile strength (Rm,nom) shall be as per the supplier’s recommendations

to meet the performance specification.


5.3.1 Flexural Strength

5.3.1.1 In addition to the strength requirements detailed above in section 4.0, the SFRC shall have a characteristic

residual flexural tensile strength fR,3 = 6.0 MPa when tested in accordance to BS EN 14651

5.3.2 Workability and uniformity

5.3.2.1 The SFRC shall be easily pumpable without causing blockages in the Rigid Inclusion Equipment

5.3.2.2 Dosages of fibre, fibre shape and fibre coatings shall be such that blockages during pumping are avoided

and lump formation is avoided. A fibre dosage of less than or equal to 45 kg/m3 is recommended however

a higher dosage is acceptable provided the Contractor demonstrates that the concrete remains

pumpable.

5.3.2.3 The fibres shall be mixed and placed in accordance with the supplier’s recommendations to ensure that

the fibres are distributed uniformly throughout the SFRC element.

5.4 Testing

5.4.1 Frequency of Testing

5.4.1.1 In addition to the cube testing required, six beam samples per 100 m3 of SFRC shall be cast and tested

according to BS EN 14651.

5.4.2 Acceptance of strength concrete

5.4.2.1 The cross sectional area of the beam being tested is very small in comparison to the element and

therefore there is likely to be a high variance of the number of fibres crossing the test area. A variation of

results is therefore likely.

5.4.2.2 For this reason, the average value of a set of 6 beams is deemed as a single result and the standard

deviation and characteristic strengths shall be calculated using the averaged values from a series of sets.

5.4.3 Trial mixes

5.4.3.1 The Contractor shall undertake trial mixes of the SFRC in accordance with 4.1 above.

5.4.3.2 In addition, the Contractor shall construct two test Rigid Inclusions as detailed in specification 1370‐CO‐

000‐C‐SP‐0010. The samples taken from the test piles shall be tested for uniformity and distribution of

fibres by visual inspection and by density.


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6.0 ADDITIONAL REQUIREMENTS FOR CONCRETE FOR PAVING

6.1 Aggregate size

6.1.1 The nominal size of the coarse aggregate shall be 37.5 mm, plus one or more of the following:

19.0 mm

13.2 mm

9.5 mm

6.1.2 Coarse aggregate shall comply with the 10% FACT values specified for aggregate used in concrete subject to

abrasion.

6.2 Concrete strength requirements

6.2.1 The specified compressive strength shall be the highest of the following four values:

35 MPa at 28 days; or

0.85 x fc1 where fc1 is the 28 day compressive strength corresponding to a 28‐day flexural strength of

4.5 MPa.

0.85 x fc2 where fc2 is the 28 day compressive strength corresponding to a water cement ratio of 0.53.

0.85 x fc3 where fc3 is the 28 day compressive strength corresponding to a cement content of 320 kg /

m3.

6.2.2 fc1, fc2, and fc3 shall be the 28 day compressive strengths determined from laboratory mixes as detailed

below.

6.3 Testing and strength monitoring

6.3.1 The relationship between 28 compressive strength and 28 day flexural strength shall be determined in a

series of preliminary tests undertaken by the contractor which shall be conducted prior to any concrete

paving works being undertaken.

6.3.2 The relationship shall be established at each of at least three water:cement ratios namely 0.48, 0.53 and

0.58.

6.3.3 In determining the relationship between compressive strength and flexural strength, the tests shall be

based on not less than six compressive‐strength specimens and twelve flexural‐strength specimens for each

water:cement ratio using the aggregates and mix proportions proposed for the works. The results of

compressive strength vs flexural strength will be plotted on a graph to determine the relationship.

6.3.4 In addition to the preliminary testing, the relationship between compressive and flexural strength shall be

monitored by confirmatory tests done from time to time at the discretion of the Supervisor. For this

purpose, samples of 6 beams and 3 cubes shall be manufactured from the same batch of concrete and

tested for flexural tensile and compressive strengths respectively. If the test results vary from those

obtained from the preliminary tests, the specified compressive strength shall be adjusted accordingly.

6.4 General requirements in respect of placing and compacting concrete

6.4.1 The provisions of sections 7107 of ‘COLTO Standard Specification for Road and Bridge Works for State Road

Authorities’ shall apply for the placing and compacting of concrete for pavements.


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7.0 ADDITIONAL REQUIREMENTS FOR SLIP FORMING/SLIDING FOR CAISSON WALLS

7.1 Formwork

7.1.1 The provisions relating to sliding formwork in SANS 2001‐CC1 section 4.3.2.2 shall apply. In addition, the

construction requirements listed in Chapter 3 of ACI 313‐97 – Standard Practices for Design and

Construction of Concrete Silos and Stacking Tubes shall also apply.


7.2.1 The sliding operation shall be undertaken in strict accordance with the provisions of SANS 2001‐CC1 Section

4.7.21.

8.0 ADDITIONAL REQUIREMENTS FOR REAR CRANE RAIL PILES

8.1.1 The material requirements for cast‐in‐place displacement piles in BS EN 12699:2015 shall apply.

8.1.2 The additional requirements for the conformity of concrete for cast‐in‐place displacement piles in BS EN

206:2013 Annexure D shall apply.


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9.0 COMPLIANCE WITH REQUIREMENTS

9.1 Testing

9.1.1 General

9.1.1.1 Concrete test results obtained from a ready‐mix production facility, as part of its quality control system,

shall not be used.

9.1.1.2 The Contractor shall provide an onsite concrete testing facility at the caisson manufacturing site which

shall be capable of testing cubes in accordance with SANS 5861‐3.

9.1.1.3 Where required the 2‐point loading method of the flexural strength tests shall be undertaken in

accordance with SANS 5864.

9.1.1.4 The Contractor shall keep on the site, and make available to the Supervisor on request, full details of the

section of concrete to which any particular test cube is related. All test cubes shall be adequately marked

for identification.

9.1.1.5 The Contractor shall prepare and test at his own expense any additional concrete cubes where he requires

to demonstrate to the Supervisor that a concrete element has achieved a particular compressive strength

after a period other than those specified for routine tests. Such cubes shall be cured under the same

conditions as the related element.

9.1.1.6 Records shall be kept by the Contractor of the positions in the Works of all batches of concrete, of their

grade, and of all tests, cores and other specimens taken from them. Copies of records shall be supplied to

the Supervisor as soon as results are available and on a regular basis to a schedule acceptable to the

Supervisor.

9.1.2 Acceptance of strength concrete

9.1.2.1 The test results may be assessed statistically in accordance with clause 5.1.2.3 of SANS 2001‐CC1.

9.1.3 Frequency of sampling

9.1.3.1 Frequency of sampling and testing shall be as specified in SANS 2001‐CC1 Section 5.13, subject to the

testing of a minimum of 3 sets of samples per day from each grade of concrete placed in each

independent structure if the concrete quantity from which these samples were taken exceeds 40 m3, and

the testing of a minimum of 2 sets of samples per day when such quantity is equal to or less than 40 m3.

9.1.4 Beam tests for SFRC

9.1.4.1 Beam tests for SFRC are detailed in Section 5.4.

9.2 Tolerances

9.2.1 Deviations shall be within the limits listed in Table 11 of SANS 2001‐CC1 for Degree of Accuracy II, unless

stated otherwise on drawings or elsewhere in the Works Information.

TRANSNET SOC LTD


LENGTHENING

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SPECIFICATION – CAISSON CONSTRUCTION AND PLACEMENT

1370‐CO‐000‐C‐SPC‐0002 Rev T‐0A

18 NOVEMBER 2016


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REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






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CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1


2.1 Reference Documents ..................................................................................................................................... 2 2.2 Standard Specifications ................................................................................................................................... 2

2.2.1 Caisson and infill panel manufacturing ......................................................................................... 2 2.2.2 Caisson launching, towing and positioning ................................................................................... 2 2.2.3 Infill panel loading, transfer and positioning ................................................................................. 2 2.2.4 Caisson quay wall joints and seals ................................................................................................. 3

2.3 Employer’s Project Specific Specifications and Standards .............................................................................. 3

3.0 DEFINITIONS ............................................................................................................................................ 4

3.1 Chart Datum Port ............................................................................................................................................ 4 3.2 Co‐ordinate System ......................................................................................................................................... 4 3.3 Tidal Levels ..................................................................................................................................................... 4 3.4 Method Statements ........................................................................................................................................ 4 3.5 Foundation Stone Bed (Load transfer Platform) ............................................................................................. 4 3.6 Geotextile Reinforcement ............................................................................................................................... 4 3.7 Slip‐forming ..................................................................................................................................................... 4 3.8 Steel Fiber Reinforced Concrete (SFRC) .......................................................................................................... 4

4.0 CAISSON AND INFILL PANEL MANUFACTURING INCLUDING CASTING YARD ESTABLISHMENT ................. 5

4.1 Method Statements ........................................................................................................................................ 5

4.1.1 Establishment of Lot 10 casting yard ............................................................................................. 5 4.1.2 Caisson manufacture ..................................................................................................................... 5

4.2 Materials ......................................................................................................................................................... 5

4.2.1 Reinforced concrete ...................................................................................................................... 5 4.2.2 Flexible pipe connector ................................................................................................................. 5

4.3 Equipment (Including Temporary Works) ....................................................................................................... 6

4.3.1 General .......................................................................................................................................... 6 4.3.2 Concrete Batch Plant ..................................................................................................................... 6 4.3.3 Caisson casting yard ...................................................................................................................... 7 4.3.4 Forms for caisson base manufacture ............................................................................................ 7 4.3.5 Slip‐form ........................................................................................................................................ 7 4.3.6 Caisson transfer (jacking and skidding) Equipment ....................................................................... 8

4.4 Methods and Procedures ................................................................................................................................ 8

4.4.1 Caisson manufacturing .................................................................................................................. 8

5.0 CAISSON LAUNCHING, TOWING AND POSITIONING............................................................................... 10

5.1 Method Statement ........................................................................................................................................ 10 5.2 Materials ....................................................................................................................................................... 10

5.2.1 Structural steel ............................................................................................................................ 10


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5.3 Equipment (Including Temporary Works) ..................................................................................................... 10

5.3.1 General ........................................................................................................................................ 10 5.3.2 Launching Equipment (Synchrolift) ............................................................................................. 10 5.3.3 Towing Equipment ...................................................................................................................... 11

5.4 Methods and Procedures .............................................................................................................................. 11

5.4.1 Launching Dock Deepening ......................................................................................................... 11 5.4.2 Launching and Towing ............................................................................................................... 11 5.4.3 Positioning of caissons ............................................................................................................... 13

6.0 CAISSONS QUAY WALL JOINTS, SEALS AND BACKFILL ............................................................................ 14


6.2.1 Geotextile filter fabric/separation layer ...................................................................................... 14 6.2.2 Grout socks .................................................................................................................................. 14 6.2.3 Stone fill to create platforms for return caissons ........................................................................ 15 6.2.4 Stone fill between caissons ......................................................................................................... 15 6.2.5 Grout ........................................................................................................................................... 15 6.2.6 Reclamation sand fill ................................................................................................................... 15

6.3 Methods and Procedures .............................................................................................................................. 15

6.3.1 Filling, grouting and sealing ......................................................................................................... 15 6.3.2 Quay wall monitoring .................................................................................................................. 16

7.0 PRECAST INFILL PANEL MANUFACTURE, LOAD OUT, TRANSIT AND POSITIONING ................................. 17


7.2.1 Reinforced Concrete .................................................................................................................... 17

7.3 Equipment (Including Temporary Works) ..................................................................................................... 17 7.4 Methods and Procedures .............................................................................................................................. 17


8.1 Tolerances ..................................................................................................................................................... 18

8.1.1 Caisson construction ................................................................................................................... 18 8.1.2 Caisson placement ...................................................................................................................... 18


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1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the construction of concrete caissons and

their placement in a marine environment. It covers Materials, Equipment, quality, manufacture, construction,

testing and tolerances.

Construction of the new Berths 203 to 205 utilises precast concrete caissons, which shall be cast and transported to

the site where they shall be sunk on a prepared foundation bed.

This specification covers:

a) Manufacturing of caissons

- Establishment and maintenance of caisson casting yard

- Casting of caisson bases and slip forming caisson walls

b) Caisson transit

- Lot 10 Launching dock deepening

- Installation and commissioning of Synchrolift

- Caisson launching

- Caisson towing

- Caisson positioning

c) Caissons Quay Wall joints, seals and backfill

- Stone fill between caissons

- Joints and grouting

- Sand‐fill and reclamation are covered only in relation to construction sequencing. Material,

construction and performance specifications for the filling and vibro‐compaction are provided in

specification 1370‐CO‐000‐C‐SPC‐0004 – Dredging and Reclamation (Including Vibro Compaction).

d) Manufacturing, lifting, loading and positioning of precast infill panels.


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e) 1370‐CO‐060 series of drawings – Caisson Quay Wall

f) Method statement prepared by the Contractor, as described in Section 4.0

g) Project Geotechnical Reports, included in Part 4 ‐ Site Information.


2.2.1 Caisson and infill panel manufacturing

The governing code for these parts of the specification shall be SANS 2001‐CC1:2012 – Concrete works (structural).

The following Standards, Standard Specifications and Recommended Practices are also referenced in this

specification:

a) ACI 313‐97 – Standard Practice for Design and Construction of Concrete Silos and Stacking Tubes

b) SANS 2001‐CS1:2012 – Structural Steel Work

c) SANS 121:2011/ISO 1461:2009– Hot‐dip (galvanized) Coatings on fabricated iron and steel articles

2.2.2 Caisson launching, towing and positioning

The following standard specifications are applicable to this section of the specification:

a) DNV‐OS‐C502 – Offshore Concrete Structures, September 2012

b) DNV‐OS‐H101 – Marine Operations, General

c) DNV‐OS‐H102 – Marine Operations, Designed Fabrication, January 2012

d) DNV‐OS‐H201 – Load Transfer Operations, April 2012 (for launching of caissons using the synchrolift)

e) DNV‐OS‐H202 – Sea Transport Operations, October 2015, VMO Standard Part 2‐2 (for towing of

caissons)

f) DNV‐OS‐H203 – Transit and Positioning of Offshore Units, February 2012

g) DNV‐OS‐H204 – Offshore Installation Operations, November 2013, VMO Standard Part 2‐4 (for

positioning of the caissons)

2.2.3 Infill panel loading, transfer and positioning


a) DNV‐OS‐H101 – Marine Operations, General

b) DNV‐OS‐H102 – Marine Operations, Designed Fabrication, January 2012

c) DNV‐OS‐H201 – Load Transfer Operations (for load out)

d) DNV‐OS‐H202 – Sea Transport Operations, VMO Standard – Part 2‐2 (for towing of barge)

e) DNV‐OS‐H205 – Lifting Operations (VMO Rules Part 2‐5) for lifting and placement of the infill panels,

April 2014

f) International Maritime Organization, International Code on Intact Stability, 2008

g) International Maritime Organization (IMO), International Code of Safety for High Speed Craft 2000,

2008 Edition, Annexure 8

h) Bureau Veritas, Towage at Sea of Vessels or Floating Units, NR183, 1986

i) DNV‐RP‐H101 – Risk Management in Marine and Subsea Operations, January 2003

j) DNV‐RP‐H103 – Modeling and Analysis of Marine Operations, February 2014

k) DNV‐RP‐H104 – Ballast, Stability and Watertight Integrity‐Planning and Operating Guidance,

September 2011


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2.2.4 Caisson quay wall joints and seals


a) BS 812 – British Standards Institution – Method for sampling and testing mineral aggregates (or

equivalent BS EN revision)

b) CIRIA, C683 – The Rock Manual, The use of rock in hydraulic engineering (2nd Edition), 2007, Revised

August 2008

c) BS EN 13251:2014 +A1:2015 – Geotextiles and geotextile‐related products. Characteristics required

for use in earthworks, foundations and retaining structures

d) BS EN 446:2007 – Grout for prestressing tendons – Grouting procedures

e) BS EN 447:2007 – Grout for prestressing tendons – Basic requirements



a) 1370‐CO‐000‐C‐SPC‐0001 – Concrete for Marine Construction

b) 1370‐CO‐000‐C‐SPC‐0004 – Dredging and Reclamation (Including Vibro Compaction)

c) 1370‐CO‐000‐C‐SPC‐0010 – Ground Improvement: Rigid Inclusions and Foundation Stone Bed

(Caisson Load Transfer Platform)

d) Environmental Management Plan (EMP)


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3.0 DEFINITIONS


the construction of the Works.



For the purpose of this specification, the technical definitions and abbreviations given in SANS 2001, together with


3.1 Chart Datum Port

Chart Datum Port refers to the reference level used in the Port of Durban, which is 0,900 m below Mean Sea Level.

All levels referred to in this document are relative to Chart Datum Port (CDP).

3.2 Co‐ordinate System

The co‐ordinate system to be used for all setting out and survey shall be World Geodetic System 1984 (WGS84),

L031, referred to as WG31.

3.3 Tidal Levels

The Astronomical Tide Predictions as defined by the SA Navy Hydrographer and Chart SAN 2006 are as follows:

Table 3.1 – Tide Data

Tide Abbreviation Level m, Chart Datum Port

Highest Astronomical Tide HAT 2.287

Mean High Water Springs MHWS 1.997

Mean Level ML 1.097

Mean Low Water Springs MLWS 0.197

Lowest Astronomical Tide LAT ‐0.013


Method Statements shall be compiled by the Contractor for all activities. The Method Statements shall be submitted

to the Supervisor for acceptance three weeks in advance of the particular activity being undertaken. Full details of all

proposed Equipment (including temporary works) and methods shall be provided for acceptance by the Supervisor.

No activity shall commence until the method statement has been accepted by the Supervisor.

Further details of the requirements of particular method statements are provided in sections 4.0 to 7.0.

3.5 Foundation Stone Bed (Load transfer Platform)

The term foundation stone bed refers to the stone constructed above the ground reinforced with rigid inclusions.

This layer is also known as the “load transfer platform (LTP)”. It forms the platform on which the structure is placed

and transfers the majority of the structures load towards the rigid inclusion heads through an arching mechanism.

This layer is composed of compacted stone with geotextile reinforcement at its base.

3.6 Geotextile Reinforcement

This term refers to the geotextile placed at the base of the foundation stone bed functioning as a reinforcement,

separation and filtration layer. The geotextile directs load towards the rigid inclusion heads through membrane

action. Additionally the geotextile prevents the mixing of the foundation stone bed and in situ soil, while still allowing

the though flow of water.

3.7 Slip‐forming

The term ‘Slip‐forming’ refers to the process of constructing a vertical structure using a continuously moving form.

Slip‐forming is also referred to as ‘Sliding’ in SANS 2001‐CC1:2007 and all such clauses are applicable to the slip‐

forming operation.

3.8 Steel Fiber Reinforced Concrete (SFRC)

This term refers to concrete with steel fibres added to the concrete mix.


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4.0 CAISSON AND INFILL PANEL MANUFACTURING INCLUDING CASTING YARD ESTABLISHMENT


Method statements shall be compiled by the Contractor for all activities and for all stages of the establishment,

casting, launching, towing and placement work. The method statements shall be submitted to the Supervisor for

acceptance three weeks in advance of the particular activity being undertaken. Full details of proposed Equipment

and methods shall be provided for acceptance by the Supervisor.

No activity shall commence until the method statement has been accepted by the Supervisor. Methods and

procedures described in the statements shall comply with the relevant sections of the specifications, standards and

recommended practices listed in Section 2 above.

The method statements for this section shall include inter alia:

4.1.1 Establishment of Lot 10 casting yard

a) Layout of Lot 10 including space requirements for batch plant, caisson casting yard and precast item

casting yard.

b) Details of establishment at casting yard including details of planned renovations/amendments to

existing casting beds and transfer beams.

c) Batch plant layout.

d) Details of provisions for concrete supply for 24 hour slip forming operation (including provision for

concrete supply in the event of site batch plant breakdown).

4.1.2 Caisson manufacture

a) Details of concrete mix designs in accordance with specification 1370‐CO‐000‐C‐SPC‐0001 – Concrete

in Marine Environment

b) Detailed design and drawings of:

c) Caisson jacking and skidding system for caisson transfer

d) Slipform system for caisson wall casting

e) Synchrolift

f) Proposed schedule for caisson manufacture including production rates for casting of bases and slip

forming of walls.

g) Details of shift work making allowance for overlapping of shifts for handover.

h) Emergency procedures for dealing with breakdowns, power failures etc. to ensure that the slip form

operation is not halted.

i) Full methodology for casting, jacking, transferring the caissons to the launching dock and launching

caissons.

j) Overall schedule for caisson manufacturing taking into account phased nature of work and limited

space available for storage of caissons.

k) Proposals for manufacturing and transporting of special caissons and caisson infill panels.

4.2 Materials

4.2.1 Reinforced concrete

All Materials for concrete works for the caissons and infill panels shall be in accordance with Employer

Specification 1370‐CO‐000‐C‐SPC ‐0001 – Concrete for Marine Construction.

4.2.2 Flexible pipe connector

The flexible pipe connector gasket cast into the caisson walls shall be in accordance with ASTM C‐923:

‘Standard specification for resilient connectors between reinforced concrete manhole structures, pipes and

laterals’.


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4.3 Equipment (Including Temporary Works)

4.3.1 General

The Contractor shall provide all the Equipment required to Provide the Works associated with the caisson

and infill panel manufacturing which shall include inter alia:

a) Concrete batch plant(s)

b) Tower and mobile cranes

c) Scaffolding and specialized equipment for working at height

d) Forms for caisson bases.

e) Equipment for Slip‐forming caisson walls

f) Temporary works for Caisson manufacture and transfer including casting beds, jacking beams and

transfer beams

g) Jacking and rigging Equipment for caisson transfer

h) Props to Lot 10 Launching Dock

i) Navigation lighting for stored caissons

j) Adequate power supply as well as stand by generators such that the casting and handling of the

caissons will not be interrupted by potential power failures.

k) Lighting for night operations

All lifting and rigging Equipment shall comply with the OHS Act and be provided with current test

certificates. The Contractor shall procure the services of a Registered Professional Engineer to design and

sign off all Equipment including the slip‐form system, jacking and transfer beams, jacks and any associated

jacking stools, chairs or beams; and shall submit these designs for acceptance to the Supervisor.

4.3.2 Concrete Batch Plant

The general requirements for the concrete batch plant are detailed in specification 1370‐CO‐000‐C‐SPC‐

0001 Concrete for Marine Construction.

The fine and course aggregate storage bins shall have a minimum stockpile/storage capacity for 2 weeks

supply.

The cement storage silos shall have a minimum storage capacity for 2 weeks supply.

A standby batch plant shall be available in the event of breakdown of the main batch plant.


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4.3.3 Caisson casting yard

The Employer shall make available the old Lot 10 Casting Yard at the Bayhead for production of Caissons.

This is an existing facility located at the Bayhead off Hamburg Road in the Port of Durban which was

developed some years ago for the purpose of caisson construction for the extension of the Point area quay.

It has not been used for several years and requires significant clearing, refurbishment and re‐equipping to

refit it for its purpose. At present the site is overgrown and it has been used as a dumping ground and

storage space.

Details of the existing infrastructure at Lot 10 including an assessment of the condition of the previous

casting infrastructure are provided in report “Lot 10 Casting Yard – Condition Survey” included in Part C4.1

Site Information. Drawings showing the layout, sections and details of the casting yard and launching dock

as used by the previous contractor are provided in the annexures to the report.

The Contractor shall remove all vegetation, spoil material, debris, rubble, equipment and miscellaneous

material in Lot 10 to make space available for the establishment of the batching plant and the casting yards.

The Contractor shall undertake a condition survey of the existing casting beds and transfer beams and

undertake repairs, alterations or additions to the beams and beds as required.

4.3.4 Forms for caisson base manufacture

The provisions relating to formwork of Specification 1370‐CO‐000‐C‐SPC‐0001 – Concrete for Marine

Construction shall apply.

The Contractor shall provide a bottom formwork panel to fill the gap in the casting bases under the caisson

and transfer the load from the caisson to the jacks.

4.3.5 Slip‐form

The provisions relating to formwork of Specification 1370‐CO‐000‐C‐SPC‐0001 – Concrete for Marine

Construction shall in general apply to the Slip‐form. In addition, the construction requirements listed in

Chapter 3 of ACI 313‐97 – Standard Practices for Design and Construction of Concrete Silos and Stacking

Tubes shall also apply.

The Slip‐form shall be robust so that it can be stripped and reassembled with ease to the original

dimensions.

Forms shall be tight and rigid to maintain the finished concrete wall thickness within the specified

dimensional tolerances.

The formwork shall be supported on a number of jacking yokes of the Contractor’s design. The formwork

shall be raised on jacking rods placed inside pipe formers and lifted by hand‐over‐hand hydraulic jacks.

The jacks shall be controlled by a central power pack capable of raising the whole formwork structure

simultaneously and evenly as well as being capable of regulating the movement of each jack individually to

correct for verticality.

Slip‐form systems must be capable of adjusting the rate of slipping to suit the reinforcing and concreting

operations.

An upper working platform shall be provided to fix reinforcing, place concrete and storage of Materials to

be cast in. The platform shall be equipped with guardrails, toeboards and ladders and other such safety

measures in accordance with Health and Safety requirements for working at heights.

Internal and external hanging platforms shall be provided for rendering the exposed concrete surfaces.

Lasers are to be used for verticality checking.

Sufficient and safe access shall be provided to the Slip‐form platforms.


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4.3.6 Caisson transfer (jacking and skidding) Equipment

The Contractor shall provide the following Equipment for the caisson transfer:

a) Sets of jacks which are to be set up in the two slots in the casting bases, capable of raising the

caisson base, weighing an estimated 1155 tonnes plus 20 % safety margin.

b) Transverse travel mechanisms to transfer the caisson base once cast and to lower it onto the

intermediate beams.

c) Sets of jacks to be set up adjacent to the intermediate beams, capable of raising the complete

caisson, weighing an estimated 2360 tonnes plus 20 % safety margin.

d) Transverse travel mechanisms to transfer the complete caisson and to lower it onto the launching

beams.

e) All localised, fixed and moveable diesel powered hydraulic power packs and jacks to control lifting

and transverse/longitudinal motions.

f) Long travel mechanism to raise the completed caisson and transfer it in stages to the Synchrolift

platform.

4.4 Methods and Procedures

4.4.1 Caisson manufacturing

The Contractor shall make use of the existing casting facilities for the manufacturing of the caissons. The

caissons have been designed such that they fit within the existing facilities and jacking and skidding points

have been aligned with the existing facilities. The existing facilities make allowance for the simultaneous

production of six caisson bases and six caisson walls.

Caisson bases shall be cast on the outer ends of the side transverse beams on concrete casting platforms. A

total of six bases can be in production simultaneously. The slots in the bases require separate soffit

formwork which shall form part of the transverse jacking system. In order to prevent adhesion between

the bases and the casting platform, the bases shall be cast on plastic sheeting.

The caisson bases shall not be jacked or moved off the caisson base casting bed prior to the concrete

achieving a minimum strength of 27 MPa. The Contractor shall determine the jacking layout, number of

jacks and size of bearing plates such that the jacking/bearing pressure on the concrete base for this

operation is limited to 3.5 MPa. The jacks shall be positioned in the existing transverse beam slots. Once

the required concrete strengths have been achieved, the partly completed caisson base shall be jacked off

the casting base, moved to the inner position and lowered onto the transverse beams. This allows the

jacking equipment to be withdrawn and re‐positioned for the next base to be cast.

The caisson walls shall be cast using a slip‐form method of construction which shall continue on a 24/7

basis. This shall be a continuous process in which the reinforcement is fitted at the same time as the

formwork climbs and wet concrete is mixed with wet concrete. The Contractor shall propose methods for

concrete placement by crane and bucket or by pumping. The concrete mix design shall take account of both

the method of placement, (which could require plasticizers) and the requirement for the concrete to have

sufficient stiffness as it emerges from the sliding formwork during jacking. The setting rate of the concrete

shall be constantly monitored to match the speed of the slip. The concrete shall be in accordance with

specification 1370‐CO‐000‐C‐SPC ‐0001 – Concrete for Marine Construction. From the suspended platforms

directly below the formwork, the concrete surface that appears under the formwork shall be smoothed and

brushed before the concrete hardens.

Openings and embedded items shall be accommodated in accordance with the drawings. Certain caissons

require an opening for the storm water pipe – the gasket for the pipe connection shall be cast‐in during the

slip form process.

Construction joints in the caisson walls are not be permitted.

The complete caissons shall not be jacked, moved or transferred to the longitudinal beams prior to the

concrete in the base achieving its full design strength and the concrete from the last pour for the caisson

walls achieving a minimum strength of 18 MPa. The Contractor shall determine the jacking layout, number


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of jacks and size of bearing plates such that the jacking pressure on the concrete base for this operation is

limited to 7.5 MPa. Once the required concrete strengths have been achieved, caissons are sequentially

transferred to the longitudinal launching beams, where further curing shall take place.

Cured caissons shall be moved by skidding and jacking equipment down the centre longitudinal launching

beam to the launching dock. Horizontal jacking/skidding forces are to be applied to the jacks or skids

themselves and not to the caisson.

Jacking rods required during the slip forming of the caisson walls are to be removed after completion of

casting and the holes for the rods are to be grouted up with a cementitious, non‐shrink grout with a

minimum compressive strength of 50 MPa.

The Contractor to temporarily seal all openings including storm water pipe openings prior to launching

caisson. Temporary seals to be designed to resist water pressure during launching of towing.

The caissons shall not be launched into the water prior to concrete surrounding the proposed towing

attachment points achieving its full design strength and the concrete from the last pour for the caisson

walls achieving a minimum strength of 32 MPa.

The Contractor shall employ specialist personnel with extensive experience in heavy lifts for the purposes of

lifting, moving and launching the caissons.

The Contractor shall plan the setting up of the casting yard and its production capability to ensure the

following:

a) Special caissons and infill panels required for corners and transitions are produced in time

b) Standard caissons are constructed, cured and ready for launch at a suitable rate to meet his full

construction program for Phase 1 at Berth 205.

c) Excess stock caissons shall be towed to the dedicated storage area located in the basin adjacent to

the sandbank opposite Berths 205 to 203. The caissons shall be temporarily ballasted onto the

seabed clear of the scour protection at the toe of the deepened basin after dredging to ‐16.5 m. All

stored caissons are to be ballasted onto a level even bed and marked with lights and navigation

marks in accordance with IALA and TNPA’s requirements.

d) For the later phases, the Contractor may then at his option:

e) Suspend operations at the Casting Yard until production is necessary for Phase 2 at Berth 204 and

subsequently for Phase 3 at Berth 203; or

f) Continue with caisson production and store the finished caissons by sinking them in the dedicated

storage area in accordance with the above requirements.


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5.0 CAISSON LAUNCHING, TOWING AND POSITIONING

5.1 Method Statement


a) Methodology for installing props required for launching dock deepening.

b) Detailed design and drawings of the Synchrolift.

c) Detailed methodology for installing Synchrolift.

d) Synchrolift commissioning and operating procedures including emergency procedures.

e) Detailed stability and hydrodynamic study for caisson towing to determine optimum towing layouts,

distances and speed.

f) Limiting wave and wind conditions for caisson towing.

g) Forecasting system to ensure caisson is not towed during adverse wind and wave conditions.

h) Procedures for launching, turning and towing caissons, including emergency procedures.

i) Schedule for launching and towing of caissons taking into account limitation of launching on rising

tide above MSL.

j) Procedures for checking caisson draft and for ballasting or additional buoyancy in the event of

significant listing.

k) Details of towing equipment including tugs, barges, towing bridles, tow ropes, tailing ropes,

emergency anchors and caisson attachment points.

l) Details of ballasting for sinking of caissons.

m) Methodology for refloating caissons.

n) Methodology for placing of caisson within required tolerances taking into account effects of

aquaplaning/skating as base approaches seabed.

5.2 Materials

5.2.1 Structural steel

The structural steel for the Lot 10 launching dock props shall be Grade 350W to SANS 1431.

Galvanising shall be carried out in accordance with SANS ISO 1461. The coating thicknesses shall be 25%

greater than the standard table 2, in accordance with SANS Specific Permit Conditions 1336/2494.


5.3.1 General

The Contractor shall provide all the Equipment required for launching, towing and positioning of the caisson

which shall include inter alia:

Synchrolift for caisson launching

Marine Equipment for caisson towing

Marine Equipment for caisson placement and refloating

The Contractor shall procure the services of a Registered Professional Engineer and Naval Architect to

design and sign off all Equipment for the launching, towing and positioning of the caissons and shall submit

these designs for acceptance to the Supervisor.

5.3.2 Launching Equipment (Synchrolift)

The Contractor shall design, procure, deliver, install, commission and maintain the Synchrolift required for

the caisson launching.

The launching Equipment shall comply with the requirements of Section 4 of DNV‐OS‐H201.

The synchrolift platform shall be lifted and lowered using a set of hydraulic strand jacks supported on the

two existing upstand concrete lifting beams.

The strand jacks shall be provided with full instrumentation, load sensing mechanisms and a position

holding and adjusting system that shall maintain the platform of the synchrolift at exactly the same level, to

a tolerance of < 5 mm over the long dimension of the caisson, while the load is transferred sequentially

from the long travel system to the synchrolift.


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The synchrolift shall be capable of lowering the caisson into the water, while retaining its level to the above

tolerance.

The Contractor shall maintain ownership and responsibility for operating the Synchrolift for the duration of

the Contract. Upon Completion of the works, the Contactor shall decommission the Synchrolift and remove

it from site.

5.3.3 Towing Equipment

The Contractor shall provide the following Equipment for the towing of caissons:

A sufficient number of suitable vessels with qualified marine crew to tow and steer the caisson

ensuring the caisson does not deviate off the specified tow path even in high winds.

Towing bridles, tow ropes, tailing ropes and an emergency anchor.

Emergency towing arrangements

A portable pump system capable of removing rainwater or leakage and to avoid the instability

resulting from free surface effects.

Navigation lighting for stored caissons.

All Equipment shall be sized and designed in accordance with the requirements of DNV‐OS‐H202.

The emergency towing arrangement shall consist of a single spare towing connection located at the aft end

of the caisson relative to the direction of tow, attached at an approved location. A pennant shall be

connected to the connection and led aft to a floating line. The pennant and towing connections shall be

sized similarly to the main towing equipment.

All marine equipment used shall be subject to the requirements and approval of the South African Maritime

Safety Association (SAMSA).

Contractor's floating equipment shall be maintained in a satisfactory and seaworthy condition, shall have

adequate attendance by competent seamen at all times, shall be fully provided with sound and satisfactory

ropes, line and moorings and shall be fully equipped with lights.

At all times the Contractor shall be wholly responsible for the protection and safety of all floating craft

engaged by him.

The Contractor shall immediately and at his own cost re‐float or raise and remove any Contractor's

Equipment (floating or otherwise), vessel, craft or Materials (including the caisson itself) or any other

property in his care or belonging to him or to any Subcontractor, which may be stranded or sunk in the

course of execution and completion of the works. Until such sunken object is raised and removed the

Contractor at his own cost shall set buoys and display such lights and do all such things for the safety of

navigation as may be required by the authorities concerned or by the Supervisor.


5.4.1 Launching Dock Deepening

The caissons shall be launched into the water at the existing Lot 10 launching dock. Prior to installing the

Synchrolift, the Contractor shall dredge the launching dock to provide sufficient depth for the launching and

towing of the caissons. The launching dock is to be dredged to a level of ‐12.62 m CD to create sufficient

draft for the installation of the Synchrolift and for the launching of the caissons. Props and toe piles are to

be installed at the launching dock to ensure the existing sheet pile walls remain stable at this dredged

depth. Details of the props and piles are shown on drawings 1370‐CO‐020‐C‐DWG‐0011 Sheets 1 to 3. The

dredging of the launching dock is covered in specification 1370‐CO‐000‐C‐SPC‐0004 Dredging and

Reclamation (Including Vibro Compaction).

5.4.2 Launching and Towing

The launching operation shall be planned and undertaken in accordance with DNV‐OS‐H201 with particular

reference to Section 4.

The towing operation shall be undertaken in accordance with DNV‐OS‐H202 with particular reference to

Sections 4 and 5.5.


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The Contractor shall be responsible for undertaking stability and hydrodynamic studies of the caissons to

determine safe and optimal towing procedures, Equipment, and speeds.

Attachment points for the towing of the caisson are shown on the drawing and are to be cast in during

caisson manufacture. The Contractor is responsible for selecting the type and size of attachment and shall

inform the Employer’s Designer of the proposed attachment for incorporation in the design of the caisson.

Prior to launching of the caissons, the Contractor shall seal all openings including towing attachment points.

The temporary seals to openings are to be designed to resist all static and hydrodynamic forces during

launching and towing.

The entire towing launching and towing operation shall be done in close co‐operation with the Harbour

Master.

For launching, the caisson shall be moved onto the synchrolift platform, which shall be carefully controlled

to compensate for the load and remain level while the caisson is lowered into the water until it floats.

The anticipated draft of the typical Type 1 caissons while floating is 11.6 m, while the launching dock will

have a depth of only ‐11 m CDP with the Synchrolift lowered. The Contractor shall therefore launch during

a rising tide with tide level > 1.4m to ensure sufficient clearance between the caisson bottom and the

Synchrolift platform, allowing for the depth of the synchrolift platform itself. Tides are to be strictly

monitored using either tide gauges installed by the Contractor or using the port’s tide gauges. The

Contractor shall check the draft at four points immediately after launching. If there is any significant list (>

2.5 degrees), the Contractor shall ballast the caisson or provide additional buoyancy to bring the caisson to

an even draft.

The Contractor is made aware that certain of the caisson special types are not symmetrical and the

Contractor shall make provisions for additional buoyancy or ballasting to account for eccentricities.

Floating out of the caisson from the launching dock shall be undertaken in a controlled manner at

sufficiently low towing speeds to ensure that the caisson does not list within the dock. Sudden

accelerations during pull off and towing shall be avoided.

Once the caisson has been floated out of the launching dock, the caisson shall be rotated 90 degrees such

that the toes of the caisson base are perpendicular to the line of towing. The caisson shall be towed on a

rising tide to the Maydon Wharf Channel (dredged to ‐12.2 m CDP) and down the Esplanade Channel to the

Berth 203 – 205 basin. This shall be accomplished without grounding in the main navigation channels or

basin.

The Contractor shall ensure that no appreciable change to list or particularly fore and aft trim occurs that

could result in the toe of the caisson making contact with the floor of the channel. Wind generated waves

and the effects of wind on towing operations are to be taken into account to maintain adequate safe

clearances while towing the caissons. Lights and navigation beacons shall be provided on the caissons

during towing.

It shall be permissible to ground and store the caissons in the channel just outside the launching dock to

await suitable conditions for towing, provided the Contractor has ensured that the dredged channel is even

and level and no obstructions could damage the caisson or result in it settling unevenly and that the caisson

is sufficiently ballasted to prevent it from re‐floating and drifting uncontrolled. A maximum of 3 caissons

shall be stored in this area at any one time. Should the Contractor elect to store a caisson in this area, the

Contractor shall provide lights and buoys attached to the caisson to demarcate the caisson to the

satisfaction of the Harbour Master.

Once the caisson has been towed into the Maydon Wharf channel, the remainder of the towing procedure

to the construction site or to the demarcated temporary storage area adjacent to Pier 2 shall be undertaken

in a single continuous operation as no storage of caissons shall be permitted within the main navigation

channels.


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Should the Contractor fail to meet the foregoing obligations the Employer may buoy and light each sunken

object and re‐float or raise and remove the same (without prejudice to the right of the Employer to hold the

Contractor liable) and the Employer shall be entitled to recover from the Contractor the cost thereof or may

deduct the same from any monies due or that become due to the Contractor.

The channels along the tow route will be dredged by the Employer to ‐12.2 CDP at the Contract Date.

Thereafter, it is the Contractor’s responsibility to conduct ongoing bathymetric surveys of the tow route to

determine if any siltation causing high spots have occurred that may affect the towing of the caissons. The

Contractor shall be responsible for maintaining the dredged depth of the tow route until all caisson towing

for the project has been completed.

5.4.3 Positioning of caissons

The positioning operation shall be planned and undertaken in accordance with DNV‐OS‐H204 with

particular reference to Section 5.

The foundation stone bed under the caisson shall be signed off in respect of evenness of bed and level

(refer to specification 1370‐CO‐000‐C‐SPC‐0010) prior to placing of the caisson. The Contractor shall

conduct a final dive inspection of the bed to ensure it is clean and there is no build‐up of silt or other

detritus. All silt material shall be removed via an airlift operation.

Prior to positioning the caisson, all drain pipes, mating faces and in particular recesses for grout socks are to

be clean and free of barnacles or marine growth.

Prior to lowering, the caissons shall be towed to its final position in plan and shall position it accurately in

respect of orientation, line and gap between it and the adjacent caisson (Nominal gap 60 mm ± 50 mm).

The Contractor shall provide adequate mooring and control mechanisms allowing for tide and wind.

The Contractor shall sink the caisson slowly and evenly to its required grounded position by pumping sea

water into it. The Contractor is made aware that based on experience from previous projects, the caissons

have a tendency to aquaplane/skate in the transverse directions as the base approaches the stone bed due

to the effect of water trapped between the base and the stone bed. The Contractor shall plan the

grounding methodology and provide suitable holding and mooring equipment accordingly to deal with this

and shall ensure the bases are placed within tolerance.

The Contractor shall check the tolerance of placement as soon as it has reached the bed and if satisfactory

fill it completely with water.

If it is out of tolerance, water shall be pumped out and the caisson correctly positioned.


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6.0 CAISSONS QUAY WALL JOINTS, SEALS AND BACKFILL



a) Detailed installation methodology for installation of seals, grouting and filter fabric

6.2 Materials

6.2.1 Geotextile filter fabric/separation layer

A geotextile is to be placed between the sand backfill and rock fill to prevent the intermixing of the two

layers and at the caisson and capping beam joints. This shall be a nonwoven, needle punched, continuous

filament, polyester geotextile. The geotextile shall conform to the properties given in Table 6.1.

Table 6.1: Required Properties of Separation Geotextile

Product: Nonwoven, needle punched, continuous filament, polyester geotextile

Intended use For separation and filtration, in construction of earthworks, foundations and retaining

structures.

Tensile Strength

(200 mm wide strip) In weaker direction kN/m 26*

BS EN 13251

EN ISO 10319

Elongation at

maximum load In weaker direction % 50‐70

BS EN 13251

EN ISO 10319

Resistance to static

puncture CBR test kN 4.8*

BS EN 13251

EN ISO 12236

Dynamic

perforation

resistance

Diameter of hole (max) mm 13* BS EN 13251

EN ISO 13433

Water permeability Normal to the plane l/m2s 70* BS EN 13251

EN ISO 11058

Characteristic

opening size O95W μm 130*

BS EN 13251

EN ISO 12956

Durability In accordance with the relevant clause of EN 13251,

Annex B for service lives up to 50 years ‐ ‐

BS EN 13251

Annex B

* Mean value – Manufacture shall provide tolerance values corresponding to the 95% confidence level.

The geotextiles shall be manufactured under a quality management system that is third party certified to

ISO 9001:2000 standards.

Geotextile filaments shall be rot‐proof and chemically stable. Filaments shall resist delamination and

maintain their relative dimensional stability in the geotextile.

The Contractor shall submit to the Supervisor certified test results and statements of quality that show

without exception that the proposed geotextiles meet the requirements of this specification.

Geotextiles shall not be exposed to temperatures in excess of those recommended by the manufacturer.

Outdoor storage shall not be for periods that exceed the manufacturer’s recommendations. Geotextiles

shall not be exposed to direct sunlight prior to installation for more than 14 days.

On site quality control shall be in accordance with PD CEN/TR 15019.

6.2.2 Grout socks

Grout socks shall be specially formulated geo‐socks used as a grout retainer to prevent loss of grout. The

grout sock shall be designed to prevent grout bleeding through and shall expand and mould itself to the

shape of the void formed by the adjacent caisson nibs.

Sock fibres shall be robust and not susceptible to damage during installation. The socks shall be supplied in

a single length per void and no on site jointing or splicing is permitted.

The exact size of the sock shall be determined in accordance with the actual measured gap achieved

between the caissons.


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6.2.3 Stone fill to create platforms for return caissons

The stone used to create the platforms for the return caissons shall have the properties listed below. Except

where noted, all testing shall be done in accordance with BS 812 series of standards for the assessment of

aggregates.

Size, fines and uniformity

60 mm ≤ D50 ≤ 75 mm

D85/D15 ≤ 4

Percentage fines (<0.063 mm) < 5%

Density ‐ Ten density determinations shall be made, each determination being carried out on a different

randomly selected stone. The average density of quarry stone shall be at least 2 700 kg/m3 with 90% of the

stones having a density of at least 2 600 kg/m3.

Water Absorption ‐ Ten water absorption determinations shall be made, each determination being carried

out on a different randomly selected stone. The average water absorption of quarry stone shall be less than

2%, and the water absorption of nine of the individual stones less than 2.5%.

Strength and durability

The aggregate impact value (AIV) shall not be more than 30 % for standard test fraction.

The 10% fines aggregate crushing value (10%FV) shall be not less than 120 kN

The aggregate abrasion value (AAV) shall not be more than 15 %.

6.2.4 Stone fill between caissons

The stone fill between adjacent caissons shall have the same properties as those prescribed in 6.2.3, except

for the size, and uniformity which shall be:

19 mm <= D50 <=35 mm

D60/D10 <= 5

Percentage fines (<0.063 mm) < 5%

6.2.5 Grout

All grout shall comply with the requirements of SANS 2001‐CC1:2007 with particular reference to Sections

4.2.7 and 4.9.3.

6.2.6 Reclamation sand fill

The material for the sand filling of the caissons and for reclamation backfill between the caissons and the

existing quay wall is specified in specification 1370‐CO‐000‐C‐SPC ‐0004 – Dredging and reclamation

(Including Vibro Compaction).


6.3.1 Filling, grouting and sealing

Filling, grouting and sealing of the caissons shall proceed as soon as any caisson has been accepted by the

Supervisor in respect of its placement in position. The Contractor shall proceed with the operations in the

accordance with the following sequence:

a) Fit drainage strips and geo‐textiles over drain pipes openings

b) Install rear grout sock and fill with 1 – 13 mm graded stone.

c) Place filter fabric over land side joint between caissons

d) Place conveyor belt over inside face of seaside joint between caissons to prevent stone fill

penetrating into gap between caissons.

e) Fill main gap between caissons with approved 19 – 35 mm graded stone fill and cover with filter

fabric.

f) Place approved sand fill material into the caisson by grab or pumping whilst monitoring the flow of

displaced water at all times and ensuring that turbidity limits are not exceeded.

g) Complete placement of all caissons including return caissons and infill panels for a particular phase.


