Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) Tender Documents For Ho Chi Minh City Urban Railway Construction Project Ben Thanh - Suoi Tien Section (Line 1) CONTRACT PACKAGE-1B: CIVIL (UNDERGROUND SECTION FROM KM 0+615 TO KM 2+360) VOLUME Outline Construction Specifications October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) Tender Documents For Ho Chi Minh City Urban Railway Construction Project Ben Thanh - Suoi Tien Section (Line 1) CONTRACT PACKAGE-1B: CIVIL (UNDERGROUND SECTION FROM KM 0+615 TO KM 2+360) VOLUME – OUTLINE CONSTRUCTION SPECIFICATIONS TABLE OF CONTENTS Clause Page STANDARDS 1-1 1.1 1-1 Guidance Note to the Specification EARTHWORKS 2-1 2.1 Earthworks Definitions and Classifications 2-1 2.2 Clearing and Grubbing 2-3 2.3 Excavation 2-6 2.4 Fill 2-12 2.5 Excavation and Backfill for Structures 2-14 2.6 Embankment 2-21 2.7 Removal of Existing Structures 2-27 ROADWORKS 3-1 3.1 Subbase and Base 3-1 3.2 Bituminous Prime Coat 3-4 3.3 Bituminous Tack Coat 3-5 3.4 Bituminous Plant-Mix Material – Asphalt Concrete 3-6 PILING AND DIAPHRAGM WALLING 4-1 4.1 General 4-1 4.2 Precast Concrete Piles 4-3 4.3 Bored Cast In-Place Piles 4-11 4.4 Pile Load Testing 4-29 4.5 Diaphragm Walling 4-45 CONCRETE 5-1 5.1 Materials 5-1 5.2 Concrete Mix Design 5-4 5.3 Trial Mixes 5-5 5.4 Sampling of Concrete 5-6 5.5 Quality Control of Concrete 5-6 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 5.6 Testing of Concrete for Structures 5-7 5.7 Failure to Meet Requirements 5-8 5.8 Batching and Mixing Concrete 5-9 5.9 Ready Mixed Concrete 5-10 5.10 Formwork 5-11 5.11 Falsework 5-12 5.12 Curing Agents 5-12 5.13 Release Agents 5-12 5.14 Compacting Equipment 5-13 5.15 Concrete Workmanship 5-13 5.16 5.17 Patching and Repairs 5-22 Control of Thermal Cracks in Massive Structures 5-23 PRESTRESSING 6-1 6.1 General 6-1 6.2 Materials 6-1 6.3 Grout Trials 6-4 6.4 Testing of Prestressing Tendons 6-5 6.5 Testing of Duct Friction 6-6 6.6 Protection of Prestressing Tendons 6-7 6.7 Installation 6-9 6.8 Placing Concrete 6-12 6.9 Installing Tendons 6-12 6.10 Post-Tensioning Operations 6-13 6.11 Grouting Operations 6-17 6.12 Pre-Tensioning 6-21 6.13 Protection of End Anchorages 6-22 STRUCTURAL STEELWORKS 7-1 7.1 General 7-1 7.2 Materials 7-1 7.3 Shop Drawing 7-2 7.4 Test certificate 7-2 7.5 Steelwork Construction 7-3 7.6 Painting steel structures 7-10 ARCHITECTURAL AND BUILDING WORKS 8-1 8.1 General Requirements 8-1 8.2 Bricklayer 8-1 8.3 Pavior 8-4 8.4 Roofer 8-9 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 8.5 Carpenter and Joiner 8-14 8.6 Steel and Metal Worker 8-19 8.7 Plasterer and Tiler 8-34 8.8 Glazier 8-37 8.9 Painter 8-39 TUNNELING 9-1 9.1 Introduction 9-1 9.2 General 9-1 9.3 Survey 9-1 9.4 Diversion and Protection of Exiting Utilities and Roads 9-1 9.5 Monitoring 9-2 9.6 Protection Works for Existing Structures 9-2 9.7 Excavation 9-3 9.8 Tunneling by Tunnel Boring Machine (Shield Machine) 9-6 9.9 Segmental Tunnel Linings 9-7 9.10 Spheroidal Graphite Iron Lining (SGI Lining) 9-10 9.11 Precast Concrete Linings 9-15 9.12 Alternative Tunnel Lining 9-19 9.13 Grouting 9-19 9.14 Watertightness of Tunnel 9-21 9.15 As-built Tunnel Survey (Wriggle Survey) 9-22 9.16 Daily Records 9-22 9.17 Backfilling of Shafts and Adits 9-22 9.18 Working under Compressed Air 9-22 10 CUT AND COVER CONSTRUCTION 10-1 10.1 Introduction 10-1 10.2 General 10-1 10.3 Survey 10-1 10.4 Diversion of Existing Utilities and Roads 10-1 10.5 Monitoring 10-2 10.6 Protection Works for Existing Structures 10-2 10.7 Retaining Wall 10-2 10.8 Support Work 10-2 10.9 Road Surface Decking 10-3 10.10 Excavation 10-3 10.11 Main Structure 10-4 10.12 Waterproofing 10-5 10.13 Backfilling 10-6 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 11 NOT USED 11-1 12 NOT USED 12-1 13 STEEL REINFORCEMENT 13-1 13.1 General 13-1 13.2 Materials 13-1 13.3 Handling and Storage 13-2 13.4 Cutting and Bending Reinforcement 13-2 13.5 Fixing Reinforcement 13-2 13.6 Tolerances 13-3 13.7 Testing 13-3 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) STANDARDS 1.1 Guidance Note to the Specification 1.1.1 Introduction The Materials and workmanship specification as follows has been based on International Standards as scheduled below The Contractor will be responsible for detailing in his specification of the standards on which his materials and workmanship will be based, and these shall be of similar or higher standard than those listed below In accordance with the Vietnamese regulations, the Contractor shall be also responsible for getting the approval by the Vietnamese competent organizations for the international standards which are not included in the list below and in Appendix 28 to the Employer’s Requirements in Volume but are applied by the Contractor in detailing his specification, additionally The Contractor is required to review in the first instance the Vietnamese Industrial