288 M Spec Rev T1

ENGINEERING SYSTEMS DESIGN LTDWOODTHORPE STUDIO88 CHORLEY NEW ROADBOLTONBL1 4DHTEL: 01204 465 420FAX: 01204 238 101EMAIL: [email protected]: WWW.ESDCONSULTANTS.CO.UK

CLIENT:

PRAXIS REAL ESTATE MANAGEMENT LTD1ST FLOORTHE CHAMBERS13 POLICE STREETMANCHESTERM2 7LQ

MECHANICAL SERVICES SPECIFICATIONFORCOMPASS HOUSE,CAMBERLEY

REF: 261/ME/PG/DE/13.04 REV C1

CONSTRUCTION ISSUE

http://WWW.ESDCONSULTANTS.CO.UK/

mailto:[email protected]

COMPASS HOUSECAMBERLEY

CONTENTS

1.0 General Conditions 81.01 Definitions 81.02 Form of Contract 81.03 Schedule of Alternatives 81.04 Scope of Works 81.05 Health and Safety 91.06 Contract Documents 101.06.1 Discrepancies In or Divergences Between Documents 101.06.2 Property of Documents 101.06.3 Return of Documents 101.07 Examination of Contract Documents and Site 101.08 Tenders 101.09 Statutory Obligations 111.10 Fire Precautions 111.11 Watching, Lighting Etc. 111.12 Attendance 111.13 Builders Work 121.14 Setting out of Work 121.15 Delivery, Goods and Cranage 121.16 Sub-Contractors Drawings 121.17 Control of the Works 131.18 Quality of the Works 141.19 Protection of Plant and Equipment 151.20 Instructions – See Employer’s Requirements 151.21 Payment 151.22 Publicity 171.23 Mock ups and samples 171.24 Site Working Limitations 171.25 Insurances 181.26 Liaison between Contractors 181.27 Storage, Plant, Equipment and Tools 191.28 Training of Employer’s Staff 191.29 Dilapidation Schedule 191.30 Other Works and Contractors 19

2.0 General Preliminaries 212.01 Schedules of Alternatives 212.02 Scaffolding 212.03 Temporary Buildings 212.04 Debris 21

261/M/Spec Rev C1 2

2.05 Off-Loading and Movement of Materials 212.06 Connections to Existing Installation 222.07 Noise and Disturbance 222.08 Notices, Byelaws Etc. 232.09 Safety Precautions 232.10 Cartridge-Operated Fixing Tools 232.11 Bacteria Free Materials 242.12 Delivery and Construction Programme 242.13 Schedule Showing Make-Up of Summary of Tender Items 242.14 Engineering Clerk of Works 252.15 Supervision of Labour 252.16 Foreman 252.17 Incompetent Workmen 262.18 Setting Out 262.19 Builderswork 262.20 Make Good 262.21 Attendance of other Trades 262.22 Plans and Dimensions 272.23 Instructions to Attendant 272.24 Defects Liability 272.25 Site Safety 282.26 Items for Approval 282.27 Hazardous Substances 282.28 The Electricity at Work Regulations 282.29 Visit to Site 28

3.0 Pipework Installation 313.01 General 313.02 Material Standards and Quality 313.03 Materials For Piped Services 323.04 Pipework Location Requirements 333.05 Method of Jointing 383.06 Mild Steel Pipework Fittings 413.07 Screwed Joints 423.08 Welded Joints 433.09 Flanged Joints 443.10 Copper Pipework Joints 453.11 Fitting for Copper Pipework 453.12 Support and Fixings 463.13 Cover Plates 493.14 Expansion and Contraction 493.15 Anchor Points 513.16 Pipe Sleeves 513.17 Vibration Isolation and Noise Insulation of Pipework Installations 523.18 Air Venting of Pipework 53

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3.19 System Drain Down Requirements 533.20 Venting And Drainage, Pipe Gradients 543.21 Dirt Pockets 543.22 Protective Painting And Coverings 543.23 Gas Equipment and Pipework 553.24 Valves, Cocks, Strainers and Vents 553.25 Valve Labels 623.26 Safety Valves and Boiler Fittings 623.27 Strainers 623.28 Test Points, Gauges and Thermostat Pockets 623.29 Water Meters 643.30 Fire Hydrants 64

4.0 Ductwork Installation 664.01 General 664.02 Installation and Shop Drawings 664.03 Standard and Quality of Work 664.04 Materials 674.05 Circular/Flat Oval Ductwork 674.06 Supports and Brackets 674.07 Joints and Sealants for Sheet Metal Ductwork 684.08 Manual Volume Control Dampers (VCD’s) 684.09 Automatic Control Dampers 704.10 Fire Dampers 704.11 Access Openings 714.12 Vibration and Noise Insulation in Ductwork Installations 734.13 Flexible Joints 734.14 Flexible Ductwork 744.15 Builders Work Duct Connections 744.16 Connections to External Louvres 754.17 Roof Penetrations 754.18 Instrumentation and Control Equipment 754.19 Plastic Ductwork 754.20 Ductwork Cleanliness 76

5.0 Thermal Insulation Standards 785.01 General 785.02 Scope Of Works 795.03 Materials 805.04 Insulation Finishes 815.05 Standards and Workmanship 835.06 Insulation Thickness 885.07 Thermal Insulation of Heat Exchanger Cylinders and Buffer Tanks 895.08 Internal And External Water Storage Tanks 89

261/M/Spec Rev C1 4

5.09 Painting of Equipment, Steelwork And Exposed Pipework in Plantrooms, Boiler Houses and Major Service Ducts 89

5.10 Contract Identification 90

6.0 Testing and Commissioning 926.01 General Requirements 926.02 Pipework Testing, Commissioning and Regulation 936.03 Ductwork Testing, Commissioning and Regulation 936.04 Ductwork Air Leakage Testing 946.05 Refrigeration Installation 946.06 Gas Installation 946.07 Equipment And Commissioning Certificate, Schedules And Drawings 946.08 Pre-Commissioning Cleaning and Sterilisation of Pipework Systems 956.09 Instruments Used in Testing 966.10 Underground Mains: Pigging 966.11 Automatic Control Systems 976.12 Systems Witnessing and Proving 976.13 Test Certificates 98

7.0 Record Drawings and User Manuals 1007.01 Operation and Maintenance Manual 1007.02 Demonstrations & Training 103

8.0 Controls and Control Panel Installation 1058.01 General 1058.02 Scope of Works 1058.03 Testing, Supervision, Commissioning And Proving 1068.04 Controls Description 108

9.0 Health and Safety 110

10.0 PARTICULAR MECHANICAL SERVICES REQUIREMENTS 11210.01 General 11210.01.1 Requirements 11210.02 Scope of Works 11410.03 Removal of Existing Services 11510.04 Heat Pump Installation 11510.04.1 Air Conditioning Installation Specification - "R2" Series Systems 11610.04.2 In Room Units 11610.04.3 BC Controllers 11710.04.4 System Controllers 11710.04.5 VRV Condensing Units 11810.04.6 Air Conditioning Installation Specification - "M" Series Systems 11910.04.7 In Room Units 11910.04.8 System Controllers 119

261/M/Spec Rev C1 5

10.04.9 VRV Condensing Units 12010.04.10 General Installation Specification 12010.04.11 External Condenser Frame 12110.04.12 Controls Wiring 12110.04.13 Equipment Power Supplies 12110.04.14 Refrigeration Pipework 12110.04.15 Refrigerant Pipework Insulation 12310.04.16 Condensate Drains 12310.5 Ventilation System 12310.5.1 General 12310.5.2 Dampers 12410.5.35 Vibration 12410.5.4 Acoustics 12410.5.5 Ductwork 12510.5.6 Grilles, Diffusers and Louvres 12510.06 Domestic Water System 12610.06.1 Hot Water Heaters 12610.06.2 Cold Water Storage Tank 12610.7 Pumps 12710.08 Flue Installation 12810.09 Humidifier Installation 12810.09 AHU & Ductwork Cleaning 12810.10 Contingency Sum 129

261/M/Spec Rev C1 6

SECTION ONE

GENERAL CONDITIONS

261/M/Spec Rev C1 7

1.0 General Conditions

1.01 Definitions

This document sets down the performance criteria and particular requirements for the Mechanical and Electrical Engineering services associated with the project.

The Contractor shall include for the (the design were indicated) supply, delivery to site, unloading, storage, hoisting, distributing, installing and fixing, setting to work, testing and commissioning, proving of the performance of the works, instruction of the Employer’s staff and all requirements as described in the Contract Documents.

1.02 Form of Contract

The contractor shall refer to main contract documents for details of the type of contract.

It is the Contractor’s responsibility to refer to all the relevant sub-contractors the preliminaries and conditions associated with these works.

1.03 Schedule of Alternatives

In cases where materials are to be supplied and/or services are to be provided by a specific manufacturer as detailed in this specification or on the drawings, the Contract Tender must be based on these materials. Alternative manufacturers will only be considered where cost savings can be provided. The Contractor shall provide in writing confirmation that any proposed alternative materials or items of equipment are equivalent to satisfy all requirements of the specified article. If he so desires, the Contractor may submit a schedule of alternatives by completing the Schedule of alternatives in the Form of Tender indicating the cost savings, implications and any other factor, which affects the execution of the works.