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h) Place backfill material for reclamation behind caisson to top of caisson level

i) Vibro‐compact caisson sand fill and back fill material.

j) Insert grout bag in front (seaward side) seal slot and inject grout

Grouting shall be carried out with a suitable tremie tube placed so that the grout is injected from the

bottom of the grout sock upwards under a controlled pressure in one continuous operation. Care shall be

taken to ensure that the injection pressures are not so high as to cause bursting of the grout sock. Grouting

shall be carried out in accordance with SANS 2001‐CC1 Section 4.9.3.

The Contractor shall undertake a diver inspection with underwater video of the joints between the caissons

over the full height to check integrity of grouted seal.

Construction and performance specifications for the filling and vibro‐compaction of the caisson sand fill and

reclamation fill behind the caisson are provided in specification 1370‐CO‐000‐C‐SPC‐0004 – Dredging and

reclamation (Including Vibro Compaction).

Drain pipes that penetrate through the caissons to discharge into the sea shall be sealed where they

penetrate the caisson walls and adequately protected from damage during backfilling.

The Contractor shall ensure that the various filter fabrics, drainage strips and grout socks are not damaged

during the placement of sand fill and stone fill. The Contractor shall ensure that stone and sand are not

dumped directly onto areas where filter fabric is attached to the walls of the caisson and is instead dumped

away from the walls such that the material falls naturally onto the walls to reduce impact damage.

6.3.2 Quay wall monitoring

The Contractor shall undertake monitoring of the caissons from time of placement until handover of the

berth. Monitoring shall be undertaken using two methods, the primary method being electronic

inclinometers and a secondary back up system being a surveyed baseline. Details of the proposed

monitoring system are to be submitted by the Contractor to the Supervisor for acceptance.

The inclinometer system shall consist of an articulated chain of sensor elements (segments). The segments,

each containing a multi‐axial accelerometer, shall be interconnected in such a manner that they can move

in relation to one another in all directions but shall not twist. The instrument shall be capable of following

and presenting deformation and tilt with a resolution of 0.01 mm per 500 mm in the direction

perpendicular to the quay wall. The accuracy, expressed as lateral deviation over a length of 30 m of casing

shall be 6.00 mm x 30 m. The inclinometers shall be calibrated with a calibration tool after installation.

The inclinometers shall be mounted in casings firmly attached to the caisson. The inclinometer chain shall

extend from the foundation level of the wall all the way up to the top of the caisson. The bottom end shall

serve as a fixed reference point. Inclinometers shall be installed on the front face of each caisson at the mid

wall.

The reading units that interrogate the sensors shall be housed in a central instrumentation room set up

within the Contractor’s on site offices. The data collected shall be processed on a PC using dedicated

software in accordance with manufacturer’s specification.

The instrumentation shall be capable of operating in temperatures ranging from 0°C to 50°C and shall be

capable of operating in the wet and the dry.

Data collation and submission to the Supervisor shall be on a daily basis during caisson placement and reclamation and then shall revert to a weekly basis during capping beam and paving construction.

In addition to the inclinometer monitoring, the Contractor shall also establish a surveyed baseline in the

form of steel pins inserted into the caissons along the entire length of the existing quay prior to any berth

dredging works. The Contractor shall, on a bi‐weekly basis, survey the baseline and shall compare the data

with that obtained from the inclinometers to verify the electronic system.


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7.0 PRECAST INFILL PANEL MANUFACTURE, LOAD OUT, TRANSIT AND POSITIONING



a) Layout of casting yard for infill panel manufacturing.

b) Details of formwork and casting beds for panel manufacturing.

c) Details of methodology and Equipment for transporting panels from casting bed to position of load

out.

d) Details of methodology and Equipment for load out of panels.

e) Details of methodology for sea fastening panels

f) Details of methodology and Equipment for towing of panels.

g) Details of methodology and Equipment for positioning of panels.

7.2 Materials

7.2.1 Reinforced Concrete

All concrete works for the panels shall be in accordance with Employer specification 1370‐CO‐000‐C‐SPC ‐

0001 – Concrete for Marine Construction.


The Lot 10 yard shall be used for construction of the precast infill panels for the caisson quay wall. The

Contractor shall be responsible for establishing all casting beds required for the infill panels.

Precast Infill Panel formwork shall comply with the provisions of specification 1370‐CO‐000‐C‐0001 –

Concrete for Marine Structures.

The Contractor shall provide all cranage and barges for lifting, transporting and placing infill panel units.

The Equipment for Lifting shall comply with the requirements of DNV‐OS‐H201, DNV‐OS‐H202 and DNV‐OS‐

H205.


The provisions of SANS 2001‐CC1:2007 Section 4.8 ‐ Precast Concrete and Section 4.10 Handling and

erection of precast concrete units shall apply

The infill panels shall be transported to site via a waterside operation. Landward transport of the units is

not permitted.

The loadout operation (transfer of infill panels from land onto a barge) shall be planned and undertaken in

accordance with DNV‐OS‐H201 with particular reference to Section 3.

The tow route shall be as per the route for the caissons as described above.

Towing shall be planned and undertaken in accordance with DNV‐OS‐H202 with particular reference to

Section 4 and 5.

Lifting and positioning operations shall be planned and undertaken in accordance with DNV‐OS‐H205.


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8.1 Tolerances

8.1.1 Caisson construction

Deviations shall be within the limits listed in SANS 2001‐CC1:2007 – Concrete works (structural) for Degree

of Accuracy II, specified in clause 6, unless stated otherwise.

The caisson base formwork shall be set out on the casting base platforms entirely level, to an accuracy of ±

10 mm over the longest dimension of the base.

Once the caisson is moved to the interim beams, the base shall be level to within the same tolerance.

The walls shall be cast by the sliding formwork entirely vertically and at right angles to the base. In

particular the sealing faces between caissons shall achieve an accuracy of ± 25 mm. The mating faces shall

be straight to a maximum deviation of 5 mm over any gauge length of 2 m, with a total deviation from

straightness of not more than 50 mm over the whole height.

Before a slide is started, reference points shall be established and verticality during sliding shall be

measured, using laser equipment. Measurements shall be taken before sunrise to minimise the effects of

thermal distortion of the slide and concrete.

8.1.2 Caisson placement

Caissons shall be placed to the following tolerances:

a) Gap between caisson mating faces 60 mm ± 50 mm

b) Deviation of front faces from theoretical straight line ± 75 mm

c) Verticality of front face maximum 100 mm at top from plumb line passing through corresponding

point at bottom over the full caisson height

d) Height compared to theoretical top elevation of +2 m CDP shall be ± 150 mm

e) In situ tolerances for adjacent caissons shall be such that mating surfaces for grout pockets remain

fit for purpose, i.e. tolerances shall not be cumulative between adjacent caissons, thus rendering the

grout pockets ineffective.

Note – Accumulation of tolerances with respect to dredging of foundation trench, placement of foundation stone

bed, caisson manufacturing and caisson placement is not permitted.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – COPE, SERVICE TUNNELS, QUAY FURNITURE AND SERVICES

1370‐CO‐000‐C‐SPC‐0003 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN



REVISIONS


BY

CHECKED

BY

APPROVED

BY

T‐00 31 May 2016 Issue for Review MC DC JZ

T‐0A 18 November 2016 Issue for Tender MC DC JZ

AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1


2.1 Reference Documents ..................................................................................................................................... 2 2.2 Standard Specifications ................................................................................................................................... 2

2.2.1 Concrete Capping Beams, Service Tunnels and Rear Crane Rail Beam ......................................... 2 2.2.2 Fenders .......................................................................................................................................... 2 2.2.3 Bollards .......................................................................................................................................... 3 2.2.4 Crane Rails ..................................................................................................................................... 3 2.2.5 Quay Furniture and Access Covers ................................................................................................ 3 2.2.6 Water............................................................................................................................................. 3 2.2.7 Sewer ............................................................................................................................................. 4 2.2.8 Stormwater Drainage .................................................................................................................... 4 2.2.9 Tunnel Dewatering ........................................................................................................................ 4 2.2.10 Electrical Cable Ducts .................................................................................................................... 4

2.3 Employer’s Project Specific Specifications and Standards .............................................................................. 4

3.0 DEFINITIONS ............................................................................................................................................ 5

3.1 Chart Datum Port ............................................................................................................................................ 5 3.2 Co‐ordinate System ......................................................................................................................................... 5 3.3 Tidal Levels ...................................................................................................................................................... 5 3.4 Method Statements ........................................................................................................................................ 5

4.0 CONCRETE CAPPING BEAMS, QUAYSIDE TUNNELS AND REAR CRANE RAIL BEAM ................................... 6

4.1 Materials ......................................................................................................................................................... 6

4.1.1 Concrete ........................................................................................................................................ 6 4.1.2 Cementitious Grout ....................................................................................................................... 6 4.1.3 Epoxy Seating Mortar .................................................................................................................... 6 4.1.4 Joints and Seals ............................................................................................................................. 6 4.1.5 Ducts Cast into Reinforced Concrete ............................................................................................. 7


4.2.1 Cope plank manufacturing, transport and lifting .......................................................................... 7 4.2.2 Caisson capping beam construction .............................................................................................. 8 4.2.3 Return quay cope beam construction ........................................................................................... 8 4.2.4 Joints ............................................................................................................................................. 9 4.2.5 Access manholes and cast‐in items ............................................................................................... 9

4.3 Compliance with Requirements ...................................................................................................................... 9

4.3.1 Tolerances ..................................................................................................................................... 9

5.0 FENDERS ................................................................................................................................................ 10

5.1 Standards and specifications ......................................................................................................................... 10 5.2 Design and performance criteria .................................................................................................................. 10 5.3 Materials ....................................................................................................................................................... 11

5.3.1 Rubber fender units .................................................................................................................... 11 5.3.2 Steel fender panels ...................................................................................................................... 11 5.3.3 Fender attachments .................................................................................................................... 11 5.3.4 Material testing and certification ................................................................................................ 11


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5.4 Installation .................................................................................................................................................... 12 5.5 Spare fenders ................................................................................................................................................ 12 5.6 Compliance with Requirements .................................................................................................................... 12

5.6.1 Tolerances ................................................................................................................................... 12 5.6.2 Testing ......................................................................................................................................... 12

6.0 BOLLARDS ............................................................................................................................................. 14

6.1 Design and Performance Criteria .................................................................................................................. 14 6.2 Materials ....................................................................................................................................................... 14 6.3 Installation .................................................................................................................................................... 14

6.3.1 Shipping and storage ................................................................................................................... 14 6.3.2 Holding down bolts and grouting ................................................................................................ 14 6.3.3 Protective Coating ....................................................................................................................... 15

6.4 Spare Bollards ............................................................................................................................................... 15 6.5 Testing and Records ...................................................................................................................................... 15

7.0 CRANE RAILS, SOLE PLATES AND RAIL CLIPS ........................................................................................... 16

7.1 General .......................................................................................................................................................... 16 7.2 Materials ....................................................................................................................................................... 16

7.2.1 Rails ............................................................................................................................................. 16 7.2.2 Pads ............................................................................................................................................. 16 7.2.3 Sole Plates and holding down bolts ............................................................................................. 16 7.2.4 Rail clips and studs/bolts ............................................................................................................. 16 7.2.5 Grout ........................................................................................................................................... 17

7.3 Installation .................................................................................................................................................... 17

7.3.1 General ........................................................................................................................................ 17 7.3.2 Sole plate holding down bolts ..................................................................................................... 17 7.3.3 Welding of crane rails .................................................................................................................. 17 7.3.4 Sole plate grouting ...................................................................................................................... 17

7.4 Compliance with Requirements .................................................................................................................... 17

7.4.1 Tolerances ................................................................................................................................... 17

8.0 MISCELLANEOUS QUAY FURNITURE AND ACCESS COVERS .................................................................... 18

8.1 Materials ....................................................................................................................................................... 18

8.1.1 General ........................................................................................................................................ 18 8.1.2 Mild Steel .................................................................................................................................... 18 8.1.3 Stainless steel .............................................................................................................................. 18 8.1.4 Ductile Cast Iron .......................................................................................................................... 18 8.1.5 Chemical Anchors ........................................................................................................................ 18 8.1.6 Access Covers .............................................................................................................................. 18

8.2 Fabrication and installation ........................................................................................................................... 19

9.0 SERVICES ............................................................................................................................................... 20

9.1 Water/Medium Pressure Pipelines ............................................................................................................... 20

9.1.1 Supporting Specification ............................................................................................................. 20 9.1.2 Materials ..................................................................................................................................... 20 9.1.3 Construction ................................................................................................................................ 21 9.1.4 Testing ......................................................................................................................................... 21


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9.2 Sewer ............................................................................................................................................................ 22

9.2.1 Supporting Specification ............................................................................................................. 22 9.2.2 Materials ..................................................................................................................................... 22 9.2.3 Plant ............................................................................................................................................ 23 9.2.4 Construction ................................................................................................................................ 23 9.2.5 Testing ......................................................................................................................................... 24

9.3 Stormwater Drainage .................................................................................................................................... 24

9.3.1 Supporting Specification ............................................................................................................. 24 9.3.2 Materials ..................................................................................................................................... 24 9.3.3 Construction ................................................................................................................................ 24

9.4 Tunnel Dewatering System ........................................................................................................................... 25

9.4.1 Plant and Materials ..................................................................................................................... 25

9.5 Electrical cable ducts ..................................................................................................................................... 25

9.5.1 Supporting Specification ............................................................................................................. 25 9.5.2 Materials ..................................................................................................................................... 25

10.0 REMEDIAL WORKS FOR EXISTING CAPPING BEAM AND SERVICE TUNNELS ............................................ 26

10.1 Scope ............................................................................................................................................................. 26 10.2 Materials ....................................................................................................................................................... 26 10.3 Construction .................................................................................................................................................. 26


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1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the cope, service tunnels, rear crane rail

beam, quay furniture and services, which includes the following:

Reinforced concrete cope including quayside service tunnels to caisson quay wall

Reinforced concrete cope to steel cellular caisson return quay

Connecting cross service tunnels and tunnel links

Remedial works to existing quayside cope and tunnels

Rear crane rail beam

Fenders, bollards and other quay furniture

Crane Rails

Water and sewer services

Storm water drainage

Cable ducting for electrical and communications infrastructure


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- 1370‐CO‐060 series of drawings – Caisson Quay Wall

- 1370‐CO‐070 series of drawings – Return Quay

- 1370‐CO‐090 series of drawings – Capping Beam and Service Tunnels

- 1370‐CO‐100 series of drawings – Rear Crane Rail Piles and Beam

- 1370‐CO‐110 series of drawings – Quay Furniture

- 1370‐CO‐120 series of drawings – Water Supply

- 1370‐CO‐130 series of drawings – Sewer

- 1370‐CO‐140 series of drawings – Electrical and C&I Infrastructure

- 1370‐CO‐150 series of drawings – Storm Water



2.2.1 Concrete Capping Beams, Service Tunnels and Rear Crane Rail Beam

All concrete works shall be in accordance with specification 1370‐CO‐000‐C‐SPC‐0001 – Concrete for Marine

Construction.

The following additional standard specifications are also referenced in this section of the specification:

a) COLTO – Standard Specifications for Road and Bridge Works for State Authorities, 1988

b) ASTM C1107 / C11 07M‐ 14a – Standard Specification for Packaged Dry, Hydraulic‐Cement Grout (Non‐

shrink)

c) DNV‐OS‐H201 – Load Transfer Operations, April 2012

d) DNV‐OS‐H202 – Sea Transport Operations, October 2015, VMO Standard Part 2‐2

e) DNV‐OS‐H203 – Transit and Positioning of Offshore Units, February 2012

f) SANS 2001‐CC1:2012 ‐ Concrete Works (structural)

g) SANS 967:2014 ‐ Unplasticized poly(vinyl chloride) (PVC‐U) soil, waste and vent pipes and pipe fittings.

2.2.2 Fenders

The governing specification for the design, supply and installation of the fender panels is PIANC – Report of Working

Group 33 ‐ Guidelines for the Design of Fenders Systems 2002.

The following standard specifications are also referenced in this section of the specification:

a) BS EN 10025:2004 ‐ Hot rolled products of structural steels

b) BS EN ISO 12944 ‐ Paints and varnishes. Corrosion protection of steel structures by protective paint

systems

c) ASTM 240/A 240M – 04a ‐ Standard Specification for Chromium and Chromium‐Nickel Stainless Steel

Plate, Sheet, and Strip for Pressure Vessels and for General Applications

d) ASTM A391/A391M‐07 ‐ Standard Specification for Grade 80 Alloy Steel Chain

e) BS EN ISO 1461:2009 Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and

test methods

f) PIANC – Report of Working Group 33 ‐ Guidelines for the Design of Fenders Systems 2002.


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2.2.3 Bollards

The following standard specifications are referenced in this section of the specification:

a) ASTM A536 ‐ 84(2014) Standard Specification for Ductile Iron Castings

b) BS 3692:2014 ‐ ISO metric precision hexagon bolts, screws and nuts. Specification

c) BS EN ISO 1461:2009 Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and

test methods

d) ASTM C1107 / C1107M – 14 a – Standard Specification for Packaged Dry, Hydraulic‐Cement Grout (Non‐

shrink).

e) BS EN ISO 12944 ‐ Paints and varnishes. Corrosion protection of steel structures by protective

paint systems.

2.2.4 Crane Rails


a) DIN536: 2:1991 ‐ Crane Rails

b) BS EN 10025‐2:2004 ‐ Hot rolled products of structural steels. Technical delivery conditions for non‐alloy

structural steels

c) BS 3692:2014 ‐ ISO metric precision hexagon bolts, screws and nuts. Specification

d) BS EN ISO 898‐1:2013 ‐ BS EN ISO 898‐1:2013 Mechanical properties of fasteners made of carbon steel

and alloy steel. Bolts, screws and studs with specified property classes. Coarse thread and fine pitch

thread

e) BS EN 13811:2003 Class 45 ‐ Sherardizing – Zinc diffusion coatings on ferrous products

f) BS EN 1563:2001 or ASTM A536

2.2.5 Quay Furniture and Access Covers


a) BS EN 10025:2004 ‐ Hot rolled products of structural steels.

b) BS EN 13811:2003 Class 45 ‐ Sherardizing – Zinc diffusion coatings on ferrous products

c) BS EN ISO 12944‐5:2007 ‐ Paints and varnishes. Corrosion protection of steel structures by

protective paint systems. Protective paint systems

d) ASTM 240/A 240M – 04a ‐ Standard Specification for Chromium and Chromium‐Nickel Stainless Steel

Plate, Sheet, and Strip for Pressure Vessels and for General Applications ASTM A536 ‐ 84(2014) Standard

Specification for Ductile Iron Castings

e) BS EN 1090‐2:2008+A1:2011 Execution of steel structures and aluminium structures. Technical

requirements for steel structures

f) AWS D1.1/D1.1M:2015, American Welding Society ‐ Structural Welding Code ‐ Steel

2.2.6 Water

The governing specification for the water services shall be SANS 1200L – Medium Pressure Pipelines.


a) SANS 1200 DB:1989 ‐ Earthworks (pipe trenches)

b) SANS 1200 LB:1983 ‐ Bedding (pipes)

c) ISO 4427:2007 ‐ Plastics piping systems

d) SANS 1835:2009 ‐ Ductile iron pipes, fittings, accessories and their joints, for use in high and low

pressure systems for potable and foul water

e) SANS 1217:2015 ‐ Internal and external organic coating protection for buried steel pipelines

f) SANS 1123:2015 ‐ Pipe flanges

g) BS EN 10025:2004 ‐ Hot rolled products of structural steels

h) BS EN 13811:2003 Class 45 ‐ Sherardizing – Zinc diffusion coatings on ferrous products

i) SANS 664:2011 ‐ Wedge gate and resilient seal valves for waterworks

j) SANS 1128‐1:2010 ‐ Firefighting equipment Part 1: Components of underground and above‐ground

hydrant systems


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k) ISO 4064‐1:2014 ‐ Water meters for cold potable water and hot water ‐‐ Part 1: Metrological and

technical requirements

l) SANS 10268‐2:2004 ‐ Welding of thermoplastics ‐ Welding processes Part 2: Electrofusion welding

2.2.7 Sewer

The governing specification for the sewer services shall be SANS 1200L – Medium Pressure Pipelines.


a) SANS 1200 LD:1982 ‐ Sewers

b) SANS 1200 DB:1989 ‐ Earthworks (pipe trenches)

c) SANS 1200 LB:1983 ‐ Bedding (pipes)

d) ISO 4427:2007 ‐ Plastics piping systems

e) SANS 1835:2009 ‐ Ductile iron pipes, fittings, accessories and their joints, for use in high and low

pressure systems for potable and foul water

f) SANS 1123:2015 ‐ Pipe flanges

g) BS EN 10025:2004 ‐ Hot rolled products of structural steels

h) BS EN 13811:2003 Class 45 ‐ Sherardizing – Zinc diffusion coatings on ferrous products

i) SANS 664:2011 ‐ Wedge gate and resilient seal valves for waterworks

j) ASTM 240/A 240M – 04a ‐ Standard Specification for Chromium and Chromium‐Nickel Stainless Steel

Plate, Sheet, and Strip for Pressure Vessels and for General Applications

k) SANS 10268‐2:2004 ‐ Welding of thermoplastics ‐ Welding processes Part 2: Electrofusion welding

2.2.8 Stormwater Drainage

The governing specification for the stormwater drainage shall be SANS 1200LE – Stormwater Drainage.


a) ASTM C‐923‐08(2013) ‐ Standard Specification for Resilient Connectors Between Reinforced Concrete

Manhole Structures, Pipes, and Laterals

2.2.9 Tunnel Dewatering


a) ISO 4427:2007 ‐ Plastics piping systems

b) BS EN 10025:2004 ‐ Hot rolled products of structural steels

c) BS EN 13811:2003 Class 45 ‐ Sherardizing – Zinc diffusion coatings on ferrous products

2.2.10 Electrical Cable Ducts

The governing specification for the electrical cable ducts shall be SANS 1200LC – Cable Ducts.


a) SANS 61386‐24:2005 / IEC 61386‐24:2004 ‐ Particular requirements ‐ Conduit systems buried

underground




b) 1370‐CO‐000‐C‐SPC‐0002 – Caisson Construction and Placement

c) 1370‐CO‐000‐C‐SPC‐0007 – Paving

d) 1370‐CO‐000‐C‐SPC‐0009 – Steel Sheet Piling

e) Environmental Management Plan (EMP)


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3.0 DEFINITIONS



Where the standard specifications referenced in this specification refer the “Engineer”, replace this term with the


For the purpose of this specification, the following definitions shall apply:






LO31, referred to as WG31.

3.3 Tidal Levels






Mean Level ML 1.097




Method statements shall be compiled by the Contractor for all activities. The method statements shall be submitted




Further details of the requirements of particular method statements are provided in Sections 4 to 10.


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4.0 CONCRETE CAPPING BEAMS, QUAYSIDE TUNNELS AND REAR CRANE RAIL BEAM

4.1 Materials

4.1.1 Concrete

All concrete shall be in accordance with specification 1370‐CO‐000‐C‐SPC ‐0001 – Concrete for Marine Construction,

as required to ensure durability in a marine environment

4.1.2 Cementitious Grout

Cementitious grout shall be in accordance with ASTM C1107 / C1107M ‐ 14a ‐ Standard Specification for Packaged

Dry, Hydraulic‐Cement Grout (Non‐shrink).

4.1.3 Epoxy Seating Mortar

The epoxy shall be a high strength, flowable, self‐levelling epoxy grout designed for applications such as machine

bases and bridge bearing pads. The grout shall be solvent free, amine cured, flowable epoxy comprising a resin

hardener system and pre‐packed aggregates applied in accordance with the manufacturers recommendations, The

mortar shall have a compressive strength of 45 MPa in seven days and be resistant to aliphatic solvents, oils, petrol,

diesel fuel, and chemical attack.

4.1.4 Joints and Seals

4.1.4.1 General

4.1.4.1.1 All materials used in forming, constructing and sealing permanent joints shall be subject to the

acceptance of the Supervisor.

4.1.4.1.2 The Contractor shall submit test certificates issued by an approved, independent testing authority to

confirm that the respective materials comply with the specified requirements, or a certificate by the

patent holder or supplier certifying that manufactured item or material complies in all respects with the

relevant product specifications.

4.1.4.2 Joint Filler

4.1.4.2.1 Joint filler shall consist of sheets or strips of rigid forms of expanded polyethylene, polyurethane or

polystyrene complying with BS 4840 or BS 3837. Wherever polystyrene or similar material susceptible to

damage is used for forming joints, it shall be lined with 6mm hardboard on the side to be concreted. The

hard surface shall be sufficiently resilient, to ensure that the joint and surfaces can be formed free of

defects.

4.1.4.3 Sealants

4.1.4.3.1 Thermosetting chemically curing sealant shall comply with the requirements of ASTM C.920 or BS 4254.

The final BRHD hardness of the sealant shall be 20 ± 5.

4.1.4.3.2 Preformed elastomeric compression seals shall comply with the requirements of SABS 1023. The seals

shall be manufactured in accordance with an extrusion process from elastomeric material consisting

entirely of polychloroprene which is subsequently vulcanised.

4.1.4.3.3 Silicone Sealant shall be a one component material. The silicone sealant shall be a one‐component

material with low‐modulus properties which comply with the following requirements:

Tensile stress at 150% expansion determined in accordance with ASTM D 412 (Matrix C) after

seven days curing at 23°C ± 2°C: ‐ 0,31 MPa max

Extrusion rate, tested with a pneumatic caulking gun with a 3,18 mm nozzle at a pressure of

0,62 MPa:

- Material temperature ‐ 18°C: min 75 g/min

- Material temperature ‐ 38°C: max 250 g/min

Relative density determined in accordance with ASTM D 794 Method A: 1,01 to 1,515

Durometer hardness deter‐mined in accordance with ASTM D 2240 at ‐18°C after 7 days'

curing at 23°C ± 2°C and relative humidity 50% ± 5%: 8 ‐ 20 Shore A


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Shelf life: at least 6 months after manufacture

Ozone and UV resistance determined in accordance with ASTM D 793‐75: no pulverisation,

cracking or loss of bond after 5 000 hours

Adhesion to cement‐mortar briquettes determined in accordance with COLTO clause 8113:

0,34 MPa min

Non‐adhesion period determined in accordance with COLTO clause 8113: max 90 min

Deformation capability and adhesion in accordance with COLTO clause 8113: no adhesion or

cohesion after 10 cycles at ‐18°C

Colour: Grey

4.1.4.4 Waterstops

4.1.4.4.1 Waterstops shall be of extruded, plasticized, flexible PVC and of the type specified or shown on the

drawings and shall have an elongation at break of 300%.

4.1.4.4.2 Flexible rubber waterstops shall comply with the requirements of CKS 389.

4.1.4.5 Bond Breakers

4.1.4.5.1 Polyethylene tape, coated paper, metal foil or similar material may be used where bond breakers are

required.

4.1.5 Ducts Cast into Reinforced Concrete

4.1.5.1 Duct pipes shall be manufactured from unplasticised polyvinyl chloride (uPVC) and shall comply with the

following:

Ducts up to 200 mm SANS 967

Ducts 200 mm and larger SANS 966 class 4


4.2.1 Cope plank manufacturing, transport and lifting

4.2.1.1 The Lot 10 yard shall be used for construction of the precast cope panels. The Contractor shall be

responsible for establishing all casting beds required for the casting of the cope panels.

4.2.1.2 Precast cope panel formwork shall comply with the provisions of specification 1370‐CO‐000‐C‐0001 –

Concrete for Marine Structures.

4.2.1.3 The Contractor shall provide all cranage and barges for lifting, transporting and placing cope panel units.

4.2.1.4 The Equipment for shall comply with the requirements of DNV‐OS‐H201, H202 and H205.

4.2.1.5 The provisions of SANS 2001‐CC1:2012 Section 4.8 ‐ Precast Concrete and Section 4.10 Handling and

erection of precast concrete units shall apply

4.2.1.6 The infill panels shall be transported to site via a waterside operation. Landward transport of the units is

not permitted.

4.2.1.7 The loadout operation (transfer of infill panels from land onto a barge) shall be planned and undertaken

in accordance with DNV‐OS‐H201 with particular reference to Section 3.

4.2.1.8 The tow route shall be as per the route for the caissons as described in specification 1370‐CO‐000‐C‐SPC‐

0002 – Caisson Construction and Placement.

4.2.1.9 Towing shall be planned and undertaken in accordance with DNV‐OS‐H202 with particular reference to

Section 4 and 5.

4.2.1.10 Lifting and positioning operations shall be planned and undertaken in accordance with DNV‐OS‐H205.


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4.2.2 Caisson capping beam construction

4.2.2.1 All activities relating to the capping beam and service tunnel construction shall only be undertaken once

the compaction of the caisson fill and reclamation fill material in the area has been completed and has

passed the performance test such that the fill material provides adequate support and that settlement of

the fill during compaction does not damage the superstructure or the services.

4.2.2.2 All works for the capping beam construction shall be done in accordance with specification 1370‐CO‐000‐

C‐SPC‐0001 ‐ Concrete for Marine Structures.

4.2.2.3 Prior to placing the cope planks, the Contractor shall cast an in situ levelling slab to take up any

differences in level associated with caisson placement tolerances to ensure the cope planks are set at the

defined design level. The thickness of the levelling slab will vary depending on the final placed level of the

caisson after settlement due to backfill has occurred. If the level is such that the thickness of the slab is

less than 50 mm, the levelling slab shall be made from cementitious non‐shrink grout. For thickness

greater than 50 mm, the slab shall be 45 MPa mass concrete.

4.2.2.4 Prior to constructing the levelling slab, the top of the caisson walls shall be chipped back to expose the

aggregate and leave a sound irregular surface. The surface shall be treated with a wet to dry epoxy prior

to casting.

4.2.2.5 The levelling slab shall be recessed as shown on the drawings to allow for the seating of the precast cope

planks.

4.2.2.6 To accommodate possible soffit irregularities in the precast cope plank, the cope plank shall be lowered

onto a layer of seating epoxy. The cope plank shall be propped until the epoxy has hardened into a

wedge.

4.2.2.7 The Contractor shall design and install temporary supports for the cope planks which shall be designed to

support the weight of the cope plank until the cope plank has become integral with the in situ capping

beam after the 2nd capping beam in situ cast. The Contractor shall remove the temporary supports after

the 2nd in situ cast and shall make good with an approved epoxy mortar all attachment points.

4.2.2.8 The in‐situ capping beam shall be cast in 3 layers, with horizontal construction joints as shown on the

drawing.

4.2.2.9 The Contractor shall determine the position of the vertical construction joints in the capping beam to suit

his construction sequence and pour sizes. The vertical construction joints shall not be located at cope

plank joints.

4.2.2.10 Vertical and horizontal construction joints in the capping beam and service tunnels shall be formed in

accordance with section 4.7.12.1 of SANS 2001‐CC1:2012.

4.2.3 Return quay cope beam construction

4.2.3.1 The cope beam to the top of the steel sheet piles of the return quay shall only be constructed once

dredging in front of the cope has taken place. The cope beam shall follow the deformed shape of the steel

piles.

4.2.3.2 All works for the capping beam construction shall be done in accordance with specification 1370‐CO‐000‐

C‐SPC‐0001 ‐ Concrete for Marine Structures.

4.2.3.3 The cope beam shall be cast in situ.

4.2.3.4 The formwork for the in situ cope beam shall be water tight. Prior to casting, the interior of the forms

shall be dewatered of all seawater by pumping. The interior shall then be filled and flushed with fresh

water which shall then also be removed by pumping prior to placing concrete.

4.2.3.5 The in situ cope beam shall be cast in single layers without horizontal construction joints.

4.2.3.6 The Contractor shall determine the position of the vertical construction joints in the cope beam to suit his

construction sequence and pour sizes.

4.2.3.7 Vertical joints in the cope beam shall be formed in accordance with section 4.7.12.1 of SANS 2001‐

CC1:2012.


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4.2.4 Joints

4.2.4.1 Waterstops and seals shall be cast‐in in strict accordance with the supplier’s installation specification.

4.2.4.2 Waterstops are to be fully tied to the re‐bar to eliminate possible displacement during the concreting and

vibrating process. Waterstops shall be clipped to the reinforcing and not punched to ensure that the

material does not tear during concreting.

4.2.4.3 The concrete around the waterstops shall be carefully and thoroughly compacted in order to eliminate

any voids or honeycombing in that area.

4.2.4.4 The Contractor shall provide sufficient support to the waterstops to ensure that they remain stable and

do not fold during concreting works.

4.2.4.5 Any waterstop found to be leaking will be declared a defect and the Contractor shall repair the defect in

accordance with the Contract.

4.2.5 Access manholes and cast‐in items

4.2.5.1 The following items are to be cast‐in during cope plank, capping beam and service tunnel construction.

Material and fabrication details of the cast‐in items are provided in section 5.0, 6.0, 7.0 and 8.0 and on

the 1370‐CO‐090, 1370‐CO‐100, and 1370‐CO‐110 series of drawings:

Pipe Slot, cable slot and access manhole frames

Wharf ladder anchor sockets

Bollards holding down bolts

Fender anchor sockets

STS crane tie‐down anchors

STS crane storm pin anchors

Electrical manhole frames

Water / fire hydrant manhole frames

STS crane turn over funnels

Sole plate holding down bolts

4.2.5.2 Cast‐in items shall be sufficiently secured such that they are not displaced during concrete placement and

vibration. If stainless steel bolts or cast‐in items make contact with other dissimilar metals (including

reinforcement), they shall be electrically insulated to prevent bi‐metallic corrosion.

4.3 Compliance with Requirements

4.3.1 Tolerances

4.3.1.1 Deviations shall be within the limits listed in Table 11 of SANS 2001‐CC1 for Degree of Accuracy II, unless

stated otherwise on drawings or elsewhere in the Works Information.

4.3.1.2 Crane rail recesses and cast‐in anchors for STS cranes shall be Degree of Accuracy I.


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5.0 FENDERS

5.1 Standards and specifications

5.1.1 The governing specification for the design, supply and installation of the fender panels is PIANC – Report of

Working Group 33 ‐ Guidelines for the Design of Fenders Systems 2002.

5.2 Design and performance criteria

5.2.1 Fenders shall be designed and supplied by a reputable manufacturer able to demonstrate a

satisfactory supply record over a number of years for the type of fender being proposed.

5.2.2 The fenders shall be able to absorb the required berthing energy (namely largest energy stipulated) under

the combinations of direct and angular compression indicated below.

5.2.3 The fenders shall have a design life of 20 years with a factor of safety for abnormal berthing = 2.0.

5.2.4 The fenders shall be designed for the following design vessel:

Design ship New Panamax – Partial laden

Displacement 190,000 m³

Bow flare radius 160 m @ 14.5 m draft

Overall length 366 m

Beam 51.2 m

Draft 14.5 m (partially laden 11,000 TEU)

The fenders are not required to be designed for belted vessels

5.2.5 Berthing requirements

Berthing speed 0.15 m/s

Maximum design berthing angle 10°

Permissible hull pressure 200 kPa

Maximum quay reaction limit 250 tonnes

Quay type ‐ Caisson type with composite precast and in situ cope reinforced concrete beam

5.2.6 Fenders shall be cylindrical or cone shaped rubber fenders with steel fender panel. V‐Shaped fenders are

not permissible.

5.2.7 The fender position and panel size shall be as follows:

The level of the top of the fender shall be at least as high as the top of the coping (+4.25 m CDP) and

the level of the bottom of the fender shall be at least as low as the bottom of the coping or at ‐0.5 m

CDP, whichever is the lower.

Maximum fender projection – 2,000 mm

5.2.8 The steel fender panels shall be stiffened closed box panels, structurally designed by appropriately qualified

structural engineers to accepted Codes of Practice. Panels shall be structured with suitable stiffening

members. It shall be appropriately designed to resist the reaction forces imposed by the fender and its

supporting chains (if any), and keep in equilibrium with the vessel berthing force.

5.2.9 The steel panels shall be sized to exert a hull pressure not more than 200 kPa. It shall be located to

accommodate all possible contact elevations of the various vessels, intending to use the facility, under the

given geometry of tidal levels and quay structure.

5.2.10 Panels shall have a minimum overall depth of not less than 300 mm and shall be sealed and pressure

tested. Plate thickness shall not be less than 10 mm for all external plates and 8 mm for internal stiffening

plates. All panel edges shall be chamfered.


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5.3 Materials

5.3.1 Rubber fender units

5.3.1.1 Rubber fender units shall be compression moulded from natural or synthetic or both rubber compounds

in compliance with Appendix A of “Procedure to Determine and Report the Performance of Marine

Fenders”, Section 7.3 of PIANC “Guidelines for the Design of Fenders Systems 2002: Report of Working

Group 33”.

5.3.1.2 The rubber shall be fully vulcanised and homogeneous with no foreign particles, and free from voids,

cracks and cuts. Steel plates shall be fully embedded and fully adhered to the rubber during the

vulcanisation process to avoid separation between the rubber and the steel.

5.3.1.3 The rubber compound of the fenders shall comply with the specifications stipulated in the Table 5.1.

5.3.1.4 Rubber fenders shall be tested in accordance with the requirements of Appendix A of the PIANC

guideline.

5.3.2 Steel fender panels

5.3.2.1 Fender panels shall be fabricated from mild steel supplied in accordance with EN 10025 Grade S355J2 or

S355J0.

5.3.2.2 Structural steel panels shall be corrosion protected with C5M‐J class paint systems in accordance with ISO

12944 or approved equal.

5.3.3 Fender attachments

5.3.3.1 Panel facings

5.3.3.1.1 Low friction pads materials shall be of synthetic resin, such as Ultra High Molecular Weight Polyethylene

(UHMW‐PE) having a thickness of at least 50 mm.

5.3.3.1.2 Edge pads shall be chamfered to match the chamfered panels, and pads planed to ensure that there are

no steps in excess of 1 mm between pads.

5.3.3.1.3 Panel facings are to be fixed to the steel panels using stainless steel studs or bolts of at least 20 mm

diameter.

5.3.3.2 Bolts and fixings

5.3.3.2.1 All anchor sockets, bolts, nuts and washers shall be stainless steel UNS Designation S31603 (Type 316L) to

ASTM 240/A 240M – 04a or such other stainless steel having an equivalent or higher Pitting Resistance

Equivalent Number (PREN).

5.3.3.2.2 Thread clearances and lubrication shall be used to avoid galling of threads.

5.3.3.3 Chains attachments

5.3.3.3.1 If necessary, fender restraint chains shall be provided for vertical and lateral restraint.

5.3.3.3.2 The chains shall be Grade 80 Alloy Chain in accordance with ASTM A391/A391M‐07 and shall be supplied

hot dip galvanised to BS EN ISO 1461.

5.3.4 Material testing and certification

5.3.4.1 The fender manufacturer shall supply:

Quality certificate of ISO 9002 or equivalent.

Supply history of the offered fenders.

Type Approval Testing and Verification Testing Reports and Certification in accordance with PIANC –

Guidelines for Design of Fender Systems: 2002: Appendix A. Testing reports with fender

performance curves, clearly specifying the Rated Performance Data (RPD), shall be supplied for each

different fender type/size at the time of delivery. Verification testing of fender performance and

rubber material properties are to be third party witnessed.


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Rubber properties certificate ‐ Physical properties of rubber certificate shall be supplied at the time

of delivery

Mill certificate for steel attachments ‐ A mill certificate for steel panels, chains and bolts should be

supplied at the time of delivery in accordance with ASTM 240.

Certification of corrosion protection in accordance with ISO 12944.

5.4 Installation

5.4.1 Concrete embedments, including anchor bolts, anchor bolt inserts and chain anchors, shall be no closer

than 250 mm to the edge of the concrete. If stainless steel bolts or fender anchors make contact with other

dissimilar metals, they shall be electrically insulated to prevent bi‐metallic corrosion.

5.4.2 Comprehensive shipping, handling, storage, and installation procedures shall be prepared and submitted to

the Supervisor for review and approval and shall be in strict accordance with the manufacturer’s

instructions.

5.5 Spare fenders

5.5.1 In addition to the fenders to be installed, the Contractor shall supply two additional sets of fenders

complete with all components, chains, fixings and anchorages. Spare fenders are to be delivered to the

Employer’s store.


5.6.1 Tolerances

5.6.1.1 The fenders shall be installed within 20 mm, vertically and horizontally of the prescribed position. The

individual anchor sockets shall be precision installed relative to one another to permit the fixing of bolts

without stressing or distortion of the fender attachment.

5.6.2 Testing

5.6.3 Factory testing and certification of the fenders is covered in section 5.3. No further site tests are required

for the fenders.


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Table 5.1

Property Testing Standard Condition Requirement

Tensile strength ASTM D412 Die C; S 180.2; BS

903.A2; ISO 37; JIS K6301 Item 3,

Dumbell 3

Original 16 MPa (Min)

Aged for 96 hours at

70oC

12.8 MPa (Min)

DIN 53504 Original 15 N/mm2 (Min)


70oC

12.75 N/mm2 (Min)

Elongation at break ASTM D412 Die C; BS 903.A2; ISO

37; JIS K6301 Item 3, Dumbell 3

Original 400% (Min)


70oC

320% (Min)

DIN 53504

Original 300% (Min)


70oC

280% (Min)

Hardness ASTM D2240; BS 903.A6; ISO 815;

JIS K6301 Item 5A Tester

Original 78o (Max) Shore A


70oC

Original Value + 6o

points increase

DIN 53505 Original 75o (Max) Shore A


70oC Original Value + 5o

points increase

Compression set ASTM D395; BS 903.A6; ISO 815; JIS

K6301 Item 10

Aged for 22 hours at 70o 30% (Max)

DIN 53517 Aged for 24 hours at 70o 40% (Max)

Tear resistance ASTM D624; BS 903.A3: ISO 34.1;

JIS K6301 Item 9, Test Piece A

Die B 70 kN/m (Min)

DIN 53507 80 N/cm (Min)

Ozone resistance ASTM D1149; BS 903.A43; DIN

53509; ISO 143/1

1 ppm at 20% strain at

40oC for 100 hours

No cracking visible by

eye

Seawater resistance DIN 86076, Section 7.7 28 days in artificial

seawater at 95oC 2oC Hardness 10o (Max)

Shore A

Volume + 10/‐5%

(Max)

Abrasion resistance BS 903.A9 Method B, 1000

revolutions

0.5 cc (Max)

DIN 53516 100 mm3 (Max)

Bond strength steel to

rubber

BS 903.A21 Method B 7 N/mm (Min)


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6.0 BOLLARDS

6.1 Design and Performance Criteria

6.1.1 Bollards shall be designed and supplied by a reputable manufacturer able to demonstrate a satisfactory

supply record over a number of years for the type of bollard being proposed.

6.1.2 The Contractor shall supply bollards of new material produced by an approved and authorised

manufacturer. The Contractor shall submit for review and acceptance by the Supervisor, all the

manufacturer’s catalogue data and information, for the proposed type of bollards.

6.1.3 Bollards shall be new Double T‐head 300 tonne cast steel bollard as shown on the drawing 1370‐CO‐110‐C‐

DWG‐003‐01.

6.1.4 Bollards shall have a designated load capacity of 300 tonnes in the direction of ‐10° to +70° in the vertical

plane and 0° to 160° in the horizontal plane.

6.1.5 Each bit shall have a designated load capacity of 150 tonnes.

6.1.6 The theoretical point of loading for the line pull shall be the intersection of the bollard vertical axis

centreline and the horizontal axis running through the centre of the horns.

6.1.7 The bollard shall include a full set of anchor bolts and their accessories, supplied by the bollard

manufacturer.

6.1.8 Bollards shall be designed with a minimum factor of safety against failure of 3.0 for Spheroidal Graphite

Cast‐Iron Grade 65‐45‐12.

6.1.9 Holding down bolts shall also be designed with a minimum factor of safety of 3.0.

6.1.10 The supplied bollards shall include all test certificates issued by a specialised laboratory for their compliance

with the performance and standards. Approval by the Supervisor shall not, in any manner, relieve the

Contractor from full responsibility for the bollard’s performance and quality as specified.

6.2 Materials

6.2.1 Bollard material shall be stress‐relieved ductile cast iron (spheroidal graphite) conforming to ASTM A536

Grade 65/45/12.

6.2.2 Holding down bolts shall be Gr. 8.8 to BS 3692, hot dip galvanised to BS EN ISO 1461.

6.2.3 Mill test reports shall be submitted to the Supervisor certifying that materials meet the specified standards.

6.2.4 Grout used around base of bollard shall have a minimum 40 MPa compressive stress and a maximum

aggregate size of 10 mm and shall be in accordance with ASTM C1107 / C1107M ‐ 14a ‐ Standard

Specification for Packaged Dry, Hydraulic‐Cement Grout (Non‐shrink).

6.3 Installation

6.3.1 Shipping and storage

6.3.1.1 The bollards, with all anchor bolts and accessories, shall be stored neatly and in orderly manner, at the

storage areas. The anchor bolts and their accessories shall be stored in boxes.

6.3.2 Holding down bolts and grouting

6.3.2.1 Holding down bolts are to be supplied by the bollard manufacturer to ensure proper fit.

6.3.2.2 The Contractor shall prepare templates with the exact location of the anchor bolts according to the type

and size of the bollard. The anchor bolts shall be fixed in their location in the forms with the assistance of

the template.

6.3.2.3 The anchor bolts shall be perpendicular to the top plan of the forms and shall be tied to them in such a

manner that they shall not move from their place during all the casting procedure. The anchor bolts shall

not be tied to the cope beam reinforcement.


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6.3.2.4 After the casting‐in of the anchor bolts they have to be protected until the installation of the bollards.

6.3.2.5 Bollard bases shall be levelled on top of a grout bed. Nuts shall be hand tight before grouting of base.

6.3.2.6 After grouting has cured for seven days, nuts shall be tightened using full manual effort with a 1 m long

spanner extension to approximately 200 Nm.

6.3.2.7 Areas around nuts in bollard base shall be filled with a non‐shrink grout so as to prevent standing water.

6.3.2.8 To prevent damage to vessel mooring lines, no sharp edges around bolting area shall exist after

installation.

6.3.3 Protective Coating

6.3.3.1 The bollards shall receive a protective coating system that shall protect the bollards against marine, highly

corrosive environment class C5M in accordance with ISO 12944‐5.

6.3.3.2 The paint system shall be A5M.06 or A5M.07 to BS EN ISO 12944‐5:2007 with coats and dry film thickness

as shown below in Table 6.1.