Standards, Japanese Industrial Standards (JIS), Japan Society of Civil Engineers (JSCE) Standard Specifications, Design Standards for Railway Structures and Commentary (RTRI), the Japanese Geotechnical Society (JGS) Standards and AASHTO & ASTM Standards The specification will be based on the above three standards to the extent that they are applicable Relevant standards of JIS, JSCE, AASHTO and ASTM are scheduled below: Section 2: Earthworks AASHTO T99 The Moisture-Density Relations of Soils using a 5.5lb (2.5kg) Rammer and a 12in (305mm) Drop AASHTO T193 The California Bearing Ratio AASHTO T 180 The Moisture-Density Relations of Soils using a 10lb (4.54kg) Rammer and a 18in (457mm) Drop AASHTO T27 Sieve Analysis of Fine and Coarse Agregate AASHTO T89 Determining the Liquid Limit of Soils AASHTO T90 Determining the Plastic Limit and Plasticity Index of Soils AASHTO T191 Density of Soil In-Place by the Sand-Cone Method Section 3: Road Works Section 1-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) AASHTO T96 Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine AASHTO T89 Determining the Liquid Limit of Soils AASHTO T90 Determining the Plastic Limit and Plasticity Index of Soils AASHTO T180 The Moisture-Density Relations of Soils using a 10lb (4.54kg) Rammer and a 18in (457mm) Drop AASHTO M81 Cut-Back Asphalt (Rapid-Curing Type) AASHTO M82 Cut-Back Asphalt (Medium-Curing Type) AASHTO T245 Resistance to Plastic Flow of Bituminous Mixtures using Marshall Apparatus AASHTO T209 Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures AASHTO M29 Fine Aggregate for Bituminous Paving Mixtures AASHTO M20 Penetration-Graded Asphalt Cement AASHTO T230 Determining Degree of Pavement Compaction of Bituminous Aggregate Mixtures AASHTO T167 Compressive Strength of Bituminous Mixtures Section 4: Piling and Diaphragm Walling JIS R5210 Portland cement ASTM C150 Standard Specification for Portland Cement JIS A5372 Precast reinforced concrete product JIS A5373 Precast Prstressed concrete product JIS A5530 Steel pipe sheet piles ASTM D4945 Standard Test Method for High-Strain Dynamic Testing of Piles JGS 1811 Standard Test Method for Vertical Load Testing of Piles JGS 1816 Standard Test Method for Impact Load Testing of Piles JGS 1831 Standard Test Method for Horizontal Load Testing of Piles The American Petroleum Institute Standard 13A JSCE Standard Specifications for Tunneling -2006 (Cut and Cover Tunnel) Section 5: Concrete JIS R5210 Portland cement ASTM C150 Standard Specification for Portland Cement Section 1-2 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) ASTM C260 Air-Entraining Admixtures for Concrete (equivalent with AASHTO M154) ASTM C309 Liquid Membrane-Forming Compounds for Curing Concrete (equivalent with AASHTO M148) ASTM C494 Chemical Admixtures for Concrete (equivalent with AASHTO M194) ASTM C1611 Standard Test Method for Slump Flow of Self-Consolidating Concrete AASHTO M6 Fine Aggregate for Portland Cement Concrete AASHTO M80 Coarse Aggregate for Portland Cement Concrete AASHTO M148 Liquid Membrane-Forming Compounds for Curing Concrete AASHTO M154 Air-Entraining Admixtures for Concrete AASHTO M157 Ready-Mixed Concrete AASHTO M194 Chemical Admixtures for Concrete AASHTO T2 Sampling of Aggregates AASHTO T11 Materials Finer Than 75-µm (No.200) Sieve in Mineral Aggregates by Washing AASHTO T21 Organic Impurities in Fine Aggregates for Concrete AASHTO T22 Compressive strength of Cylindrical Concrete Specimens AASHTO T23 Making and Curing Concrete Test Specimens in the Field AASHTO T24 Obtaining and Testing Drilled Cores and Sawed Beams of Concrete AASHTO T27 Sieve Analysis of Fine and Coarse Aggregates AASHTO T71 Effect of Organic Impurities in Fine Aggregate on Strength of Mortar AASHTO T84 Specific Gravity and Absorption of Fine Aggregates AASHTO T85 Specific Gravity and Absorption of Coarse Aggregates AASHTO T96 Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine AASHTO T104 Soundness of Aggregate by Use of Sodium Sulfate or Magnesium Sulfate AASHTO T112 Clay Lumps and Friable Particles in Aggregate AASHTO T113 Lightweight Pieces in Aggregate AASHTO T119 Slump of Hydraulic Cement Concrete ACI 304 R Guide for Measuring, Mixing, Transporting, and Placing Concrete Section 1-3 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) JSCE Standard Specification for Concrete Structures -2002, Construction, Clause Section 6: Prestressed Members JIS G3536 Uncoated stress-relieved steel wires and strands for prestressed concrete JIS G3109 Steel bars for prestressed concrete ASTM A416 Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete ASTM A421 Standard Specification for Uncoated Stress-Relieved Steel Wire for Prestressed Concrete ASTM A722 Standard Specification for High-Strength Steel Bar for Prestressed Concrete AASHTO M235 Epoxy Resin Adhesives ASTM C940 Standard Test Method for Expansion and