The Contractor shall provide in writing confirmation that any proposed alternative material/item of equipment equivalent to and satisfies all the requirements of the specified article.

1.04 Scope of Works

This document sets down the performance criteria and particular requirements for the Mechanical and Electrical Engineering services associated with the project.

261/M/Spec Rev C1 8

The Contractor shall include for the design, supply, delivery to site, unloading, storage, hoisting, distributing, installing and fixing, setting to work, testing and commissioning, proving of the performance of the works, instruction of the Employer’s staff and all requirements as described in the Contract Documents.

1.05 Health and Safety

The Contractor shall ensure complete compliance with all health, safety and welfare legislation and requirements of the land.

The Contract Administration may issue instructions requiring the dismissal from the works any person who gives cause the breach of any health, safety or welfare requirements.

The Contractor shall comply with the statutory requirements of Health and Safety Policies of the HSE, details of, which are available upon request. Additionally, the Contractor shall provide a complete Health and Safety document for the project, which shall outline all the relevant risk analyses.

The Construction (Design and Management) Regulations 2007 apply to this project.

The Health and Safety Plan identifies the Client, CDM Co-ordinator and Principal Contractor under the terms of the Regulations.

The Contractor shall be required to compile a Health and Safety file, which shall be handed to the Client upon completion of the works. The contents of the Health and Safety file shall include, but not be limited to: -

Record Drawings, including plans, details and schematics (see section six of this Specification).

Operating and Maintenance Manual (see section four of this Specification).

General details of construction/installation methods and materials used.

Details on the location and nature of utilities and services

Information on any hazards, which may affect a person operating, maintaining, altering or demolishing any part of the structure and services.

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1.06 Contract Documents

1.06.1 Discrepancies In or Divergences Between Documents

Any discrepancy or divergences between the documents shall be qualified by the Tenderer when submitting his Tender for the works.

1.06.2 Property of Documents

The documents shall remain the property of the Employer, and shall be regarded as strictly confidential.

No part of the documents shall be used by the Contractor for any purpose other than this contract, and shall not be copied without written consent from the Employer.

1.06.3 Return of Documents

Upon final payment the Contractor shall forthwith return to the Employer all drawings, details, schedules and other documents of a like nature which bear the name of the Employer.

1.07 Examination of Contract Documents and Site

The Contractor shall be deemed to have: -

Thoroughly examined all contract documents.

Visited the site and made himself fully acquainted by his own independent observations and enquires as to the nature, extent and practicability of the works, means of access, space for storage of materials, the positions relative thereto of buildings, structures and any underground or existing services and all other similar points which can n any way affect the price.

Any monetary or other claim made by the Contractor on the ground of want of knowledge of any or all of the aforesaid matters or things will not be entertained by the Employer.

1.08 Tenders

261/M/Spec Rev C1 10

The formal Tenders shall be submitted on the Forms of Tender provided which shall remain unaltered, and shall include a breakdown of the Tender price into the elements for which the Employer requires the specified schedule of rates to be prepared in the event of the Tender being successful.

Upon request, the Contractor shall provide a complete schedule of rates applicable to each section of work, all fully priced and summated to the section total to be brought forward to the summary of tender. Information of all sub-contractor’s prices and associated percentage mark up/on-costs shall be included.

1.09 Statutory Obligations

The Contractor shall comply with, and give all notices required by, any rule or order or any regulation or Bye-Law of any Local Authority or of any Statutory undertaker which has any jurisdictions with regard to the works and shall pay all fees and charges arising there from.

The Contractor shall provide attendance to any Local Authority or Statutory undertaker when they are carrying out any works on site, and shall make due allowance in his Tender for any such event.

1.10 Fire Precautions

All necessary precautions shall be taken to prevent any outbreak of fire. This shall cover all temporary power supplies, lighting, distribution and equipment.

Any inflammable solvents, paint or other fluids, and gas storage bottles shall be stored in a purpose – made external enclosure displaying the Statutory notices. Gas bottles were required to be moved to and from the workplace shall be retained in the upright positions at all times by a purpose – made container fully in compliance with the Statutory requirements.

1.11 Watching, Lighting Etc.

The Contractor will be provided free of charge with 240v power, water supplies and lighting together with sanitary accommodation and welfare facilities.

1.12 Attendance


The Contractor shall provide his own necessary scaffolding, builders work and clearing away of rubbish etc. At the end of each working day the Contractor shall clean the occupied area to the satisfaction of the Employer.

1.13 Builders Work

The Contractor shall provide, under the auspices of the Contract, all builders’ work including cutting away, making good holes through walls, floors, ceilings and partitions etc. and the redecoration of damaged surfaces. The temporary removal of false ceilings and floors together will the cutting of holes and forming new openings.

The works shall be executed by a trade’s recognised master builder in a domestic sub-contract agreement with the Contractor.

1.14 Setting out of Work

Immediately upon acceptance of the contract works the Contractor shall supply the Employer with two compete sets of builders work drawings or schedule (refer to Clause 1.16).

The provision of these drawings will not absolve the Contractor from attendance on site in order to instruct any Sub-Contractors and supervise all builders work etc.

No builder’s work will be allowed without the approval of the drawings by the Employer. Any costs which may occur through the Contractor’s failure to supply the drawings or through lack of supervision will be paid for by the Contractor.

1.15 Delivery, Goods and Cranage

The Contractor shall include for all delivery, off-loading and handling into final position all goods and material provided by him.

Where cranage is required for any plant/equipment the Contractor shall include for the provision of same along with any third party insurance cover etc.

Delivery of the goods shall be provided in accordance with the Employer’s programme and submitted to the Employer.


1.16 Sub-Contractors Drawings

The Contractor shall note that the Tender drawings contain concepts only. The Contractor shall be responsible for providing full design drawings as well as the following detail drawings in order to avoid site-related problems.

Builders work Drawings and/or schedule shall indicate the size and accurate location of all holes and chases required, weight and size of all plant and equipment, sizes and location of all bases/plinths and the size and type of any fixings and brackets.

Working Drawings showing co-ordination/inter-relationship with other trades or service routes and ceiling/floor layout. These drawings shall show the agreed location of equipment and all dimensions between the building and also other trades.

Manufacturer’s Drawings and writing diagrams for all equipment and plant items.

The following metric scales shall be used for the drawings: -

Builders detail 1:50

General layout 1:50

Detail layout 1:20

Drawings shall be produced AutoCAD format. The quality of drawings work (e.g. clarity etc.) shall be to a good standard and the recommended procedure of ‘working drawings production’ shall be in accordance with the Application Guide 1/76 by the Building Services Research and Information Association.

The drawings shall be produced to suit the Contract Programme. Allowance shall be made for the necessary approval period required by the Employer and Employer and for the incorporation of any amendments caused by such amendments.

The Tender shall include for issuing up to four sets of the above drawings.

1.17 Control of the Works

1.17.1 Site Documents

The following documents shall be kept on site: -

1 copy of the Specification Section


1 set of the Design Drawings

1 set of Installation and Builders work Drawings

The set of installation and builders work drawings shall be amended on site with any variations as they occur. These drawings will form the basis of the record drawings.

1.17.2 Programme

Within three days of being requested the Contractor shall provide two copies of his programme for the execution of the works. This programme shall be fully detailed and shall include for: -

Phasing of the Works Adequate periods for the preparation of installation and builders work drawings.Weekly labour resource.Anticipated delivery of main plant items and equipment.

Site start Refer to Employer’s RequirementsCompletion Refer to Employer’s Requirements

1.17.3 Site ‘Manager’

The Contractor shall continually keep on site a competent person to manage and direct the works.

This person shall be fully conversant and familiar with the scope and details of the contract, the contract programme, labour resource etc. and be authorised to take any action and make any decision necessary.

This person shall remain on site for the full duration of the works and shall not be replaced without the written consent of the Employer.

1.17.4 Meetings

The Contractor’s Site Manager’ shall attend any site meeting and any project meeting as and when requested by the Employer.


1.18 Quality of the Works

All materials, goods and workmanship shall be of a good quality:

Materials and goods shall be in accordance with the types and manufacture described in this specification and/or shown on the contract drawings, and shall conform to current British Standards Specifications. All materials and goods shall be installed in accordance with the manufacturer’s installation instructions and recommendations.

Workmen shall be employed on the works that have been trained in accordance with the CITB requirements, have previous experience on the type of works involved and are careful and skilful in their trades. Any work rejected by the Employer shall be replaced by the Contractor at the Contractor’s expense.

The Contractor shall not replace any site/staff/workmen without written consent from the Employer.

1.19 Protection of Plant and Equipment

The Contractor shall take all necessary measures to protect fixed and unfixed plant and equipment at all times from damage due to negligence on any part, exposure to weather, dust or any other case.

Damage items will not be accepted and these shall be replaced at the Contractor’s expense.