6.3.3.3 The surface preparation, primer coat and intermediate coat shall be applied in the factory. The final/top

coat shall be applied on site after bollard installation.

6.3.3.4 The top coat shall be colour ‘Safety Yellow’ (BS5252 Code – 08 E 51).

6.3.3.5 Any exposed nuts are to be wrapped in DENSO tape or similar approved corrosion protection measure.

Table 6.1 – Bollard Coating System

Application System Dry Film Thickness

(DFT)( μm)

Surface Preparation

Abrasive Blasting

Degree of cleanliness – Sa 2 ½ to ISO 8501‐1

Roughness – Grade Medium G (50μm to 75μm) to ISO 8503

Primer Coat 1 Coat of two‐component zinc rich epoxy primer ≥ 80

Intermediate Coat 2 Coats of two‐component polyamide adduct‐cured

epoxy paint ≥ 220

Top Coat 1 Coat of two‐component, polyurethane top coat ≥ 20

6.4 Spare Bollards

6.4.1 In addition to the bollards to be installed, the Contractor shall supply two additional sets of bollards

complete with all anchorages. Spare bollards are to be delivered to the Employer’s store.

6.5 Testing and Records

6.5.1 The bollards shall be supplied with the following documentation pack:

Drawings of the bollard and associated anchors with installation details

Engineering calculations and analysis demonstrating load capacity

Installation procedure

Chemical analysis test reports and certificates

Mechanical test reports and certificates

Dimensional as‐built reports

Coating test reports and certificates


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7.0 CRANE RAILS, SOLE PLATES AND RAIL CLIPS

7.1 General

7.1.1 The crane rails and rail clips shall be sourced from a reputable manufacturer able to demonstrate a

satisfactory supply record over a number of years for the type of rail and rail clips proposed.

7.2 Materials

7.2.1 Rails

7.2.1.1 Rails shall comply with the relevant sections of the specification or standard to which they are made, e.g.

British crane and bridge rails to CES2: 1987, German A section rails to DIN536: 2:1991.

7.2.1.2 Rails shall be from the same rolling to obviate difference in height. Particular care shall be taken to ensure

the ends are straight as this has an impact on the ease and efficiency of welding. Rails shall be free from

all paint, oil, grease, dirt, loose rust and loose mill scale.

7.2.1.3 Existing A150 rails installed during the Durban Crane Acceleration project (approximately 1440 m) are to

be reused. The Contractor shall remove the existing rail and shall be responsible for storing the rails for

reincorporation in the works. Existing welds are to be tested in accordance with provisions of specification

1370‐CO‐000‐SPC‐0005 and if found to be defective, the rail is to be cut into original lengths, re‐welded

and re‐tested.

7.2.2 Pads

7.2.2.1 The type of resilient pad to be used shall be a reinforced resilient pad for continuously supported rails,

such as Gantrex MK6 pad or approved equal.

7.2.2.2 The width of the pad shall be nominally 5 mm less than the bottom flange width of the rail.

7.2.3 Sole Plates and holding down bolts

7.2.3.1 Steel soleplates shall be Grade S355JR to BS EN 10025‐2:2004.

7.2.3.2 Holding down bolts shall be Grade 8.8 to BS 3692:2014 and BS EN ISO 898‐1:2013

7.2.3.3 All steelwork shall be free from paint, oil, grease, dirt, loose rust, loose mill scale and sharp burrs.

7.2.3.4 Sole plates and holding down bolts shall be coated with a zinc coating applied by thermo‐diffusion coating

(Sherardizing) in accordance with BS EN 13811:2003 Class 45. Sherardizing shall take place after

fabrication of the complete element.

7.2.4 Rail clips and studs/bolts

7.2.4.1 Rail clips shall be adjustable rubber nosed boltable crane rail clips with self‐locking cam or similar and

shall be used in accordance with the supplier's recommendations.

7.2.4.2 The components shall be of the following material:

Self‐locking Cam Ductile cast iron to BS EN 1563:2011 or ASTM A536

Clip Ductile cast iron to BS EN 1563:2011 or ASTM A536

Stud/bolt Grade 8.8 to BS 3692:2014 and BS EN ISO 898‐1:2013

Pressure Block (Nose) Synthetic Rubber

7.2.4.3 Rail clips, bolts and studs shall be coated with a zinc coating applied by thermo‐diffusion coating

(Sherardizing) in accordance with BS EN 13811:2003 Class 45.


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7.2.5 Grout

7.2.5.1 The grout to the underside of the sole plates shall be flowable epoxy grout – Type Gantrex K3 or similar

approved.

7.2.5.2 The epoxy shall be a high strength, self‐levelling, epoxy grout designed specifically for precision grouting

of crane runway systems.

7.2.5.3 The grout shall be solvent free, amine cured, comprising a resin hardener system and pre‐packed

aggregates applied in accordance with the manufacturer’s recommendations.

7.2.5.4 The mortar shall have a compressive strength of 85 MPa in seven days and be resistant to aliphatic

solvents, oils, petrol, diesel fuel, and chemical attack.

7.3 Installation

7.3.1 General

7.3.1.1 The installation of the holding down bolts, sole plate, rail pad, crane rail, rail clips and sole plate grouting

shall all be undertaken in strict accordance with the Supplier’s recommendations and specifications.

7.3.1.2 The installation sequence shall be:

Cast‐in sole plate holding down bolts.

Install sole plate to level and bolt down

Install, fasten and align crane rail including crane rail welding

Grout sole plate

7.3.2 Sole plate holding down bolts

7.3.2.1 Sole plate installation shall be in accordance with the Supplier’s recommendations.

7.3.2.2 The Contractor shall cast in the sole plate holding down bolts during capping beam (seaside) and crane rail

beam (landside) construction.

7.3.2.3 The Contractor shall use a template during casting‐in of the bolts to ensure the bolts are cast in to

tolerance. No onsite cutting/slotting of bolt holes in the sole plate will be permitted if holding down bolts

are incorrectly cast‐in.

7.3.2.4 The anchor bolts shall not be tied to the crane rail beam reinforcement.

7.3.3 Welding of crane rails

7.3.3.1 Details of the crane rail welding requirements are covered under specification 1370‐CO‐000‐C‐SPC‐0005.

7.3.4 Sole plate grouting

7.3.4.1 Epoxy shall be poured from one side of the sole plate until the epoxy level rises above the sole plate

invert on the opposite side.

7.3.4.2 Voids under the sole plate are to be avoided.


7.4.1 Tolerances

7.4.2 The Contractor shall supply and install Ship‐To‐Shore (STS) crane rails, clips and accessories in accordance

with the STS Crane requirements and tolerances as shown on the drawings. An acceptance survey will be

carried out before handover of any rails.


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8.0 MISCELLANEOUS QUAY FURNITURE AND ACCESS COVERS

8.1 Materials

8.1.1 General

8.1.1.1 The required material types and corrosion protection for the various quay furniture and fixture items are

shown in Table 8.1.

Table 8.1

Item Material Corrosion Protection

Access manhole frames and covers Ductile Cast Iron ‐

Access Ladders Stainless Steel ‐

STS Tie‐Down Anchors Mild Steel Thermal Diffused

STS Storm Pin Anchors Mild Steel Thermal Diffused

STS Crane Turn‐over Funnels Stainless Steel ‐

STS Crane Cable protector Mild Steel Thermal Diffused & Painted

8.1.2 Mild Steel

8.1.2.1 Where mild steel is specified for quay furniture, fixtures and fittings, it shall be S355JR in accordance with

BS EN 10025 unless otherwise shown on the drawings.

8.1.2.2 All mild steel elements shall be coated with a zinc coating applied by thermo‐diffusion coating



8.1.2.3 Where painting is specified, the painting system shall be A7.13 to BS EN ISO 12944‐5:2007 Table A.7 –

Epoxy primer + Epoxy, Polyurethane.

8.1.3 Stainless steel

8.1.3.1 Where stainless steel is specified for quay furniture, fixtures and fittings, it shall be Type 316L to ASTM

240/A 240M – 04a.

8.1.4 Ductile Cast Iron

8.1.4.1 Where ductile cast iron /spheroidal graphite is specified for quay furniture, fixtures and fittings, it shall be

Grade 65/45/12 to ASTM A536 – 84 (2014) or equivalent grade to BS EN 1563:2011.

8.1.5 Chemical Anchors

8.1.5.1 All anchors shall be Hilti‐HSL3 Heavy Duty Anchors or similar approved.

8.1.6 Access Covers

8.1.6.1 All access covers are to be proprietary heavy duty covers designed specifically for container yards with

wheels loads in excess of 20 tonnes – ‘Gatic Type F900 – DMR recessed’ or similar approved.

8.1.6.2 Covers to be certified to a test load of 900 kN.

8.1.6.3 Covers to be made from ductile cast iron.

8.1.6.4 Units to be coated with black bituminous solution for protection during transit.

8.1.6.5 Covers to be recessed type to receive concrete infill.

8.1.6.6 Concrete to infill and to surround/rebate to be strength grade 45 MPa.


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8.2 Fabrication and installation

8.2.1 All steel work shall be fabricated in accordance with BS EN 1090‐2:2008 Execution of steel structures and

aluminium structures.

8.2.2 Welding shall be in accordance with BS EN 1090‐2:2008 Chapter 7 – Welding or alternatively in accordance

with the requirements of AWS D1.1/D1.1M:2015.

8.2.3 The Service Category, Production Category and Execution Class determined in accordance with BS EN 1090‐

2:2008 Clause 4.1.2 and Annex B – Guidance for the determination of execution classes, shall be as follows:

The Service Category for the structure shall be SC2.

The Production Category for welds to the sheet piles shall be PC2.

The Execution Class for the structure shall be EXC3.


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9.0 SERVICES

9.1 Water/Medium Pressure Pipelines

9.1.1 Supporting Specification

9.1.1.1 The governing standard shall be SANS 1200L as amended and added to below.

9.1.2 Materials

9.1.2.1 Pipes, couplings and fittings

9.1.2.1.1 All pipes for water supply to be:

HDPE PE 100

Pressure Class 16

Standard Diameter Ratio (SDR) = 11

9.1.2.1.2 All couplings are to be PE 100 electrofusion couplings with a Pressure Class of 16.

9.1.2.1.3 All pipes and couplings shall conform to ISO 4427:2007 ‐ Plastics piping systems — Polyethylene (PE) pipes

and fittings for water supply

9.1.2.1.4 Fittings shall be ductile cast iron flanged typed in accordance with SANS 1835:2009. External and internal

surfaces of all fittings shall be protected with a water resistant, non‐toxic and non‐tainting, fusion bonded

epoxy pipe coating to a minimum thickness of 300 μm in accordance with SANS 1217.

9.1.2.2 Flanged Connections, Back‐up ring, Bolts and Nuts

9.1.2.2.1 Flange connections shall comply with SANS 1123 Table 15, drilled to suit mating flanges and shall be

installed square to the axis of the pipeline. Reaming of bolt holes to oversize dimensions in order to make

a particular piece fit will not be permitted.

9.1.2.2.2 Back‐up rings shall be mild steel Grade S275JR to BS EN 10025 coated with a zinc coating applied by

thermo‐diffusion coating (Sherardizing) in accordance with BS EN 13811:2003 Class 45.

9.1.2.2.3 Bolts, nuts and washers shall comply with ANSI B16.5 or the relevant sections of SANS 1700 as applicable,

in sizes appropriate to the class of pipe or special and of Grade 316 stainless steel. The length of the bolt

shall be such that, after the bolt has been tightened, the end of the bolt projects a minimum of one

thread above the nut and to a maximum of three full threads.

9.1.2.2.4 All buried flange connections shall be further protected by means of a protective paste / primer (Denso

Mastic or similar approved) and then wrapped with two layers of an approved impregnated tape (Denso

Tape or similar approved)

9.1.2.3 Gate valves, hydrants and water meters

9.1.2.3.1 All gate valves shall be Class 16, double flanged, resilient seal, cast‐iron waterworks pattern valves, with

non‐rising spindles, conforming to SANS 664:2011.

9.1.2.3.2 Gate valves shall be flanged to SANS 1123 Table 15 and shall be fitted with valve caps per SANS 664.

9.1.2.3.3 The direction of closing shall be CLOCKWISE and clearly indicated on the valve body.

9.1.2.3.4 Quayside hydrants shall be cast‐iron gate‐valve outlet bends with a bayonet type outlet according to SANS

1128‐1:2010.

9.1.2.3.5 Water meters shall be cast‐iron, double flanged Woltman type according to ISO 4064‐1:2014.

9.1.2.3.6 External and internal surfaces of valves and hydrants shall be protected with a water resistant, non‐toxic

and non‐tainting, fusion bonded epoxy pipe coating of minimum thickness of 300μm in accordance with

SANS 1217.


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9.1.2.4 Brackets

9.1.2.4.1 Supporting brackets and frames shall be fabricated from mild steel Grade S355JR in accordance with BS

EN 10025 unless otherwise shown on the drawings.

9.1.2.4.2 All mild steel elements shall be coated with a zinc coating applied by thermo‐diffusion coating



9.1.3 Construction

9.1.3.1 Trenches and bedding

9.1.3.1.1 Excavation for pipe trenches and bedding for the pipes shall be in accordance with SANS 1200 DB and

SANS 1200 LB respectively.

9.1.3.2 On‐Site Storage

9.1.3.2.1 The Contractor shall be responsible for all materials stored on site until such time that the water main has

been tested and handed over to the main Contractor.

9.1.3.2.2 Pipes should be stored on level ground that is free from stones and sharp objects, and should be so

stacked (in a stack of cross formation) that the load on each pipe is uniform throughout its length.

9.1.3.2.3 Socketed pipes should be stacked that the sockets are at different ends in each alternate layer and

protrude from the stack.

9.1.3.2.4 The height of the stack should not exceed 1 m, and pipes of different diameters and class should not be

stacked together. Protective packing should not be removed until immediately before use.

9.1.3.3 Electrofusion Welding

9.1.3.3.1 All joints and connections shall be done using electrofusion couplings with electro‐fusion

coupling/welding done in accordance with SANS 10268‐2:2004 – ‘Welding of thermoplastics – Welding

processes Part 2: Electrofusion welding’.

9.1.3.4 Decommissioning of existing pipelines

9.1.3.4.1 Existing pipeline within the service tunnels that is to be decommissioned shall be drained, dismantled and

removed. Dismantled pipe lengths are to be as long as is practicably possible to allow for possible future

re‐use by the Employer.

9.1.3.4.2 Existing buried pipelines that are to be decommissioned shall be drained, sealed and abandoned.

9.1.4 Testing

9.1.4.1 Testing shall be in accordance with SANS 1200L clause 7.

9.1.4.2 The pipe line shall be tested between gate valves and pipe termination points at a pressure of 20 Bar.

9.1.4.3 Testing shall be undertaken at the completion of each phase prior to handover of each berth.


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9.2 Sewer


9.2.1.1 The governing standard for the sewer raising mains shall be SANS 1200L as amended and added to below.

Other sewer related infrastructure shall be in accordance with SANS 1200 LD.

9.2.2 Materials

9.2.2.1 Pipes, couplings and fittings

9.2.2.1.1 All pipes for water supply be:

HDPE PE 100

Pressure Class 10





9.2.2.1.4 Fittings shall be ductile cast iron flanged typed in accordance with SANS 1835:2009. External and internal

surfaces of all fittings shall be protected with a water resistant, non‐toxic and non‐tainting, fusion bonded

epoxy pipe coating to a minimum thickness of 300 μm in accordance with SANS 1217.

9.2.2.2 Flanged Connections, Back‐up Ring, Bolts and Nuts

9.2.2.2.1 Flange connections shall comply with SANS 1123 Table 15, drilled to suit mating flanges and shall be

installed square to the axis of the pipeline. Reaming of bolt holes to oversize dimensions in order to make

a particular piece fit will not be permitted.

9.2.2.2.2 Back‐up rings shall be mild steel Grade S275JR to BS EN 10025 coated with a zinc coating applied by

thermo‐diffusion coating (Sherardizing) in accordance with BS EN 13811:2003 Class 45.

9.2.2.2.3 Bolts, nuts and washers shall comply with ANSI B16.5 or the relevant sections of SANS 1700 as applicable,

in sizes appropriate to the class of pipe or special and of Grade 316 stainless steel. The length of the bolt

shall be such that, after the bolt has been tightened, the end of the bolt projects a minimum of one

thread above the nut and to a maximum of three full threads.

9.2.2.2.4 All buried flange connections shall be further protected by means of a protective paste / primer (Denso

Mastic or similar approved) and then wrapped with two layers of an approved impregnated tape (Denso

Tape or similar approved)

9.2.2.3 Gate Valves and non‐return valves

9.2.2.3.1 Gate valves shall be Class 10, double flanged, resilient seal, cast‐iron waterworks pattern valves, with non‐

rising spindles, conforming to SANS 664:2011.

9.2.2.3.2 Non‐return valves shall be Class 10, double flanged, swing door checked type, cast‐iron with an external

lever arm and counter weight conforming to SANS 664:2011.

9.2.2.3.3 All valves shall be flanged to SANS 1123 Table 15 and shall be fitted with valve caps per SANS 664.

9.2.2.3.4 The direction of closing shall be CLOCKWISE and clearly indicated on the valve body.

9.2.2.3.5 External and internal surfaces of valves shall be protected with a water resistant, non‐toxic and non‐

tainting, fusion bonded epoxy pipe coating to a minimum thickness of 300 μm in accordance with SANS

1217.


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9.2.2.4 Brackets

9.2.2.4.1 Supporting brackets and frames shall be fabricated from mild steel Grade S355JR in accordance with BS

EN 10025 unless otherwise shown on the drawings.

9.2.2.4.2 Valve straps shall be stainless steel grade 316L to ASTM 240/A 240M – 04a.




9.2.2.5 Concrete

9.2.2.5.1 All concrete work for the sewer pump stations shall be in accordance with specification 1370‐CO‐000‐C‐

SPC‐0001.

9.2.3 Plant

9.2.3.1 Foul sewer pump manhole

9.2.3.1.1 Each foul sewer pump manhole shall be equipped with 2 Robot DWP4 ‐ 32 BR submersible sewage pumps

with 10 m cable for D.O.L. starting Klixons and Probes included.

9.2.3.1.2 The pumps shall be supplied with:

100 mm diameter wire embedded rubber pulp and slurry pipe (length dependent on sump

depth) fitted with quick release coupling.

Mercury operated float switches

Electrical control panel housed in waterproof free standing kiosk, manufactured from 3CR12

and housing all required associated electronics.

Flashing alarm light and screen

Stainless steel lifting chains

9.2.3.1.3 The electrical supply to the kiosk will be by Others.

9.2.3.1.4 The pump shall be commissioned in accordance with the Supplier’s recommendations.

9.2.4 Construction

9.2.4.1 Trenches and bedding

9.2.4.1.1 Excavation for pipe trenches and bedding for the pipes shall be in accordance with SANS 1200 DB and

SANS 1200 LB respectively.

9.2.4.2 On‐Site Storage

9.2.4.2.1 The Contractor shall be responsible for all materials stored on site until such time that the water main has

been tested and handed over to the main Contractor.

9.2.4.2.2 Pipes should be stored on level ground that is free from stones and sharp objects, and should be so

stacked (in a stack of cross formation) that the load on each pipe is uniform throughout its length.

9.2.4.2.3 Socketed pipes should be stacked that the sockets are at different ends in each alternate layer and

protrude from the stack.

9.2.4.2.4 The height of the stack should not exceed 1m, and pipes of different diameters and class should not be

stacked together. Protective packing should not be removed until immediately before use.

9.2.4.3 Electrofusion Welding

9.2.4.4 All joints and connections shall be done using electrofusion couplings with electro‐fusion

coupling/welding done in accordance with SANS 10268‐2:2004 – Welding of thermoplastics – Welding

processes Part 2: Electrofusion welding.

9.2.4.5 Decommissioning of existing sewer pipelines


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9.2.4.5.1 Existing pipeline within the service tunnels that is to be decommissioned shall be flushed, drained,

dismantled, removed and disposed of by the Contractor at a registered disposal site of the Contractor’s

choice.

9.2.4.5.2 Existing buried pipelines that are to be decommissioned shall be flushed, drained, sealed and abandoned.

9.2.5 Testing

9.2.5.1 Testing shall be in accordance with SANS 1200L clause 7.

9.2.5.2 The pipe line shall be tested between gate valves and pipe termination points at a pressure of 12.5 Bar.

9.2.5.3 Testing shall be undertaken at the completion of each phase prior to handover of each berth.

9.3 Stormwater Drainage


9.3.1.1 The governing standard shall be SANS 1200LE – Stormwater Drainage as amended and added to below.

9.3.2 Materials

9.3.2.1 Pipes

9.3.2.1.1 The storm water pipes shall be class 100D precast reinforced concrete pipes conforming to SANS 677 with

"Spigot and Socket" joints and rubber collars throughout.

9.3.2.2 Filter fabric

9.3.2.2.1 The filter fabric to be used to wrap pipe joints shall be per the filter fabric specified in specification 1370‐

CO‐000‐C‐SPC‐002 for the caisson joints.

9.3.2.3 Connection to caisson

9.3.2.3.1 The storm water pipes shall be connected to the caissons using a flexible connector to allow for hinging

due to settlement of the back fill.

9.3.2.3.2 The connector shall be proprietary type Z.LOK STM or similar approved.

9.3.2.3.3 The connector shall be in accordance with ASTM C‐923‐08(2013) ‐ Standard Specification for Resilient

Connectors between Reinforced Concrete Manhole Structures, Pipes, and Laterals.

9.3.2.4 Prefabricated Chambers and Shafts

9.3.2.4.1 The types of manholes to be constructed are indicated on the drawings. No masonry manholes are

permitted.

9.3.2.5 Slot Drains

9.3.2.5.1 Slot drains shall comprise of a precast concrete top set on a cast in‐situ reinforced concrete base on a bed

of mortar in accordance with the drawings.

9.3.2.6 Concrete

9.3.2.6.1 All concrete work for the slot drains and storm water manholes shall be in accordance with specification

1370‐CO‐000‐C‐SPC‐0001.

9.3.3 Construction

9.3.3.1 Joints

9.3.3.1.1 The caisson connector shall be installed strictly in accordance with the supplier’s specification.

9.3.3.1.2 All joints are to be wrapped with filter fabric.


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9.4 Tunnel Dewatering System

9.4.1 Plant and Materials

9.4.1.1 Sump Pumps

9.4.1.1.1 Two types of sump pumps are to be supplied and installed at the positions shown on the drawings.

9.4.1.1.2 The three phase pump shall be Type FLYGT ‐ BS 2071.010 or similar approved.

9.4.1.1.3 The single phase pump shall be Type FLYGT – BS 2008.212 (Ready 8 MT 1)

9.4.1.1.4 Pumps are to be supplied with automatic controls with float switches in combination with magnetic

starter type controls.

9.4.1.1.5 The electrical supply to the pumps will be by Others.

9.4.1.1.6 The pump shall be commissioned in accordance with the Supplier’s recommendations.

9.4.1.2 Pipes and Couplings

9.4.1.2.1 All pipes for water discharge be:

HDPE PE 100

Pressure Class 10





9.4.1.3 Steelwork

9.4.1.3.1 Supporting brackets, frames and plates to the sump shall be fabricated from mild steel Grade S355JR in

accordance with BS EN 10025 unless otherwise shown on the drawings.




9.5 Electrical cable ducts


9.5.1.1 The governing standard shall be SANS 1200LC – Cable Ducts as amended and added to below.

9.5.2 Materials

9.5.2.1 Buried Cable Ducts

9.5.2.1.1 Buried ducts shall be HDPe ducts to SANS 61386‐24 (Resistance to compression ‐ Type 450N, Resistance to

impact‐ Normal, Resistance to bending ‐ Rigid) with sleeve type couplings.

9.5.2.1.2 All ducts shall be installed with draw wires. Polyester yarn with a minimum breaking strength of 400 kg or

galvanised wire (nominal diameter 2.5 mm) shall be used as a draw wire.

9.5.2.2 Concrete

All concrete work for the slot drains and storm water manholes shall be in accordance with specification

1370‐CO‐000‐C‐SPC‐0001.


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10.0 REMEDIAL WORKS FOR EXISTING CAPPING BEAM AND SERVICE TUNNELS

10.1 Scope

10.1.1 Repairs and remedial works to the existing capping beam and service tunnels include the following:

Sealing existing abandoned anchors and chambers

Sealing existing crane rail slots

Sealing existing busbar tunnels

Extending/raising various existing tunnel access points, pipe slots and cable slots

10.2 Materials

10.2.1 Where shown on the drawings, hydraulic, cementitious non shrink grout shall be used for sealing slots and

small voids.

10.2.2 Cementitious grout shall be in accordance with ASTM C1107 / C1107M ‐ 14a ‐ Standard Specification for

Packaged Dry, Hydraulic‐Cement Grout (Non‐shrink).

10.2.3 Concrete and steel shall be as specified in 8.1 above.

10.3 Construction

10.3.1 Where existing steel chambers are to be filled with mass concrete or non‐shrink grout, the steel surface is

to be cleaned with an approved de‐greasing agent and wire brushed prior to filling

10.3.2 Where crane rail slots and concrete chambers are to be filled, the concrete surface is to be scabbled to

expose the aggregate and cleaned to remove all loose particles and dust. A wet to dry epoxy shall be

applied to the surface prior to filling.

10.3.3 The existing busbar tunnels shall be closed in accordance with the details shown on the drawings. The

existing steel covers shall be recovered and delivered to the Employer’s store.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – DREDGING AND RECLAMATION (INCLUDING

VIBRO COMPACTION)

1370‐CO‐000‐C‐SPC‐0004 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN

SPECIFICATION – DREDGING AND RECLAMATION (INCLUDING VIBRO COMPACTION)


REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1

1.2.1 Dredging ........................................................................................................................................ 1 1.2.2 Reclamation ................................................................................................................................... 1 1.2.3 Surveying and testing .................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 3

3.1 Chart Datum Port ............................................................................................................................................ 3 3.2 Co‐ordinate System ......................................................................................................................................... 3 3.3 Tidal Levels ..................................................................................................................................................... 3 3.4 Method Statements ........................................................................................................................................ 3 3.5 Approved Disposal Site .................................................................................................................................... 3 3.6 Approved Offshore Borrow Site ...................................................................................................................... 3 3.7 Berth Dredging ................................................................................................................................................ 3 3.8 Dredging .......................................................................................................................................................... 3 3.9 Reclamation .................................................................................................................................................... 3 3.10 Vibro Compaction ........................................................................................................................................... 3

4.0 REQUIREMENTS ....................................................................................................................................... 4


4.1.1 Dredging and disposal ................................................................................................................... 4 4.1.2 Compaction of reclaimed material ................................................................................................ 4

4.2 Materials ......................................................................................................................................................... 4

4.2.1 Nature of material to be dredged – Basin and berth dredging ..................................................... 4 4.2.2 Material within Lot 10 ................................................................................................................... 4 4.2.3 Material for sandbank extension .................................................................................................. 5 4.2.4 Material for reclamation and caisson infill .................................................................................... 5

4.3 Equipment ....................................................................................................................................................... 6

4.3.1 General .......................................................................................................................................... 6 4.3.2 Basin and Berth Dredging Equipment ........................................................................................... 6 4.3.3 Discharge Equipment .................................................................................................................... 7 4.3.4 Silt curtains .................................................................................................................................... 7 4.3.5 Compaction Equipment ................................................................................................................. 7 4.3.6 Survey Equipment ......................................................................................................................... 7


4.4.1 Dredging and dredge material disposal ......................................................................................... 9 4.4.2 Dredging Surveys ......................................................................................................................... 12 4.4.3 Reclamation compaction ............................................................................................................. 15


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5.1 Sampling, Testing, Commissioning and Completion ..................................................................................... 16

5.1.1 Dredging Completion .................................................................................................................. 16 5.1.2 Sampling and testing of reclamation material ............................................................................ 16 5.1.3 Acceptance criteria for compaction of reclamation material ..................................................... 16

5.2 Tolerances ..................................................................................................................................................... 18

5.2.1 Dredging ...................................................................................................................................... 18 5.2.2 Infill reclamation ......................................................................................................................... 18 5.2.3 Reclamation compaction ............................................................................................................. 18


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1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for dredging and reclamation, which includes the

following:

1.2.1 Dredging

a) The deepening and extension of the basin including the turning circle and entrance channel as indicated

on drawing 1370‐CO‐020‐C‐DWG‐0002‐01. Where dredging of the existing crane yard is to be undertaken

to extend the basin and berth 205, this specification covers all dredging below +2.2 m CDP. Removal of

the material above +2.2 m CDP is covered under the demolition and site clearance specification 1370‐CO‐

000‐C‐SPC‐0018 Demolition and Site Clearance.

b) Berth dredging for the new Berths 203 to 205 to provide caisson founding trench and scour protection

trench as shown on drawings 1370‐CO‐020‐C‐DWG‐0004‐01 to 1370‐CO‐020‐C‐DWG‐0006‐01.

c) Dredging of Lot 10 launching dock to allow for launching and towing of caissons as shown on drawing

1370‐CO‐020‐C‐DWG‐0011‐01.

1.2.2 Reclamation

a) Reclamation of areas between new caisson wall and existing quay wall including vibro‐compaction

b) With regards to the extension of the sandbank, which involves dredging of material from within the basin

and from the offshore sand‐winning site and depositing adjacent to the existing sandbank, only the

dredging portion of the works is covered by this specification. The works involving the placement of the

material to form the extended sandbank are covered in specification 1370‐CO‐000‐C‐SPC‐0016 Sandbank

Extension.

1.2.3 Surveying and testing

All necessary surveying and testing for the dredging and reclamation works.


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e) 1370‐CO‐020 series of drawings – Dredging and reclamation

f) Method statement prepared by the Contractor, as described in Section 4.1

g) Project Geotechnical Reports, included in Part 4 ‐ Site Information


The standard specifications listed in this section shall, inter alia, be read in conjunction with this specification:

a) SANS 1200 D:1988 ‐ Earthworks

b) BS 6349‐5:1991 – Maritime Structures – Code of practice for dredging and land reclamation

c) PIANC Report No 100 – 2009 – Dredging Management Practices for the Environment

d) PIANC Report No 144 – 2016 – Classification of Soils and Rocks for the Maritime Dredging Process

e) BS EN 1997‐2: 2007 ‐ Geotechnical design – Ground investigation and testing

f) BS EN ISO 22476‐1:2012 ‐ Geotechnical investigation and testing ‐ Field testing ‐ Electrical cone and

piezocone penetration test.

g) IHO Standards for Hydrographic Surveys, Special Publication No.44, 5th Edition, February 2008.

h) BS 1377‐7:1990 ‐ Methods of test for soils for civil engineering purposes. Shear strength tests (total stress)

– Determination of shear strength by direct shear (small shearbox apparatus)

i) BS 1377‐4:1990 ‐ Methods of test for soils for civil engineering purposes. Compaction‐related tests –

Determination of the maximum and minimum dry densities for granular soils


a) The Employer specifications listed in this section shall, inter alia, be read in conjunction with this

specification:

b) 1370‐CO‐000‐C‐SPC‐0008 – Scour Protection and Revetments

c) 1370‐CO‐000‐C‐SPC‐0010 – Ground Improvement: Rigid Inclusions and Foundation Stone Bed (Caisson

Load Transfer Platform)

d) 1370‐CO‐000‐C‐SPC‐0016 – Sandbank Extension

e) 1370‐CO‐000‐C‐SPC‐0018 – Demolition and Site Clearance

f) Environmental Management Plan (EMP)


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3.0 DEFINITIONS












3.3 Tidal Levels






Mean Level ML 1.097








Further details of the requirements of particular method statements are provided in Section 4.

3.5 Approved Disposal Site

The Approved Disposal Site refers to a site located offshore, the locality of which is shown on drawing 1370‐CO‐020‐

C‐DWG‐010‐01.

3.6 Approved Offshore Borrow Site

The Approved Offshore Borrow Site refers to a site located offshore, the localities of which are shown on drawing

1370‐CO‐020‐C‐DWG‐010‐01.

3.7 Berth Dredging

Dredging of material below ‐16.5 m CDP for the caisson foundation trench, scour trench and the slope that extends

from the caisson foundation trench to the existing wall. Material within this area above ‐16.5 m CDP is classified as

Basin Dredging.

3.8 Dredging

Excavation of all types of material within the marine environment, above or below water level, regardless of the type

of Equipment or methods employed.

3.9 Reclamation

The process of creating new land or extending the sandbank with dredged/imported material.

3.10 Vibro Compaction

Vibro Compaction (VC) is a ground improvement technique that uses a specially‐developed depth vibrator to direct

horizontal compactive energy at the required improvement depth. Improvement is achieved by rearranging the soil

matrix to a tighter packing, resulting in an increase in the in situ density and shear strength of the soil mass.


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4.0 REQUIREMENTS


The Contractor shall prepare method statements that shall include, inter alia:

4.1.1 Dredging and disposal

a) Description of the Equipment (type of dredger, basic dimensions and specifications, booster pump

stations, hopper barge capacity, power characteristics, production rates per material and per length of

delivery pipe etc.).

b) The planned cycle times, production rates, expressed in terms of the in‐situ bulk volume (m³) of solids

dredged per week and per hour, allowing for mechanical and weather downtime and also capacity

variation with respect to length of discharge pipeline and booster stations (if required).

c) The sea state conditions under which the Equipment may operate safely for survival conditions and

operational conditions for dredging, dumping and reclamation.

d) The Contractor’s methodology for controlling sedimentation and turbidity within the vicinity of dredging

and discharge activities.

e) The Contractor’s proposed layout of discharge pipelines for the reclamation.

4.1.2 Compaction of reclaimed material

a) Details of the compaction methodology and Equipment to be used including vibration frequencies,

energies etc.

b) Work procedures and control criteria.

c) A work plan for the production work outlining the spacing/grid layout, location and depth of the probes to

achieve the criteria outlined in this specification.

d) A work plan for the performance testing by CPT of completed work outlining the spacing/grid layout,

location and depth of the probes to achieve the criteria outlined in this specification.

4.2 Materials

4.2.1 Nature of material to be dredged – Basin and berth dredging

Various geotechnical investigations of the basin have been undertaken and the results thereof are provided in the

various reports included in annexure A of the Site Information. The Contractor will be deemed to have made its own

assessment of the materials to be dredged from the information provided in the Site Information and from the

Contractor’s own visual inspection of the Site and available cores.

The Contractor is in addition referred to the Demolition Works specification (1370‐CO‐000‐C‐SPC‐0018) and drawings

regarding the nature of the material below and adjacent to the existing return quay wall that is to be demolished.

The Contractor is to note that various sections of the dredged slope for the caisson foundation trench will intersect

the rock rubble founding bed below the existing quay wall and the Contractor shall make allowance for the dredging

of this rock rubble material. In addition, the Contractor shall make allowances for dredging the stone bed and rock

rubble associated with the demolished existing return quay.

The Contractor is made aware that the dredging operations are in a working port and adjacent to operational quays.

The presence of debris or foreign matter, e.g. wires, chains, tyres and scrap can be expected. The Contractor shall

plan his Dredging Equipment and procedures accordingly to minimise delays associated with encountering obstacles.

The Contractor shall in planning its dredging works take note that there is a risk of encountering unforeseen objects

or obstructions below ground level or seabed level, and shall maintain the ability to divert his dredging work to other

areas until such time as the Contractor is able to remove the obstruction. The Contractor is to notify the Project

Manager or Supervisor immediately if obstructions in the dredge area are identified.

4.2.2 Material within Lot 10

The launching dock was previously project dredged to ‐11 m CDP and the access channel beyond it was dredged to ‐

10.5 m CDP. From the bathymetric surveys conducted by Others, it is known that siltation has occurred with the

level varying from ‐12.2 m CDP at the boundary of the Maydon Wharf Channel to approximately ‐8 m CDP at the


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launching dock. The launching dock is to be dredged to a level of ‐12.62 m CD to create sufficient draft for the

installation of the synchrolift and for the launching of the caissons.

The Contractor is made aware that as the proposed dredged level is lower than the previously dredged level, the

dredge material below ‐10.5 m CDP will be harbour beds and contains interbedded layers of sand and firm to very

stiff clays. Further information is provided in the geotechnical report contained in the Site Information.

4.2.3 Material for sandbank extension

Details of the material required for the sandbank extension are provided in specification 1370‐CO‐000‐C‐SPC‐0016

Sandbank Extension.

4.2.4 Material for reclamation and caisson infill

The material for the reclamation behind the caissons will be dredged from the offshore borrow site. The Contractor

shall compile a dredging plan to ensure material dredged for the infill falls within the borrow site and shall provide

the Supervisor with detailed track plots as described in section 4.4.1.9 to confirm compliance.

Report “Geophysical and Sediment Sampling Survey Of Two Proposed Sand Winning Areas In The Durban Bight by

W.R.Miller and R. Leuci; Report No. 2001‐0158, Council for Geoscience”, included in annexure 1 of the Site

Information, details investigations, tests and classifications of the material at the offshore borrow site. The material

generally comprises a calcareous sand.

The Contractor is responsible for interpreting the information available and for selecting a compaction method that is

suitable for the type of material available for the infill.

The material for the reclamation and caisson infill shall have the following requirements:

a) Fines content (percentage passing 0.63 m sieve) <= 10%


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4.3 Equipment

4.3.1 General

The Contractor shall take full and entire responsibility for the sufficiency of his Equipment to Provide the Works. The

Contractor shall submit details of all Equipment to be used to the Supervisor for acceptance at least 3 weeks prior to

dredging and reclamation work commencing.

All marine Equipment used to provide and inspect the works shall be subject to the requirements of the South

African Maritime Safety Association (SAMSA). Floating Contractor's Equipment shall be maintained in a satisfactory

and seaworthy condition, shall have adequate attendance by competent seamen at all times, shall be fully provided

with sound and satisfactory ropes, line and moorings and shall be fully equipped with lights. At all times the

Contractor shall be wholly responsible for the protection and safety of all floating craft engaged by him. The

Contractor shall be cognisant of the expected sea and wave conditions within the port as well as outside of the port

en route to and from the sand winning and disposal sites. The Contractor shall ensure the adequacy of his

Equipment to operate in such conditions such that the program for the works is not affected by weather and wave

conditions that fall within the 1:10 year return period storm conditions for the Port of Durban area as well as the

offshore sand winning and disposal areas.

The Contractor shall immediately and at his own cost re‐float or raise and remove any Contractor's Equipment

(floating or otherwise), vessel, craft or Materials or any other property in his care or belonging to him or to any Sub‐

Contractor, which may be stranded or sunk in the course of execution and completion of the works. Until such

sunken object is raised and removed the Contractor at his own cost shall set buoys and display such lights and do all

such things for the safety of navigation as may be required by the authorities concerned or by the Supervisor.

Should the Contractor fail to meet the foregoing obligations the Employer may buoy and light each sunken object and

re‐float or raise and remove the same (without prejudice to the right of the Employer to hold the Contractor liable)

and the Employer shall be entitled to recover from the Contractor the cost thereof or may deduct the same from any

monies due or that become due to the Contractor.

The provisions of this Section shall apply to all Contractor's Equipment, vessel, craft, Materials and property therein

referred including such Contractor's Equipment, vessel, craft, materials and property which may be declared a total

loss or may be covered by insurance.

Where work is carried out from pontoons or other un‐powered floating equipment, a suitably powered craft shall be

in attendance at all times.

The Contractor's floating equipment shall be in contact with T NPA, Port Control via radio on a VHF channel to be

prescribed by the Harbour Master. An additional channel shall be made available for emergencies.

4.3.2 Basin and Berth Dredging Equipment

The specification is non‐descriptive in terms of the type of dredging Equipment to be employed (other than the

constraint of NOT permitting Trailer Suction Hoppers Dredgers (TSHD) for Berth Dredging) and the Contractor is

responsible for selecting the type of Equipment and method of dredging to be employed to Provide the Works in

accordance with the technical and environmental specifications. The Contractor shall interpret the various

geotechnical reports contained in Annexure 1 of the Site Information and shall select the dredging Equipment

accordingly, in particular to meet the specified tolerances for the various aspects of the dredging works. The

dredging and excavation Equipment used for the Works shall be suitable for the work required, taking into

consideration the volumes of material to be dredged, the type of material to be dredged, the programme to Provide

the Works, the climatic and sea conditions, the disposal of dredged material and the dredge and excavation

tolerances specified.

Trailer Suction Hopper Dredgers are NOT permitted for Berth Dredging or for any dredging within 20 m of an existing

structure.

The Contractor shall provide and maintain on board all dredging Equipment a position fixing systems giving the

position of plant to an accuracy of +/‐0.5 m in the horizontal plane, together with competent operators to ensure

that the position of dredging plant can be accurately located.


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All hoppers for transporting of material shall have load indicator equipment on board in order to ensure that the

hopper doors are not leaking and that no part of the load is deposited anywhere other than in the designated

disposal site. The hoppers shall, in addition, be fitted with track plotting equipment.

4.3.2.1 Lot 10 Dredging Equipment

Dredging within the Lot 10 launching dock is restricted due to the lateral extent of the launch dock. As detailed in

section 4.2.2, very stiff clay is expected at the dredge depths. The Contractor is to select suitable Equipment

accordingly.

4.3.3 Discharge Equipment

4.3.3.1 Offshore disposal

Disposal of the material at the offshore disposal site shall be via bottom‐dumping and the hoppers shall be suitably

equipped to facilitate bottom dumping.

4.3.3.2 Discharge for reclamation behind caisson wall

Material for the reclamation behind the caisson wall shall be placed using a floating pipeline with a diffuser.

4.3.3.3 Discharge for sandbank extension

Equipment for the discharging of material for the sandbank extension is covered under specification 1370‐CO‐000‐C‐

SPC‐0016 Sandbank Extension

4.3.4 Silt curtains

The Contractor shall provide silt curtains as may be required to create paddocks for minimising spread of fines within

the reclamation area. The silt curtains shall be provided as follows:

a) Silt curtains shall be sourced from reputable manufacturers with a proven track record.

b) Silt curtains shall be designed for the specific application and shall follow the manufacturer’s

recommendations and guidelines for setting up and maintaining such items as well as guidelines for

installation and safety measures.

Silt curtain requirements for the sandbank extension are detailed in specification 1370‐CO‐000‐C‐SPC‐0016 Sandbank

Extension.

4.3.5 Compaction Equipment

It is envisaged that a form of Vibro Compaction will be used for the densification of the infill material. However, it is

ultimately the Contractor’s responsibility for selecting a suitable compaction method to achieve the required

performance based CPTu acceptance criteria. The Contractor shall evaluate the material available from the borrow

site and shall select suitable Equipment.

The Contractor shall supply all compaction equipment with the following minimum requirements:

a) Compaction Equipment capable of imparting sufficient energy at an optimum frequency to achieve the

required compaction.

b) Compaction equipment with sufficient power output to achieve compaction over the full depth of the

reclamation material.

c) Instrumentation and markings allowing visual determination of depth of treatment.

d) Instrumentation to measure power output, frequencies and amperage (if applicable).

e) CPTu testing equipment capable of testing the full depth of treatment.

4.3.6 Survey Equipment

The Contractor shall provide Equipment required for the in‐surveys, out‐surveys and surveys of the off shore disposal

and borrow sites as specified. This survey equipment is to be provided by the Contractor when the surveys are

required, and is not required full time on site.

The minimum Equipment to be made available for surveys is the following:

a) A seaworthy boat with a cabin suitable to accommodate and operate survey Equipment consisting of a

sonar survey system capable of doing a continuous underwater survey of the seabed in the basin and the

seabed at the offshore disposal site. The Contractor shall supply the necessary survey vessel suitable for


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the hydrographic and multibeam swath surveys, taking into account the different water depths, winds,

waves, currents and other significant site conditions that may be experienced on site. All lighting, safety

features and equipment required for the safe operation and mooring of vessels must be supplied by the

Contractor and must be approved by the relevant Maritime Safety Authority. The Contractor shall provide

qualified personnel to operate the boat as well as the survey equipment and shall keep the equipment in

working and seaworthy order at all times.

b) A differential GPS system capable of a horizontal positioning accuracy of better than 250 mm at the 95%

confidence level must be used for all positioning. The DGPS receiver(s) aboard the vessel must be

configured such that satellites below 8 degrees above the horizon are not used in position computations.

The age of pseudo‐range correctors used in position computation must not exceed 20 seconds. Horizontal

Dilution of Precision (HDOP) must be monitored and recorded, and should not exceed 4 nominally.

Satellite geometry alone is not a sufficient statistic for determining horizontal positioning accuracy. Other

variables, including satellite pseudo‐range residuals, are to be used in conjunction with HDOP to estimate

DGPS horizontal accuracy. A minimum of four satellites must be used to compute all positions. Horizontal

and vertical offsets between the GPS antenna and transducer(s) shall be observed and applied with a

precision better than 0.05 m.

c) Navigational instruments and vessel motion sensors including:

─ Roll, heave and pitch sensors.

─ Heading: Gyro/Fluxgate compass.

─ Navigational computer for on‐line navigational control during the survey.

─ Digital acquisition (data logging) of all the above sensor outputs.

d) A high quality multibeam echosounder with a frequency of not less than 200 kHz is to be used for the

surveys. The multibeam sonar must have an effective beam width of no greater than 1.5 degrees in both

the along‐track and cross‐track directions and lateral coverage of at least 30 m for depths greater than

10 m. The system shall be capable of measuring to depths of up to 90 m.

e) Logging and Processing Equipment including:

─ A data logger system having adequate electronic storage capabilities. The system shall store

multiple inputs (Date, Time, X, Y, Z Position, vessel movements and heading and echo sounder

data) on an electronic medium, which can be transferred to a personal computer. The data shall

be stored at 1‐second intervals or less.

─ Post processing, for motion correction of the ship movements and heading.

─ Conversion of all bathymetry data into absolute (x, y, z) files for Digital Terrain Models (DTM) for

producing special reports with maps, contours, cross profiles, etc.

The Contractor shall be responsible for calibration of the survey Equipment required on the survey boat and provide

the Supervisor with proof thereof. The Contractor shall also be responsible for arranging of tidal recordings

concurrent with underwater surveys where the tide is required to determine surveyed underwater levels.

The Contractor shall provide all personnel to operate the launch as well as the survey Equipment and shall ensure

that the equipment is in working and seaworthy order when required by the Supervisor.

The Contractor shall provide and maintain for the duration of the Contract durable temporary automatic,

continuously recording tide gauges at two locations agreed by the Supervisor. The Equipment shall be fixed in readily

visible positions where practicable, and shall be arranged so that the tide level is readable to an accuracy of +/‐ 25

mm at any time. At least one gauge shall be installed within 500 m of any area within which soundings or dip surveys

are to be taken.