Bleeding of Freshly Mixed Grouts Laboratory ASTM C942 for Preplaced-Aggregate Concrete in the Standard Test Method for Compressive Strength of Grouts for Preplaced-Aggregate Concrete in the Laboratory Section 7: Structural Steelwork JIS G3101 Rolled steels for general structure JIS G3106 Rolled steels for welded structure JIS G3444 Carbon steel tubes for general structural purposes JIS G3452 Carbon steel pipes for ordinary piping JIS G4304 Hot-rolled stainless steel plates, sheet and strip JIS G5101 Carbon steel casings JIS B1186 Sets of high strength hexagon bolt, hexagon nut and plain washers for friction grip joints JIS Z3211 Covered electrodes for mild steel JIS Z3801 Standard qualification procedure for manual welding technique JIS Z3104 Methods of radiographic examination for welded joints in steel JIS Z3060 Method for ultrasonic examination for welds ferritic steel AASHTO M111 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products Section 1-4 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) AWS D1.1/D1.1M : 2008 Structural Welding Code Section 8: Architectural and Building Works TCXDVN PROCEEDING OF VIETNAM CONSTRUCTION STANDARDS, VOL8, VOL10, VOL11 (Vietnamese Standard) ASTM C779/C779M-00 Standard Test Method for Abrasion Resistance of Horizontal Concrete Surfaces ASTM D1730-03 Standard Practices for Preparation Aluminum-Alloy Surfaces for Painting of Aluminum and ASTM B449-93(2004) Standard Specification for Chromates on Aluminum ASTM D2244-09a Standard Practice for Calculation of Color Tolerances and Color Differences from Instrumentally Measured Color Coordinates ASTM D4214 Test Methods for Evaluating the Degree of Checking of Exterior Paint Films ASTM D2247-02 Standard Practice for Testing Water Resistance of Coatings in 100% Relative Humidity ASTM D714 Standard Test Method for Evaluating Degree of Blistering of Paints ASTM B117 Standard Practice for Operating Salt Spray (Fog) Apparatus ASTM D523 Standard Test Method for Specular Gloss ASTM D968 Standard Test Methods for Abrasion Resistance of Organic Coatings by Falling Abrasive ASTM C920 Standard Specifications for Elastomeric Joint Sealant ASTM A167 Standard Specification for Stainless and Chromium-Nickel Steel Plate, Sheet, and Strip ASTM A480/A480M Standard Specification for General Requirements for Flat-Rolled Heat-Resisting Stainless and Heat-Resisting Steel Plate, Sheet, and Strip ASTM A743/A743M Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application (equivalent with AASHTO M163/M163-00) ASTM A36/A36M Standard Specification for Carbon Structural Steel ASTM C509 Standard Specification for Elastomeric Cellular Preformed Gasket and Sealing Material Section 1-5 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) Primary grouting to shafts constructed by underpinning with segmental linings shall be carried out after the erection of each ring The gap around the perimeter of the bottom ring to be grouted shall be sealed to prevent loss of grout under pressure and the seal maintained until the grout has set 9.13.10 In-situ Linings and Junctions All voids remaining unfilled outside the in-situ concrete permanent linings in tunnels and shafts, including junctions, headwalls and the like, shall be grouted and filled up 9.13.11 Performance The minimum strength requirement for the grout as measured from testing 100 mm cubes at 24 hours shall be 1.0 N/mm2 The Contractor shall carry out his grouting operations consistent with his method statement and with due cognizance of the ground conditions at the time Setting times must be verified at the site with the aim of minimizing ground movement and floating of the tunnel lining 9.13.12 Verification (1) The Employer's Representative may require proof drilling to be carried out in the crowns of tunnels and/or elsewhere at suitable locations and frequencies All voids encountered shall be fully grouted, and all drill holes filled using consented-to non-shrink material (2) In the event that the cavities are not filled or the specification for watertightness is not achieved after secondary grouting, further grouting through additional injection points shall be carried out Re-grouting and the further grouting shall be continued until a consented-to grouting pressure of up to 600 KN/m can be sustained for minute This pressure shall be dependent upon the overburden and the presence of adjacent structures 9.14 Watertightness of Tunnel (1) The watertightness of the tunnels as completed is to be as described in the Outline Design Specifications (2) The defense against leakage into the Works shall be provided by the cavity grouting, the sealing strip incorporated into the tunnel rings and as a final measure, grommeting and caulking (3) Underground water leakage above the tunnel axial level shall be stopped by sealing or injection with suitable materials Where stopping of leakage is impossible, water shall