1.20 Instructions – See Employer’s Requirements

All instructions shall be issued by the Employer) and will be confirmed by the issue of an appropriate variation order. The Contractor must not accept any instructions from any unauthorised personnel unless these persons are specifically named by the Employer. Any unauthorised works carried out by the Contractor shall be at the Contractor’s expense.

1.21 Payment

1.21.1 Certificate and Payments


The Contractor shall issue a copy of his interim valuation to the Quantity Surveyor and Employer seven days prior to the agreed valuation date. This valuation shall indicate: -

The total value of the completed works, and percentage against each tender summary section.

The total value of the materials and goods delivered to the works for incorporation therein.

The Contractor shall attach to the valuation a detailed breakdown indicating to the Employer’s satisfaction the make-up of the values of completed works and the value and quantity of unfixed materials and goods. This shall include the production of all original invoices when requested. Copies of the original invoices will not be accepted. All invoices will be returned to the Contractor after inspection and a photocopy retained.

The Contractor shall include for rendering all reasonable assistance to the Employer in maintaining close control of contract cost including further elemental analysis of the quantified schedule of rates as a basis for interim valuations.

1.21.2 Overtime

Any overtime or weekend working which is necessary to complete the work in accordance with the contract conditions will be deemed to have been included for the Contractor. Any additional overtime which involves extra charge will only be permitted if authorised in writing by the Employer.

1.21.3 Valuation of Variations and Provisional Sum work

Schedule of Rates

The Contractor shall, within seven days of request, provide a schedule of rates for the whole of the works. The schedule shall include the following:-

A unit for each item of work, which shall be split into both labour and material content.

The quantity for each unit of work.

A breakdown of the labour rate, which shows the method by which the labour rate has been calculated.

Indicate the material percentage overhead.


These schedules of rates shall be used for the valuation of all variations where such work is of a similar character.

Where the work is not of a similar character the work shall be valued at fair rates and prices. The labour rate given in the schedule of rates shall be used when determining such rates.

Where the valuation relates to the omission of work included in the contract documents the rates and prices in the schedule of rates for such work shall determine the valuation of the work omitted.

Daywork

The valuation of any additional or substituted work cannot properly be valued by measurement shall be valued as day work items. No works shall be carried out on this basis without prior authority in writing, by the Employer or his authorised representative.

The valuation shall be calculated in accordance with the Contract Conditions using the percentage additions, which have been used in the Tender.

The Contractor shall submit vouchers specifying the time daily spent upon the work, the workmen’s names, the plant and materials employed for verification to the Employer or his authorised representative not later than the end of the week following that in which the work has been executed.

Agreement of Final Payment

The Contractor shall submit to the Employer or his authorised representative all documents necessary for the computation of the ascertained final contract sum.

1.22 Publicity

No photographs shall be taken or articles written for publication without the Architect’s written approval of publicity and of the contents thereof.

1.23 Mock ups and samples

The Contractor shall if requested provide a mock up on site for a typical room layout indicating lighting and power etc. layout for approval by the Employer. He shall also supply any samples requested and these shall become the property of the Employer.


1.24 Site Working Limitations

1.24.1 Hours of Work

The Contractor shall include within the tender all hours of work required to execute the works within the contract period. Normal working hours shall be Monday to Friday 0800 to 1700. However due to the building being occupied a proportion of the works will need to be completed outside normal working hours. The works being carried out outside normal working hours are within the occupied office spaces. The Contractor’s attention is drawn to the requirement for no transistor radios to be played on site and the site operatives will be required to comply with a No Smoking policy whilst on site.

1.24.1 Possession of the Site

The Contractor will be provided with access to the site in order to undertake the works. The site shall remain the possession of the Employer at all times.

The Employer will require the Contractor to provide on a daily basis a schedule of areas where he proposes to work.

1.24.2 Access to the Site

Access is by the roadway and reasonable parking is permitted. Number of parking spaces are to be agreed with the client.

1.24.3 Site Restrictions

The Contractor shall confine his operation and his employees and sub-Contractor to the area of the site necessary for these works. He must not use the site for any other purpose other than carrying out the works.

1.25 Insurances

Insurance requirements will be up to £5,000,000 (five million) Public Liability coverage for any on incident or consequence thereof.

The amount of insurance that the Contractor is required to provide for this contract shall not be less than the amount stated in the Contract documents for any one occurrence or series of occurrences.


1.26 Liaison between Contractors

The Contractor will be required to establish good working relationships with all other sub-contractors early in the Contract Stage and shall liaise with any other contractors otherwise employed by the Employer.

1.27 Storage, Plant, Equipment and Tools

The Contractor will provide areas for storage of plant and equipment: however, the areas are limited and the Contractor is advised to stagger deliveries of equipment.

The Contractor shall supply all hand tools, transformers, cabling, scaffolding, towers etc. to carry out the Contract Works, including relevant sub-contractors, within the stated contract period.

1.28 Training of Employer’s Staff

The Contractor shall allow for his appointed representative to instruct the Employer’s staff in operating, maintaining servicing the entire installation for a minimum period of 2 working days.

1.29 Dilapidation Schedule

The Contractor shall, prior to carrying out any works, prepare an extensive dilapidation schedule of the existing building and fabric. This shall be backed up with photographs and notes of all damages to the structure, internal finishes, fixtures and fittings.

1.30 Other Works and Contractors

It shall be noted that works not related to this contract shall be carried out during the contract period. These works shall consist of minor refurbishment to areas and building finishes which shall be carried out by others.


SECTION 2

GENERAL PRELIMINARIES


2.0 General Preliminaries

2.01 Schedules of Alternatives

In cases where materials are to be supplied and or services are to be provided by a specific manufacturer as detailed in this Specification or on the Drawings, the Contract Tender must be based on these materials. If he so desires the Contractor may submit a Schedule of alternatives indicating the cost implications and any other factor, which affects the execution of the works.

Alternative equipment and or services must comply with all aspects of this Specification with regard to British Standards, performance tests. The Contractor shall ensure and be responsible for the physical compatibility, accessibility and maintainability of all alternatives submitted.

2.02 Scaffolding

The Contractor shall include in his tender for providing and erecting any special scaffolding and plant required for the execution of the Works and shall dismantle and cart away on completion.

2.03 Temporary Buildings

The Contractor shall include in his tender for providing, erecting, maintaining and later clearing away all temporary store sheds positioned within the allocated site compound for such buildings. Shared Office space and welfare facilities will be provided by the Employer within the generator building. The contractor shall allow for the installation of adequate lighting within the building off the building’s power supply and also installation of water heaters within the toilets.

2.04 Debris

The Contractor shall ensure that all debris occasioned by his works are cleared off the site and the engineering installations and building in the vicinity thereof are left in a clean and tidy condition. Any, material and or fittings not required for the purpose of the Contract Works shall be removed from site from time to time and at any time within 48 hours of being instructed in writing so to do by the Employer.

2.05 Off-Loading and Movement of Materials

The Contractor shall allow in his tender for the unloading of materials supplied as part of the Works and any other materials which are included in the Schedule or on the drawings.


The Contractor shall provide any necessary crane, lifting tackle, movable platform, labour force etc. for the unloading and positioning of large and heavy items of plant and equipment.

The strength and load bearing capacity of any roadway, footpath or floor across which the Contractor intends to move any heavy load shall be checked in good time before such a load is applied so that adequate precautionary and additional supporting measures can be taken if required without delaying the movement of the load.

The Contractor shall inform the Employer when any of the above circumstances arise.

The Contractor shall be responsible for the provision of safe storage facilities for all equipment delivered to the site. Plant, equipment and material shall not be deposited on roadways or footpaths, in corridors or rooms other than the occupied site unless prior permission has been obtained in writing.The Contractor shall be responsible for the full reinstatement of any surface, fixtures or fittings damaged during the off-loading and movement of his materials, plant or equipment.

2.06 Connections to Existing Installation

Where the Contractor has to break into existing services, as detailed on the drawings and or within the specification, he must include within his tender for any necessary overtime for carrying out this work at a time to suit the Employer, which may be at night or weekend, so as to involve the minimum of interruption to the services.

The Contractor shall include in his tender for the provision of any temporary connections to existing services, so as to maintain services necessary to prevent undue interference with the operation of the existing services, as required by the Employer.

The Contractor shall allow for isolating and draining down the mains to be broken into and re-filling, venting, testing and re-balancing the circuits after the new connections have been made.

Under no circumstances shall the Contractor disconnect any service without prior consent of the Employer.

2.07 Noise and Disturbance


Where work is entailed on existing installations and in buildings that are in use, the work shall be carried out with as little disturbance as possible to the occupants of the building and only after consultation with the Employer.

The Contractor shall take all reasonable steps to limit noise to a minimum. The use of noisy mechanical tools or equipment shall only be permitted by arrangement with the Employer and should any request be declined or specific instructions issued that such noise cannot be accepted, this decision must be accepted and the Contractor shall make alternative arrangements at his own expense.

The Contractor shall ensure that all measures to control the noise levels produced by his operations on site required under or by virtue of any enactment or regulations, or the working rules of any industry, are strictly complied with.