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4.4.1 Dredging and dredge material disposal

4.4.1.1 Extent of work

The extent of work, dredge profiles and levels are as shown on the 1370‐CO‐020 series of drawings. The following

dredging and disposal cycles shall be undertaken:

a) Dredge from sand rich zones within the basin (Zones A and B as shown on drawings 1370‐CO‐020‐C‐DWG‐

009‐01) and discharge on south bank of sandbank for sandbank extension. Should the material available

in the sand‐rich zones within the basin prove of insufficient quantity to complete the sandbank extension,

the Contractor shall dredge from the offshore borrow site and discharge on south bank of sandbank for

sandbank extension.

b) Dredge from foundation and scour trench and basin, other than Zones A and B, and dispose of at offshore

disposal site.

c) Dredge from offshore borrow site and discharge in and behind caissons for reclamation/infill.

d) Dredge from Lot 10 launching dock and connecting link from dock to channel and dispose of at offshore

disposal site.

e) Contractor is responsible for ensuring that Esplanade Channel and approaches from Lot‐10 remain at

design depths for safe caisson towing.

4.4.1.2 Dredging methodology

All excavation and dredging works shall be carried out in accordance with the principles contained in BS 6349: Part 5:

1991, except as amended herein.

The Contractor shall dredge any material which, during the periods between the dates of commencement and

completion of all excavation and dredging operations, accumulates above the specified dredged levels within the

areas to be dredged as defined in the drawings. For berth dredging, this applies until such time as the stone bed and

caisson have been placed.

Agitation dredging, being the attempted removal of material by the use of natural water currents or artificially

induced water currents, shall not be permitted.

When dredging is undertaken adjacent to structures, due care shall be taken to avoid damage to these structures.

Should any damage or alleged damage to a structure take place, the Contractor shall arrange, in conjunction with the

Supervisor, for an inspection. In the case where the damage is underwater, the Contractor shall arrange for a diver’s

inspection. Any damage to structures caused by the Contractor's operations shall be repaired at the Contractor's

expense. The repair schemes shall be agreed with the Supervisor and any affected third party.

The Contractor shall profile all slopes to the gradients and levels shown on the drawing in a controlled manner that

prevents slope failure during dredging. Dredging/undercutting at the toe of the slope to intentionally cause slope

failure and slumping of material is not permitted.

The Contractor shall compile a dredging plan to ensure material dredged for the sandbank extension falls within the

demarcated zones and shall provide the Supervisor daily with detailed track plots as described in section 4.4.1.9 to

confirm compliance. Any material used for sandbank extension that is not dredged from the demarcated zones shall

be removed by the Contractor at his own cost and shall be deposited at the offshore disposal site.


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4.4.1.3 Sailing and navigation constraints

Vessels conveying material to and from the disposal and borrow sites will be required to navigate within the confines

of the Port of Durban and its immediate approaches. All vessel movements are controlled by Port Control to ensure

safe navigation. The Contractor shall allow for the fact that commercial shipping will take precedence over dredging

vessel movements.

The fullest collaboration between the Contractor, Harbour Master and the Supervisor is essential with regard to the

working of the port. All correspondence, applications and notices with the Port Authorities shall be directed through

the Supervisor.

Dredging operations shall be planned and executed in conjunction with Port Control in order to limit the impact of

dredging operations on port operations. The Contractor must take note that all works are subject to the provisions of

the Harbour Regulations. It is the duty of the Contractor to obtain the regulations from the port authorities.

The Contractor’s method for dredging and transporting materials shall be such as to avoid leakage, spillage, scouring

on land or the deposition of dredged material in shipping channels, basins or berths. In the event of any such leakage

or deposition occurring, the Contractor shall remove such leaked materials, repair scoured areas, or restore such

channels, basins or berths to their original depths.

The Contractor is responsible for establishing limiting sea states for his vessels, obtaining forecasts of approaching

weather and operating his vessels safely in terms of the criteria.

No vessel shall leave port if the forecast weather conditions are expected to approach any of these limits and the

vessels shall return to port immediately if such conditions arise while out of port.

The Contractor shall take all precautions, and shall at all times maintain radio communication between all his vessels

and Port Control. The Contractor shall comply at all times with the instructions of Port Control regarding shipping

and navigation safety. Any disruption of port shipping due to encroachment of the Contractor’s moorings into the

designated shipping channel will not be permitted.

4.4.1.4 Offshore disposal

The approved offshore disposal sites are identified on drawing 1370‐CO‐020‐C‐DWG‐0010‐01. The dumping of any

material outside the approved disposal site is not allowed. Disposal of the material at the offshore disposal site shall

be via bottom‐dumping. The Contractor shall ensure that material is not concentrated locally in the disposal site and

shall ensure as even a spread as practicable with no dumping on top of an area that has had a load previously

dumped on. The Contractor shall provide the Supervisor with a track plot of the dump location of each load as

detailed in 4.4.1.9.

4.4.1.5 Discharge in caissons

The caissons will be ballasted full of seawater during installation to lower the caissons on to the stone foundation.

Filling with approved sand material shall be carried out immediately after the caisson has been placed. The material

is to be placed using a floating pipe line fitted with a diffuser. Discharge is to be in a controlled manner (position of

pipeline outlet and rate of discharge is to be controlled) to ensure that segregation of fines is minimised and the fill is

placed in evenly spread, homogenous layers. The maximum differential in height of the fill during placement within

the caisson shall not exceed 1 m.

4.4.1.6 Discharge behind caissons

Filling behind the caissons shall only take place once all caissons, including the infill panels, have been placed for a

particular phase such that the reclamation area is cut off from the open basin.

The material is to be placed using a floating pipe line fitted with a diffuser. Discharge is to be in a controlled manner

(position of pipeline outlet and rate of discharge is to be controlled) to ensure that the fill is placed in evenly spread,

homogenous layers. The fill is to be brought up in layers, with a maximum layer height of 2 m.

Acceptance of the compacted reclamation is based on performance testing. The Contractor is responsible for

selecting appropriate placement methods such that the material placed is able to meet the performance criteria

once compacted. Segregation of fine material will result in pockets of silt or clay forming that are unlikely to meet

the performance criteria. The Contractor shall therefore employ suitable placement methods to minimise

segregation.


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The quantity of material to be placed in this area shall be to meet the levels shown on the drawings. The Contractor

shall place material to a certain level above the final design level such that the design level is achieved after

compaction allowing for settlement of the fill due to densification. The Contractor is responsible for estimating this

allowance for settlement.

The Contractor shall provide and lay all placement pipelines inclusive of fittings and booster pumps, from the

dredging plant in such a manner that other construction activities and commercial shipping is not interrupted or

affected in any way. The Contractor shall arrange to repair pipeline leaks immediately. The proposed route of all

reclamation pipelines shall be subject to acceptance by the Supervisor.

Should the Contractor require hardened surfaces for access or haul roads on the reclaimed fill in the execution of

these works, he may construct such temporary roads subject to the approval of the Supervisor.

4.4.1.7 Sequencing of dredging works

The following sequence shall be adopted for completion of the dredging works:‐

Phase 1 – Berth 205 Dredging, Basin Dredging and Berth 205 Reclamation

a) Dredge Lot 10 Launching Dock and link to Esplanade Channel to allow for installation of synchrolift. b) Commence with basin dredging excluding Zone B. Zone A material to be deposited on the sandbank and the

remainder of the basin material to deposited off shore. c) Zone B basin dredging to commence in vicinity of existing return quay only once temporary sheet piles to

retain dredge slope have been installed (refer to 1370‐CO‐080 series of drawings for details of temporary sheet piles). Zone B dredging to be undertaken in conjunction with existing return quay wall demolition such that demolition / removal of the return quay takes place in a controlled manner.

d) Zone B dredging to proceed in a westerly direction but shall be halted before encroaching on the piling construction works ongoing for the new return quay. Zone B basin dredging shall be halted at a sufficient distance away from the new return quay to ensure a stable slope and sufficient working space for the return quay construction.

e) Berth 205 dredging (foundation and scour trench) to proceed after basin dredging and demolition of existing return quay. Dredging to start at 205 / 204 interface and proceed in westerly direction towards return quay.

f) After completion of the steel piling for the cellular caisson return quay, the remainder of Zone B dredging can be commence.

g) After completion of Zone B dredging, the remainder of the berth dredging and the dredging of the return quay scour trench can commence.

Phase 2 ‐ Berth 204 Dredging and reclamation

a) The berth dredging for Berth 204 can only commence once the Contractor is given access to Berth 204 which is after completion and handover of Berth 205.

Phase 3 ‐ Berth 203 Dredging

a) The berth dredging for Berth 203 can only commence once the Contractor is given access to Berth 203 which is after completion and handover of Berth 204.

4.4.1.8 Monitoring of existing quay wall during dredging

The Contractor shall undertake monitoring of the existing quay wall during berth dredging. Monitoring of the existing

quay wall shall be undertaken using two methods, the primary method being electronic inclinometers and a

secondary back up system being a surveyed baseline. Details of the proposed monitoring system are to be submitted

by the Contractor to the Supervisor for acceptance.

The inclinometer system shall consist of an articulated chain of sensor elements (segments). The segments, each

containing a multi‐axial accelerometer, shall be interconnected in such a manner that they can move in relation to

one another in all directions but shall not twist. The instrument shall be capable of following and presenting

deformation and tilt with a resolution of 0.01 mm per 500 mm in the direction perpendicular to the quay wall. The

accuracy, expressed as lateral deviation over a length of 30 m of casing shall be 6.00 mm x 30 m. The inclinometers

shall be calibrated with a calibration tool after installation.

The inclinometers shall be mounted in casings firmly attached to the existing quay wall. The inclinometer chain shall

extend from the foundation level of the wall all the way up to the top of the capping. The bottom end shall serve as

a fixed reference point. Inclinometers shall be installed at a spacing of 20 m along the face of the existing quay wall.


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The reading units that interrogate the sensors shall be housed in a central instrumentation room set up within the

Contractor’s on site offices. The data collected shall be processed on a PC using dedicated software in accordance

with manufacturer’s specification. The data shall be collated on a daily basis and shall be presented to the Supervisor

daily during the dredging operations.

The instrumentation shall be capable of operating in temperatures ranging from 0°C to 50°C and shall be capable of operating in the wet and the dry.

The inclinometers shall remain in place until reclamation begins. During periods when dredging has been completed

but reclamation has not yet begun (e.g. during Rigid Inclusion installation and caisson placement), data collation and

reporting shall be on a weekly basis.

In addition to the inclinometer monitoring of the existing quay wall, the Contractor shall also establish a surveyed

baseline in the form of steel pins inserted into the existing capping beam at 10 m centres along the entire length of

the existing quay prior to any berth dredging works. The Contractor shall, on a bi‐weekly basis, survey the baseline

and shall compare the data with that obtained from the inclinometers to verify the electronic system.

4.4.1.9 Dredging track plots

A Global Positioning Satellite (GPS) record is to be kept for all dredging and disposal activities. This record shall

include the following data:

a) Start time, end time and location of individual track plots for dredging (filling of hopper).

b) Departure time from the dredge site (off shore borrow site or basin).

c) Route followed by the vessel (GPS track) to disposal/discharge site (offshore disposal site, reclamation or

sandbank extension).

d) Time of arrival at the disposal/discharge site.

e) Position of the vessel at the time of starting to discharge the dredge spoil.

f) Heading and speed of the vessel at the time of starting to discharge the dredge spoil.

g) Position of the vessel at the time of completion of discharge of the dredge spoil.

h) Quantity of material discharged.

i) Heading and speed of the vessel at the time of completion of discharge of the dredge spoil.

j) Time of departure from disposal site.

k) Route followed by the vessel on route back to the dredge site.

The daily long track plot shall be recorded electronically on a compact disk in ASCII format and shall be submitted to

the Supervisor on a daily basis.

4.4.1.10 Dredging progress reporting

The Contractor shall keep daily written records as required by the Supervisor, and submit a signed copy to the

Supervisor not more than 3 days after the date to which the record relates. The records shall give details of the

dredging area, the material being dredged and any delays to the dredging operation.

The Contractor shall prepare a weekly report to cover the work executed each week from midnight on Sunday. The

report shall be submitted to the Supervisor by Tuesday noon following the week covered by the report. The report

shall include a return of the Contractor's Equipment and Personnel employed the previous week and of the works on

which they were engaged. The Contractor shall submit to the Supervisor, on a weekly basis, a coloured chart

showing the extent of dredging and profiling, together with the areas from which material has been dredged.

On the first weekday following the issue of the Contractor’s monthly progress report to the Supervisor, the

Contractor shall attend the Supervisor’s office for a meeting to discuss the progress achieved during the previous

month and the progress planned for the current month.

4.4.2 Dredging Surveys

4.4.2.1 Requirements of marine surveys

All co‐ordinates used during this contract shall be to WG31.

All survey work shall be carried out and certified by a qualified hydrographic surveyor (IHO Cat A/B recognised

hydrographic surveying course or equivalent). The Contractor shall give the Supervisor unlimited access to the survey

vessels at all times.


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4.4.2.1.1 Tidal Data

Regardless of whether RTK GPS is used for position fixing, independent tidal measurements for purposes of water

level corrections are required. The tide gauge must be calibrated using a local benchmark to determine the

installation level to within 2 cm. Tidal records shall be corrected for onsite barometric pressure changes.

4.4.2.1.2 Multibeam Echosounder

The hydrographer shall ensure that the multibeam coverage shall have an overlap of at least 50% in order to check

the surveyed data. Heave, roll, pitch, heading, and navigation timing error (latency) corrections shall be applied to

multibeam soundings to correct the effect of vessel motion caused by waves and swells (heave, roll, pitch), the error

in the vessel’s heading, and the time delay from the moment the position is measured until the data is received by

the data collection system (navigation timing error). Heave shall be observed in no coarser than 0.05 m increments.

Roll and pitch shall be observed in no coarser than 0.05 degree increments. Heading shall be observed in no coarser

than 0.1 degree increments. Navigation timing error shall be observed in no coarser than 0.01 second increments.

4.4.2.1.3 Multibeam Sonar Calibration

Prior to commencing the survey operation, the hydrographer shall conduct a system accuracy test to quantify the

accuracy, precision, and alignment of the multibeam system. Testing shall include determination of residual biases in

roll, pitch, heading, and navigation timing error. These values will be used to correct the initial alignment and to

calibrate the multibeam system. System accuracy testing should be conducted in an area similar in bottom profile

and composition to the survey area, and during relatively calm seas to limit excessive motions and ensure suitable

bottom detection. The order in which these biases are determined may affect the accurate calibration of the

multibeam system. The hydrographer should determine the biases in the following order: navigation timing error,

roll, pitch, and heading (yaw).

4.4.2.1.4 Sound Velocity Profile

To ensure that the overall depth measurement accuracy criteria are met, velocity of sound observations shall be

taken with sufficient frequency, density, and accuracy. The accuracy with which the speed of sound correction can

be determined is a complex function of the accuracy with which salinity, temperature, and depth, or alternately,

sound speed and depth, can be measured. The sound speed profile in the survey areas must be measured and

monitored at sufficient frequency and to an appropriate depth to assure that the bathymetric data provided meets

the required depth accuracy specification. The sound speed profile should be determined with a calibrated system

capable of measuring the speed of sound with errors no greater than 2 m/sec (at the 95% confidence level). A

calibrated sound speed measuring system capable of measuring the sound‐speed profile to at least 95% of the

deepest anticipated depth in the survey area must be available, though collection of sound speed data to 95% of the

full depth of the survey area will only be required before and after the completion of the surveys. Velocity of sound

correctors shall be applied to soundings to compensate for the fact that echosounders may only display depths

based on an assumed sound velocity profile while the true velocity may vary in time and space.

4.4.2.1.5 Error Budget Analysis for Depths

The accuracy of measured depths in the hydrographic survey applies to the systematic measurement of general

water depths and to the least depths determined over any obstructions. The total sounding error in a measured

depth at the 95 percent confidence level, after systematic and system specific errors have been removed, shall not

exceed ± 100 mm (Z co‐ordinate) and the Total Horizontal Uncertainty (THU) 250mm horizontal (X and Y co‐

ordinates). The maximum allowable error in measured depth includes all inaccuracies due to residual systematic and

system specific instrument errors; the velocity of sound in water; static vessel draft; dynamic vessel draft; heave, roll,

and pitch; and any other sources of error in the actual measurement process. The hydrographer shall document in

the Descriptive Report the methods used to minimize the errors associated with the determination of depth

(corrections to echo soundings).

4.4.2.1.6 Towed Side Scan Sonar

Dual frequency digital side‐scan sonar and PC‐based acquisition system is required to collect the sonar graphs. The

scan range on the sonar should be set to 37 m or less in order to image any potential debris on the sea floor and

200% bottom coverage is required. Both frequencies must be processed to enable target detection. The towfish

altitude must be kept between 10‐20% of the scan range used in order to obtain an acceptable slant range.


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4.4.2.1.7 Deliverables and Data Presentation

The Contractor shall submit a survey quality control plan to the Supervisor. A survey report shall be submitted to the

Supervisor on completion of all in and out surveys. It must give a clear account of how the survey was carried out, the

results achieved, the difficulties encountered and the shortcomings. Emphasis must be placed on the analysis of

achieved accuracies.

The Contractor upon completion of the survey shall produce the following:

a) Shoal‐biased (or median biased) high‐resolution multi‐beam colour bathymetric image map of the areas,

inserted geographically referenced into a DXF or DWG file, contoured at 0.5m intervals.

b) Two hard copies of the bathymetric image map and electronic copies (pdf) are required.

c) Track Chart of all survey lines in DXF or DWG format.

d) ASCII data files of all the points recorded.

e) ASCII data files reduced to give one point per square meter (mean of all points in a m2).

f) All details with regards to the co‐ordinate transformation and calibration procedures and results.

g) A report detailing the findings and all details with regards to the survey. This is to include: Survey personnel,

date, time, area, conditions, survey vessel, positioning system, equipment used, software used, accuracies

achieved and the respective confidence levels, etc.

4.4.2.2 In‐surveys

Before any dredging, profiling, reclamation or sandbank extension may commence, the Contractor shall carry out

surveys of the area to be dredged or profiled, including adjacent side slopes. The survey shall include the areas

within the current basin where reclamation and sandbank extension will take place. These surveys shall be carried

out in collaboration with the Supervisor. Both parties shall agree on the existing sea bed levels before commencing

work. A copy of the final agreed in‐survey shall be furnished to the Supervisor for record purposes.

The in‐survey shall form the basis for calculations of quantities of materials dredged or profiled as detailed in the

Pricing Instructions.

4.4.2.3 Out‐surveys

The following out‐surveys are required:

a) On completion of the placement of the offshore material at the sandbank extension, a survey of the

partially completed extension shall be undertaken for payment purposes.

b) On final completion of the sandbank extension, a survey of the completed extension shall be undertaken to

ensure compliance with the placement tolerances for the sandbank.

c) On completion of dredging and profiling within the basin, the entire basin area (excluding the berth pocket

dredging) shall be surveyed to ensure compliance with the dredging tolerances.

d) On completion of berth dredging for the caisson and scour trench (berth pocket dredging), the trenches

shall be surveyed to ensure compliance with the dredging tolerances.

e) On completion of all dredging and reclamation, a survey of the offshore disposal and borrow sites.

The respective areas shall be surveyed as per 4.4.2.1 and the final levels shall be recorded on a drawing. The results

of this survey shall be made available to the Supervisor for acceptance.

The Contractor may also be required to undertake interim dip surveys of the caisson and scour trench to ensure

compliance with the required tolerances. Scour and caisson trench levels shall be taken on a 3m x 3m grid and the

levels shall be recorded to one decimal of a metre. The Contractor will also be required to undertake underwater

video inspections of the scour trench and cut slope.

Should it be found that the correct levels have not been achieved, the Contractor shall carry out further work until

the prescribed levels have been achieved.

The out‐surveys will be used by the Supervisor for assessing the acceptability of the work, and will be accepted as the

in‐survey for construction of the scour protection and stone bed layer.

A final survey of the basin for certification of Completion will be undertaken by the Employer’s surveyor.


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4.4.2.4 Timing of surveys

Surveys shall be carried out as follows

a) In‐surveys: no longer than two weeks before commencing dredging or profiling in the relevant area.

b) Out‐surveys: as soon as dredging or profiling of the relevant area has been completed and the required

tolerances have been achieved.

All surveys shall be witnessed by the Supervisor. The Contractor shall notify the Supervisor of his intention to carry

out surveys at least 24 hours prior to commencement of the survey and shall provide facilities for the Supervisor to

witness the survey when required.

4.4.3 Reclamation compaction


The extent of the area and depth requiring compaction is shown on drawings 1370‐CO‐020‐C‐DWG‐008‐01. The

works include compaction of both the material within the caissons and the reclamation material behind the caisson

wall.

The work shall consist of compaction, performance monitoring and testing of compaction as identified in this

specification within the defined extents to meet the acceptance criteria presented in section 5.1.3 of this

specification. It shall be the Contractor’s responsibility to determine and implement the systems to achieve the

specified acceptance criteria.

4.4.3.2 Compaction methodology

With regards to the compaction of the reclamation material, this specification in non‐descriptive and is instead

performance based. It is envisaged that a form of Vibro Compaction will be used for the densification of the infill

material however it is ultimately the Contractor’s responsibility for selecting a suitable compaction methodology to

achieve the acceptance criteria. The Contractor shall evaluate the material available from the borrow site and shall

select a suitable methodology to achieve the required densified soil parameters. The Contractor is responsible for

determining spacing between compaction points, vibration frequencies, energies etc.

Densification shall be achieved by a form of compaction. Chemical treatment or soil reinforcement of the material to

achieve the specified parameters is not permitted.

During compaction of the material within the caisson and directly behind the caisson, care is to be taken to prevent

any damage to the caisson walls. The vibratory probe shall be kept at a minimum of 1m away from the walls of the

caisson (measured from wall face to outer envelope of probe).

4.4.3.3 Quality Control

All compaction shall be performed under the oversight of the Supervisor. Monitoring and logging of all compaction

operations for all production work shall be done by the Contractor and records submitted to the Supervisor. Final

acceptance of satisfactory quality of the compaction works once complete will be carried out by in situ CPT testing.

4.4.3.4 Compaction record keeping

For the production work, the Contractor shall perform tests and take measurements. The following measurements

shall be recorded for each Compaction location:

a) Compaction/probe number

b) Start and finish time of compaction/probing

c) Depth of treatment/probing

d) Approximate backfill quantity

e) Comments or unusual observations

The Contractor shall be responsible for ongoing sampling, testing and monitoring of the material placed during the

reclamation to ensure that the required performance can be achieved with the Contractor’s selected compaction

methodology.

4.4.3.5 Monitoring of Caisson Quay Wall during reclamation

Details of monitoring requirements for the new caisson quay wall during reclamation are provided in specification

1370‐CO‐000‐C‐SPC‐0002 Caisson Construction and Placement.


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5.1 Sampling, Testing, Commissioning and Completion

5.1.1 Dredging Completion

Certification of dredging Completion will be by the Supervisor and shall be determined based solely on the levels

obtained from the Employer’s survey measured against the levels shown on the drawings.

5.1.2 Sampling and testing of reclamation material

The Contractor shall be responsible for sampling, testing and monitoring of material dredged and placed for the

reclamation infill to ensure the material meets the required design classification. On a daily basis during the progress

of filling, the Contractor shall take two bag samples (of 25 kg each) of the materials placed in the reclamation at

locations directed by the Supervisor. Samples shall be taken at a maximum depth of 0.5 m. The Contractor shall carry

out sieve analysis tests on each of the bag samples and shall submit result to the Supervisor daily. The samples shall

be taken from the material placed on the sandbank extension (i.e. not from within the hopper) and shall be taken

before the subsequent layer is placed.

5.1.3 Acceptance criteria for compaction of reclamation material

All testing to determine specification compliance will be provided by the Contractor. CPTu testing is specified for the

compaction of the reclamation fill and the caisson infill to confirm compliance with required design densities,

strengths and stiffness. Testing of the material within the caissons shall be undertaken prior to construction of the

capping beam. Testing of the material behind the caisson wall shall be undertaken prior to construction of the

layerworks for the paving. If the required results are not achieved the Contractor shall adjust his compaction

methodology accordingly and retest until the required result are achieved.

CPTu testing shall be carried out in strict accordance with BS EN ISO 22476‐1:2012. CPTu testing shall be carried out

as follows:

a) A minimum period of 2 weeks should be allowed to lapse between completion of any ground densification

and the commencement of testing in that area.

b) The location of the probe shall coincide with the centroid location of a compaction grid cell or as otherwise

directed by the Supervisor

c) The frequency of the in situ testing shall be one test per 100 meters squared of site surface area treated,

and shall extend to the bottom of the Compaction treatment depth.

5.1.3.1 Establishing acceptance criteria

The Employer’s designer requires an internal angle of friction (Ø) of the placed and compacted fill of 37°. The

Contractor shall demonstrate by means of CPTu testing that the compacted fill has met this criteria. This shall be

demonstrated as follows:

a) The Contractor shall undertake shear box testing and minimum and maximum density testing, in

accordance with BS 1377‐7:1990 and BS 1377‐4:1990 respectively, of a sample of the placed material

selected by the Supervisor.

b) The shear box testing shall establish a relationship of Ø vs relative density for the borrow site material

(refer to typical example shown in Figure 5‐1).

c) The required relative density shall then be established by reading off the relative density required to

achieve Ø of 37 deg. In the example shown in Figure 5‐1 the relative density required is 53% however this

will vary depending on the results of the shear box test.

d) The required relative density shall not be less than 60%. The required relative density shall be the greater of

the minimum value (60%) and the value established by shear box testing as described above.


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e) The appropriate CPTu performance graph will then be selected from figure 5.2 as the accepted performance

criteria for the onsite CPTu testing. The acceptance of the compaction work shall be solely based on the

results of the post‐treatment CPTu’s in relation to the selected CPTu acceptance profile.

f) The results from the CPTu testing shall be averaged over a two meter rolling average to account for

localised spikes and then plotted against the acceptance profile.

Figure 5‐1: Example of (F) vs Relative Density Graph for a Sandy Gravel (after Selig 1973)

‐30

‐25

‐20

‐15

‐10

‐5

0

5

0.0 10.0 20.0 30.0 40.0 50.0

Depth (m CDP)

Corrected cone resistance, qt (MPa)

ID = 60 %

ID = 70 %

ID = 80 %

ID = 90 %


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5.2 Tolerances

5.2.1 Dredging

Dredging shall be carried out to the required levels and profiles or such modified levels and profiles. Any out of

tolerance work will be rectified by the Contractor at his own cost. For final acceptance the following tolerances shall

be applied to dredged areas:

5.2.1.1 Basin dredging

Horizontal (x,y) lines: A maximum deviation of +1.5 m (overdredging) shall be permitted. No negative tolerance shall

be allowed.

Levels: A deviation of +0mm above the theoretical CD (Port) level as shown on the drawings will be required. There

is no restriction on the over‐dredging below the levels shown on the drawings. Although there are no restrictions on

overdredging, there is a restriction on the amount of material allowed for disposing of offshore. The maximum

volume is stated in the Project Environmental Specification (PES) and the Contractor is to ensure that the amount of

material disposed of, and hence the amount of material dredged, is below the value stated in the PES.

Within 20 m of any existing structure or proposed new structure the maximum permitted over‐dredge, below the

specified dredged levels, shall be 500 mm. Ploughing of material from under‐dredged areas into over‐dredged areas

is only permitted for final levelling of areas; the Contractor shall not intentionally over‐dredge and adopt this method

as his main dredging methodology.

5.2.1.2 Berth dredging for caisson and scour trench

A tolerance of + 150 mm to ‐350 mm from the designated levels shall be acceptable, whilst the tops and toes of the

side slopes shall be within 1 m of the locations shown on the drawings.

5.2.1.3 Side slopes

Slopes shall be profiled such that the average gradient of the slope indicated on the drawings is not exceeded.

5.2.2 Infill reclamation

A tolerance of + 150 mm/ ‐ 150 mm from the designated levels shall be acceptable.

5.2.3 Reclamation compaction

a) The Contractor is to provide a plan layout of the proposed compaction grid. Probes shall be performed

within 300 mm of the planned location.

b) The vibrator tip shall penetrate to the full reclaimed depth which is based on the dredged profile.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – CRANE RAIL WELDING

1370‐CO‐000‐C‐SPC‐0005 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN



REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 INTRODUCTION ....................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1


2.1 Reference Documents ..................................................................................................................................... 1 2.2 Standard Specifications ................................................................................................................................... 1 2.3 Reference Employer’s Project Specific Specifications and Standards ............................................................. 1

3.0 DEFINITIONS ............................................................................................................................................ 1


4.0 REQUIREMENTS ..................................................................................................................................... 2

4.1 General ............................................................................................................................................................ 2 4.2 Method Statement .......................................................................................................................................... 2 4.3 Arc Welding Of Crane Rail Joints ..................................................................................................................... 2

4.3.1 General .......................................................................................................................................... 2 4.3.2 Preparation .................................................................................................................................... 2 4.3.3 Welding ......................................................................................................................................... 2 4.3.4 Finishing ........................................................................................................................................ 2 4.3.5 Tolerances ..................................................................................................................................... 3

4.4 Exothermic Welding Of Crane Rail Joints ........................................................................................................ 3

4.4.1 Preparation .................................................................................................................................... 3 4.4.2 Fitting of half moulds and sealing ................................................................................................. 3 4.4.3 Preheating of joint ......................................................................................................................... 3 4.4.4 Loading the crucible ...................................................................................................................... 3 4.4.5 Pouring .......................................................................................................................................... 4 4.4.6 Removing mould and trimming ..................................................................................................... 4 4.4.7 Finishing ........................................................................................................................................ 4 4.4.8 Acceptance Standards ................................................................................................................... 4 4.4.9 Tolerances ..................................................................................................................................... 4

5.0 COMPLIANCE WITH REQUIREMENTS: RECORDS AND TESTING ................................................................ 5

5.1 Records ........................................................................................................................................................... 5 5.2 Tests ................................................................................................................................................................ 5


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1.0 INTRODUCTION

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the welding of crane rails into continuous

lengths. The Contractor may make use of either an arc welding or exothermic welding process. Requirements for

both welding procedures are covered herein.



The following industry standardised specifications are referenced in this specification and form part of the Works

Information.


a) This Specification.

b) Industry Codes, Standards and Specifications as listed in Section 2.2.

c) Employer’s Project Specific Technical Specifications as listed in Section 2.3.


─ 1370‐CO‐110‐C‐DWG‐0009‐01, Crane Rails & Cable Protector Details and Installation.

e) Method statement prepared by the Contractor, as described in Section 4.



a) SANS 532: 2009 Standard and Specifications for Industrial, Medical, Propellant, Food and Beverage Gases,

Refrigerants and Breathing Gases.

b) SANS 1774: 2007 Liquefied petroleum gases.

c) AWS D1.1/D1.1M:2015, American Welding Society ‐ Structural Welding Code – Steel.

2.3 Reference Employer’s Project Specific Specifications and Standards


a) 1370‐CO‐000‐C‐SPC‐0003 – Cope, Service Tunnels, Quay Furniture and Services.

b) Environmental Management Plan (EMP).

3.0 DEFINITIONS





For the purpose of this specification, the definitions and abbreviations given in AWS D1.1/D1.1M:2015, shall apply.








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4.0 REQUIREMENTS

4.1 General

Welding of joints shall be by either the exothermic or by the arc welding process.

Only welders who are qualified in the approved welding procedure in accordance with the tests laid down in the

relevant AWS standard, or who have attained a similar standard, shall be employed on the Works.


At least a week before any joint is welded the Contractor is to supply the Supervisor with a welding method

statement which must include, but is not limited to the following:

a) Proof of welders’ proficiency.

b) A detailed joint design.

c) Proposed heating and cooling control factors to achieve required hard facing specification (cooling rates

and conditions).

d) Proposed methods for determining that the rail ends are at the correct/specified temperature.

e) Proposed method for determining that the rail crown is of the correct contour after being ground down.

f) Proposed method for determining whether the required standards specified in Section 4.4.8.

The Contractor shall submit with his tender a detailed health and safety plan, indicating the safety and precautionary

measures to be adopted for storage of flammable substances, prevention of explosions from working in close

proximity to open flames and/or sparks, protective clothing for welders, fire fighting plans, dealing with toxic fumes

from igniters, etc.

4.3 Arc Welding Of Crane Rail Joints

4.3.1 General

Crane rails of any quality steel with not more than 2% Mn, may be arc welded into continuous lengths, provided that

the welders are certified and qualified as stipulated in Section 3.

Completed welds must be certified by a certified welding inspector.

4.3.2 Preparation

Before a joint is welded:

a) The gap between the rail ends shall be adjusted to 16 mm.

b) An 8 mm thick copper plate shall be placed under the gap and the rail ends upset approximately 2 mm.

c) The rail ends shall be aligned.

d) The rail ends must be cleaned of all foreign matter, scale etc. by grinding

Electrodes for initial welding shall be low hydrogen, 5 mm diameter class R, either Superweld LH 56 or Supercito. For

hardfacing the following electrodes are to be used:

Superweld 300; OK83‐28; OK Hardtrode 2, Various LH, Citro‐rail or Gridur 42.

Approximately 100 mm of each rail end at the joint shall be heated to 350 oC before welding starts.

4.3.3 Welding

The weld shall be built up in layers approximately 5 mm thick using stringer beads. The top 5 mm shall be hardfaced

to the rail supplier’s specification.

4.3.4 Finishing

After welding is complete, the copper plate, the U shaped copper strips, packing plates and wedges shall be removed

and discontinuities restored and the joint heated to 500o C to relieve stresses.


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4.3.5 Tolerances

After the rail has cooled to ambient temperature the joint shall be ground to the following tolerances:

On the crown, a 0.4 m feeler shall not enter anywhere between the top of the rail and a 1.5 m straight edge placed

centrally over the joint and parallel to the rail axis.

On the running edge (or edges if the crane wheels are double flanged) a 1 mm feeler shall not enter between the

running edge and a 1.5 m straight edge placed centrally to the joint and parallel to the top of the rail.

4.4 Exothermic Welding Of Crane Rail Joints

4.4.1 Preparation

The rail must be brought to line and level for 3 m on either side of the joint to be welded.

While the rail is being prepared, the welder must ensure that the crucible is clean and that all moisture is removed by

heating the lining.

The rail ends must be cleaned of all foreign matter and a gap between 16 and 18 mm wide must be made either by

moving the rails or by cutting.

The joint must be set‐up approximately 2 mm as measured at the ends of a 1.5 m straight edge. The correct set‐up

for prevailing conditions must be established by the welder when he checks the first finished joint after grinding.

Special jacks or steel wedges must be used to support the rails in the set‐up position during welding.

4.4.2 Fitting of half moulds and sealing

The half moulds must be placed in the mould shoes, fitted centrally to the rail joint, securely clamped into position

and the edges sealed against the rail.

While the moulds are being sealed, the top must be covered so that nothing which can contaminate the weld can fall

into the mould.

The pouring cup and slag tray must be fitted to the mould shoes and sealed. The face of the pouring cup must be

sealed lightly. (If a heavy seal is applied to this face, the sealing compound will be carried into the mould and

contaminate the weld.) The crucible stand and torch holder must then be clamped to the rail.

4.4.3 Preheating of joint

The rail ends must be heated with a torch using oxygen and liquefied petroleum gas. The most suitable pressures and

flame for quick heating are as follows:

Liquefied petroleum gas: 35 to 45 kPa

Oxygen: 125 to 140 kPa

Types of flame: slight excess L.P. gas

After the flame is adjusted, the torch must be clamped in the torch holder and set with the nozzle vertical and central

over the gap approximately 16 mm from the rail surface.

The rail ends must be heated to approximately 1100 oC ‐ orange‐red colour. This normally takes from 10 to 12

minutes. As the pressure of petroleum gas depends on the rate of evaporation, a constant watch must be kept and

adjustments made to the flame to ensure correct heating.

Rail ends must not be melted because a layer of oxide will form between the parent metal and the weld metal

causing incomplete fusion.

4.4.4 Loading the crucible

During the preheating period, the crucible must be placed in the crucible stand, the tapping bin, asbestos plug,

sealing powder and thermit portion placed in the crucible ready for igniting and the crucible swivelled into position

over the pouring cup.

When the rail ends are at the correct temperature, the thermit portion must be ignited by means of an igniter

submerged approximately 20 mm into the thermit compound.

The heating torch must be released from its clamp and held by hand with the flame still directed onto the rail ends

until the crucible is ready for tapping.


PORT OF DURBAN



Page | 4

4.4.5 Pouring

When, after about 30 seconds, the reaction in the crucible is complete, the tapping pin must be given a sharp upward

blow by means of the tapping spade and the melt run into the pouring cup from where it will flow into the mould

through the pouring gate. The slag will run over the top of the mould and into the slag tray.

After each weld, any loose slag remaining in the crucible must be removed. After every fifth weld, the crucible lining

must be cleared of all slag, since the presence of slag in the crucible is detrimental to the thermit metal.

The joint must be allowed to solidify without being disturbed.

4.4.6 Removing mould and trimming

After the joint has solidified, the top of the mould and the sealing compound must be removed. The mould shoes

and toggle clamp must be left in position while the riser on the crown of the rail is cut away by means of a hot‐set.

After this is done, a period of 2.5 minutes must elapse before the toggle clamp, mould shoes and excess metal on the

side of the crown are removed.

As soon as the excess metal has been removed, the joint must be rough‐ground with a portable rail head grinder.

Only weld metal must be ground away.

The jack or wedges must be removed and the joint left to cool.

4.4.7 Finishing

After the joint has cooled to the ambient temperature, all sand should be cleaned off the joint and final grinding

done to conform to the standards set out hereinafter.

Welded joints shall be so ground that the rail crown will be smooth and of the correct contour. Rail burn due to

excessive grinding speed must be avoided.

If the sides of the crown of welded joints are mismatched to a maximum of 1.0 mm, they must be ground so that the

difference is run out over a distance of 150 mm.

If a finished joint is found to be beyond the tolerance allowed, it must be corrected by the application of heat or by

the use of a jim‐crow.

4.4.8 Acceptance Standards

The weld must be free of slag‐inclusions and foreign matter, and there must be no cracks.

The weld must not be undercut or porous and it must be free of craters.

The reinforcing metal must be well formed and free of oxidation.

4.4.9 Tolerances

On the running top of the rail, a 0.4 mm feeler shall not be able to be inserted at any point along a 1.5 m straight

edge placed centrally over the joint, it being understood that only a gradual sweep is permitted from the end to the

center of the straight edge. (The thickness of the rail crown must now be reduced through grinding by more than

0.4 mm)

On the running edges of the rail, a 1.0 mm feeler shall not be able to be inserted at any point along a 1.5 m straight

edge placed centrally over the joint on the side of the crown.


PORT OF DURBAN



Page | 5

5.0 COMPLIANCE WITH REQUIREMENTS: RECORDS AND TESTING

5.1 Records

The Contractor shall punch a number at each weld on the field side of the railhead to uniquely identify the weld.

The Contractor shall record the following information for each joint made by welding:

a) The unique consecutive weld number.

b) The date of the weld.

c) The location of the joint including:

─ The chainage distance of the joint relative to the rail chainages indicated on the drawings.

─ Whether in the land or seaside rail.

d) The welder number who performed the specific joint.

The Contractor shall sign and date the record and hand it to the Supervisor on completion of the work for the day.

5.2 Tests

All welds shall be tested by means of ultrasonic, Non‐Destructive Testing (NDT). The acceptance standard for the

interpretation of non‐destructive testing shall be the latest edition of API 5L.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – REAR CRANE RAIL PILES

1370‐CO‐000‐C‐SPC‐0006 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN



REVISIONS


BY

CHECKED

BY

APPROVED

BY

T‐00 31 May 2016 Issue for Review AH MC JZ

T‐0A 18 November 2016 Issue for Tender AH MC JZ

AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Definitions ....................................................................................................................................................... 1 1.3 Scope ............................................................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 2

3.1 Chart Datum Port ............................................................................................................................................ 2 3.2 Co‐ordinate System ......................................................................................................................................... 2 3.3 Tidal Levels ..................................................................................................................................................... 2 3.4 Method Statements ........................................................................................................................................ 2

4.0 REQUIREMENTS ....................................................................................................................................... 3

4.1 Method Statements ........................................................................................................................................ 3 4.2 Materials ......................................................................................................................................................... 3

4.2.1 General .......................................................................................................................................... 3

4.3 Equipment ....................................................................................................................................................... 3 4.4 Methods and Procedures ................................................................................................................................ 3

4.4.1 General .......................................................................................................................................... 3 4.4.2 Methodology ................................................................................................................................. 3 4.4.3 Enlarged base ................................................................................................................................ 4 4.4.4 Sequence of installation ................................................................................................................ 4 4.4.5 Driving assistance .......................................................................................................................... 4 4.4.6 Trimming of the pile to cut‐off level .............................................................................................. 4

4.5 Record Keeping ............................................................................................................................................... 4

5.0 COMPLIANCE WITH REQUIREMENTS ....................................................................................................... 5

5.1 Sampling and Testing of Concrete .................................................................................................................. 5 5.2 Supervision and Monitoring ............................................................................................................................ 5 5.3 Pile Testing ...................................................................................................................................................... 5 5.4 Tolerances ....................................................................................................................................................... 5


PORT OF DURBAN



Page | 1

1.0 SCOPE

1.1 Project



1.2 Definitions





1.3 Scope

The scope of this specification covers the Employer’s requirement for the installation of a group of cast in situ

displacement piles which support the rear crane rail beam.


The following Employer and industry standardised specifications are referenced in this specification and form part of

the Works Information.







1370‐CO‐100 series of drawings – Rear Crane Rail Piles and Beam

e) Method statement prepared by the Contractor, as described in Section 4

f) Project Geotechnical Reports, included in Part 4 ‐ Site Information


The governing standard for this specification shall be the latest version of:

a) BS EN 12699:2015. Execution of special geotechnical works. Displacement piles

Which shall apply in its entirety except for the variations and additions detailed in the specification clauses

below.

The following standard specifications are also referenced in this specification:

a) SANS 1200 F:1983 – Piling.

b) BS EN 16228:2014. Drilling and foundation equipment. Series on safety.





c) 1370‐CO‐000‐C‐SPC‐0007 – Paving

d) Environmental Management Plan (EMP)


PORT OF DURBAN



Page | 2

3.0 DEFINITIONS





For the purpose of this specification, the technical definitions and abbreviations given in BS EN 12699, together with








3.3 Tidal Levels






Mean Level ML 1.097




Method Statements shall be compiled by the Contractor for all activities. The Method Statements shall be submitted






PORT OF DURBAN



Page | 3

4.0 REQUIREMENTS



a) Details of the all the Materials and Equipment as per Section 4.2 and Section 4.3.

b) Descriptions and ratings of other installation Equipment not covered here including cranes and

power packs.

c) Details of the methods and procedures for the safe use of all of the Equipment and for all of the

piling activities.

d) Details of the methods and procedures for transport, handling and storage of all of the Materials and

Equipment.

e) Details of the methods and procedures for installing the piles.

f) Details of the methods and procedures for expanding the base of the piles.

g) Details of the methods and procedures to help facilitate driving.

h) Details of the methods and procedures for cutting and trimming piles.

i) Details of the methods and procedures for monitoring the pile installation.

j) Details of the methods and procedures for the pile load tests.

k) Details of the method and procedures for ensuring the piles are installed to the tolerances specified

in Section 5.4.

4.2 Materials

4.2.1 General

All material and products shall meet the requirements detailed in the project specification, Concrete for marine

construction (1370‐CO‐000‐C‐SPC‐0001) and this specification.

4.3 Equipment

The piling Equipment shall comply with EN 12699 and EN 16228.


4.4.1 General

All plant, materials and operations employed in the formation of a pile shall be such as to ensure that the completed

pile satisfies the minimum required cross section and material requirements of this specification.

4.4.2 Methodology

The piles shall be installed by driving a closed ended tube (concrete shell or temporary casing) forming the hole. An

enlarged base shall be formed followed by placement of the reinforcing cage and high slump concrete. The

temporary shell or casing is finally extracted.

The method of forming the enlarged base shall be as follows:

1. A plug is placed in the piling tube.

2. The tube is driven.

3. On reaching the founding level the tube is held by the extracting gear while the plug is expelled.

4. Measured quantities of relatively dry concrete are expelled from the toe of the tube thus forming an

enlarged base.


PORT OF DURBAN



Page | 4

4.4.3 Enlarged base

The enlarged base shall have a volume of 0.32 m3 as shown on the drawings. The detailed methodology for

base enlargement shall be agreed with the Supervisor before the commencement of the work.

4.4.4 Sequence of installation

The rear crane pile shall be installed after the reclamation compaction (Project specification SPC‐0004) and before

the installation of the pavement layerworks (Project specification SPC‐0007).

4.4.5 Driving assistance

Driving assistance such as predriving, preboring, water jetting, shall be planned by the Contractor and approved by

the Supervisor prior to start of work and shall only be permitted if it has no adverse effect on the pile end bearing

and friction capacity.

4.4.6 Trimming of the pile to cut‐off level

The cut‐off levels for the piles are shown on the drawings. The top 300 mm of the pile shall be broken down or cut‐

off after casting, removing any poor quality concrete.

4.5 Record Keeping

a) Site records shall be in accordance with BS EN 12699.

b) Pile load test reporting and record keeping shall be in accordance with SANS 1200 F.


PORT OF DURBAN



Page | 5


5.1 Sampling and Testing of Concrete

All sampling and testing of concrete shall comply with the project specification, Concrete for marine construction

(1370‐CO‐000‐C‐SPC‐0001).

5.2 Supervision and Monitoring

Supervision and monitoring shall be in general accordance with BS EN 12699.

The full driving record of the piles should be recorded.

5.3 Pile Testing

The Contractor is required to undertake a minimum of two static pile load tests per construction phase. Additional

static loads tests may be requested by the Supervisor following a review of the pile load test results.

The load tests shall be in accordance with SANS 1200F and the “British Procedure”. The test pile location shall be

approved by the Supervisor.

In addition to the requirements of clause 7.6 of SANS 1200 F, the total deflection of the top of a piles (including

elastic shortening of the pile) shall not exceed the following:

a) When the pile is loaded to the working load the total vertical deflection shall not exceed 10 mm.

b) When the pile is loaded to 1.5 times the working load the total vertical deflection shall not exceed 18 mm.

c) The individual pile working load is 200 kN.

5.4 Tolerances

The tolerances on position, verticality, dimensions and bow shall be in accordance with Section 6 of SANS 1200 F.

For the recording of construction deviations the centre of a cast in situ pile is considered as the centre of the largest

circle which can be drawn within the section of the pile head.