be led through drain pipes down to the track-side drain Section 9-21 of 22 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 9.15 As-built Tunnel Survey (Wriggle Survey) (1) The Contractor shall undertake an as-built tunnel survey upon completion of the lining and first trackbed concrete The survey will include measuring the position of the lining at m interval cross-sections, at the crown, invert, axes positions and at intervening quarter points (2) The Contractor shall be responsible for analyzing the results of the as-built survey to demonstrate that there are no infringements of the required cross-sections, and for reviewing the track alignment where appropriate and as may be agreed by the Employer's Representative 9.16 (3) Permanent survey monuments, at 40 m maximum intervals, shall be established in the tunnel crown, or as directed for the use of the Employer's Representative (4) The results of the as-built survey shall be provided to the Package-3 Contractor for trackwork, and others as directed by the Employer's Representative Daily Records Daily records shall be kept at all tunnel faces of line, level, square, roll and plumb and the diameter measured horizontally, vertically and diagonally of each ring erected Equivalent records shall be kept for shafts The results obtained shall be tabulated and/or plotted each day and copies of these held in the Contractor's site office where they shall be available for inspection by the Employer's Representative For TBM drives daily records shall include details of the shield location and alignment, shove-jack pressures, face pressures, spoil volume and grouting volumes and pressures 9.17 Backfilling of Shafts and Adits Temporary shafts and adits shall be completely backfilled on completion of the Works Backfill material shall be suitable material consented by the Employer’s Representative which may be placed either wet or dry Adits shall be backfilled in sections working from the Permanent Works 9.18 Working under Compressed Air All work in compressed air shall be executed in accordance with Standards Specifications for Tunneling - 2006 : Shield Tunnels, JSCE Section 9-22 of 22 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 10 CUT AND COVER CONSTRUCTION 10.1 Introduction This section specifies materials, methods and workmanship required for the construction of cut and cover tunnels and open cut transition structures 10.2 General (1) All aspects of cut and cover tunnel and transition structure construction shall comply with the relevant requirements of Employer’s Requirements, Outline Design Specifications, this Outline Construction Specifications, and followings; - Design Standards for Railway Structures and Commentary (Cut and Cover Tunnel), Railway Technical Research Institute, Japan (RTRI-J) - (2) Standard Specifications for Tunneling - 2006 : Cut and Cover, Japan Society of Civil Engineers (JSCE) All works related to the construction of cut & cover tunnel and transition structure shall be carried out in compliance with the Health and Safety requirements as detailed in the Employer's Requirements (3) The safety and security of all excavations and structures either surface or underground, shall, at all times during the execution of the contract, be the responsibility of the Contractor The Contractor shall implement such measures, including supporting, stanchioning, dewatering and consolidation, as may be necessary to fulfill this obligation The Contractor shall submit full details of the Temporary Works and stabilization proposals to the Employer's Representative for his consent at least 21 days in advance of commencing such work This consent shall in no way relieve the Contractor of any of his obligations under the Contract No work shall commence prior to the Employer's Representative's consent being given 10.3 Survey Prior to the commencement of retaining wall work, the Contractor shall establish the surveying system including coordination and elevation Main structure survey shall be often carried out, and the contents of the survey of the main structure shall be fully studied in order to take care that surveying is not wasteful 10.4 Diversion of Existing Utilities and Roads The Contractor shall divert the existing utilities such as electricity, water, telephone, etc and roads prior to the commencement of the Works based on the diversion plan consented-to by the relevant authorities and Employer’s Representative Section 10-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 10.5 Monitoring The Contractor shall carry out the following monitoring, 1) environmental monitoring, 2) monitoring for protection of existing structures, and 3) monitoring for safety construction Details are described in the Sub-Clause 9.5 of the Outline Construction Specifications 10.6 Protection Works for Existing Structures The Contractor shall execute the protection works for