The Contractor’s attention is drawn in particular to the Control of Pollution Act, 1974 and BS 5228:1975 “Code of Practice for Noise Control on Construction and Open Sites” and all amendments thereto.

2.08 Notices, Byelaws Etc.

The Contractor shall give all necessary notices and strictly conform with all Government and Local Acts and Bylaws and all Police Regulations or instructions. The Contractor shall pay all fees incurred.

2.09 Safety Precautions

The Contractor shall notify the Employer in writing of his intention to use on site equipment utilising substances of a type, which might endanger life or property. At all times he should ensure that safe methods of working are followed when using such equipment and shall take all necessary precautions to safeguard against damage by fire or explosion where the execution of the work may involve the presence of flames or sparks.

Petroleum products and other flammable or vaporising fluids shall only be used in accordance with the relevant regulations applicable to the storage and us of such products. When equipment and vessels containing flammable or dangerous fluids are not in use, they shall be removed to a safe place of storage in accordance with the regulations pertaining.

The Contractor shall include for complying with all current Statutes, Regulations, Codes and Agreements relating to the Building Industry in respect of Health and Safety.


2.10 Cartridge-Operated Fixing Tools

Cartridge operated fixing tools shall be designed, constructed and operated in accordance with BS 4078. Each complete tool and its individual parts shall have satisfied the Gun Barrel proof Act 1968 on testing by an approved Proof House.

Tools shall not be operated unless fitted with a suitable splinter guard.

Cartridges shall be clearly marked with the strength of the charge and only those corresponding to specifications issued by the maker of the tool shall be used.

The recommendations detailing use and maintenance of the tool contained in Appendix A of BS 4078 shall be considered as mandatory.

Cartridges shall be kept in a dry and secure store and strict control kept of their issue to each operator. A count shall be made at the end of each day’s work of the spent and unspent cartridges, which shall tally, exactly with the amount issued. The number of cartridges brought on to the site and the number taken away at the completion of operations shall also be taken and an exact balance struck. All cartridges, spent or unspent shall be removed from the site on completion of the work.

2.11 Bacteria Free Materials

The Contractor shall ensure that all materials shall be of a type that will not support bacteria. No acoustic insulation or sound deadening material shall be manufactured with any form of animal hair.

2.12 Delivery and Construction Programme

The Contractor shall agree a detailed building programme at the earliest possible date. The programme shall include delivery dates of all goods and materials vital to the programme. Evidence shall be provided that the Contractor has checked with his suppliers, including nominated suppliers, that such goods and materials can be made available at the required times.

The responsibility for preparing an accurate and practicable programme and for complying with it rests entirely with the Contractor but two copies of the programme shall be submitted to the Employer for his information as soon as it has been agreed.

2.13 Schedule Showing Make-Up of Summary of Tender Items

Upon request by the Employer, without any acceptance of the Tender being given or implied, the Contractor shall deposit with the Employer a fully priced schedule to


agree with the amount given in the Summary of Tender showing in detail the quantities and pricing.

The quantities of materials shown in this schedule shall be sufficient to complete the Works. No claim or claims in respect of failure of the Contractor to include sufficient quantities will be considered.

2.14 Engineering Clerk of Works

The Clerk of Works, when/if appointed by the Employer for the Engineering Works, will operate in conjunction with the Building Clerk of Works and shall endeavour to ensure that all aspects of the work are carried out and installed in accordance with the Specifications.

The Contractor shall work closely with the Engineering Clerk of Works in arranging inspections and tests which must be approved by him or the Employer and must comply with any instruction given by him concerning the removal of defective workmanship or material either before or after installation.

The appointment of an Engineering Clerk of Works shall not in any way reduce the Contractor’s own responsibility for supervision of quality and workmanship.

2.15 Supervision of Labour

The Contractor must at all times employ a Supervisor (none working foreman based on site) to keep overall supervision of the Works.

The Engineering Designer or Supervisor shall be responsible for the quality of workmanship and general co-ordination with other trades. He shall prepare or obtain from suppliers when necessary all drawings called for in the Specification.

The Supervisor shall be responsible for detailed co-ordination with other trades and for ensuring the work is done in accordance with the Specification and drawings.

All Contract Work shall be carried out by competent operatives possessing the relative skills in the appropriate trades.

Trade Customs in the employment of the appropriate grades of workpeople shall be followed and the Contractor will be held responsible for ensuring that such customs are complied with.

2.16 Foreman


A competent engineering foreman shall be placed in charge of the work and the Contractor shall not remove him at any time except with the permission of or at the request of, the Employer. The foreman shall keep a copy of all drawings, specifications and instructions of works. Any direction given to such foreman shall be held to have been given to the Contractor.

2.17 Incompetent Workmen

The Contractor shall, on the request of the Supervising Office, immediately remove from the Works any person employed thereon by him who may, in the opinion of the Employer, be incompetent or misconduct himself. Such person shall not again be employed on the Works without the permission of the Employer.

2.18 Setting Out

The Contractor shall set out the whole of the Works and during the progress of the Works shall amend at his own cost any errors arising from inaccurate setting out unless the Employer shall otherwise decide.

The Contractor shall attend site before commencing installation work in order to provide and position all necessary brackets, supports, hangers, ducts, sleeves etc. required for building-in.

The Contractor shall be held responsible for any extra costs incurred by himself or to others due to his non-or late compliance with this Clause.

2.19 Builderswork

As soon as possible after the Contractor has received notification of the acceptance of his Tender, he shall prepare Builderswork Drawings, fully dimensioned, of all foundations, bases, plinths, holes etc. required for the Works. Copies shall be forwarded to the Employer.

Builderswork such as cutting away and making good all holes through walls and floors, building in of brackets etc and formation of bases is the Principal Contractor’s responsibility. The Contractor however, will be responsible for marking the correct positions of all holes to be cut etc and all incidental Builderswork.

All simple fixings such as screws and bolts, using rawl plugs or similar, shall be carried out by the Contractor.

2.20 Make Good


The Contractor shall be entirely responsible for any damage that may occur to the Works themselves or to any adjoining works or property whether such damage be caused by accident or design. Should any injury take place he shall reinstate the work at his own cost so that on completion the whole shall be perfect in all respects.

2.21 Attendance of other Trades

The Contractor shall be represented at site meetings and attend upon all other trades when required.

2.22 Plans and Dimensions

The Contractor shall take his own dimensions and prepare his own quantities both for the preparation of his tender and for the carrying out of his work. He alone shall be responsible for the accuracy of such quantities, dimensions and any drawings made there from.

2.23 Instructions to Attendant

Before “hand-over” of the building to the Employer, the Contractor shall be responsible for instructing the Employer’s Attendant in the correct running of all systems and equipment. The Contractor shall ensure that the Attendant thoroughly understands how to work and control the plant and equipment.

At the time of “hand-over” the Attendant will be requested to give confirmation of his full confidence to operate the plant etc. and shall illustrate this to the Employer. Only when the Employer is satisfied that the Attendant has been correctly instructed will the building be considered for hand-over.

2.24 Defects Liability

The Contractor shall make good, at his own expense, any defect which occurs during the execution of the Works and during the period of 12 months from the Date of Practical Completion of the Work, unless the defect arises from causes for which, in the opinion of the Employer, the Contractor is not responsible.

The issue of a Certificate of Practical Completion shall not exonerate the Contractor from liability with regard to the making good of Defects.

Defects shall be made good by the Contractor by substitution and not by patching, at his expense and under the direction of the Employer and, in the case of default by the Contractor, the Employer may recover from him as liquidated damages the actual cost of making good the same, and if any payments are still due to the


Contractor they shall be suspended until such defective work has been made good to the satisfaction of the Employer.

The Employer shall notwithstanding and before the issue of any Completion Certificate be at liberty to use the plant/installations or any part thereof as soon as the Employer considers the installation of such parts fit for use. The Contractor’s attention is brought to the fact that in some instances it may be essential for the Employer to have use of certain plant or installations to allow the building to function whilst the remainder of the work is carried out. The use of any plant/installations will not in any way indicate or imply the commencement of the 12 months Defects Liability Period.

Any costs that the Contractor may have, associated with the above, must be included within the contractor’s tender.

2.25 Site Safety

The Contractor shall follow all guidance produced by the Health and Safety Executive in relation to construction activities.

2.26 Items for Approval

The Contractor shall note that where the term “approved” is used in the Specification/Bill of Quantities where it refers, for example, to “approved equipment” and/or “approved practices” being used or to items that must be “equal or approved” – the terms shall mean approved in writing by the Employer for incorporation in the Works.

It shall remain the Contractor’s responsibility to request approval from the Employer not less than 21 days (twenty one days) prior to the date, which is the latest date acceptable to the Contractor for approval.

In order to obtain the Employer’s approval, samples of materials, equipment and/or information regarding equipment or practices shall be provided by the Contractor free of charge to the Employer and as required by the Employer.

2.27 Hazardous Substances

Contractors must comply with the “Control of Substances Hazardous to Health” (COSHH) Regulations particularly regarding the identification and notification of hazardous substances, storage, processes and places where substances are used, potential health risk of each substance and persons likely to be exposed to risk.