TRANSNET SOC LTD

DCT BERTHS 203 T0 205 – RECONSTRUCTION, DEEPENING AND

LENGTHENING

PORT OF DURBAN

SPECIFICATION – PAVING

1370‐CO‐000‐C‐SPC‐0007 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN


1370‐CO‐000‐C‐SPC 0007 Rev T‐0A November 2016

REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






PORT OF DURBAN


1370‐CO‐000‐C‐SPC 0007 Rev T‐0A November 2016

CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 2

3.1 Chart Datum Port ............................................................................................................................................ 2 3.2 Co‐ordinate System ......................................................................................................................................... 2 3.3 Tidal Levels ..................................................................................................................................................... 2 3.4 Method Statements ........................................................................................................................................ 2 3.5 Technical Definitions ....................................................................................................................................... 2

4.0 GENERAL REQUIREMENTS ....................................................................................................................... 4

4.1 Method Statement .......................................................................................................................................... 4 4.2 Sequencing ...................................................................................................................................................... 4 4.3 Compaction Equipment .................................................................................................................................. 4 4.4 Demolition of existing concrete and asphalt pavement ................................................................................. 4 4.5 Roadbed preparation ...................................................................................................................................... 4 4.6 G7 Selected Layer ............................................................................................................................................ 4 4.7 Road and Stack Markings ................................................................................................................................ 4

4.7.1 Surface preparation ....................................................................................................................... 4 4.7.2 Paint .............................................................................................................................................. 5

5.0 CONCRETE PAVEMENT REQUIREMENTS .................................................................................................. 6

5.1 Scope ............................................................................................................................................................... 6 5.2 Asphalt Separation Layer ................................................................................................................................ 6 5.3 G1 Crushed Stone Base ................................................................................................................................... 6 5.4 Concrete Pavement ......................................................................................................................................... 6 5.5 Jointing ............................................................................................................................................................ 6

6.0 FLEXIBLE PAVEMENT REQUIREMENTS ..................................................................................................... 7

6.1 Scope ............................................................................................................................................................... 7 6.2 Prime Coat (COLTO 4100) .............................................................................................................................. 7 6.3 Continuously Graded Asphalt Base Layer (COLTO 4200) ................................................................................ 7 6.4 Tack Coat (COLTO 4200) .................................................................................................................................. 7 6.5 Semi Rigid Asphalt Surface .............................................................................................................................. 7

6.5.1 Materials ....................................................................................................................................... 7 6.5.2 Equipment ..................................................................................................................................... 7 6.5.3 Construction .................................................................................................................................. 7


PORT OF DURBAN



Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the construction of a jointed unreinforced cast

in situ concrete pavement and asphalt paving in the marine environment. The scope of this portion of the works may

be summarised as follows:

a) The demolition and construction of a concrete pavement, and

b) The construction of asphalt paving.

Asphalt paving is to be constructed between the back face of the capping beam and the slot drain.

Concrete paving is to be constructed between the slot drain and the landside crane beam. The concrete paving shall

continue from the landward crane beam over the existing quay and tie in with the existing busbar tunnel.










1370‐CO‐160‐C series of drawings – Paving

1370‐CO‐170‐C series of drawings – Stack Markings, Road Markings and Fencing

e) Method statement prepared by the Contractor, as described in Section 4


The governing standard for this specification shall be the latest revision of:

a) COLTO – Standard Specifications for Road and Bridge Works for State Authorities, 1988

The following codes and standards shall supplement, but not supersede the primary codes and standards:

a) SANS 121:2011 / ISO 1461:2009 Hot dip galvanized coatings on fabricated iron and steel articles ‐

Specifications and test methods

b) SANS 920: 2011 Steel Bars for Concrete Reinforcement

c) SANS 4635:2004 / ISO 4635:1982: 2016 Rubber, vulcanized ‐ Preformed compression seals for use between

concrete motorway paving sections ‐ Specification for material

d) AASHTO M153: 2006 Standard Specification for Preformed sponge rubber and cork expansion joint fillers

for concrete paving and structural construction





C) Environmental Management Plan (EMP)


PORT OF DURBAN



Page | 2

3.0 DEFINITIONS












3.3 Tidal Levels


Table 3.1 – Tide data




Mean Level ML 1.097









3.5 Technical Definitions

a) Construction Joint means a joint made by design or made necessary by a prolonged interruption in placing

of concrete.

b) Longitudinal Joint means a joint parallel to the direction of construction.

c) Transverse Joint means a joint at right angles to the direction of construction.

d) Panel Length means the distance between 2 transverse joints.

e) Panel Width means the distance between 2 longitudinal joints.

f) Weakened Plane Joint means a plane of weakness created by sawing a groove in the surface of the

concrete.

g) Dowelled Weakened Plane Joint means a weakened plane joint at which the saw cut is made over the

centre line of a row of dowels cast into the concrete.

h) Tied‐Weakened Plane Joint means a weakened plane joint at which the saw cut is made along the centre

line of a row of tie‐bars cast into the concrete.

i) Butt Joint means a joint between adjacent slabs of concrete at which the meeting faces are plane surfaces.

j) Keyed Construction Joint means a joint between adjacent slabs of concrete at which a groove in one slab is

filled by a tongue of concrete in the adjacent slab.

k) Dowelled Or Tied Construction Joint means a butt or keyed joint at which dowels or tie‐bars are set in the

concrete with half their length on either side of the joint line.


PORT OF DURBAN



Page | 3

l) Isolation Joint means a butt joint at which there is no intimate contact between a concrete slab and an

adjacent fixed structure or another concrete slab.

m) Filler means a non‐extruding pre‐moulded compressible material is used to fill the gap at an expansion

joint.

n) Dowel means a plain mild steel bar set across a joint so as to permit contraction of the concrete and resist

movement of one slab relative to another in a vertical plane or parallel to the joint.

o) Tie‐bar means a steel bar with a deformed surface set across a joint so as to prevent separation of the joint

faces of adjacent slabs.

p) Bond‐Breaking Compound means a material with which dowels are coated to prevent concrete from

adhering to the dowels.

q) Concrete Infill means un‐reinforced, cast in situ concrete, placed to the dimensions as indicated on the

drawings, around rails in the rail recesses.

r) Roadbed means:

─ In front of the existing quay wall: The hydraulically placed fill on which the pavement layers are to

be constructed.

─ Behind the existing quay wall: The in situ material after excavation for pavement layers.


PORT OF DURBAN



Page | 4

4.0 GENERAL REQUIREMENTS

The clauses in this section apply to both the flexible pavement and the concrete pavement



a) Nature and sources of materials in base courses and concrete mix with test certificates and results.

b) Mix designs.

c) Details of proposed concrete mix design and programme of trial mix production.

d) Method of material storage and production, delivery and quality control.

e) Method of placing concrete including vibration

f) Curing methods.

g) Concrete pavement jointing procedures.

h) Falsework, formwork and methods of achieving specified finishes.

i) Details for positioning and securing cast‐in items to specified tolerances.

j) Details of flexible pavement materials.

4.2 Sequencing

No pavement works shall commence prior to the compacted hydraulic fill meeting the performance requirements as

specified in specification 1370‐CO‐000‐C‐SPC‐0004 Dredging and Reclamation (Including Vibro Compaction).

4.3 Compaction Equipment

Compaction equipment shall be in accordance with the relevant clauses of COLTO 3400, 3500, 3600 and 4200. In

restricted areas where the specific rollers cannot be used, compaction shall be carried out with hand operated

mechanical compaction equipment or approved smaller vibratory rollers. The revised compaction procedure shall be

submitted to the Supervisor for approval.

4.4 Demolition of existing concrete and asphalt pavement

All spoil from concrete and asphalt demolition shall be disposed of offsite at a registered disposal site of the

Contractor’s choice. Where the new concrete abuts existing asphalt or existing concrete, the existing pavement shall

be saw cut to form a neat edge.

4.5 Roadbed preparation

The roadbed (as defined in 3.5 above) shall be prepared in accordance with COLTO 3305 c) to a depth of 150mm at a

minimum compaction density of 93% MOD AASHTO (100% for sand).

4.6 G7 Selected Layer

The G7 selected layer shall be constructed between the hydraulic fill and the G1 crushed stone base. The layer shall

be compacted to 93% MOD AASHTO in accordance with COLTO 3400.

4.7 Road and Stack Markings

Stack and road markings shall be applied in accordance with COLTO 5700.

4.7.1 Surface preparation

All new and existing surfaces shall be prepared for the road and stack markings in accordance with COLTO 5705. The

Contractor shall lightly sandblast the concrete surface to which paint is to be applied to ensure the removal of curing

compound and any fine surface laitance to achieve a light (shallow) profile. All grit that is a by‐product of the

sandblasting operation must be removed to spoil outside the Port boundaries. The Contractor shall not sweep the

grit into the slot drains or harbour water.

The Contractor shall ensure that all joints and joint sealant is properly protected while the surface is being treated by

sand blasting or water jetting. The Contractor shall be held responsible for the repair of any damaged jointing.


PORT OF DURBAN



Page | 5

4.7.2 Paint

The lines or markings are to be painted with Plascon Hysheen Road and Runway Paint or similar approved, at an

application rate the rate of 0.42 l per m2. The colour of paint to be used shall be as specified on the drawing issued.

All paint shall conform to SABS 731‐1995.

The following must be noted by the Contractor in terms of SABS 731‐1:1995:

1. The paint shall be a Type 2 Paint

2. The paint shall be suitable for use on both a concrete surface and an asphalt surface

3. The paint is not required to be retro reflective

4. Drying time classification shall be Class 1

5. The colours required for the completion of the contract shall be:

a) White

b) Yellow

6. All the above colours to meet classifications according to SABS 1091.


PORT OF DURBAN



Page | 6

5.0 CONCRETE PAVEMENT REQUIREMENTS

5.1 Scope

The following activities are required to construct the concrete pavement structure:

G7 natural gravel

G1 crushed stone base

De‐bonding/separation asphalt surfacing layer over existing capping beam

Concrete including batching, placing and finishing

Jointing including galvanised steel tie bars, dowels, joint filler and sealants

One component polyurethane joint sealant (Installed as per the manufacturer’s specifications)

Alternative materials shall be considered provided that full details of the materials characteristics and applicable

specifications are submitted to the Supervisor for approval.

5.2 Asphalt Separation Layer

The layer shall be a 25 mm thick medium continuously graded asphalt surfacing layer in accordance COLTO 4200.

The existing concrete surface shall be water jetted or grit blasted prior to placement of the asphalt layer.

5.3 G1 Crushed Stone Base

The Contractor shall construct a 300 mm G1 crushed stone base with a minimum apparent relative density of 88% in

accordance with COLTO 3600. The base shall be placed and compacted in two layers of 150 mm thickness.

5.4 Concrete Pavement

A 375 mm thick un‐reinforced slab shall be constructed in accordance with the drawings and in strict accordance

with Employers specification 1370‐CO‐000‐C‐SPC‐0001 and COLTO 7100.

In accordance with COLTO 7125 the Contractor shall be responsible for the construction of the concrete pavement

which shall not exhibit any cracks. Construction of the pavement includes placing, curing and sawing of the concrete.

In accordance with COLTO 7125 (d) the Supervisor shall, in his opinion, where the strength and durability of the panel

is compromised by any form of cracking, regard such panel as a Defect. Such defects shall warrant the removal and

reconstruction of that particular panel or section of pavement. Where, in the opinion of the Supervisor, cracking is

not detrimental to the strength and durability of the pavement the Contractor shall repair such cracks, if so required

by the Supervisor. The method used to repair such superficial cracks shall be approved by the Supervisor.

Jockey slabs are deemed to be reinforced concrete and shall comply with the durability requirements of reinforced

concrete as detailed in specification 1370‐CO‐000‐C‐SPC‐0001 Concrete for Marine Construction.

5.5 Jointing

All jointing shall be in strict accordance with COLTO 7100.

Tie‐bars and dowel bars are to be hot‐dipped galvanised in accordance with SANS 121. The bond breaking cord shall be a closed‐cell expanded polyethylene cord.


PORT OF DURBAN



Page | 7

6.0 FLEXIBLE PAVEMENT REQUIREMENTS

6.1 Scope

The following activities are required to construct the flexible pavement structure:

G7 natural gravel in accordance with COLTO 3400

C3 cement stabilised base in accordance with COLTO 3500

C1 cement stabilised base in accordance with COLTO 3500

Prime Coat in accordance with COLTO 4100

Asphalt base in accordance with COLTO 4200

Tack coat in accordance with COLTO 4200

Semi rigid asphalt surfacing as detailed below

6.2 Prime Coat (COLTO 4100)

A MC‐30 cut back bitumen prime coat will be applied to the surface of the underlying G1 layer; this shall be applied

according to COLTO 4100. The application rate shall be at 0.7 l/m2 unless otherwise instructed by the Supervisor. The

prime coat shall comply with SANS 4001‐BT1.

6.3 Continuously Graded Asphalt Base Layer (COLTO 4200)

The base layer shall consist of a continuously graded 26.5 mm asphalt layer, with a 35/50 penetration grade bitumen

binder constructed to COLTO 4200 specifications. Asphalt base total thickness of 200 mm and constructed in lifts of

100 mm.

The nominal mix proportions and rates of applications are provided in COLTO tables 4202/6 to 4202/10. The

materials, climate and construction conditions must be taken into consideration when determining the rates and

proportions. A nominal mix variation in the bitumen content after approval shall be adjusted in accordance with

COLTO 4203 and 4215.

6.4 Tack Coat (COLTO 4200)

A tack coat consisting of a stable grade bituminous emulsion shall be applied to the surface of the underlying layer or

lift. The tack coat shall be applied at an application rate of 0.4 l/ m2 or as otherwise directed by the Supervisor.

Additionally, to improve adhesion a tack coat layer is required at all transverse and longitudinal joints.

6.5 Semi Rigid Asphalt Surface

6.5.1 Materials

The asphalt surfacing shall be a composite semi rigid surfacing, consisting of an open graded asphalt layer. The type

of penetration grade bitumen, shall consist of binder type 35/50 as specified in SANS 4001‐BT2 and latest

amendments.

The voids in the open graded asphalt are filled with resin modified cementitious grout. The grout shall be a Salphalt

Grout supplied and applied in accordance with the manufacturer’s specifications and recommendations.

The grading and properties of the mix are provided in Table 6.1.

6.5.2 Equipment

A paver shall be used to lay the Material. Compaction of the open graded asphalt shall be undertaken with a tandem

steel wheeled vibratory roller only. No pneumatic tyre rollers are permitted.

6.5.3 Construction

The surface shall be applied in accordance with COLTO 4200 unless otherwise noted below.

Surfacing shall be constructed in two stages as follows:

The open graded asphalt shall be laid and compacted

After asphalt has cooled to below 30 degrees Celsius, the resin modified cementitious grout shall be poured onto

the asphalt and vibrated into the voids


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Page | 8

No grouting shall be undertaken if the surface temperature rises above 40 degrees Celsius. No traffic shall be

permitted onto the layer before the grout is applied or until a period agreed to by the manufacturer after the grout

has been applied.

Table 6.1 ‐ Properties of Surface Layer

Sieve Sizing (mm)

% Passing

Min Max

19.000 100

13.200 90 100

9.500 40 60

4.750 15 30

2.360 10 15

0.600 3 8

0.300

0.150

0.075 1 3

Voids (%) 20 25

Bitumen Content (%) 3.9 4.2

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – SCOUR PROTECTION AND REVETMENTS

1370‐CO‐000‐C‐SPC‐0008 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN



REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 3

3.1 Chart Datum Port ............................................................................................................................................ 3 3.2 Co‐ordinate System ......................................................................................................................................... 3 3.3 Tidal Levels ...................................................................................................................................................... 3 3.4 Method Statements ........................................................................................................................................ 3 3.5 Technical Definitions ....................................................................................................................................... 3

4.0 REQUIREMENTS ....................................................................................................................................... 5


4.2.1 Requirement for Rock to be provided by Contractor ................................................................. 5 4.2.2 Rock Gradings and class limits ....................................................................................................... 5 4.2.3 Rock Shape .................................................................................................................................... 5 4.2.4 Rock Quality Requirements ........................................................................................................... 6 4.2.5 Geotextile ...................................................................................................................................... 6

4.3 Equipment ....................................................................................................................................................... 6

4.3.1 General .......................................................................................................................................... 6 4.3.2 Marine Equipment ........................................................................................................................ 6 4.3.3 Survey Equipment ......................................................................................................................... 6

4.4 Methods and procedures ................................................................................................................................ 7

4.4.1 Sequence ....................................................................................................................................... 7 4.4.2 Preparation of trenches and slopes .............................................................................................. 7 4.4.3 Filter fabric/geotextile ................................................................................................................... 7 4.4.4 Placing of Rock .............................................................................................................................. 7 4.4.5 Stockpiling of rock ......................................................................................................................... 8 4.4.6 Grading of rock armour layers ....................................................................................................... 8

4.5 Surveys ............................................................................................................................................................ 8

4.5.1 Requirements of Marine Surveys .................................................................................................. 8 4.5.2 In‐survey ........................................................................................................................................ 8 4.5.3 Out‐surveys ................................................................................................................................... 8 4.5.4 Timing of surveys .......................................................................................................................... 9


5.1 Testing and Sampling .................................................................................................................................... 10

5.1.1 General ........................................................................................................................................ 10 5.1.2 Sampling ...................................................................................................................................... 10


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5.1.2.1 Size and Composition of Samples ................................................................................................ 10 5.1.2.2 Methods of recovering samples .................................................................................................. 11 5.1.2.3 Transportation and identification of the samples ....................................................................... 11

5.1.3 Testing ......................................................................................................................................... 11

5.2 Tolerances ..................................................................................................................................................... 11

5.2.1 Placement of scour protection .................................................................................................... 11 5.2.2 Scour Protection Profiles and Tolerances .................................................................................... 11

5.2.2.1 Vertical tolerances ....................................................................................................................... 11 5.2.2.2 Horizontal edge tolerances ......................................................................................................... 12


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Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the supply, construction, production, testing,

transport, placement, tolerances, acceptance criteria and survey for the construction of the rock scour protection

and rock revetments. The extent of the scour protection and rock revetments is shown on the 1370‐CO‐040 series of

drawings.

Specific emphasis is placed on durability in the marine environment. It covers basic Materials, Plant, quality,

construction, tolerances, tests and acceptance criteria.

The dimensions, grading, rock layer thicknesses and layer types shown on the construction drawings shall be strictly

observed. No alterations shall be made except on the receipt of the written approval of the Supervisor.

It shall be the responsibility of the Contractor to satisfy himself that the available quarries are capable of supplying

rock of the sizes, quality and quantity required (as described in this technical specification) for the duration of the

contract, failure in which the Contractor is to source Material which meets the required specification from an

alternative source at his own cost.

The construction of the scour protection includes for the procurement of specified grading of rock from quarries in

the Durban area or alternative quarry sites.


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- 1370‐CO‐040 series of drawings – Scour protection

e) Method statement prepared by the Contractor, as described in Section 4.1

f) Project Geotechnical Reports, included in Part 4 ‐ Site Information.



a) CIRIA, C683 – The Rock Manual, The use of rock in hydraulic engineering (2nd Edition), 2007, Revised

August 2008


b) SANS 1200 A:1986 General

c) SANS 1200 C:1980 Site clearance

d) SANS 1200 D:1988 Earthworks

e) BS 6349 – Maritime Works Series

f) BS 812 – British Standards Institution – Method for sampling and testing mineral aggregates (or equivalent

BS EN revision)

g) US Army Corps of Engineers: Coastal Engineering Manual



h) 1370‐CO‐000‐C‐SPC‐0004 – Dredging and Reclamation (Including Vibro Compaction)

i) Environmental Management Plan (EMP).


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3.0 DEFINITIONS












3.3 Tidal Levels






Mean Level ML 1.097









3.5 Technical Definitions

Class limits

- The size (or weight) defined for each rock grading together with the allowable percentage of a sample that

can lie beyond that limit, is as follows:

- Extreme lower class limit (ELCL)

- Lower class limit (LCL)

- Upper class limit (UCL)

- Extreme upper class limit (EUCL)

Effective mean weight Wem

- The arithmetic average weight of all blocks in a sample excluding any stone fragments.

Fine‐graded quarry stone

- A grading which is determined with the aid of sieve sizes.

Graded quarry stone

- Quarried stone which is graded by sieve sizes or by weight of the stone.

Heavy‐graded quarry stone

- A quarried stone grading which is determined by weight for stones of mean weight of at least 300 kg

per stone.


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Light‐graded quarry stone

- A quarried stone grading which is determined by weight or size of stone for mean weights less than

300 kg per stone.

Load of quarried stone

- The quantity of quarried stone per unit of transport.

Nominal stone diameter Dn

- The nominal stone diameter, Dn, shall be calculated as the cube root of the volume of the stone. The

volume shall be calculated by dividing the mass of the stone by the saturated surface dry density.

Where a numbered subscript is given to Dn, this refers to the percentage by weight of stones in the

grading having a smaller nominal stone diameter.

Quarried stone

- Broken, natural stone.

Saturated surface‐dry

- The condition of the aggregate when all permeable pores of each particle are completely saturated

with water and its surface has no free moisture.

Stone fragment

- A piece of stone in a grading with a lesser weight or size than the extreme lower class limit (ELCL) for

that particular grading class.


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4.0 REQUIREMENTS


The Contractor shall prepare method statements that shall include inter alia:

a) Nature and sources of materials with test certificates and results

b) Method of material storage and production, delivery and quality control

c) Method of placing

4.2 Materials

4.2.1 Requirement for Rock to be provided by Contractor

The Employer does not provide any rock to be used in the Works and it is ultimately the Contractor’s responsibility to

source the rock required for the scour protection works, as shown on the drawings and detailed in this specification.

4.2.2 Rock Gradings and class limits

The following rock gradings and class limits will be required in the Works:

Designation (Size ‐ mm)

Max ‐ D50 ‐ Min

Designation (Mass ‐ kg)

Max ‐ D50 ‐ Min POSITION

150 ‐ 90 ‐ 50 9 ‐ 2 ‐ 0.3 Basin and quay wall scour – Lower layer

275 ‐ 230 ‐ 175 60 ‐ 30 – 14 Basin scour – Upper layer

650 ‐ 540 ‐ 400 730 ‐ 420 – 170 Quay wall scour – Upper layer

Class limits ‐ 150 ‐ 90 ‐ 50

Class Limit Definitions % By weight smaller

ELCL

LCL

UCL

EUCL

0.5 kg

1 kg

7.5 kg

8.7 kg

< 2% 0‐10%

70‐100%

>97%

Class limits ‐ 275 ‐ 230 ‐ 175


ELCL

LCL

UCL

EUCL

12 kg

15 kg

50 kg

58 kg

< 2% 0‐10%

70‐100%

>97%

Class limits ‐ 650 ‐ 540 ‐ 400


ELCL

LCL

UCL

EUCL

420 kg

450 kg

615 kg

645 kg

< 2% 0‐10%

70‐100%

>97%

4.2.3 Rock Shape

Sampling shall be carried out in accordance with Section 5.1.2.


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4.2.4 Rock Quality Requirements

a) Density: The average density of quarry stone must be at least 2 700 kg/m³ with 90% of the stones having a

density of at least 2 600 kg/m.

b) Water absorption: The average water absorption of quarry stone shall be less than 2%, and the water

absorption of nine (9) of the individual stones less than 2.5%.

c) Resistance to impact and mineral fabric breakage: The average point load index (in the planar direction of

the most pronounced layering, should any visible anisotropy exist) shall be at least 4,0MPa.

d) Block integrity: Blocks from heavy gradings must be free from visually observable cracks, veins, fissures,

shale layers, styolite seams, laminations, foliation planes, cleavage planes, unit contacts or other such flaws

which could lead to breakage during loading, unloading or placing.

e) Impurities: Quarried rock shall not contain visually observable or chemically detectable impurities or

foreign matter in such quantities as are damaging to the constructive application of the quarried stone, or

for the environment in which the quarried stone is applied.

4.2.5 Geotextile

Filter fabric for placement in the scour protection may be of woven or non‐woven construction, and shall conform to

the following requirements:

Table 4.1: Filter fabric/geotextile requirements

Property Units Value Test Method

Trapezoidal Tear Strength N >1 050 ASTM D4533‐85

Tensile Strength kN/m >40 SANS 0221‐88

CBR Puncture kN >6,0 SANS 0221‐88

Pore size (apparent opening size) O95H μm 50 ‐ 150 NFG 38.C17

Permeability m/s >1*10‐5 SANS 0221‐88

Porosity (non‐woven fabrics) % >60 Calculation

Percentage open area (woven fabrics) % >5 Measurement

4.3 Equipment

4.3.1 General

The Contractor shall provide for all the necessary plant to deliver the specified rock quality and gradings, transport

the rock to the site and place the scour protection, as shown in the drawings, to the required tolerances. The

Contractor shall further provide Equipment for the accurate control of placing the rock and for surveying of the scour

protection layers, to prove compliance with the relevant tolerances.

The Contractor shall provide Equipment that is suitable for controlled placement of the scour protection. Land based

or waterborne Equipment is acceptable provided the placement of rock is undertaken in a controlled manner. Refer

to section 4.4 for further details regarding examples of suitable placement methods.

4.3.2 Marine Equipment

General requirements for marine Equipment are provided in the main body of the Works Information.


The requirements for survey equipment for undertaking in‐surveys and out‐surveys is specified in the Employer’s

specification for Dredging Reclamation and Sandbank Extension. The same requirements are applicable to surveys

undertaken for the scour protection works.


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4.4 Methods and procedures

4.4.1 Sequence

The construction of scour protection shall be undertaken for the specified areas of sandbank toe, sandbanks slopes,

basin slopes and each berth consecutively, in the sequence specified for berth deepening i.e. DCT Berths 203 to 205

Reconstruction, Deepening and Lengthening Project in the Port of Durban, with completion and hand over of each

berth before occupation will be given for the commencement of construction on the following berth. The specified

order of construction is as follows:

1. Quay wall scour protection

a) Dredge caisson trench and scour trench

b) Place and fill caisson

c) Final trimming and level of the scour protection trench after caisson placement

d) Place geofabric and scour layers

2. Basin scour protection other than adjacent to sandbank

a) Scour protection to be placed within 14 days of dredging of slope

3. Scour protection adjacent to sandbank

a) Scour protection to be placed after completion of the sandbank extension

4.4.2 Preparation of trenches and slopes

The dredging, profiling and cleaning of the scour protected areas is dealt with in the Employer’s specification 1370‐

CO‐000‐C‐SPC‐0004 Dredging and Reclamation (Including Vibro Compaction).

Before placing any geotextile, a dive survey of the trench is to be undertaken and all fine transported silty material is

to be removed by airlift.

4.4.3 Filter fabric/geotextile

Prior to placing the scour protection, the geotextile shall be made continuous either by firmly stitching together using

double stitching with 500 mm overlap, or by providing overlaps of not less than 1500 mm. The fabric shall be laid

with care to avoid overstretching or puncturing of the fabric during and after laying thereof. When un‐stitched laps

are used, acceptable measures shall be implemented to ensure that the 1500 mm overlaps are maintained until the

scour protection is in position. The method of laying fabric on any dredged slopes shall be such as to ensure that the

fabric is not stretched or damaged by down‐slope creep due to stone placement.

4.4.4 Placing of Rock

Quarried rock which will be placed in the works shall be transported and handled in such a manner as to minimise

segregation and breakage of the rock.

Rock shall be placed to the position and slopes indicated on the drawings.

The underlayer shall be placed to achieve a dense underlayer but shall not be compacted. The underlayer shall be

placed carefully to avoid damage to the geotextile. The underlayer shall be placed to achieve an even distribution of

stone sizes without concentration of smaller stones.

The rocks shall be placed in such a way that they do not obtain their stability on a plane by frictional resistance alone,

but also by interlocking. The Contractor shall take measures to ensure this prior to placing further rock.

Placement of both the smaller underlayer and the larger upper layer shall be in a controlled manner. Controlled

placement is defined as either bulk armourstone placement in relatively small quantities per cycle or as the individual

placement of heavier pieces of armourstone. Uncontrolled dumping of bulk material such as end tipping from a

dump truck or bulldozing the material off a flat topped barge is not permitted. Acceptable methods of controlled

placement include:

a) Hydraulic excavator with bucket or grab attachment

b) Wire rope crane with grab

c) Placement using a tube or chute


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4.4.5 Stockpiling of rock

Subject to the acceptance of the Supervisor, the Contractor shall be permitted to stockpile rock at or near the site of

the permanent works. Separate stockpiles shall be made and identified for different rock grades. The stockpiles shall

be formed so that they do not constitute a hazard; the location, side slopes and heights and other factors affecting

safety shall be as accepted by the Supervisor.

The Contractor shall make a risk assessment for the transportation to and handling of rock on site, and implement a

strict risk control plan and maintain good operational practice throughout the period of supply and installation for

the construction of the rubble mound structures. A stockpile plan must be drawn up which is commensurate with the

overall project planning, giving due regard to the quarry output capacity and production lead‐in time. Stockpiles on

site must be sized, taking into considerations the type of grading, access, weight limitations, manoeuvring and

handling requirements (tipping or tipping and stacking) and risk of cross contamination (no overlaps of grades). If

possible, a one‐way rotation system should be instituted for controlling traffic. The stockpile area must be checked

for services to avoid risk of damages. The Contractor shall prevent unauthorized pedestrian access, keep stockpile

areas well lit during night operation, maintain equipment in adequate working condition, and keep suitable backup

equipment nearby.

4.4.6 Grading of rock armour layers

The grading of rock armour layers shall be correctly maintained and to this end the Contractor shall at his own cost

take all actions necessary to remove any rocks that may have been displaced by wave or other action and washed or

swept or otherwise moved into voids of previously placed armouring before any further armouring necessary to

complete the sections is placed.

4.5 Surveys

4.5.1 Requirements of Marine Surveys

The requirements for marine surveys are as per those specified in the Employer’s specification for Dredging

Reclamation and Sandbank Extension.

4.5.2 In‐survey

The approved in survey is a combination of the following out surveys specified in the Employer’s specification for

Dredging Reclamation and Sandbank Extension:

a) On completion of dredging and profiling within the basin, the entire basin area (excluding the berth pocket

dredging) shall be surveyed to ensure compliance with the dredging tolerances.

b) On completion of berth dredging for the caisson and scour trench (berth pocket dredging), the trenches

shall be surveyed to ensure compliance with the dredging tolerances.

c) On final completion of the sandbank extension, a survey of the completed extension shall be undertaken to

ensure compliance with the placement tolerances for the sandbank.

4.5.3 Out‐surveys

On completion of each layer of scour protection the Contractor shall carry out an out survey of the scour protection.

This survey shall be carried out in collaboration with the Supervisor who will delegate staff to check the Contractor's

work and to undertake spot checks as necessary.

The out survey will comprise a combination of a dip survey and multibeam survey as detailed below:

a) Multibeam survey on a 3m grid as specified in the Employers specification for Dredging Reclamation and

Sandbank Extension.

b) Dip survey of the scour protection to ensure compliance with the required tolerances. The stone levels shall

be taken on a 3 m x 3 m grid and the levels shall be recorded to an accuracy of 50mm. The Contractor will

also be required to undertake underwater video inspections of the scour protection.

c) Dip survey measurements to survey the profile shall be carried out using a probe with a spherical end of

diameter 0.5 Dn50. For a land‐based survey this will generally be connected to a staff or EDM target; for an

underwater survey it will generally be a weighted ball on the end of a sounding chain.

d) The multibeam survey will be calibrated against the dip survey.


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The results shall be recorded on a drawing to a scale of 1:1000, which shall be submitted to the Supervisor. Relevant

features such as design depths, buoys, identification of ground survey control stations and quay numbers shall

be shown on the drawing. The orientation (north point) shall be indicated together with the drawing scale. The

datum to be used shall be Chart Datum Port.

The out‐surveys shall be used for checking tolerances only and will not form the basis for re‐measurement.

4.5.4 Timing of surveys

Surveys shall be carried out as follows:

a) In‐surveys – no more than two weeks before commencing the lower stone layer scour protection

placement in any area of the trench.

b) Out‐surveys – as soon as the relevant stone layer has been completed and the required tolerances have

been achieved.


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5.1 Testing and Sampling

5.1.1 General

Except where noted in this specification, all inspection, sampling and testing shall be done in accordance with BS 812

or similar approved industry standard.

When, on the basis of visual judgement of the quarried rock batch to be inspected, non‐homogeneity or possible

non‐homogeneity of the batch is considered to exist with regard to one or more of the relevant qualities, that batch

shall be divided into parts considered to be homogeneous. Sampling shall then be carried out on the individual

parts.

When one of the parts does not satisfy the requirements, the whole batch of quarried stone shall be considered

unsatisfactory.

If separation of the divided part(s), which does (do) not satisfy the requirements, is possible without difficulty, the

remaining part of the batch may be regarded as a separate batch.

Samples used for testing may be reincorporated into the works provided they have met the required specification.

Samples failing the specification or damaged during testing shall be disposed of by the Contractor.

5.1.2 Sampling

5.1.2.1 Size and Composition of Samples

Samples for determining particle distribution:

For the determination of the particle distribution of a fine‐graded quarry stone, at least six sub‐ samples shall be

taken if the sampling takes place from a stockpile or a ship's load. In all other cases the number of sub‐samples shall

be at least three.

The numerical value of the weight in kilograms of each sub‐sample must be at least equal to the numerical value of

the upper limit in millimetres of the designation of the grading concerned, if that upper limit is less than or equal to

100 mm. The numerical value of the weight of each sub sample, in kilograms, must be at least twice the numerical

value of the upper limit in millimetres of the grading designation if the upper limit is greater than 100 mm.

Samples for determining weight distribution:

For the determination of the weight distribution of the light or heavy graded quarry stone, at least six sub‐samples

shall be taken if the sampling takes place from a stockpile or a ship's load. In all other cases the number shall be at

least three.

The sub‐samples, including all the rock fragments, together constitute one sample. This sample must contain at least

200 pieces of stone heavier than the extreme lower class limit of the designated grading class.

When the determination of the weight distribution concerns a ship's load containing less than 200 pieces of stone,

the whole load is taken to be one sample.

Samples for determining shape and rock quality:

The numbers of stones of specified sizes constituting samples for rock shape and quality tests as enumerated above.

Samples for determining grading designated by size and average weight:

At least four sub‐samples shall be taken if sampling is from a ship's load or from a stockpile. In all other cases, the

number shall be at least two.

The sub‐samples, including all rock fragments, together constitute one sample. This sample must contain at least 100

pieces of stone retained on the square hole of size 500 mm x 500 mm for the light grading class.


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5.1.2.2 Methods of recovering samples

The necessary care shall be exercised to ensure that representative samples are recovered and that during sampling,

the degree of filling of a grab, or other extraction equipment, does not adversely affect the representivity of the

sample recovered.

5.1.2.3 Transportation and identification of the samples

For the transportation of a sample, precautions shall be taken to avoid loss or deterioration of the material, and to

ensure that the sample is not contaminated. All samples shall be accompanied by a certificate which contains the

following information:

a) A reference to this specification

b) The name of the producer and location of the quarry

c) The description and class designation of the grading

d) The number of stone pieces in the sample

e) Details on location and method of sampling, including the date of sampling

f) The name of the individual who took the sample

5.1.3 Testing

Testing shall be carried out in accordance with BS 812 and shall include but not be limited to the following:

g) Weighing

h) Determination of shape

i) Determination of rock density

j) Determination of water absorption at atmospheric pressure

k) Determination of block integrity by the drop test breakage index (CIRIA 1991)

Reports shall be generated by the Contractor and submitted to the submitted to the Supervisor for approval for all

testing as per the requirements of BS 812.

5.2 Tolerances

5.2.1 Placement of scour protection

Tolerances for the dredging and profiling of the scour protection trench and slopes are given in the Employer’s

specification for Dredging Reclamation and Sandbank Extension.

5.2.2 Scour Protection Profiles and Tolerances

5.2.2.1 Vertical tolerances

Scour protection shall be constructed to the dredge profile and rock layer profile levels as shown on the drawings

and shall comply with the vertical tolerances in Table 5.1 below.

Notwithstanding the tolerances in Table 5.1, the following shall apply to armour layers:

a) The tolerances on two consecutive mean actual profiles shall not be negative.

b) Notwithstanding any accumulation of positive tolerances on underlying layers, the thickness of the layer

shall not be less than 80% of the nominal thickness when calculated using mean actual profiles.


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Table 5.1: Vertical Placing Tolerances for Primary Armour Rock

Depth of placing below Chart

Datum

All Primary Armour

On individual measurements Design profile to actual*

Dry, i.e. above Chart Datum ± 0.3 Dn50 + 0.35 Dn50

‐ 0.25 Dn50

Below Chart Datum ± 0.5 Dn50 + 0.60 Dn50

‐ 0.40 Dn50

*All tolerances refer to the design profile to actual mean profile unless stated otherwise.

5.2.2.2 Horizontal edge tolerances

Lines: A maximum deviation of +0.5 m shall be permitted. No negative tolerance shall be allowed.

TRANSNET SOC LTD


LENGTHENING

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SPECIFICATION – STEEL SHEET PILING

1370‐CO‐000‐C‐SPC‐0009 Rev T‐0A

18 NOVEMBER 2016


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REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






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CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 3

3.1 Chart Datum Port ............................................................................................................................................ 3 3.2 Co‐ordinate System ......................................................................................................................................... 3 3.3 Tidal Levels ...................................................................................................................................................... 3 3.4 Method Statements ........................................................................................................................................ 3 3.5 Bent Piles ......................................................................................................................................................... 3 3.6 Cellular Caisson ............................................................................................................................................... 3 3.7 Followers ......................................................................................................................................................... 3 3.8 Jetting .............................................................................................................................................................. 3 3.9 Junction Piles ................................................................................................................................................... 3

4.0 REQUIREMENTS ....................................................................................................................................... 4


4.2.1 General .......................................................................................................................................... 4 4.2.2 Straight web sheet piles ................................................................................................................ 5 4.2.3 HZ and AZ sheet piles .................................................................................................................... 5 4.2.4 Anchorage ..................................................................................................................................... 6

4.3 Equipment ....................................................................................................................................................... 6

4.3.1 General .......................................................................................................................................... 6 4.3.2 Storage and handling Equipment .................................................................................................. 6 4.3.3 Pile driving Equipment .................................................................................................................. 7

4.4 Nature of In Situ Material ............................................................................................................................... 9 4.5 Methods and Procedures ................................................................................................................................ 9

4.5.1 General precautions ...................................................................................................................... 9 4.5.2 Safety ........................................................................................................................................... 10 4.5.3 Storage and handling ................................................................................................................... 10 4.5.4 Welding ....................................................................................................................................... 10 4.5.5 Pile toe modification ................................................................................................................... 10 4.5.6 Guides and templates.................................................................................................................. 10 4.5.7 Pile driving ................................................................................................................................... 10 4.5.8 Vibration and noise control ......................................................................................................... 12 4.5.9 Cutting and trimming piles .......................................................................................................... 12 4.5.10 Anchorage ................................................................................................................................... 12


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4.6 Record Keeping ............................................................................................................................................. 12

4.6.1 Pile driving ................................................................................................................................... 12 4.6.2 Monitoring of new sheet pile structures ..................................................................................... 13 4.6.3 Monitoring of existing structures ................................................................................................ 13


5.1 Pile Driving Wave Equation Analyses ............................................................................................................ 14 5.2 Pile Driving Trials ........................................................................................................................................... 14 5.3 Pile Inspection Tests ...................................................................................................................................... 14 5.4 Testing and Inspection of Welds ................................................................................................................... 14 5.5 Pile Driving Monitoring ................................................................................................................................. 14 5.6 Monitoring of the New Sheet Pile Wall and Existing Quay Wall ................................................................... 15 5.7 Tolerances ..................................................................................................................................................... 15

5.7.1 Sheet piles ................................................................................................................................... 15 5.7.2 Anchorage ................................................................................................................................... 15


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1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the supply, delivery, handling and installation

of steel sheet piles, which includes the following:

a) Construction of the return quay cellular caissons using straight web sheet piles, bent piles and junction

piles.

b) Construction of temporary sheet piling.


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c) Employer’s Project Specific Technical Specifications as listed in Section e)


- 1370‐CO‐070 series of drawings – Return Quay

- 1370‐CO‐080 series of drawings – Temporary Sheet Piling





a) BS EN 12063:1999. Execution of special geotechnical work. Sheet pile walls

which shall apply in its entirety except for the variations and additions detailed in the specification clauses below.

The following standards are also referenced in this specification:

a) BS EN 1993‐5:2007. Eurocode 3. Design of steel structures. Piling.

b) BS EN 16228:2014. Drilling and foundation equipment. Series on Safety.

c) BS 7121‐1:2016. Code of practice for safe use of cranes ‐ Part 1: General.

d) BS EN 10248‐1:1996. Hot rolled sheet piling of non alloy steels. Technical delivery conditions.

e) BS EN 10248‐2:1996. Hot rolled sheet piling of non alloy steels. Tolerances on shape and dimensions.

f) BS EN 10060:2003. Hot rolled round steel bars for general purposes. Dimensions and tolerances on shape

and dimensions.

g) BS EN 12699:2015. Execution of special geotechnical works. Displacement piles. Section 10. Records.



a) 1370‐CO‐000‐C‐SPC‐0002 – Caisson Construction and Placement


c) 1370‐CO‐000‐C‐SPC‐0017 – Corrosion Protection

d) Environmental Management Plan (EMP).


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3.0 DEFINITIONS





For the purpose of this specification, the technical definitions and abbreviations given in SANS‐1200‐F‐1983 and BS

EN 12063:1999 and as appropriate, together with the definitions given below shall apply:







3.3 Tidal Levels






Mean Level ML 1.097









3.5 Bent Piles

Bent piles are straight web sheet piles pre‐bent at the mill and can are used to set up structures or parts of structures

with small radii

3.6 Cellular Caisson

A caisson structure made up of a series of relatively closely spaced circular cells linked by connecting arcs. The

circular cells and linking arcs are formed by a series of individual straight web sheet piles. Each cell is a self‐

supporting structure.

3.7 Followers

A steel member placed between the pile hammer and pile that allows the pile to be driven below the reach of the

leader.

3.8 Jetting

Jetting is the use of pressurised fluid to temporarily reduce the toe resistance of the piles to be inserted. Depending

on the soil and jetting method the skin friction and interlock friction can also be reduced by rising water.

3.9 Junction Piles

Junction piles and bent piles are modified straight web sheet piles that are used to join circular cells and intermediary

arcs. Junction piles have additional straight web sheet piles welded to a standard straight web sheet pile at

connecting angle of 35 degrees.


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4.0 REQUIREMENTS


The Contractor shall prepare method statements that shall include inter alia, the following information:

a) Details of all the Materials and Equipment as per Section 4.2 and Section 4.3.

b) Descriptions and ratings of other installing Equipment not covered here including cranes and power packs.

c) Details of the methods and procedures for the safe use of all of the Equipment for all of the piling activities.

d) Details of the methods and procedures for transport, handling and storage of all of the Materials and

Equipment.

e) Details and calculations of the template design for the main cell and arc wall of the cellular caissons.

f) Details of the methods and procedures for the installation of the various piling templates and any other

temporary works.

g) Details of the pile driving wave equation analysis demonstrating pile drivability.

h) Details of the methods and procedures for driving the piles.

i) Details of the methods and procedures to help facilitate driving in the event of an obstruction.

j) Details of the methods and procedures used to reduce piling vibration and noise.

k) Details of the methods and procedures for cutting and trimming piles.

l) Details of any pile driving trials to be undertaken.

m) Details of the methods and procedures for pile driving monitoring.

n) Details of the methods and procedures for monitoring the new and existing structures during construction.

o) Details of the method and procedures for ensuring the piles are installed to the tolerances specified in

Section 5.7.

4.2 Materials

4.2.1 General

All sheet piles shall be fabricated in accordance with BS EN 10248. The piles for the cellular caisson shall be corrosion

protected in accordance with 1370‐CO‐000‐C‐SPC‐0017.

All welding shall be in accordance with EN 12063.

All sheet piles and connectors shall be submitted to inspection and testing in accordance with EN 10248. Inspection

document “type 3.1” based on specific inspection shall be issued by the manufacturer declaring that the products are

in compliance with the requirements of the order (EN 10248‐1, clause 10, option 8).

The Supervisor reserves the right to carry out inspections of the finished product at the manufacturers works prior to

shipping to South Africa (EN 10248‐1, clause 10, option 9). The Contractor shall inspect the sheet piles jointly with

the Supervisor after offloading in Durban, and any damaged items or defects shall be replaced or repaired by the

Contractor to the satisfaction of the Supervisor.

One product analysis shall be carried out for each cast for the determination of the chemical composition of the

product as specified in Table 1 of EN 10248‐1 (EN 10248‐1, clause 10, option 10).

All sheet piles shall be supplied by the manufacturer with colour markings defining sheet pile, length and steel grade

(EN 10248‐1, clause 10, option 11).

All sheet piles shall be supplied with a 50 mm diameter lifting hole on the centreline of the sheet pile through the

web, 250 mm from the head of the pile.

Sheet piles shall conform to the dimensional and mass tolerances specified in EN 10248‐2; where there is a conflict

between these two tolerances, the dimensional tolerances shall apply.

All profiling and strengthening of the pile toes shall be made using material of the same grade as the pile.

The required sheet pile materials are shown on the drawings. No provision has been made for additional piles that

may be required (e.g. due to damage). If the Contractor for whatever reason requires additional piles over and

above those shown on the drawings, then the Contractor will be responsible for procuring and supplying the

additional piles. All costs related to procuring and supplying of these piles will be for the Contractor’s account.


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4.2.2 Straight web sheet piles

The straight web sheet piles, bent piles and junction piles shall be fabricated from steel grade S430GP. Detailed

sections of these piles are shown on the drawings. Table 4.1 details the characteristics of the straight web sheet

piles.

Table 4.1: Characteristics of Straight Web Sheet Piles

Section Width Web

thickness

Deviation

angle

Perimeter Sectional

area

Mass Mass per

m2 of

wall

Moment

of

inertia

Section

modulus

b t δ

mm mm ° cm cm2 kg/m kg/m2 cm4 cm3

AS‐500‐12.5 500* 12.5 4.5** 139 97.2 76.3 153 201 51

* The effective width taken for layout purposes is 503 mm for all straight web sheet piles

**This angle has been limited to 3° and where deviation angles exceed this value in the arc walls bent piles have been used

to maintain this value.

All straight web sheet pile, bent piles and junction piles shall be able to interlock with each other. The minimum

strength of all interlocks shall be 5500 kN/m (EN 10248‐1, clause 10, option 7).