the existing structures in such a way that the influence of the ground movement is kept within the specified limits 10.6.1 The Contractor shall ensure that ground movements and changes to the piezometric pressure which may affect adjacent subway works, utility services and any adjacent buildings, surface or underground structures are kept to a minimum 10.6.2 Prior to the commencement of retaining wall work, the Contractor shall establish an agreed protection plan in accordance with Clause 28 of the Outline Design Specifications 10.7 10.7.1 Retaining Wall For the Cut and Cover construction, to prevent the collapse of the ground and excessive deflection, the Contractor shall employ retaining walls appropriate for the scale of the excavation and construction, ground and environmental conditions 10.7.2 The method of designing retaining walls shall be determined considering the scale and depth of the excavation The methods of building retaining walls are described in Clause 35.1.2 of Outline Design Specifications 10.8 Support Work In planning the retaining wall support work, the following shall be considered (1) Selection of materials for the supporting members (2) Arrangement of supporting members matching the permanent structure construction (3) Special measures to be taken at portions where the normal arrangement of supporting members is impossible due to existence of buried facilities (4) Positions of joints of supporting members (5) Method of filling gaps between retaining walls and wales (6) Sequence of support provision in consideration of the procedures of excavation and structure building (7) Method of provision/removal and machines used (8) Necessity and extent of preloading to restrain the deflection of retaining wall Section 10-2 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) (9) Necessity of measuring the axial forces induced in struts and locations of axial force meters 10.9 (10) Passages for maintenance (11) Method of replacing supporting members at the time of removal Road Surface Decking 10.9.1 Prior to commencement of road decking, the Contractor shall establish the road decking plans taking account of the road widths, traffic volume, working hours and other site conditions based on the design drawings and specifications 10.9.2 In removing the road pavements for trench excavation, care must be taken so that buried facilities are not damaged The joints between decks and roads shall be paved smooth without gaps 10.9.3 Where the road surface is steep, road support beams shall be provided with safety devices against overturning 10.10 Excavation 10.10.1 Prior to carrying out excavation, based on the design drawings and specifications, the Contractor shall establish the execution plans taking account of the scale of excavation, construction schedule, state of the ground, surrounding environment, and other site conditions The followings shall be considered in the excavation plan (1) Excavation block setting and excavation sequence (2) The scopes of human and mechanical excavation (3) Selection of excavating machines and equipment (4) Transportation and disposal plan for surplus soil (5) Preventive measures against adjacent ground settlements (6) Measures for preventing bad effects on the buried facilities and buildings adjacent to the excavation (7) Drainage in the excavation and auxiliary methods (8) Environment preservation measures (noise, vibration, ground settlement, groundwater lowering, groundwater contamination, dust scattering, obstruction to traffic, disposal of construction by-products and environmental arrangement (9) Countermeasures against wind and flood damages 10.10.2 Supplementary Retaining Wall at Interrupted Portion Section 10-3 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) Where discontinuity occurs in the watertight retaining wall due to existence of e.g buried utilities, the supplementary retaining wall shall be built securing the continuity to the existing walls in strength and watertightness with the downward advance of excavation 10.10.3 Excavation base stability The Contractor shall take the following measures as prescribed in Clauses 35.1.4 and 35.1.5 of Outline Design Specification (1) Risk of ground heaving shall be examined for excavating the soft cohesive soils (2) Risk of groundwater boiling or piping shall be examined for excavating sandy strata under high groundwater pressure (3) Risk of excavation base upheaval shall be examined for excavating impermeable cohesive strata underlain by over-pressurized water bearing strata 10.11 Main Structure 10.11.1 Prior to commencement of the main structure building, based on the design drawings and specifications, the building plan shall be established considering the scale and form of the structure, process, working and other site conditions 10.11.2 Base formation Upon completion of excavation, the excavation base shall be