2.28 The Electricity at Work Regulations


The Contractor must observe the requirements of Statutory Instrument 1989 No. 635 Health and Safety -The Electricity at Work Regulations and shall ensure that all works executed by the Contractor and/or his representative comply with the requirements.

2.29 Visit to Site

The Contractor shall inspect the site before tendering to acquaint himself with the conditions of accessibility, nature and scope of the work to be carried out, and shall also carefully read the General Conditions, Specification and Drawings and the attached Conditions of Contact and shall include in his tender any sum necessary to cover compliance therewith, as no allowance will be made for errors or omissions due to ignorance of the conditions obtaining or for any lack of information in these respects.


SECTION THREE

PIPEWORK INSTALLATION


3.0 Pipework Installation

3.01 General

3.01.1 Scope of Works

This Section of the Specification provides installation details for the piped services encountered within this project.

Installation of all pipework shall follow the details set out in the contract drawings, due allowance being made for the nature of same and shall be in accordance with the best accepted practice.

The details set out in the following clauses of this section are generally appropriate to all piped services except where specifically stated.

3.01.2 Domestic Water Services

All elements of the domestic hot and cold water services installations shall be installed tested and set to work in full compliance with the British Standards.

3.02 Material Standards and Quality

3.02.1 Piped Materials

All pipework and tubing used for the installation of the various systems described in this Specification shall be free from imperfections, straight, cleanly finished, round in cross section, free from cracks, surface flaws, laminations and other defects and shall be free from rust, scale and similar deteriorations.

The piped materials to be used for the various services to be installed are given in Clause 3.3 and shall not be varied without written permission.

Steel pipe shall be varnished externally throughout their length after manufacture.

Light gauge copper tube shall be used where specified and all tubes shall be solid drawn from phosphorous de-oxidised non-arsenical copper to BS 6017 free from any deleterious film. Copper tube shall be half hard temper, complying with the requirements of BS 2871: Part 1: Table X.


3.02.2 Water Authority Bye-Laws

Water installation and its components shall comply fully with the Water Authority Regulations relating to the local water authority.

Where a system type and associated components are covered by a current edition of the British Standard and British Standard Code of Practice then the installation shall comply fully with the Standard.

3.03 Materials For Piped Services

The following table provides the pipe material type, grade and finish to be used for the various listed services types.

Service Bore MaterialLPHW Up to 150mm dia Black mild Steel (HQ) to

BS 1387

LPHW buried in screeds and plaster etc

14mm dia Wirsbo-Radipex conduit system with no joints

LPHW cold water feed Up to 150mm dia Light gauge copper tube to BS 2871:Part 1:Table X

LPHW Open Vent Up to 150mm dia Galvanised mild steel (HQ) to BS 1387

Domestic Hot and Cold Water Services in Screed and Plaster

15mm to 22mm dia Wirsbo-Tappex conduit system with no joints

Domestic hot and cold water services

Up to 150mm dia Light gauge copper tubes to BS 2871:Part 1:Table X

Natural Gas Up to 150mm dia Black mild steel (HQ) to BS 1387


Condensed Water Up to 150mm dia Black mild steel (HQ) to BS 1387 and galvanised after manufacture

175mm – 300mm dia Black mild steel Class C to BS 3601 and galvanised after manufacture

Chilled Water Up to 150mm dia Black mild steel (HQ) to BS 1387

175mm – 300mm dia Black mild steel Class C to BS 3601

Oil Pipework Up to 150mm dia Black mild steel (HQ) to BS 1387. Alternatively 15mm to 35mm in copper tubes to Table X

Materials For Piped Services (Continued)

Services Bore MaterialHose reels Up to 150mm Dia Galvanised mild steel

(HQ) to BS 1387 where separate installation. Copper tubes to BS 2871:Part 1:Table XWhere combined with cold water services or whenever this is a requirement of the local water authority

3.04 Pipework Location Requirements

The following clauses provide the installation requirements appropriate to the internal, external, on view or buried location of piped systems.


3.04.1 Installation of Piped Services Generally

Internal

Installation of all pipework shall follow the details and information set out in the Contract Drawings, due allowance being made for the nature/design purpose of the drawings and in accordance with the best accepted practice.

Pipework shall be adequately supported on hangers or on brackets with rollers, according to position, in order to permit free movement due to expansion and contraction and the amount of such movement shall be proportioned throughout the system by the provisions of anchors at suitable points. All pipework shall be arranged to accommodate without distortion the linear expansion when heated and shall incorporate allowances, expansion loops or devices whether or not shown on the design intent drawings. Pipe supports shall be of the type, which will allow full movement of the pipes except at fixed locations, which shall be provided as necessary between expansion points. The fixed locations shall be secured by anchors of accepted design.

Pipes shall be spaced in relation to one another and to the building structure so as not to interfere with any other services and to allow for the required method and thickness of thermal insulation as specified. Insulation spacing shall also be in consideration of the inspection and maintenance of the services in general.

Adequate clearance between pipework/insulation surfaces and finished walls, floors, ceilings and other fixtures should be allowed for cleaning purposes, future dismantling etc. and shall not be less that the distance given below:-

- Pipework to pipework minimum distance 50mm.

- Pipework to ceiling minimum distance 100mm.

- Pipework to floor minimum distance 100mm.

- Pipework to walls minimum distance 100mm.

The installation of exposed pipe runs shall be arranged to present a neat appearance and be parallel to adjacent pipes and structure wherever practical but taking due regard of the grading, venting and draining requirements. All vertical pipes shall be plumb unless indicated otherwise. All pipe runs shall be arranged so that the longest length of tube practicable is used between bends, tees and flanges or unions. Jointed short lengths of pipe forming a longer straight length shall not be employed.


Pipe supports, anchors and guides shall be designed in such a manner that any obstruction of other services and building elements shall be avoided and shall be capable of maintaining a true and regular pipework installation within the tolerances of the building construction.

The position of all valves, drains and supports shall be determined in consideration of routine maintenance requirements. An orderly arrangement of valves, unions, flanges etc. shall be preferred to scattered siting. Pipework, valves, fittings and equipment forming a system installation shall be erected so that it can be dismantled and is accessible for repair and replacement.

In this context “accessible” means that the provision for dismantling the flange, union etc., and be reached and worked upon either in the open or else by removal of a purpose made duct cover, manhole or similar cover. The fitting is not accessible if, as fixed, it cannot be manipulated. Pipework passing through walls, floors, ceilings or similar manner shall be complete with flanges or unions enabling the system to be dismantled as may be necessary. No joints shall be formed within the thickness of walls, floors, or ceilings. Unions or flanges shall be provided generally at a maximum spacing of one per twelve metres or as agreed with the Employer.

For concealed pipework having screwed joints to air vents, drain cocks and pressure gauges, then full access shall be provided to allow complete inspection, dismantling, removal, replacement and re-jointing.

Pipework system shall be routed to set around all columns and structural projections and shall be set to take up any imperfections within the structural surface. Due allowance shall be made in all cases for obtaining full details relating to the skirting heights, sill heights and floor finishes. However, pipework off-sets shall be allowed on pipework visible in rooms only by prior agreement. Purpose made fittings shall be employed at all times unless it is impractical and prior approval has been obtained to form bends etc. Bends, springs and off-sets shall be formed by use of an efficient bending machine. Fire sets shall not be employed. Copper tube may have its bends, springs and offsets formed with springs or a bending machine.

All changes of direction formed shall be made with a minimum of loss of local wall thickness and for the cross section diameter shall remain true. Crinkled or scored pipework resulting from such manipulation will not be accepted.

All cuts from standard lengths of pipe shall have all burr and swarf removed; the ends shall be trimmed square and should be thoroughly cleaned before erection. The Employer shall reserve the right to inspect a number of joints to determine that such burrs have been removed by cutting the joints open. Should burrs or swarf be discovered, the cost of replacing the joint shall be met by the Sub-Contractor,


otherwise the Employer will pay the costs incurred in the removing, testing and replacing the sections of pipework.

Care shall be taken to avoid damage to pipe surfaces or malleable fitting “flats” through indiscriminate use of wrenches, vice jaws etc. Any pipework or fittings so damaged shall not be fitted.

Where pipework is contained in floor ducts the installation shall be carried out with a minimum of site joints. When the site joints have been completed the installation shall be hydraulically tested to twice the working pressure of the installation for a period of not less than four hours.

Due allowance shall be made to protect the open ends of all pipework. Suitable caps, plugs or plastic covers only shall be used to cover open ends. Wood, rag or paper plugs shall not be used. Valves fitted to the open ends of tubes or pipes shall not be used to prevent the entry of dirt. The right is reserved to instruct the pipework to be dismantled for as far as considered necessary and the pipework to be cleaned internally should the above requirements not be observed. This work shall be carried out free of cost to the Employer including the removing, cleaning and replacing of the sections of pipework.

3.04.2 External Underground Pipework – Cold Water

Cold water pipework installed underground shall be carried out using one of the following:-

Medium density polyethylene (MDPE) pipework up to 63mm. To BS 6572 (WRC Specification 4-32-02) with fittings to WRC Specification 4-32-4, jointed using butt fusion.