Standard junction piles shall be fabricated with a connecting angle of 35 degrees by welding in accordance with EN

12063. Bent piles shall be fabricated with a bend angle of 6 degrees. All junction and bent piles shall be pre‐welded

and pre‐bent at the mill.

The straight web sheet piles, bent piles and junction piles shall be rolled in the mill to the lengths shown on the

drawings. The Contractor shall not weld two or more sheet piles together to achieve the lengths shown on the

drawings.

4.2.3 HZ and AZ sheet piles

HZ and AZ sheet piles shall be fabricated from steel grade as indicated below. The RH, RZD, RZU and C9 connectors

shall be fabricated from steel grade S430GP.

Where the HZ sections are longer than the maximum rolling length, either longer sections may be requested from

the mill or two HZ sections shall be welded together in accordance with Section 4.5.4

HZ sheet piles are to be supplied with RH, RZD and RZU connectors pre‐welded to the sheet piles as applicable. The

connectors are the same length as the sheet piles. The welds shall be 6 mm discontinuous fillet welds applied over

10% of the length (100mm/m), over the whole connector length; and 500 mm continuous welds at the top and toe of

the connector.

Where two HZ sheet piles form a corner, special C9 connectors shall be welded onto the main sheet pile at the

appropriate location and angle.

HZ sheet piles shall have a shaped toe with flange and web plates welded to the section to provide additional

strength.

AZ piles shall be supplied as double piles (clutched together in pairs) in standard Form I. Pairs shall be crimped

together with at least 4 crimping points per meter.


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The HZ and AZ sheet piles and RH, RZD and RZD connectors shall be used to form the following Arcelor Mittal

designation combination walls:

Berth 203 Extension:

a) HZ 880M C – C1 (Steel grade S430 GP)

Berth 205 Extension:

a) HZ 880M C – C23 (Steel grade S355 GP)

b) HZ 880M C – 12 / AZ 18‐700 (Steel grade S355 GP)

c) HZ 880M C – 24 / AZ 18‐700 (Steel grade S355 GP)

A modified combination wall shall be fabricated onsite by cutting and welding together three HZ 88M C – C1 sections

as shown in detail three on drawing 1370‐C0‐080‐C‐DWG‐0002‐01.

4.2.4 Anchorage

The anchorage system shall comprise tie bars, waling’s, bearing plates, link plates, turnbuckles and couplers, washers

and nuts in accordance with the Anker Achroeder ASDO 355 M115/90 system or similar approved. The tie bars are

fabricated from ASDO 355 steel grade 355 (fy = 350 MPa)

The anchor tie bars shall conform to the dimensional and mass tolerances specified in EN 10060.

Two combinations anchor systems are required. These are shown on the drawings and are described as follows:

a) Type 1 anchor system transfers the forces from the sheet pile to the anchor bar through waling

sections that run the length of the wall. Both horizontal and vertical articulations are possible.

b) Type 2 anchor system comprises machined and factory welded tension plates placed either side of

the HZ web and passed through burnt holes in the flange. Forces are transferred from the HZ sheet

piles to the forged eye anchor bar through a pin connection with articulation in the vertical plane.

The required anchor system components are shown on the drawings. No provision has been made for additional tie

bars or other accessories that may be required (e.g. due to damage). If the Contractor for whatever reason requires

additional tie bars or accessories over and above those shown on the drawings, then the Contractor shall be

responsible for procuring and supplying the additional materials. All costs relating to procuring and suppling of these

additional materials shall be for the Contractors account.

Tie bars and other accessories shall be handled, transported and stored with all necessary precautions to prevent

damage and bending. The Contractor shall supply the necessary supports and protectors to enable safe handling and

stacking.

All anchor and coupling components shall be from a single propriety anchor system supplier, subject to the approval

of the Supervisor.

4.3 Equipment

4.3.1 General

The Contractor shall take full and entire responsibility for the sufficiency of his Equipment to provide the Works. The


the execution of this work commencing.

It is the Contractor’s responsibility for selecting a suitable installation method to provide the works. The Contractor

shall evaluate the in situ material conditions as discussed in Section 4.4 and select suitable Equipment.

4.3.2 Storage and handling Equipment

4.3.2.1 Support packing and spacers

When storing the sheet piles the Contractor shall support the piles on timber dunnage or similar product to avoid

sagging. Additionally timber or steel spacers and support packing shall be used to separate individual bundles and

provide stability to the stack.


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4.3.2.2 Lifting beams, slings, hooks and protectors

Depending on the lifting methodology the Contractor shall use lifting beams, lifting slings and lifting hooks. When

handling with chains or steel cable slings the Contractor shall use protectors to avoid damage to the sheet pile

interlocks.

4.3.3 Pile driving Equipment

4.3.3.1 General

All pile driving Equipment, including the pile driving hammer, hammer cushion, helmet, and other accessories to be

furnished by the Contractor shall be approved by the Supervisor before any driving can take place. In this regard the

Contractor shall submit a description of all pile driving Equipment to the Supervisor. The description shall contain

sufficient detail so that the proposed driving system can be evaluated by wave equation analysis.

Approval of pile driving Equipment shall not relieve the Contractor of responsibility to drive piles, free of damage, to

the required pile toe level shown on the drawings.

In selecting the driving Equipment to be used, the Contractor shall take cognisance of nearby marine structures and

shall select a driving method which will not destabilise or cause damage to nearby structures or piles.

Noise levels during pile installation shall be limited to the maximum allowed by the Project Environmental

Management Plan (EMP).

The Contractor is made aware of the low flexural stiffness of the straight web sheet piles, and shall select suitable

Equipment for handling, pitching and driving to the required depths without the sheet piles declutching or being

damaged.

4.3.3.2 Hammers

Piles shall be driven with an impact or vibratory hammer, or both. This Specification is non‐specific regarding the

type of hammer to be used and it left to the experience of the Contractor to select suitable Equipment to provide the

Works. The Contractor shall conform to the hammer manufacturer’s recommendations and shall ensure the

following minimum requirements are met when selecting a suitable hammer:

Drop Hammer:

a) Drop hammers shall not be used for sheet pile driving whose nominal resistance exceeds 600 kN.

b) The ram shall have a weight not less than 10 kN and the height of the drop shall not exceed 3.7 meters.

c) The ram weight of the drop hammers shall not be less than the combined weight of the helmet and pile.

Air/steam Hammers:

a) The Equipment furnished for air‐hammers shall have sufficient capacity to maintain, under working

conditions, the pressure at the hammer specified by the hammer manufacturer. The hose connecting the

compressor with the hammer shall be at least the minimum size recommended by the hammer

manufacturer.

Diesel Hammers:

a) Double acting diesel hammers shall be equipped with a bounce chamber pressure gauge, mounted near

ground level so as to be easily read. The Contractor shall provide a correlation chart of bounce chamber

pressure and potential energy.

Hydraulic Hammers:

a) Hydraulic hammers shall be equipped with a built in system for determining the ram velocity just prior to

impact.

Vibratory Hammers:

a) Vibratory pile driving methods may be used for pile driving and extraction.

b) Vibratory drivers shall have an operating frequency range suited to the onsite ground conditions.


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4.3.3.3 Driving Accessories

Hammer Cushion:

All impact pile driving equipment shall be equipped with a suitable thickness of hammer cushion material to prevent

damage to the hammer or pile. Hammers designed such that the hammer cushion is not required shall be excluded

from this requirement.

Where applicable, hammer cushions shall be made from durable manufactured material that will retain uniform

properties during driving. Wood, wire rope, or asbestos hammer cushions shall not be used. A striker plate shall be

placed on the hammer cushion to ensure uniform compression of the cushion material. The hammer cushion shall be

replaced by the Contractor before driving is permitted to continue whenever there is a reduction in the hammer

cushion thickness exceeding 25 percent of the original thickness or, for air hammers, when the reduction in thickness

exceeds the manufactures recommendations.

Driving Cap:

Piles driven with impact hammers shall be fitted with a driving cap to distribute the hammer blow uniformly and

concentrically to the pile head. The surface of the driving cap in contact with the pile shall be plane and smooth and

shall be aligned parallel with the hammer base and the pile top. It shall be guided by the leads and not be free‐

swinging. The driving cap shall fit the pile head in such a manner as to maintain concentric alignment of hammer and

pile.

For special types of piles, appropriate driving heads, mandrels, or other devices shall be provided so that the piles

may be driven without damage.

Leader:

Pile driving leaders that align the pile and the hammer in proper positions throughout the driving operation shall be

used as required. Leaders shall be constructed in a manner that affords freedom of movement of the hammer while

maintaining alignment of the hammer and the pile to ensure concentric impact for each blow.

Leaders may be either fixed or swinging type. Swinging leaders, when used, shall be fitted with a pile gate at the

bottom of the leader. The leader shall be adequately embedded in the ground or the pile constrained in a structural

frame such as a template to maintain alignment.

Followers:

When present the follower and pile shall be maintained in proper alignment during driving. The follower shall be of

such material and dimensions to permit the piles to be driven to the blow count determined to be necessary.

4.3.3.4 Jetting Equipment

Jetting Equipment shall be capable of providing the desired volume of water at the required pressure. The

Equipment shall be able to vary the jetting pressure to suit the ground conditions.

4.3.3.5 Monitoring Equipment

The Contractor shall provide an “Energy Saximter (E‐Sax)” or equivalent monitoring Equipment for each piling

operation where piles will be driven and blow counts will be recorded. The monitoring Equipment shall document

the installation process of each pile or pair of piles to assure that the driving criterion are met.

The monitoring Equipment shall allow a manual or automated collection of blow count per unit penetration and shall

measure the ram velocity at impact, and kinetic energy.

The monitoring Equipment shall display the acquired data in real time, and shall store data electronically for

transmission and permanent storage. The device shall have enough memory available for storage and download of

data at a later time.

The monitoring Equipment shall be able to record, pile name, date with start/stop times of all pile driving, blow rate,

stroke (for open end diesel hammers only), blow count versus depth, and impact velocity and kinetic energy.


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4.3.3.6 Pile Driving Guides and Templates

The Contractor shall employ suitable temporary wales, templates, guide frames or bracing as required to ensure that

the piles are installed to the required tolerances, do not declutch during driving and the pile is not damaged.

The Contractor shall design a template frame that can accommodate several HZ and AZ sheet piles at one time, and

that provides a rigid guiding system when driving the sheet piles.

A piling template shall be used for the cellular caisson construction. The template design shall take into

consideration, but not be limited to, the stability of the template structure, installation on land, number of cells to be

constructed, accuracy of template for intended use, reuse of template, length of the sheet piles, capacity of the

lifting equipment, and safety consideration for the work crew.

The exact template diameter shall be calculated to ensure correct pile positioning. The effective width of the piles

shall be taken into account in determining the dimensions of the template. The template design shall allow for

adjustment of the alignment of the structure. In this regard, the dimensions of the template shall be smaller (gap

≈ 30 mm) than the nominal dimensions of the cellular structure.

The templates shall have at least two guiding levels with sufficient distance from each other to assure proper sheet

pile alignment. The lower guide shall be positioned as close to the ground as possible. It shall be moveable to allow

easy handling during installation. Similar conditions apply to the upper guides. Additionally, the upper guide shall

provide a safe working platform for the crew.

An additional template shall be designed for the arc walls with similar design requirements as discussed above.

The templates shall be designed by professional engineers with prior experience in template design for cellular

structures. The design shall comply with Eurocode 3 or a similar national design standard.

4.4 Nature of In Situ Material

Details of the nature of the in situ material are provided in the Project Geotechnical Reports, included in Part 4 ‐ Site

Information. The Contractor is responsible for interpreting these reports and selecting a suitable methodology and

Equipment for installing the sheet piles.

The Contractor is made aware of the presence of existing foundation trench material. The Contractors Equipment

shall be capable of penetrating this material without deviating out of tolerance. The foundation trench material shall

not be classified as an obstruction.


4.5.1 General precautions

The Contractor is advised that the piling operations will take place within an operational port and that he must take

all the necessary precautions to work safely within the port and not disrupt port operations. In addition the piling

operation will take place below seawater level, within the tidal range and in close proximity to existing structures. In

this regard the Contractor shall take all the necessary precautions when working below the seawater level, or to deal

with seawater as required and to protect and minimise damage to existing structures and natural features such as

the Central Sandbank and “Little Lagoon” areas during piling operations.

Piles are to be installed in close proximity to the foundation blocks of the existing blockwork wall and existing

foundation trench (Refer to Section 4.4). The Contractor shall monitor the existing wall in accordance with Section

5.6, and notify the Supervisor immediately should any movement, settlement or rotation occur during pile

installation.


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4.5.2 Safety

The Contractor shall take all the necessary safety precautions during the execution of the sheet pile walls. The safe

use of the Equipment shall be in accordance with the recommendations of BS EN 16228 series. For the various lifting

and driving operations the Contractor shall adhere to BS 7121‐1 which gives recommendations for the safe use of

cranes in a work environment.

4.5.3 Storage and handling

The storage of the sheet piles onsite shall be at the designated site camp area as shown on the drawings. The sheet

piles and auxiliary materials shall be handled, transported and stored with all the necessary precautions to prevent

damage to the piles and auxiliary materials. The recommendations of BS EN 12063 shall be followed.

4.5.4 Welding

When the steel is to be welded, the welding procedure shall be suitable for the grade of steel and intended use or

service. All welding and weld testing shall be in accordance with EN 12063.

The required weld testing and frequency of testing is described in Section

4.5.5 Pile toe modification

The profiling and strengthening of the toe of the piles shall be made using material of the same grade as the pile.

Welding shall be in accordance with Section 4.5.4.

4.5.6 Guides and templates

The Contractor shall employ suitable temporary wales, templates, guide frames or bracing as required to ensure that

the piles are installed to the required tolerances, do not declutch during driving and are not damaged.

Guiding frames shall be used to install all the sheet pile combination walls.

With regard to the cellular caisson template construction, the following general installation procedure shall be

followed for the:

a) Position and secure the template by installing supporting piles.

b) Level and position the supporting piles with reference to the cell axis.

c) Secure the template against lateral shifting or tilting by driving the supporting piles some distance into the

ground.

d) Positioned and fix the platforms at the required elevations ensuring correct alignment.

4.5.7 Pile driving

4.5.7.1 Driving procedure

All sheet piles shall be installed such that, after driving, they fulfil the following requirements to the required

tolerances:

a) Parallelism: Every pile must stand vertically and adhere to the specified inclination.

b) Alignment: The required driving alignment must be achieved to the required tolerances.

c) Distortion/twisting: Distorting and twisting increases the risk of interlock declutching and therefore must be

prevented.

d) Spacing: The distance between the piles must be equal over their entire length, matching the system

dimension.

These requirements can only be fulfilled accurately by guiding the piles during pitching and driving as

specified in Section 4.5.6 above.

4.5.7.2 Installation sequence for straight web sheet piles

Once the template is positioned and securely anchored as described in Section 4.5.6, the following general procedure

for pitching and driving the junction piles and straight web sheet piles shall be followed:


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Phase 1:

a) Install template for main cell.

b) Pitch junction piles as shown on the drawings.

- Marks shall be placed at the circumference of the working platform of the template, in order to

indicate whether the sheet piles are spaced properly.

- The exact position of the junction piles shall be determined by survey.

- Verticality of the junction piles shall be checked.

Phase 2:

a) The straight web sheet piles shall be pitched alternately from two junction piles using the center pile or pair

of piles to complete the arc.

- Thread sheet piles on either side of junction piles.

- Install symmetrically by threading additional piles working away from the junction piles.

- Close the cell at the same distance from the junction piles.

b) All piles shall be fixed temporarily to the template.

Phase 3:

a) Remove temporary fixation of the first pile or pile pair for driving.

b) This shall be one of the junction piles.

c) Driving shall be done in stages of 0.5 m.

d) The driving shall proceed in one direction from this point on until the first junction pile is reached again.

e) The driving direction shall change between driving intervals to prevent leaning of the piles in one direction.

f) This procedure is repeated until the design depth is reached.

g) The upper guide of the template shall move stepwise with the piles (Or a suitable alternative employed i.e.

special follower).

Phase 4:

a) Pitch the connecting arcs between two completed main cells, using the arc template.

b) Drive the connecting arcs.

c) Pitching and driving procedures shall be similar to those for the main cells.

4.5.7.3 Refusal

The selection of a refusal blow count limit or penetration rate limit depends on the hammer manufacturer limitations

to prevent hammer damage. The refusal criteria shall be the more critical of the hammer manufacturer’s

recommendations and the following:

a) For impact hammers the blow count shall not exceed 400 blows/m.

b) For vibratory hammers the pile penetration rate shall not be less than 5 mm/sec.

c) In no case shall driving continue for more than 100 mm at refusal driving conditions.

4.5.7.4 Limiting driving stresses

The compressive driving stress shall not exceed 90 percent of the yield point of the pile material.

4.5.7.5 Design founding depths

The founding levels of the piles shall be as shown on the drawings and shall not be a function of driving refusal. The

Contractor shall inform the Supervisor immediately when unforeseen underground obstructions are encountered or

if the nature of the strata should vary significantly from that indicated in the Site Information.

4.5.7.6 Obstructions

If the piles encounter unforeseeable, isolated obstructions, the Contractor shall notify the Supervisor immediately.

The Contractor and the Supervisor shall agree on the method that shall be used to help facilitate driving past the

obstruction as discussed in Section 4.5.7.7 and Section 4.5.7.8.


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4.5.7.7 Jetting to facilitate driving

Jetting shall only be permitted when approved by the Supervisor. Jetting shall be used with impact driving and

vibrating in order to:

a) Achieve the necessary embedment depth under early refusal conditions or in the event an obstruction is

encountered.

b) Prevent overloading of the plant and overstressing of the sheet piles.

c) Reduce vibrations in the ground

Jetting shall not be used generally for facilitating pile installation and to reduce costs through shortening

installation times, reducing power requirements and/or enabling lighter equipment to be used.

The Contractor shall determine the number of jets and the volume and pressure of water necessary to freely erode

the material adjacent to the pile. The Contractor shall dispose of all jet water in manner satisfactory to the

Supervisor. Jet pipes shall be removed before or when the pile toe is 1.5 meters above the final toe level, and the pile

shall be driven without jetting to the final toe level.

4.5.7.8 Predrilling to facilitate driving

Predrilling to facilitate driving shall only be permitted when approved by the Supervisor. The Contractor and

Supervisor shall agree on the size and depth of hole prior to predrilling. Any void space remaining around the pile

after completion of the drilling shall be filled with sand or other approved material. Material resulting from

predrilling holes shall be disposed of as approved by the Supervisor.

4.5.8 Vibration and noise control

Noise levels during pile installation shall be limited to the maximum allowed by the Project Environmental

Management Plan (EMP).

The Contractors chosen installation methodology shall take into consideration the effects of vibrations from pile

driving or extraction on existing structures. The Contractor shall monitor the effects of vibrations on existing

structures as discussed in Section 5.6.

4.5.9 Cutting and trimming piles

Piles driven to a predetermined depth shall be stopped at the required level within the specified tolerances. Any

protruding section of pile shall be cut off at the required level. In addition to being trimmed at the required level,

sheet piles shall be cut off to allow installation of such items as the service tunnels, storm water pipes and the crane

rail beam as shown on the 1370‐CO‐070 series of drawings.

4.5.10 Anchorage

4.5.10.1 General precautions

During the installation of the anchor system over the backfill area there is no support for the tie rods as the backfill

will be no higher than +1.85mCD. The Contractor shall ensure that the tie rods are adequately supported at all times,

so that there is no sagging (see Tolerances).

4.5.10.2 Anchor installation

After driving the HZ piles, the Contractor shall cut openings in the HZ pile flanges (as detailed by the supplier) to

accommodate the tie rod eye connector. The remaining components are then assembled and connected. The

Contractor shall ensure that the tie bars are adequately supported at all times, so that there is no sagging (see

Section 5.7). Initially the tie bars shall be lightly tensioned by turning up the turnbuckle and the end nut using hand

tools.

4.6 Record Keeping

4.6.1 Pile driving

Site records and records of driving observations shall be kept in general accordance with EN 12699 section 10

“Records”. Additionally, the following shall be recoded for impact and vibratory pile driving.


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4.6.1.1 Impact hammers

The hammer make, model, energy, stoke, pile and hammer cushions and other driving equipment as described in

Section 4.3.3 shall be recorded in the pile driving record. During driving the Contractor shall record pile name, date

with start/stop times, blow rate, stroke (for open end diesel hammers only), blow count versus depth, and impact

velocity and kinetic energy.

4.6.1.2 Vibratory hammers

The hammer make, model, weight, dynamic force, frequency or range of frequencies, maximum eccentric moment,

clamping method. During driving the Contractor shall record pile name, date with start/stop times, driving rate and

frequency.

4.6.2 Monitoring of new sheet pile structures

Monitoring records of the displacement of the sheet pile walls during execution shall be as per Section 5.6.

4.6.3 Monitoring of existing structures

Monitoring records of the displacement of the existing structures shall be as per Section 5.6.


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5.1 Pile Driving Wave Equation Analyses

The Contractor shall submit to the Supervisor results of a wave equation analysis to show that the piles are drivable.

With regards to simulations of vibratory pile driving by the wave equation model, the software used shall implement

the necessary modifications to this model to produce reasonable results. All analysis assumptions shall be listed.

The following hammer efficiencies shall be used in a wave equation analysis unless better information is available.

Table 5.1: Hammer efficiencies

Hammer Type Efficiency

Drop 25 to 40 %

Single‐acting air/steam 67

Double acting air/steam 50

Diesel 80

Hydraulic or diesel with built in energy measurement 95

Vibratory 100

For the piles to be deemed drivable they shall not refuse as per the criteria in Section 4.5.7.3 and the compressive

driving stress shall not exceed 90 percent of the yield point of the pile material.

5.2 Pile Driving Trials

The Contractor shall be responsible for determining the driving conditions as described in Section 4.4, and

undertaking on site pile driving trials as may be required.

5.3 Pile Inspection Tests

Before accepting and removing the piles from the designated storage area, the Contractor shall inspect the sheet

piles, carrying out sufficient assessment of pile lengths, clutch tolerances, and any other dimensions, in order to

assure himself that the piles comply with the tolerance requirements of EN 10248‐2.

5.4 Testing and Inspection of Welds

One X‐ray test according to ISO 1106‐1:1984 on 10 % of the sheet piles and 100 % visual inspection, or Ultra sonic

tests on 10 % of the sheet piles over the whole length of the weld and 100 % visual inspection.

5.5 Pile Driving Monitoring

During installation of the sheet piles, the position and condition of the sheet piles must be checked and suitable

measurements carried out to ascertain when the intended embedment depth has been reached. Together with the

correct starting position, adherence to tolerances must be checked in sufficient intermediate phases. This shall make

it possible to detect small deviation from required position or deformations of the pile head so that early corrections

can be made and, if necessary, suitable countermeasures initiated.

The Contractor shall monitor the pile driving operations using monitoring Equipment described in Section 4.3.3.5,

and shall submit records to the Supervisor as described in Section 4.6.1.

The pile driving monitoring Equipment shall be installed prior to driving of the piles, and shall be maintained during

the installation of all piles unless otherwise directed by the Supervisor. In the event that the monitoring device is not

fully operational, the Contractor shall notify the Supervisor. For the duration the device is not operational, the

Contractor shall manually record blow counts, start/stop times, and blows per unit penetration or rate of penetration

as directed by the Supervisor.


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5.6 Monitoring of the New Sheet Pile Wall and Existing Quay Wall

Procedures for monitoring of the existing quay wall movement during dredging have been set out in specification

1370‐CO‐000‐C‐SPC‐0004 – Dredging Reclamation and Sandbank Extension. The Contractor shall undertake the same

monitoring procedure of the existing quay wall during piling operations adjacent to the existing structures. The same

base line set out for the dredging shall be used.

The Contractor shall monitor the movement of the new sheet pile walls during installation, excavation in front of the

walls and final reclamation in front of the walls. The horizontal displacements of the top of the sheet pile walls shall

be periodically measured with appropriate accuracy at predefined points. The Contractor and the Supervisor shall

agree the frequency, accuracy and location of these measurements.

5.7 Tolerances

5.7.1 Sheet piles

Piling tolerances shall be in accordance with EN 12063. Notwithstanding the tolerance requirements in EN 12063 the,

the following tolerances shall apply:

a) Refer to figure 6 of EN 12063:1999

b) Applies to both primary and secondary sheet piles

c) The plan position of the sheet piles at cut‐off level

─ Transverse tolerance (c): + 50 mm / ‐ 50 mm

─ Longitudinal tolerance (d): + 50 mm / ‐ 50 mm

d) Verticality in all directions

─ 1.5% of the embedment depth measured over the top 1 m of pile

e) Toe level and head level of piles

─ + 75 mm / ‐ 0 mm

f) The tolerances regarding position and verticality may be additive

g) Any deviations greater than these tolerances, or any other rotation or leaning that may lead to de‐

clutching, is remedied by the Contractor by either:

─ Applying corrective external loads during further driving, such that the deviation is reduced to an

acceptable level without damaging the piles, or

─ Extraction and re‐driving of the pile(s).

5.7.2 Anchorage

Tie bars shall be supported at the turnbuckle/swivel position and required intermediate positions such that the

deviation from a fish line stretched from one end of the anchor tie rod assembly to the other is less than 20 mm.

The level of the eye rod bar connector at the HZ pile shall not differ from the specified level by more than 25 mm.

TRANSNET SOC LTD

DCT BERTHS 203 TO 205 - RECONSTRUCTION, DEEPENING AND

LENGTHENING

PORT OF DURBAN

SPECIFICATION – GROUND IMPROVEMENT: RIGID INCLUSIONS AND

FOUNDATION STONE BED (CAISSON LOAD TRANSFER PLATFORM)

1370-CO-000-C-SPC-0010 Rev T-0A

18 NOVEMBER 2016

TRANSNET SOC LTD DCT BERTHS 203 TO 205 - RECONSTRUCTION, DEEPENING AND LENGTHENING

PORT OF DURBAN

SPECIFICATION – GROUND IMPROVEMENT: RIGID INCLUSIONS AND FOUNDATION STONE BED (CAISSON LOAD TRANSFER PLATFORM)

1370-CO-000-C-SPC-0010 Rev T-0A November 2016

REVISIONS


BY

CHECKED

BY

APPROVED

BY

T-00 31 May 2016 Issue for Review MC WvW JZ

T-0A 18 November 2016 Issue for Tender MC WvW JZ

AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 2

3.1 Chart Datum Port ............................................................................................................................................ 2 3.2 Co-ordinate System ......................................................................................................................................... 2 3.3 Tidal Levels ...................................................................................................................................................... 2 3.4 Method Statements ........................................................................................................................................ 2 3.5 Airlifting ........................................................................................................................................................... 2 3.6 Foundation Stone Bed (Load Transfer Platform) ............................................................................................ 2 3.7 Geotextile Reinforcement ............................................................................................................................... 2 3.8 Rigid Inclusion (RI) ........................................................................................................................................... 3 3.9 Steel Fiber Reinforced Concrete (SFRC) .......................................................................................................... 3 3.10 Trial Rigid Inclusion ......................................................................................................................................... 3 3.11 Working Platform ............................................................................................................................................ 3 3.12 Working Rigid Inclusion ................................................................................................................................... 3

4.0 REQUIREMENTS ....................................................................................................................................... 4


4.2.1 Steel-Fibre-Reinforced Concrete (SFRC) ........................................................................................ 4 4.2.2 Stone ............................................................................................................................................. 4 4.2.3 Geotextile ...................................................................................................................................... 5

4.3 Equipment ....................................................................................................................................................... 6

4.3.1 General .......................................................................................................................................... 6 4.3.2 Rigid inclusion Equipment ............................................................................................................. 6 4.3.3 Foundation stone bed Equipment ................................................................................................. 6

4.4 Nature of In Situ Material ............................................................................................................................... 6 4.5 Methods and Procedures ................................................................................................................................ 6

4.5.1 Rigid Inclusions .............................................................................................................................. 6 4.5.2 Foundation stone bed ................................................................................................................... 7

4.6 Record Keeping ............................................................................................................................................... 9

4.6.1 Rigid inclusions .............................................................................................................................. 9 4.6.2 Foundation stone bed ................................................................................................................... 9


PORT OF DURBAN




5.1 Tolerances ..................................................................................................................................................... 10

5.1.1 General ........................................................................................................................................ 10 5.1.2 Rigid inclusions ............................................................................................................................ 10 5.1.3 Foundation stone bed ................................................................................................................. 10

5.2 Surveys .......................................................................................................................................................... 10

5.2.1 Bathymetric surveys .................................................................................................................... 10 5.2.2 Dive surveys................................................................................................................................. 10

5.3 Field Testing .................................................................................................................................................. 11

5.3.1 Trial rigid inclusion ...................................................................................................................... 11 5.3.2 Foundation stone bed pressuremeter testing ............................................................................. 11


PORT OF DURBAN



Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for rigid inclusion ground reinforcement. The

ground reinforcement in its entirety is composed of a compacted stone bed with geotextile reinforcement at its base,

both of which overly the in situ soil reinforced with a grid of rigid inclusions. This specification covers the materials,

equipment, construction, tolerances and testing of the rigid inclusion ground reinforcement.








─ 1370-CO-030 series of drawings – Ground Improvement – Soft Piles


f) Project Geotechnical Reports, included in Part 4 - Site Information.


The governing standard(s) for this specification shall be:

a) BS EN 12699:2015 Execution of special geotechnical works – Displacement piles,



a) BS 6031:2009 Code of practice for earthworks

b) BS 812 – British Standards Institution – Method for sampling and testing mineral aggregates (or equivalent

BS EN revision)

c) BS EN 13251:2014+A1:2015 Geotextiles and geotextile-related products. Characteristics required for use in

earthworks, foundations and retaining structures.

d) PD CEN/TR 15019:2005 Geotextiles and geotextile-related products. On-site quality control

e) BS EN ISO 22476-4:2012 Geotechnical investigation and testing. Field testing. Ménard pressuremeter test.



a) 1370-CO-000-C-SPC-0001 – Concrete for Marine Construction

b) 1370-CO-000-C-SPC-0002 – Caisson Construction and Placement

c) 1370-CO-000-C-SPC-0004 – Dredging and Reclamation (Including Vibro Compaction)

d) 1370-CO-000-C-SPC-0009 – Steel Sheet Piling

e) Environmental Management Plan (EMP).


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Page | 2

3.0 DEFINITIONS





For the purpose of this specification, the definitions and abbreviations given in BS EN 12699, together with the

following definitions shall apply.




3.2 Co-ordinate System

The co-ordinate system to be used for all setting out and survey shall be World Geodetic System 1984 (WGS84),


3.3 Tidal Levels






Mean Level ML 1.097


Lowest Astronomical Tide LAT -0.013







3.5 Airlifting

The term airlifting refers to a diver operated dredging technique where transported material is sucked from the

seabed and transported upwards and away from its source.

3.6 Foundation Stone Bed (Load Transfer Platform)

The term foundation stone bed refers to the stone constructed above the ground reinforced with rigid inclusions.

This layer is also known as the “load transfer platform (LTP)”. It forms the platform on which the structure is placed

and transfers the majority of the structures load towards the rigid inclusion heads through an arching mechanism.

This layer is composed of compacted stone with geotextile reinforcement at its base.

3.7 Geotextile Reinforcement

This term refers to the geotextile placed at the base of the foundation stone bed functioning as a reinforcement,

separation and filtration layer. The geotextile directs load towards the rigid inclusion heads through membrane

action. Additionally the geotextile prevents the mixing of the foundation stone bed and in situ soil, while still

allowing the through flow of water.


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Page | 3

3.8 Rigid Inclusion (RI)

The term Rigid Inclusion (RI) refers to a concrete column which is cast in situ by a soil displacement technique

without the excavation or removal of in situ material. The RIs are spaced in a regular grid pattern and the term

“group” is employed.

Where BS EN 12699 or other referenced specifications refer to “pile” or “displacement pile”, replace this term with

the term “rigid inclusion”.

Where BS EN 12699 refers to “filling” this shall include techniques where concrete is pumped with a pressure higher

than the hydrostatic pressure.

3.9 Steel Fiber Reinforced Concrete (SFRC)

This term refers to concrete with steel fibres added to the concrete mix.

3.10 Trial Rigid Inclusion

This term refers to a RI used for trialling the RI installation methodology which is not included in the permanent

Works.

3.11 Working Platform

The term working platform refers to a layer of stone constructed ahead of the rigid inclusions to prevent damage to

the RIs during construction and to ensure the RIs terminate in a good quality material.

3.12 Working Rigid Inclusion

This term refers to a RI included as part of the permanent Works.


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Page | 4

4.0 REQUIREMENTS


The Contractor shall prepare method statements that shall include inter alia, the following information:

1. Detailed description of the Equipment for all activities.

2. The Contractor’s chosen methodology for installing rigid inclusions including the concrete mixing and filling

methodology.

3. Sequence of construction for all activities.

4. How the planned RI cut off level and toe level are achieved with reference to the in situ materials described

in Section 4.4.

5. Estimates of filling pressure required to achieve the required RI diameter (if applicable).

6. Predicted RI installation rates for driving and filling.

7. How the Contractor plans to meet the location and level tolerances described in Section 5.1.

8. Details of the field testing program described in Section 5.3.

9. Quality control program including certified test results and statements of quality for the materials.

4.2 Materials

4.2.1 Steel-Fibre-Reinforced Concrete (SFRC)

Steel-fibre-reinforced concrete shall be in accordance with Specification 1370-CO-000-C-SPC-0001 - Concrete for

Marine Construction.

4.2.2 Stone

The stone used for the foundation stone bed shall have the properties listed below. Except where noted, all testing

shall be done in accordance with BS 812 series of standards for the assessment of aggregates.

a) Size, fines and uniformity

- 60 mm ≤ D50 ≤ 75 mm

- D85/D15 ≤ 4

- Percentage fines (<0.063 mm) < 5%

b) Density

Ten density determinations shall be made, each determination being carried out on a different randomly

selected stone. The average density of quarry stone shall be at least 2 700 kg/m3 with 90% of the stones

having a density of at least 2 600 kg/m3.

c) Water Absorption

Ten water absorption determinations shall be made, each determination being carried out on a different

randomly selected stone. The average water absorption of quarry stone shall be less than 2%, and the

water absorption of nine of the individual stones less than 2.5%

d) Strength and durability

- The aggregate impact value (AIV) shall not be more than 30 % for standard test fraction.

- The 10% fines aggregate crushing value (10%FV) shall be not less than 120 kN.

- The aggregate abrasion value (AAV) shall not be more than 15 %.


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Page | 5

4.2.3 Geotextile

Geotextile reinforcement shall be placed at the base of the foundation stone bed. This shall be a high strength

geotextile used for reinforcement, separation and filtration in construction of earthworks, foundations and retaining

structures. The geotextile shall conform to the properties given in Table 4.2-1.

Table 4.2-1 - Required Properties of Geotextile

Product: Composite geotextile and geotextile related products

Intended use For reinforcement, separation and filtration, in construction of earthworks, foundations

and retaining structures.

Tensile strength

(TMAX)

Machine direction (MD) kN/m 200* BS EN 13251

EN ISO 10319 Cross machine direction (CMD) kN/m 200*

Elongation (εMAX) % 10*

Creep limited strength (120 years) kN/m 120* BS EN 13251

EN ISO 10319

Resistance to static

puncture CBR test kN/m 4.8*

BS EN 13251

EN ISO 12236

Water permeability Normal to Plane l/m2s 70* BS EN 13251

EN ISO 11058

Characteristic

opening size O95W μm 130*

BS EN 13251

EN ISO 12956

Durability To be declared in accordance with the relevant

clause of EN 13251, Annex B - -

BS EN 13251

Annex B

Release of dangerous

substances Less than required by national regulations - -

National Regulations

in force

* Mean value – Manufacture shall provide tolerance values corresponding to the 95% confidence level.

Rolls of the geotextile are to be procured in as large a size as is available from the supplier in order to minimise the

number of joints.

Geotextiles shall not be exposed to temperatures in excess of those recommended by the manufacturer. Outdoor

storage shall not be for periods that exceed the manufacturer’s recommendations. Geotextiles shall not be exposed

to direct sunlight prior to installation for more than the duration recommended by the manufacturer.

On site quality control shall be in accordance with PD CEN/TR 15019.

The Contractor shall submit to the Supervisor certified test results and statements of quality that show without

exception that the proposed geotextile meets the requirements of this specification.


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Page | 6

4.3 Equipment

4.3.1 General

The Contractor shall take full and entire responsibility for the sufficiency of his Equipment to provide the works. The

Contractor shall submit details of all Equipment to be used, to the Supervisor for acceptance at least 3 weeks prior to

the work commencing.

The Contractor shall be responsible for providing a working platform that can support the Contractor’s Equipment.

The floating (for jack-up platform) Equipment shall comply with the general requirement for all marine Equipment as

detailed in the main body of the Works Information.

4.3.2 Rigid inclusion Equipment

It is the Contractor’s responsibility to select a suitable installation method and Equipment to perform the RI

construction. The Contractor shall evaluate the in situ material conditions as discussed in Section 4.4, and select

suitable Equipment. The Equipment shall be able to apply sufficient force, torque or energy to penetrate to the

design RI toe level based on the subsurface conditions. The installation tool shall be of sufficient length to reach the

required RI toe level.

SFRC shall be placed using suitable pumping Equipment. The Equipment shall have a means of determining the

volume and pressure of SFRC delivered to the tool at any time during construction.

A communication system shall be maintained between the RI rig operator and the SFRC pump operator at all times.

4.3.3 Foundation stone bed Equipment

The Contractor shall provide Equipment for placement of the foundation stone bed, accurate levelling (screeding),

and compaction. This specification is non-specific regarding the placement, screeding and compaction

methodologies.

Marine screeding equipment may include a travelling screed hopper, screeding beam, stone tremie tube, other

specialist screeding equipment or a combination of these.

Marine compaction equipment may include a vibrating plate, dynamic compaction pounder, vibroflot, other

specialist equipment, or combination of these.

4.4 Nature of In Situ Material

Details of the nature of the in situ material are provided in the Project Geotechnical Reports, included in Part 4 - Site

Information. The Contractor is responsible for interpreting these reports and selecting a suitable methodology and

Equipment for installing the RIs in this material.

The Contractor is made aware of the presence of existing foundation trench material which comprises 76 mm stone.

The Contractors Equipment shall be capable of penetrating the 76 mm stone without deviating out of tolerance. The

76 mm stone shall not be classified as an obstruction.


4.5.1 Rigid Inclusions

4.5.1.1 General

The RIs shall be installed by a specialist geotechnical sub-Contractor who has previous experience of installing RIs in

the marine environment.

4.5.1.2 Installation methodology

The RI shall be cast in situ by a soil displacement method without the excavation or removal of in situ material. With

regards to the type of soil displacement method, this specification in non-descriptive. It is the Contractor’s

responsibility to select a suitable installation method that will meet the requirements of this specification.

The Contractor shall employ an installation method that ensures the void formed by the Equipment does not collapse

causing necking of the RI.

SFRC shall follow simultaneously with extraction of the tool used to form the void. The entire RI shall be concreted in

a single pour to prevent the formation of cold joints within the inclusion.


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Page | 7

Drilling fluids are not permitted for keeping the RI hole open

Should the Contractor require the use of jetting to facilitate the driving of the displacement tool through in situ

materials, any spoil shall be contained in the vicinity of the RI location.

4.5.1.3 Obstructions

The Contractor shall remove surficial obstructions preventing the advancement of the RI tool. The Contractor is made

aware of existing scour rock comprising 150 – 380 mm stone, and 100 – 300 kg scour rock which shall be removed as

part of the dredging works.

Subsurface obstructions may include but are not limited to boulders, timbers, concrete, bricks, etc. that prevent the

RIs from being installed to the required toe level. In the event that obstructions are encountered during installation

of an RI, that cannot be penetrated with reasonable driving effort, one or more of the following procedures will be

used:

a) Position the tool a short distance away from the original position

b) Remove obstruction

c) Pre-drill obstruction

Very dense or very stiff natural soil, and 76 mm foundation trench material, shall not be considered obstructions.

The Supervisor shall be notified immediately of any obstructions or unexpected early refusal.

4.5.1.4 Sequencing of works

The Rigid Inclusion works shall be undertaken after the dredging works. The sequencing of the installation of RIs and

foundation stone bed is left to the experience of the Contractor.

The sequencing of the works shall however prevent any damage to the rigid inclusions and disturbance of the soil

between the rigid inclusions. In this regard the Contractor may choose to install a working platform composed of the

same foundation stone bed material ahead of the RI installation.

The installation sequence shall account for the nature of in situ material and curing time of adjacent rigid inclusions

as detailed in BS EN 12699. If adjacent RIs are observed to be influenced by the installation of neighbouring RIs, the

Contractor shall modify the installation sequence to prevent further disturbance of RIs. The Contractor shall

complete any required modifications to the sequence at no additional cost to the Employer.

4.5.1.5 RI top level

The RI top level corresponds to the level of the dredged foundation trench and slopes as shown on the 1370-CO-030-

C series of drawings. In the event the Contractor chooses to install a working platform ahead of the RI installation,

the top of this working platform shall be defined as the RI top level. The RI tolerances described in Section 5.1 shall

apply.

4.5.1.6 Trimming of RIs

The RI top level shall allow for any required trimming or removal of low strength material at the RI top. Once

trimmed the RI shall meet the level tolerances specified in Section 5.1.2.

4.5.1.7 Rejection

RIs installed beyond the tolerances specified in Section 5.1.2, or damaged during construction, shall be abandoned

and replaced with new RIs unless the Contractor proposes a remedial measure which is agreeable to the Supervisor.

Either of these two solutions will be done at no additional cost to the Employer.

4.5.2 Foundation stone bed

4.5.2.1 Installation methodology

It is the Contractor’s responsibility to select a suitable placement, compaction and screeding methodology that will

meet the requirements of this specification.


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Page | 8

4.5.2.2 Sequencing of the Works

The Contractor shall prepare the foundation stone trench as follows:

a) Remove all transported material that may have accumulated on the foundation trench and slope by

airlifting.

b) A dive survey shall be undertaken prior to acceptance of the foundation trench and slope for placement of

the geotextile.

c) Place the geotextile and secure in place.

d) Remove all transported material that may have accumulated on top of the geotextile by airlifting.

e) A second dive survey shall be undertaken prior to acceptance of the foundation trench and slope for

placement of stone.

f) Place and compact stone.

g) Screed foundation stone bed to within the tolerances specified in Section 5.1.3

h) Undertake pressuremeter testing to verify the compaction of the foundation stone bed meets the

performance criteria detailed in Section 5.3.2.

i) Undertake a bathymetric survey to verify the level tolerances specified in Section 5.1.3 have been met.

j) The Contractor shall submit the field testing and survey results to the Supervisor for acceptance of the

Works prior to placement of the caissons.

4.5.2.3 Constraints on geotextile placement

The geotextile shall be placed perpendicular to the quay wall centre line in one continuous piece (i.e. no joints in this

direction). In the direction of the quay wall centreline geotextiles shall be made continuous either by firmly stitching

together using double stitching, or by providing overlaps of not less than 1.5 m.

When un-stitched laps are used, acceptable measures shall be implemented to ensure that the 1.5 m overlaps are

maintained until the stone trench has been completed.

The geotextile shall be laid with care to avoid any damage or puncturing of the geotextile during and after laying

thereof.

The method of laying geotextile and installing the foundation stone bed shall ensure that the geotextile is not moved

out of position by down-slope creep due to the stone bed placement and compaction.

4.5.2.4 Constraints on foundation stone bed placement and compaction

The methodology and sequence of constructing the foundation stone bed shall prevent the rigid inclusions from

being damaged. Should the Contractor damage a RI, the clauses in Section 4.5.1.7 regarding the rejection of a RI shall

apply.

The methodology and sequence of constructing the foundation stone bed shall prevent local failure of the

foundation trench slopes. The Contractor shall remediate any local slope failures by removing and disposing of any

material associated with local slope failure, and re-establish the slope using foundation stone bed material. The

remediated slope shall meet the level tolerances as specified in Section 5.1.3.

Should the Contractor choose to install a working platform ahead of the RI installation this layer shall not exceed

250 mm.

The foundation stone bed shall be filled to a level above the final design level of -18.6 m CDP such that after

compaction and screeding the final design level meets the level tolerances in Section 5.1.3. Where the compaction

has resulted in the stone bed level being below the above stated tolerance, the Contractor shall add additional stone

to bring the bed up to the required level.

The spacing between compaction points shall be designed by the Contractor to meet the performance requirements

detailed in Section 5.3.2. The Contractor must ensure a minimum thickness of 250 mm between the RI top and the

zone of compaction.

The level of compaction shall be verified by pressuremeter testing as detailed in Section 5.3.2.


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Page | 9

4.6 Record Keeping

4.6.1 Rigid inclusions

The Contractor shall keep records of the following for each individual inclusion and submit these records to the

Supervisor:

a) Date and time of installation

b) RI number

c) Working level

d) Final toe and top elevations

e) Nominal cross-section diameter

f) Seabed level and tide level (CDP) at commencement of installation of RI

g) The applied torque, thrust, rate of penetration and revolutions per minute

h) Rate of tool penetration with depth

i) Rate of tool withdrawal with depth

j) Rate of SFRC delivery to tool with depth

k) The RI rig operator shall indicate on the daily drilling log for each RI that verticality was within tolerance

l) All information regarding obstruction, delays and other interruptions to the sequence of the Work.


The Contractor shall keep records of the following for each compaction location:

a) Date time and location and volume of stone placed

b) Date and location of compaction

c) Compaction number

d) Start and finish time of compaction

e) Depth of compaction (If applicable)

f) Approximate additional stone quantity (If applicable)

g) Equipment readings (e.g. amperage)

h) Working level

i) Tide level (CDP) at commencement of compaction.


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5.1 Tolerances

5.1.1 General

The accumulation of tolerances is not permitted for dredging, stone placement, and caisson placement.

5.1.2 Rigid inclusions

Deviations shall be within the limits listed in BS EN 12699, unless stated otherwise on drawings or elsewhere in the

Works Information.

a) Plan location of rigid inclusions (measured at the RI top)

─ e ≤ 0.15m

b) Inclination of vertical rigid inclusions

─ i ≤ imax = 0.04 (0.04m/m)

c) The RI cross sectional diameter

─ Shall not be less than those shown on the drawings

d) The final RI top level

─ +150 mm / -150 mm of the levels shown on the drawings


The final foundation stone bed top level shall be within ± 150 mm of level shown on the drawings. Local undulations

within a 10 m radius shall be limited to 75 mm.