overlain by the base layer of crusher-run, ballast, sand, cement mortar, or base concrete, etc 10.11.3 Reinforcing bars Reinforcing bars shall be located at prescribed positions after eliminating harmful substance and set up firmly so that they may not move when concrete is poured To maintain the right reinforcement cover, spacers shall be provided at required intervals The location and constitution of reinforcing bar joints shall be as prescribed in the design drawings and specifications, but due considerations shall be paid to the actual site conditions 10.11.4 Placing and curing of concrete The concrete placing in a block shall be done uninterruptedly until the completion of placing operation In principle, concrete placing shall be done so that the surface of the concrete is maintained flat in a block Transportation and placing of concrete shall be done rapidly and carefully with adequate plant and equipment so as not to cause material segregation Concrete shall be cured for a prescribed period after placing by an adequate method 10.11.5 Treatment of joints Section 10-4 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) Construction joints shall be made so that bonding to the already completed concrete can be secured The structural expansion joints shall be such that they may function satisfactorily and not become the weak points in waterproofing 10.12 Waterproofing 10.12.1 General To achieve the objective satisfactorily, waterproofing shall be executed based on the design drawings and specifications according to the execution plan made taking account of the various site conditions 10.12.2 Cleaning and Preparation of Surfaces (1) No laying shall be commenced until all rough edges and excrescences have been removed from the surfaces to receive the membrane Surface depressions shall be filled in accordance with consented-to procedures and the filling allowed to set The surface to be waterproofed shall be thoroughly cleaned, dried and swept, and kept clean and dry at all stages until the work is complete (2) The surfaces of structures which are waterproofed are to be primed with the appropriate primer to ensure good adhesion between the structure and the waterproofing medium 10.12.3 Waterproofing Underground Structures (1) The method and materials for waterproofing shall comply with Chapter 7, Standard Specifications for Tunneling - 2006: Open Cut Tunnel, JSCE, and the recommendations of the manufacturer (2) The Contractor shall submit the method and materials for the Works to the Employer’s Representative for his consent prior to the commencement of the Work (3) The whole of surfaces of the underground structures shall be waterproofed by appropriate waterproofing methods and, where possible, by external waterproofing with a continuous waterproof membrane lapped at joints Where the tunnel structure is built independently of the temporary earth retaining wall, external waterproofing membrane shall be provided all around the tunnel structure Where the temporary earth retaining diaphragm wall is used as part of the permanent structure, external membrane shall be provided over and under the tunnel structure Where external membrane cannot be provided, other suitable kinds of waterproofing methods shall be employed (4) Overhead underground water leakage shall be stopped by sealing or injection with suitable materials Where stopping of leakage is impossible, water shall be led through drain pipes down to the wall-side drain Section 10-5 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 10.12.4 Waterstops All waterstops used in the Works shall be of PVC material and of a type appropriate to the location All joints shall be made with molded or prefabricated intersection pieces properly jointed in accordance with the manufacturer's instructions The waterstops shall be installed so that they are securely held in their correct positions whilst the concrete is being placed No holes shall be made through any waterstops except where provided for by the manufacturer 10.12.5 Fillers and Sealants to Expansion Joints (1) All materials used to fill expansion joints shall be such that they will accept the calculated movements of the joints without extrusion and shall not shrink away from either surface of the joints Consented-to backing strips and fillers shall be used in accordance with the manufacturer's recommendation (2) Where joints are required, joints shall be filled with consented-to poly-sulfide or poly-urethane sealants (3) The appropriate sealant grades shall be used for horizontal and vertical joints, and the joints shall be thoroughly cleaned and primed with the appropriate primer before applying the sealant The sealant shall be of a color to match as nearly as possible the color of the adjoining surfaces where it is to be permanently exposed (4) The sealing material shall be used and applied strictly in accordance