MDPE pipework above 63mm to WRC Specification 4-32-03 with fittings and joints to WRC Specification 4-32-04

Ductile iron concrete lined to BS 4772 Class C.

Centrifugally cast (spun) iron pipes to BS 1211 Class C with spigot and socket joints and fittings to BS 78 : Part 2.

Cast iron flanged pipes and fittings to BS 2035.

All copper and cast iron pipework underground shall be wrapped with bituminous hessian painted with two coats of bitumen; alternatively copper pipework may be plastic covered.


Plastic pipework shall be installed in accordance with British Standard code of Practice CP 312.

Details shall be provided by the Sub-Contractor for all trenches including size and depth and method of backfilling. Also full details of the number, location, dimensions and loading of all anchor blocks necessary for the safe working of the installation shall be provided. Details for backfilling shall include the provision of 150mm. of pea shingle all round the pipework. No backfilling shall take place without prior approval. Unless stated, all civil works associated with the underground pipework will be carried out by others.

3.04.3 Underground Pipework – Heating and CHWS

Heating and CHWS pipework in a buried underground system shall be installed strictly in accordance with British Standard 4508 : Parts 1, 3 and 4 and British Standard Code of Practice 3009.

A complete system of buried pipework shall be provided, and full co-operation offered to the Main Contractor with respect to off-loading, cranage and general builders work requirements.

Buried pipework shall be sleeved with a steel or plastic sheath as appropriate with the cavity between the service pipe and the outer sheath being filled with an insulative polyurethane foam with the provision of an air gap where appropriate. The insulation system shall be suitable for the pipework and the maximum operating pressure and temperature of the system.

The installation shall be carried out with the minimum of site joints. When the site joints have been completed the installation shall be hydraulically tested to twice the maximum working pressure of the installation or 20 bar whichever is the greater for a period of not less than four hours.

After a satisfactory test the continuous integrity of the outer casing and insulation shall be made by sealing each joint with the manufacturer’s standard jointing system.

The manufacturer and installer shall accept undivided responsibility for the design, manufacture and installation of the complete system of underground mains and shall complete an Employer/Sub-Contractor Form of Agreement and Design Warranty as detailed in Section 1. The manufacturer’s recommendations concerning the installation shall be strictly followed.


The complete installation shall be inspected and tested, including full radiography tests, by an approved Insurance Company and the installation shall be covered by an approved fifteen year insurance backed warranty.

All necessary provisions for expansion and contraction and associated anchor points shall be included for the main installation. The pipework installation shall be provided with water bars at intervals for not more than twelve metres and the addition of water bars at each end of the installation.

All existing services which are encountered on the route of the installation shall be fully protected. Any design intent drawing of existing services is diagrammatic only and may not necessarily show the whole of the existing services or their location.

Details shall be provided for all trenches, including size and depth and method of backfilling. Full details of the number, location, dimensions and loading of all anchor blocks necessary for the safe working of the installation shall be provided. Details for backfilling shall include the provision of 150mm of sand all round the pipework and no backfilling shall take place without prior approval.

Unless stated otherwise, all civil works associated with the underground pipework will be carried out by others.

3.05 Method of Jointing

All pipework shall be jointed to the recommendations shown in the following tables unless otherwise indicated in the Specification or on the drawings.

Screwed joints shall be used where the act of welding would constitute a fire hazard over and above the normal accepted level. This requirement shall overrule the general recommendations but brought to the attention of the Employer before any work proceeds.

The following joint types shall be provided to facilitate pipework removal for maintenance purposes.

Unions on welded or screwed steel pipework up to 50mm nominal bore.

Flanges on welded or screwed steel pipework above 50mm nominal bore.

Unions on copper pipework up to 65mm nominal bore.

Flanges on copper pipework above 65mm nominal bore.


Jointing materials and fittings are to be suitable for the working temperature and pressure of the system.

The manufacturer’s recommendations for materials and jointing on chemical injection systems used for water treatment shall be strictly followed.

Plant Rooms, Underground Ducts and Voids, Ceiling Voids,Electrical Switchrooms, Computer Rooms,Telecommunications Rooms, Control Gear Rooms etc.and all Inaccessible Places

Service Nominal FlangeRating PressureBar

Material Bore Method ofJointing

Low Temperature Hot Water

10 Black Mild Steel

All Sizes Welded Throughout

Natural Gas 6 Black Mild Steel

Copper

All Sizes

13-50mm

WeldedThroughout

Capillary Fittings

External IncomingWater Main

M.D.P.E. All sizes Butt Fusion

External Gas Mains

M.D.P.E. All Sizes Fusion Welded

Domestic Hot and Cold Water

Copper All Sizes Capillary Fittings

Condensate Lines

Copper All Sizes SecurexCompressionFittings


Hose Reels 10 Galvanised MildSteel

Copper

All sizes

All Sizes

Screwed

Capillary FittingsButt Fusion

Oil Lines 6 Black Mild Steel

All Sizes WeldedThroughout

Chilled Water 10 Black Mild Steel

Copper

All Sizes

15 – 30mm.

WeldedThroughout

SecurexCompressionFittings

Condenser Water

10 Black Mild SteelGalvanised

All Sizes WeldedThroughout

In Room Where Generally On View

Services Nominal FlangeRating PressureBar

Material Bore MethodJointing

Low Pressure HotWater

10

10

Black Mild Steel

Black Mild Steel

Up to 50 mm.

65 to 100mm.

Screwed

Welded

Natural Gas 6 Black Mild Steel

Copper

All Sizes

15 – 50 mm.

Welded

SecurexCompressionFittings

Domestic Hot and Cold Water

Copper All Sizes Capillary Fittings


Condensate Lines

Copper All Sizes Securex CompressionFittings

Chilled Water 10 Black Mild Steel Up to 50mm. Screwed

Condenser Water

10 Black Mild SteelGalvanised

All Sizes

Over 50mm.

WeldedThroughout

Welded

Oil Lines 6 Black Mild Steel

Copper

All Sizes

15 -50mm.

Welded

SecurexCompression Fittings

Hose Reels 10 Galvanised MildSteel

Copper

All Sizes

All sizes

Screwed

Capillary Fittings

Securex fittings used for condense pipework shall be non-dezincifiable material. On no account will ferrous pipework, nipples, unions, and bends etc. be permitted. Crane Limited bronze fittings to BS 143 or Securex BSP iron to copper adapter fittings shall be used, or equal and approved.

3.06 Mild Steel Pipework Fittings

All screwed tees, elbows and fittings for use with standard steel pipes shall be to BS 1387 ‘Heavy’ grade. Ends shall be provided with screwed taper threads to BS 21.

Malleable cast iron pipe fittings shall be to BS 143 and 1256, manufactured by the Whithart process to Grade 1 of BS 309, banded or beaded for reinforcement.

Wrought steel pipe fittings shall be manufactured from mild steel by a seamless or welded process to BS 1740, ‘Heavy’ grade.

The screwed ends of the fittings shall be provided with parallel female and taper male threads to BS 21, the axis of threads being coincident with the true axis of the


fittings. Where specified, threaded fittings shall be provided and shall be in accordance with BS143.

Unions shall be manufactured with double gunmetal seats as the ‘Navy’ pattern, and must be accessible when positioned enabling the joints to be disconnected and sprung apart.

All welding fittings shall be to BS 1965: Part 1 for steel tube to BS 1387 and be manufactured by a forged seamless process from mild steel ‘Heavy’ grade.

All bends where practicable shall be formed in the pipe run (i.e. made bends). Where standard welded fittings are used they shall be of the same quality as the pipe and shall conform to BS 1965: Part 1.

Bends shall be 90º long radius type unless space for pipework is restricted in which case the short radius welding elbow may be used, subject to approval.

For all changes in direction, the ratio of the centre line radius to the pipe bore shall be not less than 1.5 to 1.

Where bends and springs are formed on site, then cold bending by a hydraulically operated machine will be permitted for standard steel pipes have bore of 50mm and less but larger pipes shall be bent hot. All bends shall be normalised by heat treatment after manipulation.

Sets, double sets and springs shall be formed from single lengths of tube with as large a radius as possible and shall be free from distortion with the cross sectional diameter remaining true.

Branch welding fittings shall be used where the branch is 25mm diameter and above. From branch sizes below 25mm the sweep may be formed from pipework provided that junction does not restrict the branch diameter. Where junctions to steel mains are formed by factory or site welding, such work shall be carried out to confirm to BS 806. All branch tees where possible shall be formed by the use of special welded fittings of the same quality as the pipe and shall conform to BS 1965: Part 1.

Where branch bends are used in lieu of manufactured tees, the profile of the hole shall be removed from the main before the branch is welded into position. Branch ends may only be used where the branch is two or more sizes below the line size. The distance between the centres of two adjacent branch welds shall not be less than twice the diameter of the large branch.


Where practicable, all fittings shall be of the easy sweep type. Branches shall be made using swept tees or branch bends except where an air lock is liable to form, i.e. tees on rising mains etc. where square tee shall be used.