5.2 Surveys

5.2.1 Bathymetric surveys

The project bathymetric survey requirements are detailed in specification 1370-CO-000-C-SPC-0004 - Dredging and

Reclamation.

The out-survey for the berth dredging for the caisson scour trench (berth pocket dredging) shall form the in-survey

for the RI and foundation stone bed works.

On completion of the Works an out-survey is required of the final foundation stone bed top level.

5.2.2 Dive surveys

Dive surveys shall be undertaken by the Contractor to verify that all transported material has been removed prior to

placement of the geotextile and stone as indicated in Section 4.5.2.2. Verification shall be carried out by probing

measurements and video footage.

Transported material is distinguished from in situ founding soil by its very loose/very soft consistency. The

Contractor shall remove all transported material exposing the RI top, stone bed working platform, or geotextile.

The gridlines and RI positions shown on the drawings shall be used as a reference system for the dive survey and

reporting. The Contractor’s dive team shall setup a system whereby a diver may be positioned accurately with

respect to these gridlines.

The Contractor shall submit a dive survey report with video footage per gridline (No. 1 to No. 63). The report shall

include, date of dives, location of the dives, dive Supervisor, diver, summary of dive survey results, other

observations, and probing measurements.


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5.3 Field Testing

5.3.1 Trial rigid inclusion

The Contractor shall install four trial rigid inclusions ahead of the rigid inclusion works to verify that the Contractors

chosen methodology meets the requirements of this specification. In this regard the trail rigid inclusions shall verify:

a) The RI cross sectional diameter can be achieved

b) The design RI toe levels can be achieved

c) Pumpability of SFRC over long distances

The Contractor shall use the results of these tests to calibrate their methodology for the working RIs.

Two trial rigid inclusions shall be installed at exploratory borehole BHS04 and two at BHS02. The trial RIs shall

be installed as per the working RIs. The RI top level shall be at the existing seabed level prior to basin

dredging, and the RI toe level shall correspond to the toe level of the nearest working RI.

The trial RIs shall be installed prior to the basin dredging works. The Contractor shall make provision for

excavation of the seabed material around the trial RIs to a depth of -18.35 m CDP. The trial RIs shall be cut off

at -18.35 m CDP and brought to the surface in suitable lengths for inspection and subsequent disposal. The

Contractor shall label each cut off section according to RI number and depth i.e. BHS04:1-0m-2m. Once on

land the trial RIs cross sectional diameter shall be measured at 0.2 m intervals along its length.

The Contractor shall submit a report to the Supervisor detailing the trail RI tests, measurements and

calibrations prior to undertaking any working RIs.

5.3.2 Foundation stone bed pressuremeter testing

The Contractor shall undertake pressuremeter testing in the compacted foundation stone bed in order to verify that

the level of compaction meets the requirements of this specification. In this regard the angle of internal friction of

the stone bed after compaction shall be greater than or equal to 45°.

The relationship between the pressuremeter limit pressure and the angle of internal friction for rock has been used

to develop the acceptance test criteria (Yee, K., & Varaksin, S, 2012 - Ground Reinforcement in Deep Water. In

Proceedings of the International Conference on Ground Improvement & Ground Control (Vol. 45, pp. 575–585).

𝑃𝑙∗ = 2.5 × 2

Φ−40

7

The Contractor shall verify that the post compaction Net Limit Pressure (𝑃𝑙∗) is greater than or equal to 7.14 Bars

where,

𝑃𝑙∗ = 𝑃𝑙 − 𝑃0 (𝑏𝑎𝑟𝑠)

𝑃𝑙 is the measured limit pressure at test level (Bars)

𝑃0 is the horizontal earth pressure at rest at test level (Bars)

The Contractor shall carry out pressuremeter tests before and after compaction; two pressuremeter tests

shall be carried out per gridline (No. 1 to No. 63) at a location and depth agreed upon by the Contractor and

Supervisor.

The self-bored slotted tube technique shall be used and testing and reporting shall conform to BS EN ISO 22476-4.

The Contractor shall submit a pressuremeter test report per gridline to the Supervisor.

The Contractor shall carry out additional compaction if the acceptance criteria are not met followed by additional

pressuremeter testing.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – WEATHER STATION FOR WEATHER DATA RECORDING

1370‐CO‐000‐C‐SPC‐0013 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN

SPECIFICATION ‐ WEATHER STATION FOR WEATHER DATA RECORDING


REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 2


4.0 REQUIREMENTS ....................................................................................................................................... 3

4.1 Method Statement .......................................................................................................................................... 3 4.2 Location ........................................................................................................................................................... 3 4.3 Equipment ....................................................................................................................................................... 3 4.4 Baseline Data .................................................................................................................................................. 4 4.5 Data to be collected ........................................................................................................................................ 4

5.0 REPORTING AND DISTRIBUTION .............................................................................................................. 5

6.0 INSPECTION AND CALIBRATION ............................................................................................................... 5

6.1 Inspection ........................................................................................................................................................ 5 6.2 Calibration ....................................................................................................................................................... 5


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Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the provision, maintenance and operation of a

weather station for Environmental Monitoring during the entire contract period as well as for the recording and

presentation of the data recorded.

The specification details requirements of Materials, Equipment and Procedures to be adopted by the Contractor to

supply and maintain a fully automatic remote mounted weather station.




the Works Information. Standard specifications referenced within the specifications listed below also form part of






d) Method statement prepared by the Contractor, as described in Section 4.1


The standard specifications listed in this section shall, inter alia, be read in conjunction with this specification

a) DNV RP C205 – Environmental Conditions and Environmental Loads, April 2014


The specifications listed in this section shall, inter alia, be read in conjunction with this specification.

a) Environmental Management Plan (EMP)


PORT OF DURBAN



Page | 2

3.0 DEFINITIONS












3.3 Tidal Levels






Mean Level ML 1.097










PORT OF DURBAN



Page | 3

4.0 REQUIREMENTS



a) Provision of a fully automatic remote mounted weather station, with GSM wireless modem and dedicated

computer and software.

b) Provision of complete and operable packages in full accordance with all the applicable Industry Codes and

Standards, Government Regulations and Contractor Technical Requirements.

c) Installation, calibration and maintenance of the systems during the construction of the facilities.

d) Preparation and submission of complete Operating and Maintenance Manuals.

e) Proof of training of operator's personnel.

f) Provision of daily seven day forecasts of weather conditions, in particular those that may affect the contract

works.

g) Provision of weekly summary reports to the Supervisor of forecasts and the acquired data.

h) Removal of all equipment after completion of the Project.

4.2 Location

A mast mounted system is required and to maintain continuity it is proposed that it should be located on the roof of

the existing ablution block on Berth 202 which is not to be demolished.

4.3 Equipment

The external data acquisition equipment shall be a proprietary system with the following or equal approved

characteristics:

a) Fully weather proof for field mounting with weatherproof IP 65 enclosure.

b) Built in data logger.

c) Mains power with battery backup or solar power recharging.

d) Fitted with RS232 data link for set‐up and local download of data.

e) Fitted with GSM modem communications (transmitter with receiver at the Contractor’s offices) with Type

Approval Certificate issued by the Independent Communication Authority of South Africa (ICASA).

f) The sensors shall be mounted on a meteorological mast with base for bolting down.

g) The meteorological mast shall be corrosion protected to applicable specifications.

h) The height of the meteorological mast shall be of such that the height of other equipment will not influence

any parameter measured or recorded.

i) Interface electronics shall be housed in an IP68 panel.

j) A suitable lightning conductor shall be installed which is separate from and higher than the sensor mast.

k) Interface electronics shall be provided to process the various outputs from the sensors, convert them to

engineering units and transmit the data via serial data protocol to the Display Unit.

l) The software/operating system for this shall be supplied with weather station.

m) Instrumentation to collect and record the following data in real time. Alternative solid state devices with

equal or better performance may be offered by the Contractor.

i) Ambient Temperature ‐ Precision thermistor air temperature sensor, with louvered solar radiation

shield. Range ‐20 to +60°C, Error ±0.1°Cover the whole range. (Alternatively a highly accurate NTC‐

resistor.)

ii) Relative Humidity ‐ Combined Relative humidity with replaceable sensing element (chip) module and

Air Temperature sensor in a louvered solar radiation shielded housing. Range 0‐100% RH, Error ±2%

RH. (Alternatively capacitive humidity sensor.)


PORT OF DURBAN



Page | 4

iii) Atmospheric pressure ‐ Barometric pressure sensor for use at low altitude (0‐1,500 m), in IP65

weatherproof housing. Range 600 ‐ 1060 hPa (mbar) Error at 20°C ±0.5 hPa, resolution ±0.6 hPa.

(Alternatively capacitive silicon temperature corrected strain gauge device.)

iv) Wind direction ‐ Wind vane, based on 358° micro‐torque potentiometer. Range 0 to 358°. Resolution

and error 0.3° ±2° in winds >5 m/s. (Alternatively combined wind direction and speed sensor as below).

v) Wind speed ‐ Anemometer ‐ high resolution, 3‐cup rotor Digital photodiode pulse and Analogue

outputs. Range 0.15 – 75 m/s. Error 1% ±0.01 m/s. (Alternatively an acoustic system with four

ultrasound sensors to take cyclical measurements in all directions and calculate the resulting wind

speed and direction from the measured run‐time sound differential.)

vi) Rainfall ‐ Tipping bucket rain gauge. Maximum rate of rainfall – 500 mm in 1 hour. Sensitivity 2

mm/tip. (Alternatively precipitation sensor using 24 GHz Doppler radar to measures drop speed and

calculate precipitation quantity and type by correlating drop size and speed.)

vii) Solar radiation ‐ Si photodiode for solar energy measurement. Measuring range 0 to 2 kW/ m2. Error

±3% under standard lamp. Spectral response 400‐1050 nm. Operating temperature range ‐10 to +60°C.

4.4 Baseline Data

Data shall be collected by the Contractor, either through its own equipment or from other reliable and certified

sources, covering as long a period prior to commencement of the contract works for comparison with the Contract

Works weather information, but at least monthly records over a period of 6 months.

4.5 Data to be collected

Data shall be collected in real time and collated and presented weekly throughout the duration of the contract

works.

Wind recording and analysis shall be carried out as follows:

a) The hourly average, the one minute mean and the maximum 3 second gust velocity in that hour shall

be recorded at hourly intervals at 10 m above mean sea level (MSL).

b) Wind occurrence and exceedance tables shall be produced per month, per season and for full period

for 16 direction sectors.

These parameters shall be transferred in real‐time to a computer display. All recorded data shall be stored in digital

format and backed‐up on a monthly basis.


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Page | 5

5.0 REPORTING AND DISTRIBUTION

The system shall be capable of providing data recorded with the specified sensors to a central location and provide

output in real time. All recorded data shall be stored on suitable digital storage media (to be approved by the

Employer) and backed‐up on a monthly basis.

Data shall be presented to the Supervisor weekly in Excel and graphical or similar format with monthly and above

data presented on CD.

Trend analyses shall be provided monthly, quarterly, six monthly and annually.

Daily seven day weather forecasts shall be issued to the Supervisor.

Early warnings shall be provided to the Supervisor of any weather conditions which the Contractor deems to be not

in accordance with the baseline data or the Contract Works data provided.

6.0 INSPECTION AND CALIBRATION

6.1 Inspection

All equipment specifications and supporting documentation shall be supplied for approval to the Employer prior to

ordering and deploying the equipment.

The Contractor shall include a detailed description of the full monitoring system, installation procedures and

operating systems with the specifications.

6.2 Calibration

Calibration certificates shall be supplied with all equipment. After installation, a full installation and calibration report

shall be provided by the Contractor.

Routine calibration shall be carried out on 3 monthly intervals and calibration reports supplied to the Employer. If

the real time data shows that any part of the equipment is malfunctioning, the Contractor shall arrange to

investigate, replace and recalibrate the malfunctioning equipment at his own cost.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – MONITORING OF TURBIDITY DURING DREDGING AND

RECLAMATION

1370‐CO‐000‐C‐SPC‐0014 Rev T‐0B

08 DECEMBER 2016


PORT OF DURBAN

SPECIFICATION ‐ MONITORING OF TURBIDITY DURING DREDGING AND RECLAMATION

1370‐CO‐000‐C‐SPC‐0014 Rev T‐0B December 2016

REVISIONS


BY

CHECKED

BY

APPROVED

BY



T‐0B 08 December 2016 Threshold criteria adjusted ‐ Issue

for Tender MC WvW JZ

AUTHORISATION



08 December 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1

1.2.1 Dredging ........................................................................................................................................ 1 1.2.2 Reclamation ................................................................................................................................... 1

1.3 Monitoring ...................................................................................................................................................... 1

1.3.1 Baseline Monitoring ...................................................................................................................... 1 1.3.2 Surveillance Monitoring ................................................................................................................ 1



3.0 DEFINITIONS ............................................................................................................................................ 4

3.1 Chart Datum Port ............................................................................................................................................ 4 3.2 Co‐ordinate System ......................................................................................................................................... 4 3.3 Tidal levels ...................................................................................................................................................... 4 3.4 Method Statements ........................................................................................................................................ 4 3.5 Approved Disposal Site .................................................................................................................................... 4 3.6 Approved Offshore Borrow Site ...................................................................................................................... 4 3.7 Berth Dredging ................................................................................................................................................ 4 3.8 Dredging .......................................................................................................................................................... 4 3.9 Reclamation .................................................................................................................................................... 4

4.0 REQUIREMENTS ....................................................................................................................................... 5

4.1 Method statements ........................................................................................................................................ 5 4.2 Equipment ....................................................................................................................................................... 5 4.3 Calibration ....................................................................................................................................................... 5 4.4 Duration .......................................................................................................................................................... 5 4.5 Locations ......................................................................................................................................................... 6 4.6 Monitoring and Response Requirements ........................................................ Error! Bookmark not defined. 4.7 Data Recording, presentation and reporting .................................................................................................. 6


5.1 Trigger Limits ................................................................................................................................................... 7 5.2 Monitoring requirements at dredge and reclamation sites ............................................................................ 7 5.3 Monitoring requirements at offshore disposal site ........................................................................................ 7


PORT OF DURBAN



Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for measures to be adopted by the Contractor for

monitoring of turbidity during dredging, backfill and reclamation. Sampling and testing of dredged material for

reclamation and extension of the sandbank is covered under specification 1370‐CO‐000‐C‐SPC‐0004 covering the

dredging portion of the works.

A Total Suspended Solids (TSS) standard has been developed for the Contractor at the Port of Durban to ensure that

the environmental impact of dredging and reclamation is limited. The Contractor is responsible for ensuring that the

TSS standard is adhered to. This specification is associated with turbidity monitoring for the following works:

1.2.1 Dredging

a) The deepening and extension of the basin including the turning circle.

b) Berth dredging for the new Berths 203 to 205 to provide caisson founding trench and scour protection

trench.

c) Dredging of launching dock to allow for launching and towing of caissons.

1.2.2 Reclamation

a) Reclamation of areas between new caisson wall and existing quay wall.

b) Extension and reclamation of south bank of sandbank.

c) Filling the caissons with dredged material.

1.3 Monitoring

1.3.1 Baseline Monitoring

Collection of data prior to dredging works has been undertaken by Others and will be made available to the

Contractor.

The Baseline water quality measurements have been collected from a set of 20 stations distributed in the navigation

channels surrounding the main intertidal and shallow subtidal sand bank areas in the Port of Durban and include

turbidity taken at high and low tide over a five day period each season (autumn, winter, spring, summer), giving a

total of 1600 profiles over 24 months.

Turbidity data has been collected using a Seabird SBEv19 (units = NTU) at all stations with profiles through the water

column, as well as a single water sample from 2 m below the surface at each station which allows for conversion of

the NTU data to TSS (mg/l).

Figure 1‐1 indicates the location of the Water Quality Monitoring Stations.

1.3.2 Surveillance Monitoring

Surveillance monitoring, to be undertaken by the Contractor, is required to compare environmental measurements

during dredging and against a threshold value to ensure increased levels of turbidity associated with the dredging

works are not detrimental to the environment.

Independent turbidity surveillance monitoring may also be undertaken by the Environmental Control Officer for the

Project.


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Page | 2

Figure 1‐1: Location of Water Quality Monitoring Stations


PORT OF DURBAN



Page | 3








1370‐CO‐020 Series of drawings – Dredging and reclamation.



g) Central Dredging Association (CEDA) ‐ Information Paper ‐ Environmental Monitoring Procedures –

Rotterdam ‐ April 2015.



a) International Standard ISO 7027:2010‐1:2016 –Water quality—Determination of turbidity.

b) BS 6349‐5:1991 – Maritime Structures – Code of practice for dredging and land reclamation.

c) PIANC Report No 100 – 2009 – Dredging Management Practices for the Environment.


The Employer specifications listed in this section shall, inter alia, be read in conjunction with this specification:

a) 1370‐CO‐000‐C‐SPC‐0004 – Dredging and Reclamation (Including Vibro Compaction).

b) 1370‐CO‐000‐C‐SPC‐0016 – Sandbank Extension.

c) Environmental Management Plan (EMP).


PORT OF DURBAN



Page | 4

3.0 DEFINITIONS












3.3 Tidal levels






Mean Level ML 1.097









3.5 Approved Disposal Site

The Approved Disposal Site refers to a site located offshore, the locality of which is shown on drawing 1370‐CO‐020‐

C‐DWG‐010‐01.


The Approved Off‐shore Borrow Site refers to a site located offshore, the locality of which is shown on drawing 1370‐

CO‐020‐C‐DWG‐010‐01.

3.7 Berth Dredging

Dredging of material below ‐16.5 m CDP for the caisson foundation trench, scour trench and the slope that extends

from the caisson foundation trench to the existing wall. Material within this area above ‐16.5m CDP is classified as

Basin Dredging.

3.8 Dredging



3.9 Reclamation

The process of creating new land or extending the sandbank from dredged/imported material.


PORT OF DURBAN



Page | 5

4.0 REQUIREMENTS

4.1 Method statements

Prior to procuring and installation of the monitoring Equipment, the Contractor shall prepare method statements

that shall include, inter alia:

a) Details of all monitoring and measuring equipment including dedicated computer and software.

b) Details of installation, calibration and maintenance procedures for the monitoring systems

c) Details of anchoring of the stations in the specified positions

d) Templates of the weekly, monthly and annual reports which are to be submitted to the Supervisor.

4.2 Equipment

Buoy based turbidity monitoring stations are to be provided, installed and maintained by the Contractor with

measurement data provided in real time.

Measuring total suspended solids (TSS) directly is the best method for evaluating sediment concentrations. However,

it is not feasible for real‐time applications such as monitoring sediment re‐suspension during dredging operations,

since TSS can only be accurately measured by collecting water samples and conducting laboratory tests, which

require filtering the sediment from the water, drying and weighing it. This procedure is too time‐consuming for

monitoring dredge sites, considering the quick feedback required to allow timely control measures.

To achieve the required real‐time monitoring, a more practical measure of water clarity, i.e. turbidity, shall be

substituted for TSS, using remote submersible sensors to monitor for sediment re‐suspension. The Contractor shall

propose particular models of sensor, using nephelometry or backscatter technology to measure the amount of light

scattered by particles in the water. The selected turbidity sensors shall be compliant with ISO 7027 and have a wiper

to prevent fouling. Turbidity shall be measured in Nephelometric Turbidity Units (NTU). Sensors should have a

sensitivity of 0.01 NTU and an extended range to 1,100 NTU. The same type of sensor shall be used throughout the

operations. As an example, a Seabird SBEv19 was used for turbidity data collection during the baseline monitoring

phase. Each monitoring station shall house a sensor at 1m below free surface.

A dedicated computer with appropriate software shall be provided at the Contractor’s site offices for real time

monitoring display and data capturing.

4.3 Calibration

Calibration certificates shall be supplied with all equipment. After installation, a full installation and calibration report

shall be provided by the Contractor to the Supervisor. Routine calibration shall also be carried out by the Contractor,

on 3 monthly intervals and calibration reports supplied to the Supervisor. If the real time data shows that any part of

the equipment is malfunctioning, the Contractor shall arrange to investigate, replace and recalibrate the

malfunctioning equipment at its own cost.

Calibration shall be undertaken by measuring TSS directly from a single water sample taken from 2m below the

surface at each station and comparing this to the real time NTU data recordings. This will allow for calibration and

conversion of the NTU data to TSS (mg/l).

NTU readings are also to be compared against the baseline data provided to ensure they fall within the turbidity

range recorded during baseline monitoring.

The baseline data provided in the Site Information at Stations WQ3, WQ4 and WQ5 in Figure 1‐1 shall be collated by

the Contractor and compared against its own equipment at least over a period of 14 days before any dredging or

reclamation work starts.

4.4 Duration

Surveillance monitoring and data collection shall commence at a minimum 14 days before any dredging or

reclamation work starts and shall continue fulltime until 14 days after completion of all dredging and reclamation

activities.


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Page | 6

4.5 Locations

It is recognized that the threshold limits set in 0 cannot be met in the immediate vicinity of where the actual

dredging activity is taking place at that time. For this reason a mixing zone shall apply. The extent of this mixing zone

is defined as the basin adjacent to Berths 203 to 205 plus the turning circle; and accordingly monitoring will be

outside of this defined mixing zone.

It is therefore recommended that surveillance monitoring is undertaken within the Maydon Wharf Channel, in the

form of three floating sensors, buoyed and anchored in close proximity to Baseline Stations WQ 3, 4 and 5.

Furthermore, sensors are to be provided at stations WQ2 and WQ8 (control stations – see section 5.1) to measure

the natural background port turbidity.

Floating sensors may need to be moved during specific operations, but should be relocated as close to fixed positions

as possible to ensure consistency of results.

4.6 Data Recording, presentation and reporting

Data shall be recorded in real time and either downloaded by telemetry or GSM data link with a Type Approval

Certificate issued by the Independent Communication Authority of South Africa (ICASA). Results shall be monitored,

preferably by an automatic alarm system that will identify when limits are exceeded.

Data shall be collated and presented to the Supervisor as follows:

a) Weekly throughout the duration of dredging, backfill or reclamation specified above, plus

b) At any time when particular threats of pollution, not due to the contract works, may be suspected or

identified.

Records shall include:

a) Date and Time.

b) GPS location.

c) Turbidity.

d) Weather and sea conditions.

Data shall be presented in Excel and graphical or similar format with monthly and above data presented on CD.

Early warnings shall be provided to the Supervisor of any water conditions which approach trigger or threshold limits.


PORT OF DURBAN



Page | 7


5.1 Trigger Limits

A Total Suspended Solids (TSS) threshold has been developed for the dredging Works at the Port of Durban to ensure

that the environmental impact of dredging is limited. The Contractor is responsible for ensuring that the TSS

threshold is adhered to.

The TSS threshold limit is set as the greater of:

a) The 80th percentile of the baseline monitoring data, which for stations WQ3, WQ4 and WQ5 corresponds to

a TSS of 43 mg/l.

b) Ten percent (10%) greater than the natural background port turbidity. For the purposes of this project, the

natural background port turbidity is deemed to be the greater of the real‐time readings at control stations

WQ2 and WQ7.

If the TSS approaches the threshold limit set above at any of the surveillance monitoring stations (WQ3, WQ4 or

WQ5), mitigation measures are to be put in place to prevent any further increase in suspended solid concentration

(e.g. reduce rate of dredging, relocate dredger). If mean turbidity levels (average of measured values in any three

hour period) exceed the threshold, dredging is to be suspended until measured levels drop below the threshold.

5.2 Monitoring requirements at dredge and reclamation sites

All monitoring of the TSS is not required within the mixing zone (see 4.5 above) daily observation of plume extent

with distances is required to ensure the plume extent remains within the mixing zone.

5.3 Monitoring requirements at offshore disposal site

Daily observation of plume extent with an estimation of plume distance and dispersion direction is required during

offshore disposal. This is to be recorded on a sketch with the date and time of discharge and is to be submitted to the

Supervisor. This monitoring requirement is for information only and there are no limitations placed on the

Contractor in this regard.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – WAVE, CURRENT AND TIDAL MEASUREMENTS

1370‐CO‐000‐C‐SPC‐0015 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN

SPECIFICATION ‐ WAVE, CURRENT AND TIDAL MEASUREMENTS


REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1


2.1 Reference Documents ..................................................................................................................................... 1 2.2 Standard Specifications ................................................................................................................................... 1 2.3 Employer’s Project Specific Specifications And Standards .............................................................................. 1

3.0 DEFINITIONS ............................................................................................................................................ 2


4.0 REQUIREMENTS ....................................................................................................................................... 3

4.1 Method Statement .......................................................................................................................................... 3 4.2 Location ........................................................................................................................................................... 3 4.3 Equipment ....................................................................................................................................................... 3 4.4 Data to be Collected ........................................................................................................................................ 5

4.4.1 General .......................................................................................................................................... 5 4.4.2 Current Recordings ........................................................................................................................ 5 4.4.3 Wave and Tidal Recordings ........................................................................................................... 5

5.0 REPORTING AND DISTRIBUTION .............................................................................................................. 6

6.0 INSPECTION AND CALIBRATION ............................................................................................................... 6

6.1 Inspection ........................................................................................................................................................ 6 6.2 Calibration ....................................................................................................................................................... 6


PORT OF DURBAN



Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the provision and maintenance of wave,

current and tidal measuring Equipment during the entire contract period as well as for the recording, processing and

presentation of the data recorded.

The specification details requirements of Materials, Equipment and Procedures to be adopted by the Contractor to

supply and maintain wave, current and tidal measuring Equipment.

Collection of data prior to the contract works was carried out by the CSIR and will be made available to the

Contractor.







d) Method statement prepared by the Contractor, as described in Section 4.1.


The standard specifications listed in this section shall, inter alia, be read in conjunction with this specification.

a) DNV RP C205 – Environmental Conditions and Environmental Loads, April 2014.

2.3 Employer’s Project Specific Specifications And Standards


a) Environmental Management Plan (EMP).


PORT OF DURBAN



Page | 2

3.0 DEFINITIONS












3.3 Tidal Levels






Mean Level ML 1.097










PORT OF DURBAN



Page | 3

4.0 REQUIREMENTS



a) Provision of two fully automatic remote instruments for measuring directional waves and currents.

b) Provision of a Wave and Tide Recorder (WTR).

c) Provision of complete and operable packages.

d) Obtaining daily forecasts of wind and wave conditions, in particular those that may affect the marine

aspects of the contract works.

e) Provision of daily seven day forecasts of wind and wave conditions and in particular those that may affect

the contract marine works.

f) Provision of weekly summary reports to the Supervisor of the marine forecasts and the acquired data.

g) Removal of all Equipment after completion of the Project.

4.2 Location

The units are to be deployed in reasonable proximity to the positions tabulated in Table 1 and plotted in Figure 1.

Table 1: Wave, Current and Tidal Recorder

Instrument Name Latitude Longitude Depth

(m)

Height of Top of ADCP

off bottom (mm)

TRDI 600kHz ADCP ADCP – Offshore 29°52’17” 31°42’27” 20 800

TRDI 600kHz ADCP ADCP – Port 29°52’29” 31°3’4” 13 800

WTR WAVE – mw 29°52’10” 31°0’55” 12 600

4.3 Equipment

a) The external data acquisition Equipment shall be a proprietary system with the following or equal approved

characteristics: Provide two fully automatic remote bottom mounted Acoustic Doppler Current Profilers

(ADCP) with dedicated computer and software for measuring directional waves and current.

b) The Contractor shall be solely responsible for providing complete and operable packages in full accordance

with all applicable Industry Codes and Standards, Government Regulations and Contractor Technical

Requirements.

c) Wave and Tide Recorder (WTR).


PORT OF DURBAN



Page | 4

Figure 1: Wave, Current and Tidal Recorder Location


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Page | 5

4.4 Data to be Collected

4.4.1 General

Data shall be recorded in real time and collected during recovery and redeployment of the instruments at suitable

periods to suit on‐board battery life and data storage capacity throughout the duration of the contract works and to

the approval of the Employer.

4.4.2 Current Recordings

Current recording and analysis shall be carried out as follows:

a) Recording shall be continuous for 50 minutes of every hour, with 10 minutes at each hour being used for

data transfer.

b) The maximum average current velocity measured over 10 minute cycles and the associated current

direction shall be calculated every hour.

c) The maximum average current velocity (over a one minute cycle) shall be calculated for every hour.

d) Vertical directional current velocity profiles shall be calculated for the 10 minute and one minute cycles.

e) A table and histogram of current velocity distribution for 16 directional sectors shall be produced per

season and for the full data set.

f) A current rose shall be produced per season and for the full data set.

g) The latest recorded hourly average, 10 minute average and 1 minute maximum surface current speed and

direction shall be transferred in real‐time to a computer display system. All recorded data shall be stored in

digital format and backed‐up on a monthly basis.

4.4.3 Wave and Tidal Recordings

Wave and tide recording and analysis shall be carried out as follows:

a) The mean water level shall be recorded at 10 minute intervals.

b) Tidal constituent analysis shall be carried out on a six monthly basis and the derived constituents presented

to the Employer.

c) The tidal gauge shall be calibrated on a three monthly basis and be referenced to a known reference level

on the site.

d) Wave height and profile data shall be recorded in real time wave direction shall be recorded by immersed

sensors. The ADCP’s are to determine wave height, period and direction, by one or more combinations of

three measurement methods: velocities, surface tracking and bottom pressures.

e) The water level and wave data shall be displayed in real time on a computer display system. All recorded

data shall be stored in digital format and backed up on a monthly basis.


PORT OF DURBAN



Page | 6

5.0 REPORTING AND DISTRIBUTION

The system shall be capable of providing data recorded with the specified sensors to a central location and provide

output in real time. All recorded data shall be stored on suitable digital storage media (to be approved by the

Employer) and backed‐up on a monthly basis.

Data shall be presented to the Supervisor after each recovery in both raw data format and in graphical or similar

format on CD.

At least the following data shall be provided:

a) Significant Wave Height Hs

b) Peak Period Tp

c) Mean Period Tm

d) Water Level

e) Peak Wave Direction

f) Mean Peak Wave Direction

g) Long Wave Significant Wave Height

h) Long Wave Peak Periods

i) Current Direction – Graph

j) Current Direction ‐ Rose

Trend analyses shall be provided analysed into quarterly, six month and annual periods.

Early warnings shall be provided to the Supervisor of any wave conditions which the Contractor deems to be not in

accordance with the baseline data or the Contract Works data provided.

6.0 INSPECTION AND CALIBRATION

6.1 Inspection

All Equipment specifications and supporting documentation shall be supplied for approval to the Employer prior to

ordering and deploying the Equipment.

The Contractor shall include a detailed description of the full monitoring system, installation procedures and

operating systems with the specifications.

6.2 Calibration

Calibration certificates shall be supplied with all Equipment. After installation, a full installation and calibration report

shall be provided by the Contractor.

Routine calibration shall be carried out on 3 monthly intervals and calibration reports supplied to the Employer. If

the real time data shows that any part of the Equipment is malfunctioning, the Contractor shall arrange to

investigate, replace and recalibrate the malfunctioning Equipment at his own cost.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – SANDBANK EXTENSION

1370‐CO‐000‐C‐SPC‐0016 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN



REVISIONS


BY

CHECKED

BY

APPROVED

BY



AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE ...................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 2

3.1 Chart Datum Port ............................................................................................................................................ 2 3.2 Co‐ordinate System ......................................................................................................................................... 2 3.3 Tidal Levels ...................................................................................................................................................... 2 3.4 Method Statements ........................................................................................................................................ 2 3.5 Approved Offshore Borrow Site ...................................................................................................................... 2 3.6 Dredging .......................................................................................................................................................... 2 3.7 Reclamation .................................................................................................................................................... 2 3.8 Silt Curtain ....................................................................................................................................................... 2

4.0 REQUIREMENTS ....................................................................................................................................... 3

4.1 Method Statements ........................................................................................................................................ 3 4.2 Materials ......................................................................................................................................................... 3 4.3 Equipment ....................................................................................................................................................... 3

4.3.1 Discharge equipment .................................................................................................................... 3 4.3.2 Silt Curtains ................................................................................................................................... 4 4.3.3 Survey Equipment ......................................................................................................................... 4


4.4.1 Sandbank extension ...................................................................................................................... 4 4.4.2 Silt curtain installation, operation and maintenance .................................................................... 5 4.4.3 Monitoring of stability during fill placement ................................................................................. 6 4.4.4 Requirements of marine surveys .................................................................................................. 6 4.4.5 In‐surveys ...................................................................................................................................... 6 4.4.6 Out‐surveys ................................................................................................................................... 6


5.1 Testing, Commissioning and Completion ........................................................................................................ 7 5.2 Tolerances ....................................................................................................................................................... 7


PORT OF DURBAN

SPECIFICATION –SANDBANK EXTENSION


Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the extension of the existing sandbank

adjacent to Berths 203 to 205. The sandbank is being extended to compensate for the loss of existing sandbank area

due to the extension of Berth 205 into the existing sandbank.

The specification details requirements of Materials, Equipment and procedures to be adopted to ensure that the

sandbank is extended in a controlled and stable manner with minimum disruption to the environment.

The extension of the sandbank involves dredging of material from within the basin and from the off‐shore sand‐

winning site and depositing adjacent to the existing sandbank. Only works involving the placement of the material to

form the extended sandbank are covered in this specification with specification 1370‐CO‐000‐C‐SPC‐0004 covering

the dredging portion of the Works.








- 1370‐CO‐020 series of drawings – Dredging and Reclamation.





a) SANS 1200 D:1988 – Earthworks.

b) BS 6349‐5:1991 – Maritime Structures – Code of practice for dredging and land reclamation.

c) PIANC Report No 100 – 2009 – Dredging Management Practices for the Environment.

d) PIANC Report No 144 – 2016 – Classification of Soils and Rocks for the Maritime Dredging Process.

e) BS EN 1997‐2: 2007 ‐ Geotechnical design – Ground investigation and testing.

f) BS EN ISO 22476‐1:2012 – Geotechnical investigation and testing. Field testing. Electrical cone and

piezocone penetration test.

g) IHO Standards for Hydrographic Surveys, Special Publication No.44, 5th Edition, February 2008.



a) 1370‐CO‐000‐C‐SPC‐0004 – Dredging and Reclamation (Including Vibro Compaction).



PORT OF DURBAN



Page | 2

3.0 DEFINITIONS












3.3 Tidal Levels






Mean Level ML 1.097










The Approved Offshore Borrow Site refers to a site located offshore, the locality of which is shown on drawing 1370‐

CO‐020‐C‐DWG‐010‐01.

3.6 Dredging



3.7 Reclamation

The process of creating new land or extending the sandbank from dredged/imported material.

3.8 Silt Curtain

A floating geotextile material which minimizes sediment transport from a disturbed area adjacent to or within a body

of water.


PORT OF DURBAN



Page | 3

4.0 REQUIREMENTS



a) The Contractor’s chosen methodology and Equipment for placing and profiling the material for the

sandbank extension such that the profile is achieve within the required tolerances.

b) The Contractor’s proposed layout of discharge pipelines for the sandbank extension.

c) Estimated discharge rates and means of controlling the discharge rate to ensure material is placed in the

correct quantity such that the profile is achieve within the required tolerances.

d) Estimated sediment concentration at point of discharge.

e) Details of sampling and testing methodology to ensure the material placed on the sandbank meets the

required specification.

f) The Contractor’s methodology for controlling sedimentation and turbidity within the vicinity of sandbank

extension activities including details of silt curtains and methods of securing/mooring silt curtains. Detailed

strength, buoyancy and stability design calculations for all components (fabric strength, anchorages, load

lines and floatation) of the silt curtains shall be provided.

g) Details of geotextile tube including details of anchoring and filling operation to secure tube in place.

h) Details of bunding along toe of sandbank extension to ensure sandbank remains stable during placement

and to minimise material over‐spilling into the dredged basin area.

i) Details of sequencing of sandbank extension including paddock sizes and layer thickness (refer to drawings

1370‐CO‐020‐C‐DWG‐0007‐01 and 02).

4.2 Materials

The material for the sandbank extension will be won primarily from the various sand rich zones within the basin.

These zones are shown on drawing 1370‐CO‐020‐C‐0009‐01. Bathymetric and geotechnical surveys indicate that

there is sufficient material available within these sand rich zones to complete the sandbank extension. Should it be

found, for whatever reason, that there is insufficient material from the sand rich zones within the basin to complete

the sandbank extension, the remainder of the material shall be sourced from the off shore sand winning site.

The material for the sandbank shall have the following requirements:

a) Fines content (percentage passing 0.75 m sieve) <= 30%

b) Free of debris and industrial waste

To facilitate compatible marine re‐growth, the top layer (0.5 m) shall be composed of material dredged from

undisturbed areas of the existing sandbank within the Zone B dredge area as shown on drawing 1370‐CO‐020‐C‐

0009‐01.

4.3 Equipment

4.3.1 Discharge equipment

Placing of material for the sand bank extension shall be via a floating pipeline and the dredger employed shall be

equipped with a suitable pump and pipe network system to connect to the floating pipeline. At the point of

discharge, the pipe shall be fitted with a diffuser or ‘spoon’ to reduce flow velocities, prevent scouring and to assist in

providing a more even distribution of material.

Rainbowing of the material via a bow‐mounted nozzle or bottom dumping of the material is not permitted for the

material to be placed for the sandbank extension.


PORT OF DURBAN



Page | 4

4.3.2 Silt Curtains

The silt curtains provided for the sandbank extension shall comply with the following minimum specifications:

a) Silt curtains shall be designed for current velocities of up to 2.0 knots.

b) Geotextile fabric shall have a minimum grab tensile strength (in accordance with ASTM D751) of 1350 N.

c) Fabric weight shall be a minimum 750 g/m2.

d) Tear strength (in accordance with ASTM D4533) shall be a minimum of 890 N.

e) The number of joints in the curtain shall be minimized, with a minimum continuous span of 15 m between

joints.

f) Curtains shall be a bright color (yellow or "international" orange are recommended) to enhance visibility.

g) Seams in the fabric shall be either vulcanized welded or sewn, and shall develop the full strength of the

fabric.

h) Floatation devices shall be flexible, buoyant units contained in an individual floatation sleeve or collar

attached to the curtain. Buoyancy provided by the floatation units shall be sufficient to support the weight

of the curtain and maintain a freeboard of at least 75 mm above the water surface level.

i) Load lines must be fabricated into both the top and bottom of all floating turbidity curtains. The top load

line shall consist of woven webbing or vinyl‐sheathed steel cable and shall have a break strength in excess

of 50 kN. The bottom load line shall consist of a chain incorporated into the bottom hem of the curtain of

sufficient weight to serve as ballast to hold the curtain in a vertical position. Additional anchorage shall be

provided as necessary. The load lines shall have suitable connecting devices which develop the full breaking

strength for connecting to load lines in adjacent sections.

j) Anchors placed at bed level shall be used. Bottom anchors shall be sufficient to hold the curtain in the same

position relative to the bottom of the watercourse without interfering with the action of the curtain. The

anchor may dig into the seabed (grappling hook, plow or fluke‐type) or may be weighted type.

k) Handholds shall be provided along the top of the curtain between the flotation segments for ease in

handling.

l) Repair kits shall be available to patch minor tears in the fabric.


For details of the survey equipment requirements, refer to specification 1370‐CO‐000‐C‐SPC‐0004 Dredging and

Reclamation (Including Vibro Compaction).


4.4.1 Sandbank extension

Great care is required in this ecologically sensitive area. The Contractor shall be responsible for placing the material

for the sandbank extension to the profiles and tolerances specified. The Contractor shall employ a floating pipe

system for discharging of the material for the sandbank extension. No compaction of the sandbank extension is

required or permitted.

Extension of the sandbanks shall be carried out with reference to the drawing 1370‐CO‐020‐C‐DWG‐0007‐01 and 02.

The construction sequence shall be carried out as follows:

1. Demarcate setting out points of the area to be filled.

2. Conduct a video survey of the existing slopes for record purposes.

3. Place geotextile tube filled with sand along the line of the new toe of the extended sandbank to form a

low retaining structure 1 m high. Geotextile tubes shall be staggered so as to eliminate gaps.

4. Set up silt curtain and turbidity control measures as detailed in section 4.4.2.

5. Set up a silt curtain around paddock A.

6. Pump dredged material behind the geotextile tube to form a continuous 2.5 m high bund along the

length of the paddock. Care shall be taken to prevent overflow or slothing into the channel.


PORT OF DURBAN



Page | 5

7. Pump the dredged material through floating pipelines to create a layer not exceeding a thickness of 2 m

behind the sand bund. Monitor the deposition of sand behind the sand bund to ensure it is evenly

spread.

8. Move and set up silt curtains around the next paddock.

9. Repeat steps 6 to 7 until reaching the last paddock (Paddock N).

10. Move silt curtain back to paddock A.

11. Place next layer behind bund 1A.

Repeat steps 6 to 11 until the top layer of the sandbank is placed. The top 0.5 m layer of the entire sandbank

extension shall comprise material dredged from Zone B.

4.4.2 Silt curtain installation, operation and maintenance

The installation, operation and maintenance of the silt curtains shall comply with the following:

a) Floating containment silt curtains shall be provided to form a series of enclosed paddocks that can be used sequentially for sand deposition and to control turbidity by restricting movement of fines. At the top of the sandbank a shallow curtain shall be provided which shall be supported on floats at high tide.

b) Operations within silt curtains shall not continue in current velocities greater than 2.0 knots

c) Extra length (up to 10 ‐ 20%) and depth (slack) of curtains shall be included in designs to allow for tidal fluctuations and exchanges of water within the curtain.

d) The Contractor shall adopt suitable measures to ensure that the silt curtain is not:

─ Lifted out of the water during high winds.

─ Sunk due to excessive biological or silt fouling on the fabric.

e) The number of joints in the curtain shall be minimized; a minimum continuous span of at least 15 m shall be provided between joints.

f) Curtain anchor points shall be set prior to fabric installation. The anchor points shall have sufficient holding power to retain the curtain under the existing current conditions prior to putting the furled curtain into the water. Anchors shall be provided on both sides of the curtain to account for flows in both directions due to tidal movements.

g) Once anchors are secured, the furled curtain shall be secured to the anchor point and then sequentially attached to each anchor point until the entire curtain is secured in position. The furling lines should then be cut to allow the skirt to drop.

h) Anchor lines shall be attached to the flotation device and NOT to the bottom of the curtain.

i) In tidal situations, where currents move in both directions, anchors shall be attached on both sides of the curtain to hold the curtain in place and to not allow it to overrun the anchors and pull them out when the tide reverses.

j) Anchor lines shall be attached to the flotation device, not to the bottom of the curtain to prevent overstressing of the fabric material.

k) Care shall be taken during removal of silt curtains to avoid or minimize re‐suspension of settled solids.

l) Should repairs to the geotextile fabric become necessary, a manufacturer approved repair kit shall be used in accordance with the manufacturer’s specification.


PORT OF DURBAN



Page | 6

4.4.3 Monitoring of stability during fill placement

The Contractor shall continuously monitor the stability of the sandbank during placement undertaking regular single

beam echo‐sounder surveys and dive surveys of the extension. In addition to the single beam and dive surveys

undertaken during placement, the Contractor shall undertake a multi beam survey of the extension after the first

layer has been placed and thereafter after every second layer is placed. The Contractor shall immediately notify the

Supervisor if any abnormalities (slips, slothing, scour, mud slides etc.) are noticed during monitoring.

4.4.4 Requirements of marine surveys

4.4.5 In‐surveys

Before any works associated with the sandbank extension may commence, the Contractor shall carry out a survey of

the existing sandbank and the adjacent seabed where the material will be placed. These surveys shall be carried out

in collaboration with the Supervisor. Both parties shall agree on the existing sea bed levels before commencing work.

A copy of the final agreed in‐survey shall be furnished to the Supervisor for record purposes.

The in‐survey shall form the basis for calculations of quantities of materials dredged or profiled as detailed in the

Pricing Instructions.

4.4.6 Out‐surveys

In addition to the interim surveys to be undertaken as detailed in section 4.4.3, on final completion of the sandbank

extension, a survey of the completed extension shall be undertaken to ensure compliance with the placement

tolerances for the sandbank.

The respective areas shall be surveyed and the final levels shall be recorded on a drawing. The results of this survey

shall be made available to the Supervisor for acceptance.

Should it be found that the correct levels have not been achieved; the Contractor shall carry out further work until

the prescribed levels have been achieved.


PORT OF DURBAN



Page | 7


5.1 Testing, Commissioning and Completion

The Contractor shall be responsible for sampling, testing and monitoring of material dredged and placed for the

sandbank extension to ensure the material meets the required design classification. On a daily basis during the

progress of filling, the Contractor shall take two bag samples (of 25 kg each) of the materials placed in the extension

at locations directed by the Supervisor. Samples shall be taken at a maximum depth of 0.5 m. The Contractor shall

carry out sieve analysis tests on each of the bag samples and shall submit result to the Supervisor daily. The samples

shall be taken from the material placed on the sandbank (i.e. not from within the hopper) and shall be taken before

the subsequent layer is placed.

5.2 Tolerances

Tolerances shall be as follows:

a) A tolerance of + 500 mm to ‐500 mm from the designated levels shall be acceptable, whilst the toe of the

extended sandbank shall be within ‐2 m / +0 m of the locations shown on the drawings where positive

tolerance indicates encroachment towards the basin.

b) At no time during construction of the extension, shall the level of the deposited material exceed +2000 mm

above final design level.

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN

SPECIFICATION – CORROSION PROTECTION

1370‐CO‐000‐C‐SPC‐0017 Rev T‐0A

18 NOVEMBER 2016

TRANSNET SOC LTD DCT BERTHS 203 TO 205 – RECONSTRUCTION, DEEPENING AND LENGTHENING

PORT OF DURBAN



REVISIONS


BY

CHECKED

BY

APPROVED

BY

T‐00 31 May 2016 Issue for Review NW MC JZ

T‐0A 18 November 2016 Issue for Tender NW MC JZ

AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE 1

1.1 Project ..................................................................................................................................................... 1 1.2 Scope ....................................................................................................................................................... 1


2.1 Reference Documents ............................................................................................................................. 1 2.2 Standard Specifications ........................................................................................................................... 1 2.3 Employer’s Project Specific Specifications and Standards ........................................................................ 1

3.0 DEFINITIONS ............................................................................................................................................ 2

3.1 Chart Datum Port ..................................................................................................................................... 2 3.2 Co‐ordinate System ................................................................................................................................. 2 3.3 Tidal Levels .............................................................................................................................................. 2 3.4 Method Statements ................................................................................................................................ 2

4.0 REQUIREMENTS ....................................................................................................................................... 3

4.1 Method Statement .................................................................................................................................. 3 4.2 Equipment ............................................................................................................................................... 3 4.3 Methods and Procedures ......................................................................................................................... 3

4.3.1 Coatings ......................................................................................................................................... 3

4.3.1.1 Extent of work ............................................................................................................................... 3 4.3.1.2 Coating and supply and application methodology ........................................................................ 3 4.3.1.3 Anodes fabrication, supply and application methodology ............................................................ 3 4.3.1.4 Repair of damaged coatings .......................................................................................................... 4 4.3.1.5 Quality Assurance Requirements and Quality Control .................................................................. 4

ANNEXURE 1: ISINYITHI CATHODIC PROTECTION SPECIFICATIONS: PORT OF DURBAN BERTHS 203 TO 205 RETURN

WALL STEEL PILES 5690/130999 EXTERNAL COATING SPECIFICATION ....................................................................... 1 ANNEXURE 2: ISINYITHI CATHODIC PROTECTION SPECIFICATIONS: PORT OF DURBAN BERTHS 203 TO 205 RETURN

WALL STEEL PILES 5690/130999 GALVANIC ANODES SPECIFICATION ........................................................................ 2


PORT OF DURBAN



Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the provision of corrosion protection in the

form of Epoxy glass flake coatings and sacrificial aluminium anodes for the Berth 205 circular straight steel sheet pile

return quay.