with the manufacturer's instructions The Contractor's attention is drawn to the undesirability of the sealant being smeared over the adjacent surfaces, and appropriate precautionary measures, including the use of masking tape, shall be taken to avoid this 10.13 Backfilling 10.13.1 General Prior to the commencement of backfilling, based on the design drawings and specifications, the Contractor shall establish the execution plan considering materials, compaction methods and various site conditions The execution plan shall also include the use of recycled resources 10.13.2 Methods of backfilling Section 10-6 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) (1) Backfilling at the side walls shall be carried out upward successively with the progress of the structure taking account of the material used and space to the retaining wall (2) Backfilling over the completed structure shall be executed using proper methods and materials without giving detrimental effect on the buried facilities and their permanent supports (3) Where processed fluid soil is used as backfilling material, proper method of transportation and placing shall be employed considering the executing conditions In advance of execution, materials shall be tested in a laboratory to confirm that they satisfy the required standard values Section 10-7 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 11 Not Used 12 Not Used Section 11, 12-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 13 STEEL REINFORCEMENT 13.1 General This section refers to the grade, type of steel reinforcement, including furnishing and placing reinforcement bars The materials and workmanship specifications are Japanese Industrial Standards (JIS), and Standard Specifications for Concrete (Japan Society of Civil Engineers – JSCE), ASTM standards and Vietnamese Industrial Standards 13.2 Materials 13.2.1 Steel Reinforcement Steel reinforcement shall comply with the following or equivalent ASTM standards; JIS G3112 – Steel bars for concrete reinforcement JIS G 3117 – Rerolled steel bars for concrete reinforcement 13.2.2 Cover Spacers Cover spacers for reinforcement shall be concrete blocks or of a proprietary plastic or concrete type Proprietary plastic and concrete cover spacers shall be a type agreed by the Employer’s Representative Cover spacers shall be as small as practicable consistent with their purpose and shall be designed to maintain the specified cover to reinforcement Cover spacer shall be capable to supporting the weight of reinforcement and construction loads without breaking, deforming or overturning The strength and durability of concrete blocks and proprietary concrete cover spacers shall not be less than that of the supporting concrete 13.2.3 Reinforcement Couplers Reinforcement couplers shall be of a proprietary type agreed by the Employer’s Representative Reinforcement couplers for tension joint shall be cold swaged or threaded type The couplers shall be capable of developing the full tensile strength of the parent bar and comprise high tensile steel studs and seamless steel tubes fitted with protective plastic caps 13.2.4 Tying Wire Section 13-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) Tying wire for the steel reinforcement shall be 1.6mm diameter soft annealed steel wire 13.3 Handling and Storage Reinforcement shall not be subjected to rough handling, shock loading or dropping from a height Reinforcement shall be stored off a leveled, well drained and maintained hard-standing ground on level supports and in a manner, which will not result in damage or deformation to the reinforcement, or in contamination of the reinforcement Measures to protect the reinforcement from wetting and rusting caused by weather shall be proposed to the Employer’s Representative for consent Different types and sizes of reinforcement shall be stored separately 13.4 Cutting and Bending Reinforcement Reinforcement bars shall be cut and bent cold and shall be in accordance with Design Standards for Railway Structures and Commentary (Concrete Structure), (DSRSC-CS), Railway Technical Research Institute, Japan (RTRI-J) to the specified shapes and dimensions 13.5 Fixing Reinforcement Steel reinforcement and reinforcement couplers from each batch shall not be fixed until testing of the batch has been completed Reinforcement shall be fixed rigidly in position and secured against displacement A sufficient number of intersecting and lapping bars shall be tied using wire, tying devices or clips to prevent movement of the reinforcement Laps and joints in reinforcement shall be made only at the specified positions on the drawing and by the specified method Minimum lap length and anchorage length shall be in accordance with DSRSC-CS Sufficient numbers of cover spacers, chairs, supports and spacers other than cover spacers shall be provided to maintain the reinforcement in the correct