Reduction in the line size of any pipework run shall be made using reducing sockets, not bushes.

Reducing fittings on horizontal pipework shall be of the eccentric pattern fixed so as to give a smooth run to the crown of the pipe. Concentric pattern reducers shall be used on vertical pipework.

3.07 Screwed Joints

Screwed joints on steel pipework shall be in accordance with BS 21.

All steel pipe having screwed joints shall be carefully reamed out before the plain end is screwed.

When making a joint the screw thread shall be coated with a white compound to BS 5292 and hemp, all surplus jointing compounds being finally cleaned off to leave a surface suitable for painting. The joints shall be arranged so that on completion two or three threads are left showing.

Should a screwed joint prove defective under subsequent test, the section of pipework in question shall be removed and made good. Caulking will not be permitted.

3.08 Welded Joints

Steel pipe having welded joints shall be prepared for jointing in a manner suitable for the technique employed. Welds shall be carried out in accordance with BS 2971 for metal arc-welded joints and BS 2640 for oxyacetylene welded joints.

Pipes shall be prepared for welding with ends sawn or cut off by hand or with flame cut by machine or flame cut by hand with subsequent truing up by filing or grinding to a level of 37.5° as may be required. Welding rods shall in all cases be of good quality copper coated low carbon steel and the manufacturers shall provide test certificates representative of the rods used.

Welding shall in all cases be carried out by skilled craftsmen who are in possession of a current certificate of competency issued by an approved authority (which shall be produced upon request) before any work proceeds. Welding operatives shall have a suitable period of experience for the class of work in which they are engaged.


Where several welders are employed then each welder shall be assigned a reference, which shall be stamped on each weld, and when the general hydraulic tests of the completed system are carried out, as detailed elsewhere, each weld shall be lightly hammered during the time that pressure is maintained. If any leaks occur at welds the portion of the weld near the leak shall not be repaired by caulking or attempted fusion of the surrounding metal. Should a considerable portion of the welded joints made by a particular operator be found to be defective due to faulty workmanship, all such welds shall be cut out and re-welded by another operator whose work has proved satisfactory.

During the progress of the works, inspections will be made to ensure the quality of welding. The right is reserved to instruct the cutting open of a small percentage of pipework welded joints and to have these parts laboratory tested. If the test and inspection should prove that the welds are to the required standard, the Employer will pay the costs incurred in the removing, testing and replacing the sections of pipework. If however, the inspection and test show that the welds are below the class of workmanship for this class of work, or if they are found to be faulty in any respect, no cost or fees incurred by the tests shall be borne by the Employer.

If the above result suggests that the standard of workmanship on the whole of the rest of the welded work is below that required, then the right is reserved to instruct the removal of the remainder of the welded sections to conform to this Specification. In this case, no claim for the costs involved in removing and renewing these sections of the works shall be allowed, whether such welds are found to be faulty or not. For all welding and cutting operations, each welder shall be accompanied by a competent assistant equipped with suitable fire resistant mats shall be used to protect the building fabric and decorations. Every precaution shall be taken to prevent damage by scorching or fire and two portable fire extinguishers shall be proved for use by the welders in an emergency.

On completion of cutting or welding operations, all scale thus formed shall be removed from all surfaces as the work proceeds and all welded joints including internal faces, i.e. flange joints, shall be painted two coats of red lead oxide immediately on completion of the joint.

Inspection of all welding on site and/or at manufacturers’ works and the witness of all hydraulic tests shall be made by the Client’s Insurance Company and the payment of all inspection fees shall be included.

All welding shall comply in every respect with the standards required by the Client’s Insurers and the operatives shall carry out test welds if requested by the Client’s Insurers.


3.09 Flanged Joints

As required by previous tables, the appropriate steel pipes shall have flanged joints to BS 4504: Part 1 and shall be prepared to suit the method of attachment required. Flange pressure ratings shall be to the minimum set out in Clause 3.5 and to suit the particular pipeline fitting or equipment.

Pipes not galvanised shall be provided with flanges screwed or welded on for nominal bores of 50mm and below with flanges welded on for larger sizes. Galvanised pipes shall be provided with galvanised flanges screwed for nominal bores of 100mm. and below, and with flanges welded on prior to galvanising the pipe for larger sizes, or where specified for all sizes galvanised after manufacture.

Where flanges are secured by screwing, the threads on the tube shall be arranged to be just hidden by the back of the flange and so as not to interfere with the joint. After the flange has been screwed on, the tube shall be expanded into the flange by a roller expander.

All welded flanges shall be of the slip-on pattern. The pipe end shall finish 3mm behind the machined face and welded at both this part and at the rear neck of the flange. Appropriate care shall be taken not to distort the machined face.

Flanges shall be joined with 1.6mm ‘full faced’ Klingerite gasket with bolts, nuts and washers of hexagon type. Bolts for BS 4504 flanges shall be to BS 4190. 400 N/mm² minimum tensile strength. The gaskets will have graphite finish and no jointing paste will be used. All flange bolts shall protrude an equal distance through the flange of approximately two threads clear of the nut.

Where appropriate copper pipework shall have flanged joints to BS 4504: Part 2 bronze welded to BS 1724.

3.10 Copper Pipework Joints

For capillary fittings, care shall be taken to ensure that the solder used is suitable for the temperature range at which it is anticipated the system will operate and that the solder is lead free.

All jointing materials shall be manufactured from non-dezincifiable materials.

All jointing of copper tubes shall be strictly in accordance with the fitting manufacturer’s recommendations.

Excess solder and solder droppings shall be removed on completion of the joint. In particular detailed attention shall be given to removing surplus flux on completion of


the joints. During all jointing operations using capillary welded and brazing fittings, the fitter/plumber shall be accompanied by a competent assistant and suitable fireproof mats shall be used to protect the building fabric and decoration. Every precaution shall be taken to prevent damage by scorching or fire and two portable fire extinguishers shall be provided for use by the fitters/plumbers in an emergency.

All fittings and jointing materials shall be suitable for the temperature and pressure of the system. Brazing and bronze welding shall be carried out in accordance with BS 1723, BS 1724 and the Code of Practice for Brazing and Bronze Welding Copper Pipework issued by the HVCA.

Where chemical injection is employed for water treatment or for chemical cleaning the system when commissioning, then the manufacturers recommendations for materials and jointing shall be sought and adhered to.

3.11 Fitting for Copper Pipework

All capillary and compression fittings shall be to BS 864: Part 2. Fittings shall be manufactured from non-dezincifiable materials. Fittings not complying with this standard shall be replaced without cost to the Employer.

Where pipework is on view, then bends shall be formed from proprietary manufacturer’s fittings, pulled bends shall not be permitted. Similarly branch connections shall be purpose made tees either square or sweep to suit the application.

For situations where pipework is not on view, then light gauge copper tubes may be pulled on site to form bends and off-sets, the materials used shall be as for adjacent straight lengths. Tubes have nominal bores up to 28mm may be bent cold but larger sizes shall be annealed before manipulation.

Where pull bends are permissible tubes shall be loaded prior to bending with springs, low melting point alloys or inert sand, care being taken that contamination of the tube material is avoided. Where bending machines are used these shall have smooth clean guides and formers and scored or damaged tools being rejected. Pulled bends with any deformity whatsoever resulting in the forming of the bend will not be accepted.

Where it is intended to use compression fittings on underground pipework, this shall only be allowed following prior approval and the fittings shall be of the type 'B' pattern.

Unions shall be manufactured from gunmetal and shall be in accordance with BS 864: Part 2.


3.12 Support and Fixings

Pipework shall be properly supported with secure brackets and must permit, where required, adequate free and/or guided movement due to the operating conditions applicable.

Detailed drawings/illustrations of all bracket arrangements shall be submitted to the Engineer for approval before commencement of manufacture. Pre-fabricated brackets, anchor points, guides and clamps shall conform generally to the details in BS 3974: Parts 1 and 2.

Particular attention shall be made to the design and method of supports and brackets for pipework and associated equipment with due consideration being given to the incorporation of expansion devices, guides and anchors.

Particular attention shall be given to the co-ordination of adjacent pipework and separate or combination bracketry. Full information shall also be obtained concerning other services, plant and the structure of the building necessary for proper co-ordination. No extra costs will be allowed for altering pipework, which may be necessitated by non-observance of this clause.

Full and proper care shall be exercised in the positioning and marking out of all brackets and supports. Brackets and supports shall be set out so that they do not obstruct the access to valves, flanges or fittings requiring maintenance.

The support of pipework systems from each other shall not generally be permitted without the express authority. Brackets shall be installed so as not to prevent the removal of any individual pipe where necessary and provision shall be made for unequal expansion where applicable.

Pipes shall not be supported from any items of plant or equipment.

All pipes exposed to view and generally routed around rooms at floor level shall be supported on school board pattern long shank build-in or screw-on brackets.

Pipe brackets on exposed copper pipework shall be of the cast brass type. Under no circumstances will brass strip or copper strip type brackets be acceptable.