The specification details the requirements of Materials, Equipment and Procedures to be adopted by the Contractor

to supply, apply and install the corrosion protection for the return quay.



The following Employer and industry standardized specifications are referenced in this specification and form part of






c) Project Drawings:

─ 1370‐CO‐070 series of drawings – Return Quay

─ 1370‐CO‐020 series of drawings – Dredging and Reclamation (anodes installed after completion of

local basin dredging).

d) Employer’s Project Specific Technical Specifications as listed in Section 2.2.

e) Method Statements prepared by the Contractor, as described in Section 4.1.


The standard specifications listed in this section shall, inter alia, be read in conjunction with the following

specifications

a) Recommended Practice DNV‐RP‐F103 – Cathodic Protection of Submarine Pipelines by Galvanic Anodes,

2010

b) Recommended Practice DNV‐RP‐F106 – Factory Applied External Pipeline Coatings for Corrosion Control,

2011

c) SANS ISO 15589‐2: 2009, Edition 1 (ISO 15589‐2:2004, Edition 1) – Petroleum and Natural Gas Industries –

Cathodic Protection of Pipeline Transportation Systems – Part 2: Offshore Pipelines

d) SANS 53509:2009, Edition 1 (EN 13509:2003, Edition 1) – Cathodic Protection Measurement Techniques

e) Isinyithi Cathodic Protection ‐ 5690/130999 Port of Durban Berths 203 to 205 Return Wall Steel Piles

External Coating Specification

f) Isinyithi Cathodic Protection – 5890/130999 Port of Durban Berths 203 to 205 Return Wall Steel Piles

Galvanic Anode Specification



a) 1370‐CO‐000‐C‐SPC‐0009 – Steel Sheet Piling.



PORT OF DURBAN



Page | 2

3.0 DEFINITIONS



Where the standard specifications referenced in this specification refer to the “Client”, replace this term with the

term “Employer”.



For the purpose of this specification, the technical definitions and abbreviations given in SANS 15589-2:2009/ISO

15589-2:2004, (approved 2009) together with the following definitions shall apply:







3.3 Tidal Levels






Mean Level ML 1.097










PORT OF DURBAN



Page | 3

4.0 REQUIREMENTS



a) Supply and application of corrosion protection in the form of Zip‐E Epoxy glass flake coatings for the Berth

205 circular straight steel sheet pile return quay.

b) Fabrication, Supply, installation and commissioning of corrosion protection in the form of sacrificial

aluminum anodes for the Berth 205 circular straight steel sheet pile return quay.

c) Quality Plans.

4.2 Equipment





4.3.1 Coatings


a) The extent of work, corrosion protection and levels are as shown on the 1370‐CO‐070 series of drawings.

The following corrosion protection measures shall be undertaken in accordance with the specifications:

─ Isinyithi Cathodic Protection specifications: Port of Durban Berths 203 to 205 Return Wall Steel Piles

5690/130999 External Coating Specification and


5890/130999 Galvanic Anodes Specification

b) The piles will be fully coated on the sea face to reduce CP current requirements and enable the 50‐year

design life without anode replacement.

c) The top section of all piles shall be coated on both faces to 1m below the level of the capping beam to

provide supplementary protection in the intertidal zone and prevent localised corrosion of the steel

adjacent to the encasement of the capping beam.

d) The anodes shall only be installed after dredging of the basin (1370‐CO‐020 series of drawings) using bolted

mounting brackets with the welded connections above the water line.

e) All electrical connections between anodes and the pile SHALL be welded. NO bolted connections to the pile

may be employed.

4.3.1.2 Coating and supply and application methodology

Coatings supply and application methodology shall be in accordance with the requirements of Isinyithi Cathodic

Protection specification: Port of Durban Berths 203 to 205 Return Wall Steel Piles 5690/130999 External Coating

Specification.

Where this specification states in Section 3.10 Material Supplier: “No alternative products or Suppliers will be

considered”, replace this with “use of alternative products or Suppliers will be subject to the approval of the

Supplier”.

4.3.1.3 Anodes fabrication, supply and application methodology

Anodes fabrication, supply and application methodology shall be in accordance with the requirements of Isinyithi

Cathodic Protection specification: Port of Durban Berths 203 to 205 Return Wall Steel Piles 5890/130999 Galvanic

Anodes Specification


PORT OF DURBAN



Page | 4

4.3.1.4 Repair of damaged coatings

Repair of damaged coatings during transportation and installation shall be in accordance with the requirements of

Isinyithi Cathodic Protection specification: Port of Durban Berths 203 to 205 Return Wall Steel Piles 5690/130999

External Coating Specification.

4.3.1.5 Quality Assurance Requirements and Quality Control

Quality Assurance and Control shall be undertaken in accordance with the specifications:

a) Isinyithi Cathodic Protection specifications: Port of Durban Berths 203 to 205 Return Wall Steel Piles

5690/130999 External Coating Specification; and

b) Isinyithi Cathodic Protection specifications: Port of Durban Berths 203 to 205 Return Wall Steel Piles

5890/130999 Galvanic Anodes Specification.


PORT OF DURBAN


1370‐CO‐000‐C‐SPC‐0017 Rev T‐0A Annexures November 2016

Page | A1

ANNEXURE 1: ISINYITHI CATHODIC PROTECTION SPECIFICATIONS: PORT OF

DURBAN BERTHS 203 TO 205 RETURN WALL STEEL PILES 5690/130999 EXTERNAL

COATING SPECIFICATION


PORT OF DURBAN



Page | A2


DURBAN BERTHS 203 TO 205 RETURN WALL STEEL PILES 5690/130999 GALVANIC

ANODES SPECIFICATION

TRANSNET SOC LTD


LENGTHENING

PORT OF DURBAN


1370‐CO‐000‐C‐SPC‐0017 Rev T‐0A

18 NOVEMBER 2016


PORT OF DURBAN



REVISIONS


BY

CHECKED

BY

APPROVED

BY

T‐00 31 May 2016 Issue for Review NW MC JZ

T‐0A 18 November 2016 Issue for Tender NW MC JZ

AUTHORISATION



18 November 2016






PORT OF DURBAN



CONTENTS

1.0 SCOPE .................................................................................................................................................... 1

1.1 Project ............................................................................................................................................................. 1 1.2 Scope ............................................................................................................................................................... 1



3.0 DEFINITIONS ............................................................................................................................................ 3


4.0 REQUIREMENTS ....................................................................................................................................... 4

4.1 Method Statement .......................................................................................................................................... 4 4.2 Equipment ....................................................................................................................................................... 4 4.3 Methods and Procedures ................................................................................................................................ 4

4.3.1 Coatings ......................................................................................................................................... 4

4.3.1.1 Extent of work ............................................................................................................................... 4 4.3.1.2 Coating and supply and application methodology ........................................................................ 4 4.3.1.3 Anodes fabrication, supply and application methodology ............................................................ 4 4.3.1.4 Repair of damaged coatings .......................................................................................................... 5 4.3.1.5 Quality Assurance Requirements and Quality Control .................................................................. 5

ANNEXURE 1: ISINYITHI CATHODIC PROTECTION SPECIFICATIONS: PORT OF DURBAN BERTHS 203 TO 205 RETURN

WALL STEEL PILES 5690/130999 EXTERNAL COATING SPECIFICATION ....................................................................... 1 ANNEXURE 2: ISINYITHI CATHODIC PROTECTION SPECIFICATIONS: PORT OF DURBAN BERTHS 203 TO 205 RETURN

WALL STEEL PILES 5690/130999 GALVANIC ANODES SPECIFICATION ........................................................................ 2


PORT OF DURBAN



Page | 1

1.0 SCOPE

1.1 Project



1.2 Scope

The scope of this specification covers the Employer’s requirements for the provision of corrosion protection in the

form of Epoxy glass flake coatings and sacrificial aluminium anodes for the Berth 205 circular straight steel sheet pile

return quay.

The specification details the requirements of Materials, Equipment and Procedures to be adopted by the Contractor

to supply, apply and install the corrosion protection for the return quay.


PORT OF DURBAN



Page | 2



The following Employer and industry standardized specifications are referenced in this specification and form part of






c) Project Drawings:

─ 1370‐CO‐070 series of drawings – Return Quay

─ 1370‐CO‐020 series of drawings – Dredging and Reclamation (anodes installed after completion of

local basin dredging).

d) Employer’s Project Specific Technical Specifications as listed in Section 2.2.

e) Method Statements prepared by the Contractor, as described in Section 4.1.


The standard specifications listed in this section shall, inter alia, be read in conjunction with the following

specifications

a) Recommended Practice DNV‐RP‐F103 – Cathodic Protection of Submarine Pipelines by Galvanic Anodes,

2010

b) Recommended Practice DNV‐RP‐F106 – Factory Applied External Pipeline Coatings for Corrosion Control,

2011

c) SANS ISO 15589‐2: 2009, Edition 1 (ISO 15589‐2:2004, Edition 1) – Petroleum and Natural Gas Industries –

Cathodic Protection of Pipeline Transportation Systems – Part 2: Offshore Pipelines

d) SANS 53509:2009, Edition 1 (EN 13509:2003, Edition 1) – Cathodic Protection Measurement Techniques

e) Isinyithi Cathodic Protection ‐ 5690/130999 Port of Durban Berths 203 to 205 Return Wall Steel Piles

External Coating Specification

f) Isinyithi Cathodic Protection – 5890/130999 Port of Durban Berths 203 to 205 Return Wall Steel Piles

Galvanic Anode Specification



a) 1370‐CO‐000‐C‐SPC‐0009 – Steel Sheet Piling.



PORT OF DURBAN



Page | 3

3.0 DEFINITIONS



Where the standard specifications referenced in this specification refer to the “Client”, replace this term with the

term “Employer”.



For the purpose of this specification, the technical definitions and abbreviations given in SANS 15589-2:2009/ISO

15589-2:2004, (approved 2009) together with the following definitions shall apply:







3.3 Tidal Levels






Mean Level ML 1.097










PORT OF DURBAN



Page | 4

4.0 REQUIREMENTS



a) Supply and application of corrosion protection in the form of Zip‐E Epoxy glass flake coatings for the Berth

205 circular straight steel sheet pile return quay.

b) Fabrication, Supply, installation and commissioning of corrosion protection in the form of sacrificial

aluminum anodes for the Berth 205 circular straight steel sheet pile return quay.

c) Quality Plans.

4.2 Equipment





4.3.1 Coatings


a) The extent of work, corrosion protection and levels are as shown on the 1370‐CO‐070 series of drawings.

The following corrosion protection measures shall be undertaken in accordance with the specifications:


5690/130999 External Coating Specification and


5890/130999 Galvanic Anodes Specification

b) The piles will be fully coated on the sea face to reduce CP current requirements and enable the 50‐year

design life without anode replacement.

c) The top section of all piles shall be coated on both faces to 1m below the level of the capping beam to

provide supplementary protection in the intertidal zone and prevent localised corrosion of the steel

adjacent to the encasement of the capping beam.

d) The anodes shall only be installed after dredging of the basin (1370‐CO‐020 series of drawings) using bolted

mounting brackets with the welded connections above the water line.

e) All electrical connections between anodes and the pile SHALL be welded. NO bolted connections to the pile

may be employed.

4.3.1.2 Coating and supply and application methodology

Coatings supply and application methodology shall be in accordance with the requirements of Isinyithi Cathodic

Protection specification: Port of Durban Berths 203 to 205 Return Wall Steel Piles 5690/130999 External Coating

Specification.

Where this specification states in Section 3.10 Material Supplier: “No alternative products or Suppliers will be

considered”, replace this with “use of alternative products or Suppliers will be subject to the approval of the

Supplier”.

4.3.1.3 Anodes fabrication, supply and application methodology

Anodes fabrication, supply and application methodology shall be in accordance with the requirements of Isinyithi

Cathodic Protection specification: Port of Durban Berths 203 to 205 Return Wall Steel Piles 5890/130999 Galvanic

Anodes Specification


PORT OF DURBAN



Page | 5

4.3.1.4 Repair of damaged coatings

Repair of damaged coatings during transportation and installation shall be in accordance with the requirements of

Isinyithi Cathodic Protection specification: Port of Durban Berths 203 to 205 Return Wall Steel Piles 5690/130999

External Coating Specification.

4.3.1.5 Quality Assurance Requirements and Quality Control

Quality Assurance and Control shall be undertaken in accordance with the specifications:

a) Isinyithi Cathodic Protection specifications: Port of Durban Berths 203 to 205 Return Wall Steel Piles

5690/130999 External Coating Specification; and

b) Isinyithi Cathodic Protection specifications: Port of Durban Berths 203 to 205 Return Wall Steel Piles

5890/130999 Galvanic Anodes Specification.


PORT OF DURBAN



Page | A1


DURBAN BERTHS 203 TO 205 RETURN WALL STEEL PILES 5690/130999 EXTERNAL

COATING SPECIFICATION

C O N F I D E N T I A L R E P O R T

CLIENT : ZAA Engineering Projects & Naval Architecture

PROJECT : Port of Durban Berths 203 - 205 Return Wall Steel Piles

SCOPE : EXTERNAL COATING SPECIFICATION

DATE : October 2015

REF : 5690/130999 Draft for comment

Responsibility rests with the reader to verify that this is the latest revision

Report by: _____________________

N C Webb

Internal Review: _____________________

V Sealy-Fisher

Isinyithi Cathodic Protection (Pty) Ltd Page 2 of 20 5690130999 Confidential Report

Reports are submitted to clients on a confidential basis;

No reference to the work or test results in any manner will be discussed or made public without

written authorisation from the client;

All work is considered proprietary property of the client and is maintained by ICP as such.

Disclaimer: Responsibility rests with the reader to verify the latest revision of the report.


DOCUMENT CONTROL

Job Title Port of Cape Town Berth 203-205

Document title Wall Pile Coating Specification

Project Number 130999

Document Reference 5690

Revision Date Revision Description Issued for comment

0 28/10/2015 Prepared By Checked by

Name N C Webb V Sealy-Fisher

Signature

Revision Date Revision Description

Prepared By Checked by

Name

Signature



Name

Signature


TABLE OF CONTENTS

1 INTRODUCTION ........................................................................................................................ 5

2 SURFACE PREPARATION & COATING APPLICATION .......................................................... 9

3 QUALITY ASSURANCE REQUIREMENTS ............................................................................. 13

4 REFERENCE DOCUMENTS AND STANDARDS .................................................................... 16

5 SURFACE PREPARATION & EXTERNAL COATING APPLICATION OF SITE REPAIRS ..... 17

6 EXTERNAL COATING SYSTEM SUMMARY .......................................................................... 20

7 SITE REPAIR COATING SYSTEM SUMMARY ....................................................................... 20

Port of Cape Town Berth 203-205 Return Wall Pile Coating Specification


1 INTRODUCTION

1.1 Application of Specification

Unless otherwise agreed by the Engineer in writing, the materials and specifications used shall

follow strictly the clauses of this specification.

1.2 Supervision of Work

All work shall be carried out under the constant supervision of a qualified supervisor. At least one

supervisor shall be present at all times and at no period will unsupervised work be permitted.

1.3 Materials Delivered to Site or Shop

All coatings in the system shall be sourced from the specified supplier unless otherwise agreed

and be brought to site in new unopened containers. Containers shall be clearly marked with the

relevant material type, code and production batch numbers.

1.4 Approval of Manufacturer

Only approved materials may be utilised for the corrosion protection work. Therefore, the

successful Tenderer shall obtain the Engineer's prior approval of materials and manufacturer, prior

to the commencement of work.

1.5 Coating Defects

All coating application shall be free of runs and other paint film defects. All painted surfaces shall

be free from dust, dirt, blasting media, sand and salt contamination.

1.6 Cleaning

In the case of site coating, the surface shall be prepared as indicated in this specification.

No blast cleaning or coating application shall take place during inclement weather or when

conditions are such as to cause contamination of coatings. It is the Contractor's responsibility to

provide screens, covers, trestles or any other equipment necessary to minimise stoppage time

through the conditions mentioned.

No early morning or late evening coating shall take place when steel surfaces are wet owing to

overnight and early evening dew formation.



1.7 Contamination During Coating Application

The Contractor shall take adequate precautions to protect areas being coated against

contamination and fall out during painting operations, should this become necessary.

All staff involved with coating to be issued with clean disposable over shoes and over cloth

disposable overalls. A clean work area shall be maintained around the piles.

1.8 Oil or Grease Surface Contamination

No coating shall be applied to any surface contaminated by oil, grease or salt deposits. Any

contaminated surfaces are to be cleaned down by means of one or more of:

a. Potable water and bristle brush,

b. A suitable water emulsifiable degreaser,

c. High pressure water washing,

d. Hot water washing

Followed by blast-cleaning

1.9 Time Limit to Coating Blast Cleaned Surfaces

After blast cleaning, operators handling the steel shall wear oil free and lint free gloves. Handling

equipment that contacts the surface shall be dry and free from oil and grease.

Blast cleaned steel shall be coated on the same day as the blast cleaning, within the time specified

in Table 1.

TABLE 1 MAXIMUM TIME INTERVAL BETWEEN BLAST CLEANING AND COATING

Ambient Relative Humidity Maximum Time (Hours)

Up to 70% 70 - 80% Over 80%

6 2

Coating not permitted - Reblast and coat when R.H. below 80%

1.10 Freedom from Weld Spatter and Ragging

All drilled holes are to be free from drilling rag and all punched holes are to be ground free of

punching ridges. All welds shall be deslagged and all weld spatter removed prior to blast cleaning.



1.11 Repairs to the Coating System Damaged During Transport, or Other Site Activities.

If in the opinion of the Engineer, the coating system is excessively damaged during transport or

other site activities, it shall be repaired by the following procedure:

1.11.1 Test the coating surface for cure using MEK in accordance with ASTM 5402.

1.11.2 If the test indicates that the surface is not fully cured (sticky), the damaged region should be

repaired as follows:

a. Abrade the damaged area with medium grade abrasive paper (220 or 150 grit) to

clean exposed steel to a white metal finish. Abrade the coating surface for not less

than 25mm on each side of the damaged area and feather smoothly into the sound

coating

b. Remove all dust and debris.

c. Wipe the area with solvent and recoat.

1.11.3 If the test indicates that the surface is fully cured (not sticky), the damaged region should be


a. Sweep blast the damaged area to clean exposed steel to a white metal finish.

Abrade the coating surface for not less than 25mm on each side of the damaged

area and feather smoothly into the sound coating


c. Recoat

1.12 Application Method

Application shall be by brush, or spray as recommended by the manufacturer.



1.13 Ambient Conditions

No steel shall be coated when the surface temperature exceeds 40C.

No coating or final blast cleaning shall take place when the ambient temperature is below 5C or

relative humidity above 80%.

No coating or final blast cleaning shall take place if the steel temperature is less than 5°C above

dew point.



2 SURFACE PREPARATION & COATING APPLICATION

2.1 Abrasive Blasting

Abrasive blasting shall be carried out using equipment suitably designed for this purpose.

2.1.1 All blast cleaning shall be conducted as per the Coating Manufacturer’s Specifications,

Data Sheet SP1 “Surface Preparation” (Procedure 6/30) or PC1 “Pipe Coating” (Procedure

6/15).

2.1.2 Prior to blast cleaning commencing :

a. All welds shall be free of slag, slag inclusions and undercutting.

b. Adjacent areas shall be free of weld spatter and such splatter shall be removed by

grinding and/or chipping.

c. All oil and grease deposits shall be removed. In this regard, special attention shall

be paid to drillings, bolt holes, etc.

2.1.3 Blasting Conditions

Where possible the blasting shall be carried out in a controlled environment. Where

blasting is carried out in open conditions no blast cleaning shall take place during inclement

weather conditions.

2.1.4 Air Dryness

All air used for blasting shall be free from all oil and water. Suitable moisture traps shall be

incorporated on air lines to ensure that air is dry.

2.1.5 Blasting Media

Blast cleaning may be carried out using steel grit and a wheel abrator, or as approved by

the Engineer. Fresh grit shall be added daily to ensure that the required profile is achieved.

Irrespective of the material used for blasting, in all cases it shall be free of all foreign matter

such as clay, humus, chlorides, bitumen etc. The particle size distribution of the abrasive

shall be suitable to produce the specified profile.



2.1.6 Standard of Blast Cleaning

All items of structural steelwork shall be blast cleaned in accordance with the Swedish

Code of Practice ISO 8501-1 to Grade A Sa3.

An average profile of 80μm with a minimum profile of 60μm is required.

2.1.7 After the initial pre grit blast, test for retained metallic salts, to levels below 70mg/m², or

especially in the base of pits marks, using the ISO salt mix equivalent conductivity test

method.

(Wattman Potassium Ferricyanide papers may be used for preliminary screening)

Should metallic salts be identified, a decontamination cycle shall be undertaken:

A decontamination cycle will consist of

blast,

wash

re-blast

re-test.

The decontamination cycle may have to be repeated.

a. If decontamination is required, this shall be conducted using Chlor*Rid

decontamination solution (100:1 for spray) to remove metallic salts. If metallic salts

are above 70 mg/m2, repeat the decontamination procedure. Experience has shown

that each Chlor*Rid wash will approximately halve the salt concentration.

b. If required, a second grit blast shall be performed in accordance with ISO 8501-1 SA

3, white metal, maintaining a minimum roughness profile of 60 microns.

2.1.8 The entire surface of the pile to be coated is to be blasted. The blast cleaning programme

will depend on rate of coating application, environmental conditions and use of de-

humidification equipment.

2.1.9 The spent grit must be removed quickly, and preparations should be made to apply the

coating as soon after blasting as possible.



2.1.10 100% of the surface area of the pile to be coated shall be vacuumed, to remove micro dust.

Blowing down the surface of the pile with compressed air is not an acceptable method of

dust removal.

2.1.11 The surface shall be checked in accordance with SABS 769, maximum 0.3%, to verify the

level of cleanliness.

2.2 External Coating Application

2.2.1 The external coating shall be applied in accordance with the manufacturer’s specifications.

2.2.2 Verify that the relative humidity is below 80% and that the steel is at least 5ºC warmer than

the dew point temperature of the air before and during application. If required

dehumidification shall be used to maintain RH.

2.2.3 Spray operation shall be set up as per the manufacturer’s application data sheet.

2.2.4 All staff involved with coating to be issued with clean disposable over shoes and over cloth

disposable overalls, clean work area to be maintained around the pile.

2.2.5 The first coat of the coating material shall be spray applied to a DFT of 750 microns

nominal as per manufacturer’s data sheet.

2.2.6 Spray apply the second coat once the first coat has gelled sufficiently to carry the weight of

the second coat.

2.2.7 A total DFT of typical 1.5mm minimum average thickness shall be achieved for the ZipE

coating. For QC purposes the minimum thickness of any one test location (spot

measurement) in terms of SSPC PA2 is therefore 1.2mm.

2.2.8 Allow coating 24 hours to ambient cure

2.2.9 After full cure (time to be confirmed), the ZipE coating shall be tested using a 10kV high

voltage spark test, using a calibrated pulsed DC instrument, or calibrated AC instrument.

2.2.10 All holidays, pinholes and potential defects shall be marked up and repaired as per

standard procedure using flat bottomed drill and coating plug method. Applying further

material over the top of a pinhole is not permitted.

2.2.11 All repairs shall be re-spark tested at 10kV volts to ensure integrity of lining as per

manufacturer’s data sheet.

2.2.12 DFT tests shall be made using electronic non-destructive test instruments.



2.3 Masking of Areas to be Left Uncoated

2.3.1 Any areas which require not to be coated shall be suitably masked prior to coating

operations.

2.3.2 Ends of piles which may be welded on site shall be free of coating for a distance of 200mm



3 QUALITY ASSURANCE REQUIREMENTS

3.1 Contractor Qualification

The Engineer may, at his discretion, require a Quality Audit of the coating sub-contractor to ensure

that he has the management facilities, skilled staff, and quality control facilities to carry out quality

control during application of coatings to ensure compliance 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 or his

representative.

3.2 Quality Control

The Contractor shall have the necessary equipment and staff knowledgeable in test procedures to

carry out all the quality control required to ensure compliance with the specification. The contractor

will be required to produce a quality plan and a program for carrying out the work. The Contractor

shall maintain quality control records of all stages of the work, batch numbers of materials used,

environmental conditions, as required by the specification. Quality control shall be inclusive in the

Contractor’s tender price.

No coating procedures may commence until Quality Plan has been submitted and approved

by the Client, the Coating Supplier and the Engineer.

3.3 Quality Surveillance

Independent surveillance - The Engineer may employ an independent technically qualified

organisation to carry out quality surveillance of the work on his behalf

Program - The Contractor shall advise the Engineer timeously, in writing, when and where the

following processes will be carried out :

a. Completion of fettling or dressing prior to release for coating operations.

b. Blast cleaning and application of the coatings.

c. Repairs.

Failure of the Contractor to advise the Engineer of his program may result in rejection of the work.



3.4 Access For Surveillance

For the purpose of carrying out quality surveillance, the Engineer or his representative 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 surfaces which are coated, to be coated or are in the process of being

coated

3.5 Samples

The Engineer or his representative may remove or call for any reasonable samples of materials to

be used in the coating application for quality checks. Rejection of the sample will place a hold on

the use of materials 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 coated with rejected

material.

Sample plates, 300mm x 300mm, shall be blast cleaned and coated alongside the pile lengths

being coated. Sample plates shall be identified and coating operation witnessed by the

independent inspector. Two (2) sample plates shall be prepared for each shift of coating work or if

a different batch number is used in a single shift.

3.6 Destructive Testing

The Engineer or his representative will carry out reasonable tests on the samples provided to

ascertain compliance with the specification.

3.7 Cost Of Quality Surveillance

Cost of Quality Surveillance shall be borne by the Employer, except when surveillance results in

rejection of the lot or when notice by the Contractor results in a fruitless trip, in which case the cost

of Surveillance shall be debited against the Contractor's account

3.8 Quality Control Records

Proper and adequate quality control records shall be maintained by the Contractor for all stages of

the work. These records shall be available for inspection by the Engineer or his representative at

the time of Quality Surveillance. Incomplete, inaccurate or inadequate records shall be regarded

as non-compliance with the specification, and the cost of surveillance will be back charged to the

Contractor.



3.9 Data Sheets, Specifications And Codes Of Practice

The Contractor shall have available the latest issues of manufacturer's data sheets for materials to

be used, National Specifications and Codes of Practice relevant to the work to be carried out, as

well as a copy of this specification, all of which shall be available to the Contractor's Quality Control

Manager.

3.10 Material Supplier

No alternative products or suppliers will be considered.

3.11 Dry Film Thickness Measurements

SSPC-PA2

The Engineer will check, at his discretion, the dry film thickness of the total coating system as

specified. The inspection procedure and acceptance criterion shall be in accordance with SSPC

PA2.

Thickness testing shall be carried out using a suitable electro-magnetic non-destructive thickness

testing instrument calibrated in accordance with SSPC-PA2

The coating system is applied wet-on-wet to ensure intercoat adhesion. In the event of inadequate

coating thickness, the Engineer may instruct the Contractor to remove the coating system and re-

apply to the correct thickness at no cost to the client.



4 REFERENCE DOCUMENTS AND STANDARDS

4.1 Determination of Cleanliness After Abrasive Blast Cleaning Pictorial Standards:

ISO 8501:1:1988 Acceptance criteria: Sa3

4.2 Determination of Surface Profile

SABS Test Method 772. Acceptance criteria: 60µm minimum or as directed by the supplier.

4.3 Solvent Resistance of Organic Coatings

ASTM D 5402 - 06.

4.4 Freedom from Dust and Debris

ISO 8502-3 Preparation of steel substrates before application of paint and related products –

Tests for the assessment of surface cleanliness -Part 3: Assessment of dust on steel surfaces

prepared for painting (pressure sensitive tape method).

4.5 Soluble Metal Salts Test

ISO equivalent salt mix: Acceptance criteria <70mg/sqm

4.6 Dry Film Thickness Measurement (See 4.11)

SSPC-PA2 - Measurement of Dry Paint Thickness with Magnetic Gauges

4.7 Corrocoat Procedures / Data Sheets

SP1 Surface Preparation

SP4 Surface Preparation - Metallic Salts Decontamination & Measurement

PC1 Pipe Coating

Spark Testing

ZipE – Health & Safety

ZipE

Repair of ZipE



5 SURFACE PREPARATION & EXTERNAL COATING APPLICATION OF SITE REPAIRS

5.1 Prewashing

5.1.1 All piles shall be prewashed prior to coating.

5.1.2 All pre-washed piles shall be tested for soluble salts as per Corrocoat data sheet SP4.

Check point no 2 – absorption method, should be between 25-70 mg/sqm, where 70 is the

maximum allowable limit, Decontaminate using CHLORID SOLUTION, where necessary:-

5.2 Visual Inspection of Piles

5.2.1 After washing, piles may NOT stand overnight before blasting and coating.

5.2.2 Prior to blast cleaning commencing all circumferential welds shall be inspected:



grinding and/or chipping

(Corrocoat data sheet 6/40 Weld Finish).

5.3 Masking

Mask off area to be prepared using suitable tape to ensure neat working area. This shall be a minimum of 200mm from the edge of the coated area on either side of the weld.

5.3.1 The blasting area shall overlap onto the existing coating to provide a mechanical key.








An average mechanical peak to valley profile of 80μm shall be achieved, with a minimum

profile of 60 μm.

Feather blast onto the exposed pile coating to ensure a surface roughness sufficient for

subsequent coating adhesion.


No blast cleaning shall take place during inclement weather conditions.

5.4.3 Air Dryness




Blast cleaning shall be carried out using Blastrite Microblast or equivalent, or as approved

by the Engineer. In all cases the blast material shall be free of all foreign matter such as

clay, humus, chlorides, bitumen etc. The particle size distribution of the abrasive shall be

suitable to produce the specified profile.

5.4.5 Surface Cleanliness

Remove all residual grit and debris from the surface by means of a vacuum.

5.4.6 Check for soluble salts as per Corrocoat data sheet SP4. Check point no 2 – absorption

method, should be between 25-70 mg/sqm, where 70 is the maximum allowable limit,.

Decontaminate using CHLORID SOLUTION, where necessary.



5.4.7 Record Keeping:

All relevant environmental conditions are to be tabulated including ambient temperature,

relative humidity, dew point, surface temperature as well as the batch numbers of the base

and catalyst components of the ZIP E.

5.5 EXTERNAL COATING APPLICATION

5.5.1 This REPAIR coating specification is issued on the basis that the coating will cure for a

minimum of 72 hours. For installation prior to this period, pre- and post-heating may be

required – refer to manufacturer for specific procedures.

5.5.2 The coating shall be tested for full cure using the indent and solvent rub (MEK) tests. Both

tests must pass before concrete overcoating may follow.


the dew point temperature of the air before and during application.

5.5.4 Apply the ZIP E – Epoxy Glass Flake using an airless pump with ratio of 45:1.Refer to ZIP

E Technical data sheet for specifics on application.

5.5.5 Apply until the coating thickness is the same as that of the adjacent pile coating. Note: The

area to be coated is approximately 4 m², the volume of ZIP E necessary for each joint is

estimated at 8 litres, given that the wastage on the exterior field joint is higher than normal.

5.5.6 The surface temperature during the cure cycle may not fall below 10°C. To achieve this,

heating blankets may be required.



6 EXTERNAL COATING SYSTEM SUMMARY

Surface Preparation Blast clean Sa 3, 60μm min, non-metallic grit <70mg/m2 salts

Coating System Zip E Supplied by

Corrocoat SA (Pty) Ltd Contact:: Louis Pretorius Tel: 011 845-4247 Email: [email protected]

Thickness: 1.5mm minimum – SSPC PA2 methodology

Quality Control Witness & Hold

Surface preparation Coating thickness 100% spark test, samples subjected to destructive testing Independent Quality Surveillance Inspection

7 SITE REPAIR COATING SYSTEM SUMMARY

External Field Joints Surface Preparation Blast clean Sa 3,

60μm min, non-metallic grit <70mg/m2 residual salts

Coating System Zip E Epoxy Glass Flake Supplied by


Thickness: as per mainline, minimum average 1.5mm SSPC PA2


Surface preparation Coating thickness 100% spark test, Independent Quality Surveillance Inspection


PORT OF DURBAN



Page | A2


DURBAN BERTHS 203 TO 205 RETURN WALL STEEL PILES 5690/130999 GALVANIC

ANODES SPECIFICATION



PROJECT : Port of Durban Berths 203 - 205 Return Wall

SCOPE : SACRIFICIAL ANODE SPECIFICATION

DATE : JUNE 2016

REF : 5890/130999 For construction


Report by: _____________________ F L Bradfield

Internal Review: _____________________

N C Webb

Isinyithi Cathodic Protection (Pty) Ltd Page 2 of 8 5890130999.docx Confidential Report







DOCUMENT CONTROL

Job Title Port of Durban Berth 203 - 205 Return Wall – Cathodic Protection

Document title Sacrificial Anode Specification






Signature



Name

Signature



Name

Signature


TABLE OF CONTENTS

1. INTRODUCTION ........................................................................................................................................ 5 2. SUMMARY OF PARAMETERS ................................................................................................................. 6 3. SELECTION OF APPLICABLE STANDARDS ........................................................................................... 7 4. DESIGN SUMMARY OF CORROSION PROTECTION SYSTEM ............................................................ 8

Port of Durban Berth 203 - 205 Return Wall– Cathodic Protection


1. INTRODUCTION

The Return Wall for the Port of Durban Berth 203 - 205 deepening comprises cellular coffer dam

type caissons formed from steel sheet piles. The majority of the piles will be driven through existing

soils, after which the sea face will be dredged.

The caissons are 23m outer diameter, using 508mm straight sheet piles. The total pile length is

31m. The top 3,2m of the sheet pile will be encased in a concrete capping beam which extends to

500mm below LAT.

The corrosion protection system will comprise a combination of sacrificial steel corrosion

allowance, glass flake reinforced epoxy coating and sacrificial anode cathodic protection.

This specification covers the supply of Aluminium - Zinc - Indium anodes for cathodic protection.



2. SUMMARY OF PARAMETERS

a. The design life of the corrosion protection system is 50 years.

b. Sacrificial anode material selection favours Aluminium anodes rather than Zinc anodes due

to both cost and weight considerations.

c. All electrical connections between anodes and the pile will be welded. Bolted connections

are only for mounting purposes.

d. As the anodes can only be installed after dredging, angle mounting brackets are proposed

with a welded electrical connection above the water line.

e. Anodes will be installed prior to casting of the pile cap.

f. The piles will be fully coated on the sea face to reduce CP current requirements and enable

the 50-year design life without anode replacement.

g. The top section of all piles will be coated on both faces to 1m below the level of the capping

beam to provide supplementary protection in the intertidal zone and prevent localised

corrosion of the steel adjacent to the encasement of the capping beam.



3. SELECTION OF APPLICABLE STANDARDS

The cathodic protection design is based on the requirements of SANS ISO 15589-2 and EN ISO

13174 for harbour installations and takes into consideration the requirements for protection against

ALWC (Accelerated Low Water Corrosion)

For this application, bareness and breakdown factors are used for coated steel which has been

subject to piling. This is an unusual requirement as the piles are being installed prior to dig-out.

Although underwater coating repairs are possible, the extent and efficacy of these repairs cannot

be predicted.



4. DESIGN SUMMARY OF CORROSION PROTECTION SYSTEM

Refer to drawing 1370-CO-070-C-DWG-0003-01

a. Each anode is 2000mm long x 190/140mm wide (trapezoidal) x 120mm thick cast onto an

offset steel "I" strap 50 x 6mm

b. The anode straps are designed to bolt onto brackets welded to each sheet pile.

c. A 50 x 6 x 4450mm continuity strap is welded to the top of the insert after casting the anode

in order to provide electrical continuity to the pile.

d. There is one anode per pile for each pile exposed to the sea.

e. The anode is installed such that the top of the anode is 1m below the bottom of the capping

beam.

f. The rear face of the anode as well as the protruding steel sections shall be coated with the

same epoxy/glass flake coating as the external surface of the pile.

g. The total net anode mass requirement is 95kg per pile with a utilisation factor of 80%.

h. Anodes will be manufactured in accordance with SANS ISO 15589-2: 2009 (sled anodes)

i. Electrochemical capacity: 2300 A.hrs/kg

ii. Driving potential: 1050mVAg/AgCl

i. Quality control requirements will be:

i. Chemical analysis: each heat

ii. Dimensional tolerance: each anode

iii. Electrochemical testing: prequalification plus 1 per 15 tonnes

iv. Destructive testing: prequalification plus 1 per 15 tonnes.



PROJECT : Port of Durban Berths 203 - 205 Return Wall Steel Piles

SCOPE : EXTERNAL COATING SPECIFICATION

DATE : October 2015

REF : 5690/130999 Draft for comment


Report by: _____________________

N C Webb

Internal Review: _____________________

V Sealy-Fisher


DOCUMENT CONTROL

Job Title Port of Cape Town Berth 203-205

Document title Wall Pile Coating Specification






Signature



Name

Signature



Name

Signature


TABLE OF CONTENTS

1 INTRODUCTION ........................................................................................................................ 5

2 SURFACE PREPARATION & COATING APPLICATION .......................................................... 9

3 QUALITY ASSURANCE REQUIREMENTS ............................................................................. 13

4 REFERENCE DOCUMENTS AND STANDARDS .................................................................... 16

5 SURFACE PREPARATION & EXTERNAL COATING APPLICATION OF SITE REPAIRS ..... 17

6 EXTERNAL COATING SYSTEM SUMMARY .......................................................................... 20

7 SITE REPAIR COATING SYSTEM SUMMARY ....................................................................... 20



1 INTRODUCTION

1.1 Application of Specification

Unless otherwise agreed by the Engineer in writing, the materials and specifications used shall

follow strictly the clauses of this specification.

1.2 Supervision of Work

All work shall be carried out under the constant supervision of a qualified supervisor. At least one

supervisor shall be present at all times and at no period will unsupervised work be permitted.

1.3 Materials Delivered to Site or Shop

All coatings in the system shall be sourced from the specified supplier unless otherwise agreed

and be brought to site in new unopened containers. Containers shall be clearly marked with the

relevant material type, code and production batch numbers.

1.4 Approval of Manufacturer

Only approved materials may be utilised for the corrosion protection work. Therefore, the

successful Tenderer shall obtain the Engineer's prior approval of materials and manufacturer, prior

to the commencement of work.

1.5 Coating Defects

All coating application shall be free of runs and other paint film defects. All painted surfaces shall

be free from dust, dirt, blasting media, sand and salt contamination.

1.6 Cleaning

In the case of site coating, the surface shall be prepared as indicated in this specification.

No blast cleaning or coating application shall take place during inclement weather or when

conditions are such as to cause contamination of coatings. It is the Contractor's responsibility to

provide screens, covers, trestles or any other equipment necessary to minimise stoppage time

through the conditions mentioned.

No early morning or late evening coating shall take place when steel surfaces are wet owing to

overnight and early evening dew formation.



1.7 Contamination During Coating Application

The Contractor shall take adequate precautions to protect areas being coated against

contamination and fall out during painting operations, should this become necessary.

All staff involved with coating to be issued with clean disposable over shoes and over cloth

disposable overalls. A clean work area shall be maintained around the piles.

1.8 Oil or Grease Surface Contamination

No coating shall be applied to any surface contaminated by oil, grease or salt deposits. Any

contaminated surfaces are to be cleaned down by means of one or more of:

a. Potable water and bristle brush,

b. A suitable water emulsifiable degreaser,

c. High pressure water washing,

d. Hot water washing

Followed by blast-cleaning

1.9 Time Limit to Coating Blast Cleaned Surfaces

After blast cleaning, operators handling the steel shall wear oil free and lint free gloves. Handling

equipment that contacts the surface shall be dry and free from oil and grease.

Blast cleaned steel shall be coated on the same day as the blast cleaning, within the time specified

in Table 1.

TABLE 1 MAXIMUM TIME INTERVAL BETWEEN BLAST CLEANING AND COATING

Ambient Relative Humidity Maximum Time (Hours)

Up to 70% 70 - 80% Over 80%

6 2

Coating not permitted - Reblast and coat when R.H. below 80%

1.10 Freedom from Weld Spatter and Ragging

All drilled holes are to be free from drilling rag and all punched holes are to be ground free of

punching ridges. All welds shall be deslagged and all weld spatter removed prior to blast cleaning.



1.11 Repairs to the Coating System Damaged During Transport, or Other Site Activities.

If in the opinion of the Engineer, the coating system is excessively damaged during transport or

other site activities, it shall be repaired by the following procedure:

1.11.1 Test the coating surface for cure using MEK in accordance with ASTM 5402.

1.11.2 If the test indicates that the surface is not fully cured (sticky), the damaged region should be


a. Abrade the damaged area with medium grade abrasive paper (220 or 150 grit) to

clean exposed steel to a white metal finish. Abrade the coating surface for not less

than 25mm on each side of the damaged area and feather smoothly into the sound

coating


c. Wipe the area with solvent and recoat.

1.11.3 If the test indicates that the surface is fully cured (not sticky), the damaged region should be


a. Sweep blast the damaged area to clean exposed steel to a white metal finish.

Abrade the coating surface for not less than 25mm on each side of the damaged

area and feather smoothly into the sound coating


c. Recoat

1.12 Application Method

Application shall be by brush, or spray as recommended by the manufacturer.



1.13 Ambient Conditions

No steel shall be coated when the surface temperature exceeds 40C.

No coating or final blast cleaning shall take place when the ambient temperature is below 5C or

relative humidity above 80%.

No coating or final blast cleaning shall take place if the steel temperature is less than 5°C above

dew point.



2 SURFACE PREPARATION & COATING APPLICATION



2.1.1 All blast cleaning shall be conducted as per the Coating Manufacturer’s Specifications,

Data Sheet SP1 “Surface Preparation” (Procedure 6/30) or PC1 “Pipe Coating” (Procedure

6/15).

2.1.2 Prior to blast cleaning commencing :



grinding and/or chipping.

c. All oil and grease deposits shall be removed. In this regard, special attention shall

be paid to drillings, bolt holes, etc.


Where possible the blasting shall be carried out in a controlled environment. Where

blasting is carried out in open conditions no blast cleaning shall take place during inclement

weather conditions.

2.1.4 Air Dryness




Blast cleaning may be carried out using steel grit and a wheel abrator, or as approved by

the Engineer. Fresh grit shall be added daily to ensure that the required profile is achieved.

Irrespective of the material used for blasting, in all cases it shall be free of all foreign matter

such as clay, humus, chlorides, bitumen etc. The particle size distribution of the abrasive

shall be suitable to produce the specified profile.






An average profile of 80μm with a minimum profile of 60μm is required.

2.1.7 After the initial pre grit blast, test for retained metallic salts, to levels below 70mg/m², or

especially in the base of pits marks, using the ISO salt mix equivalent conductivity test

method.

(Wattman Potassium Ferricyanide papers may be used for preliminary screening)

Should metallic salts be identified, a decontamination cycle shall be undertaken:

A decontamination cycle will consist of

blast,

wash

re-blast

re-test.

The decontamination cycle may have to be repeated.

a. If decontamination is required, this shall be conducted using Chlor*Rid

decontamination solution (100:1 for spray) to remove metallic salts. If metallic salts

are above 70 mg/m2, repeat the decontamination procedure. Experience has shown

that each Chlor*Rid wash will approximately halve the salt concentration.

b. If required, a second grit blast shall be performed in accordance with ISO 8501-1 SA

3, white metal, maintaining a minimum roughness profile of 60 microns.

2.1.8 The entire surface of the pile to be coated is to be blasted. The blast cleaning programme

will depend on rate of coating application, environmental conditions and use of de-

humidification equipment.

2.1.9 The spent grit must be removed quickly, and preparations should be made to apply the

coating as soon after blasting as possible.



2.1.10 100% of the surface area of the pile to be coated shall be vacuumed, to remove micro dust.

Blowing down the surface of the pile with compressed air is not an acceptable method of

dust removal.

2.1.11 The surface shall be checked in accordance with SABS 769, maximum 0.3%, to verify the

level of cleanliness.

2.2 External Coating Application

2.2.1 The external coating shall be applied in accordance with the manufacturer’s specifications.


the dew point temperature of the air before and during application. If required

dehumidification shall be used to maintain RH.

2.2.3 Spray operation shall be set up as per the manufacturer’s application data sheet.

2.2.4 All staff involved with coating to be issued with clean disposable over shoes and over cloth

disposable overalls, clean work area to be maintained around the pile.

2.2.5 The first coat of the coating material shall be spray applied to a DFT of 750 microns

nominal as per manufacturer’s data sheet.

2.2.6 Spray apply the second coat once the first coat has gelled sufficiently to carry the weight of

the second coat.

2.2.7 A total DFT of typical 1.5mm minimum average thickness shall be achieved for the ZipE

coating. For QC purposes the minimum thickness of any one test location (spot

measurement) in terms of SSPC PA2 is therefore 1.2mm.

2.2.8 Allow coating 24 hours to ambient cure

2.2.9 After full cure (time to be confirmed), the ZipE coating shall be tested using a 10kV high

voltage spark test, using a calibrated pulsed DC instrument, or calibrated AC instrument.

2.2.10 All holidays, pinholes and potential defects shall be marked up and repaired as per

standard procedure using flat bottomed drill and coating plug method. Applying further

material over the top of a pinhole is not permitted.

2.2.11 All repairs shall be re-spark tested at 10kV volts to ensure integrity of lining as per

manufacturer’s data sheet.

2.2.12 DFT tests shall be made using electronic non-destructive test instruments.