location and maintain the specified cover at all positions Prefabricated reinforcement cages shall be adequately supported and braced before lifting Reinforcement which is free-standing shall be secured in position and braced to prevent movement due to wind and other loads Reinforcement couplers shall be fixed in accordance with the manufacturer’s recommendation and using equipment recommended by the manufacturer Reinforcement that is to be left exposed shall be protected by coating with cement slurry or Section 13-2 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) by other methods agreed by the Employer’s Representative Reinforcement shall not be contaminated or displaced as a result of access over the reinforcement Access shall be obtained by using planks and ladders or by other methods agreed by the Engineer 13.6 Tolerances The cover to the outermost layer of the reinforcement shall not be less than the minimum cover shown on the Drawings plus a tolerance of 5mm for fixing precision 13.7 Testing 13.7.1 Batch For the purpose of testing, the steel reinforcement arriving on the Site is to be subdivided into batches Each batch shall consist of reinforcement of the same steel grade, the same nominal diameter, same cast number, batch number or lot number A batch of reinforcement couplers for tension joints is any reinforcement couplers for tension joints of the same type, size and grade, manufactured by the same mill, covered by the same mil and testing certificates and delivered to the Site at any one time 13.7.2 Samples Samples of steel reinforcement, and reinforcement couplers for tension joints, shall be provided from each batch of the material delivered to the Site and at least 30 days before fixing of the reinforcement starts The number of samples to be provided from each batch shall be stated in table 13.1 Table 13.1 Rate of sampling of reinforcement Description Size of batch Steel reinforcement All sizes Reinforcement Less than 100 No 100 - 500 No Exceeding 500 No for tension joints couplers Section 13-3 of No of samples per batch October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) The number of specimens in each sample shall be as follows: (1) Steel reinforcement Table 13.2 Number of specimens Description Nominal size 6mm-16mm Nominal size Size of batch Tensile Test Bend Test 0-60 tonnes Each additional 60 t or part of 60t Nil 0-80 tonnes Each additional 80 t or part of 60t Nil 0-100 tonnes Each additional 100t or Nil 20mm-32mm Nominal size Exceeding 32mm part of 100t (2) Reinforcement couplers for tension joints : Each specimen of steel reinforcement shall be 1m long Each specimen of reinforcement couplers shall consist of one reinforcement coupler jointed two lengths of bar each 500mm long The bars shall be of the same type, size and grade as the bars to which the reinforcement coupler will be fixed in the Permanent Works Each specimen of steel reinforcement shall be taken from different bars The ends of the specimen shall be cut square before delivery to the laboratory 13.7.3 Testing Each sample of steel reinforcement shall be tested to determine the yield stress, elongation, tensile strength, bending properties and unit mass Each sample of reinforcement couplers for tension joist shall be tested to determine the tensile strength and the permanent elongation The method of testing shall be in accordance with JIS G3112 or JIS G3117 or equivalent ASTM standards These tests shall be carried out by the consented testing authority 13.7.4 Non-compliance If the result of any test for elongation, tensile strength, bending, unit mass or reinforcement couplers for tension joints does not comply with the specified requirements for the property, Section 13-4 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Construction Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) additional samples shall be provided from the same batch and additional tests for the property shall be carried out The number of additional samples and specimens shall be stated in 13.7.2 The batch shall be considered as not complying with the specified requirements for the property if the result of any additional test does not comply with the specified requirements for the property Section 13-5 of October 2012 ... 5- 8 5. 8 Batching and Mixing Concrete 5- 9 5. 9 Ready Mixed Concrete 5- 10 5. 10 Formwork 5- 11 5. 11 Falsework 5- 12 5. 12 Curing Agents 5- 12 5. 13 Release Agents 5- 12 5. 14 Compacting Equipment 5- 13 5. 15. .. 70-100 100 - - 1” 55 - 85 75- 100 100 - 3/4” 50 -80 60-90 70-100 100 3/8” 40-70 45- 75 58- 75 - No 30-60 30-60 35- 65 45- 80 No 10 20 -50 20 -50 25- 50 30-60 No 40 10-30 10-30 15- 30 20- 35 No 200 0-2 0-2... Testing 4-29 4 .5 Diaphragm Walling 4- 45 CONCRETE 5- 1 5. 1 Materials 5- 1 5. 2 Concrete Mix Design 5- 4 5. 3 Trial Mixes 5- 5 5. 4 Sampling of Concrete 5- 6 5. 5 Quality Control of Concrete 5- 6 of October