Brackets on insulated pipework, incorporating a vapour seal shall be fitted with spacers and sleeves at the time of installation of the brackets using an approved material between the bracket and pipe surface to achieve satisfactory vapour sealing. Materials for supporting and fixing the various items of piping, tubing etc., are detailed elsewhere in this specification.


It shall however, be a firm principle of all fixing that the contact of dissimilar metals must be avoided and to this end steel piping shall have steel supporting members actually in contact with the pipe, galvanised piping shall have galvanised contacts and copper tubing shall be carried exclusively from contact members constructed from copper alloy, or where mild steel clamp saddles are used, a suitable lining interposed. All spring washers, shakeproof items, lock nuts etc., shall be included.

Pipework subject to expansion that will cause distortion of hanger type brackets shall be supported using chain and roller brackets. Build-in type brackets shall only be used where satisfactory fastening cannot be attained using surface-fastening techniques. It shall be ensured that the building-in of brackets is carried out correctly.

Building structural steelwork or timber members shall not be drilled either for the passage of pipes or for the attachment of brackets, nor shall steelwork be welded to, without written permission.

All fastenings and fixings to the constructional and fabric elements of the building shall be included. In all positions throughout the building all necessary supports and brackets complete with all bolts, screws and insert or plug fastenings shall be provided. Softwood plugs will not be permitted. All methods of fixing and fastening shall be purpose designed and submitted to the Engineer for comment prior to manufacture.

For pre-cast, pre-stressed and hollow floor constructions, metal plate and rod hanger supports with associated drilling of the structure and secondary spanning steelwork shall be employed subject to written approval.

For hollow wall construction and light partitions, fixing of the spring clip or toggle type shall be used. On extremely light partitions the pipes may be supported from the floor, but approval must be obtained.

Where pipes pass through structural walls and partitions via sleeves, then these sleeves shall not be considered as supports.

Within an undercroft, pipework shall be supported on a Unistrut support system as indicatively shown on the drawings. The Unistrut primary support system shall be fixed to Unistrut inserts built into the RC slab soffit and walls throughout the undercroft. The Mechanical Sub-Contractor shall provide a detailed setting out drawing of the Unistrut support system for comment by the Engineer prior to installation of the inserts by the Main Contractor. The inserts shall be provided by the Mechanical Sub-Contractor for building in by the Main Contractor to the detailed setting out drawing. The Sub-Contractor shall ensure the programme for information release for the insert setting out is in accordance with Main Contractor’s


programme for casting the walls and the RC slab soffit. The Unistrut support system shall be post galvanised and the vertical supports shall have plastic inserts or feet where in contact with floor to avoid corrosive attack.

The following table provides information to determine pipe support for steel and copper pipework systems.

Copper Pipework Support Centres Steel Pipework Support CentresDiameter Horizontal Vertical Diameter Horizontal Vertical(mm) (m) (m) (mm) (m) (m)15 1.5 2.0 15 2.0 2.5

22 1.5 2.0 20 2.5 2.5

28 1.5 2.0 25 2.5 3.0

35 1.5 2.0 32 2.5 3.0

42 2.0 2.5 40 3.0 3.5

54 2.0 2.5 50 3.5 3.5

67 2.0 2.5 65 3.5 4.0

76 2.5 2.5 80 3.5 4.0

108 2.5 3.0 100 4.0 4.5

150 4.5 5.0

For all copper pipework above 108mm. Diameter the supportcentres shall not exceed 3.0metres.

Notwithstanding the information given above supports shall be positioned in consideration of the position of joints for dismantling purposes such that the adjoining pipework shall remain adequately supported. Supports shall also be positioned adjacent to valves, flanges and other pipe fitments that require maintenance, and at each change in direction.

Vertical pipework shall be suitably supported at the base of the riser and at all intermediate levels and at centres indicated on the above table. Branch circuit pipes shall not be used as a means of support for the riser main.


Written acceptance must be obtained of the type of brackets proposed prior to commencing manufacture of any brackets.

Pre-fabricated brackets, anchor points, guides and clamps shall conform generally to the details in BS 3974: Part 1 and Part 2.

3.13 Cover Plates

Pipes and tubes passing through walls, floors, ceilings, partitions and false ceilings of occupied rooms such that the entry/exit is exposed to view shall be fitted with a white plastic cover plate, neatly installed and secured and as manufactured by Brefco or equal and approved. Such plates shall be split on the diameter, be snug fit to the pipe concerned and provided with securing clip or screws.

3.14 Expansion and Contraction

Proposed methods of providing for expansion and contraction of pipework systems shall be submitted to the Engineer for comment prior to commencement of installation.

Whether shown on the drawings or not provision shall be made to install expansion loops formed in the pipe runs by means of long radius welded bends to the required dimension. The loops shall be formed in the mains with flanges and each leg of the loop shall be pulled cold to approximately 50% of the estimated expansion of the leg.

Expansion bellows and joints shall be installed in the pipework as an alternative or addition to expansion loops with prior permission of the Engineer. They shall be installed in accordance with BS 6129: Part 1.

Expansion bellows incorporating flanges shall be installed such that their bolt centres truly align with the adjacent pipe flange bolt centres thereby avoiding twisting stresses within the bellows.

All bellows shall be installed with due allowance having been made for cold draw which will vary according to the type and length of bellow proposed and the temperature and installation. Where ‘installation bars’ or fittings are incorporated with the bellows during delivery and erection these must be removed before heat is applied.

The full expansion rate of the bellows and/or loop shall be as indicated on the drawings or in the Specification.


A minimum of two guide sleeves shall be fitted on each side of the expansion joint unless such joint be installed adjacent to an anchor point where guides shall be fitted on the free side only.

Guides shall consist of sleeves or framework rigidly fixed but permitting axial pipe movement while restraining the pipe from the radial movement. Guides shall have a clearance of not more than 3mm between the outer surface of the pipe and the inner surface of the guide and shall be to the following lengths:-

________________________________________

Pipe Size Length________________________________________

Up to 35mm diameter 75mm

42mm to 158mm diameter 150mm

59mm diameter and over 250mm

Guides shall be installed not more than four pipe diameters from the expansion joint to the first guide and not more than fourteen pipe diameters between this guide and the next.

When installing manufactured expansion loops or bellows joints, the manufacturer’s installation recommendations shall be observed in every respect.

When bellows are employed within a system to be pressure tested, then the manufacturer’s recommendations relating to maximum pressure shall be observed and taken into account.

Provision for expansion and contraction of pipework shall be made of changes in direction and it shall be ensured that sufficient allowance is made for this.

Branch connections shall be installed with consideration of movement of the main service due to expansion and contraction.

3.15 Anchor Points

As required, mild steel anchors shall be installed to resist the maximum stresses of the pipework. The anchor points shall be fixed to heavy steelwork or main brick walls only in an acceptable manner. The anchors shall consist of heavy section iron ‘U’ straps welded to the pipework and attached to the supports by nuts and bolts.


Where fixed to brickwork short channel irons shall be attached to the wall to obtain a fixing for the ‘U’ straps.

Detail of all anchors together with loading and associated builders work shall be submitted for comment before manufacture.

All cleats, brackets and steelwork required for building-in shall be provided as necessary.

3.16 Pipe Sleeves

In those cases where pipes pass through structural walls, floors, ceilings and footings, sleeves shall be provided and these shall be installed in a permanent arrangement within the structure. Sleeves shall in no cases be used as pipe supports, a free equidistant space always being provided. Puddle flanges shall be provided on pipework passing through walls and intended to be covered by earth etc., or where passing through bund walls. Sleeves shall be of pipe cuttings properly reamed, cleaned and trimmed at 90° to bore.

Sleeves in load-bearing walls or footings shall be cast iron pipe. Sleeves in non-load bearing walls, floors, ceiling and partitions shall be in copper or mild steel or high impact plastic appropriate to the particular pipe material.

Pipework, sleeves and fire-stopping shall be installed to meet the requirements of the current Building Regulations, to the approval of the building Inspector and Local Fire Officer.

Inside diameter of sleeves shall be not less than 12mm larger than the outside diameter of the pipe, except where pipes pass through load-bearing walls or footings where sleeves shall be 100mm larger than the outside diameter of the pipe.

The space between the pipe enclosed and its sleeve shall be caulked with fire stop and intumescent mastic seal on each side of the sleeve. Alternatively a proprietary sealing system shall be used which has been shown by test to maintain the fire resistance of the structure and which has been approved by the Building Inspector.

Flashing sleeves shall be provided as required except where indicated otherwise. They shall incorporate an integral flange to which a flashing shield can be clamped or welded. The shield will be built into the membranes and the space between the sleeve and pipe shall be filled with mineral wool fire stopping and finished externally with intumescent mastic compound.


Sleeves shall normally be finished flush with the faces of the structure through which they penetrate, the exception being where it is necessary to avoid water spillage draining through a sleeve to the space below. In this case a projection of 150mm is required.

Cold water pipework shall be provided with sleeves of sufficient bore so as to allow both thermal insulation and vapour seal to be maintained and pass through the bore without restriction.

3.17 Vibration Isolation and Noise Insulation of Pipework Installations

All dynamic machinery shall be isolated from the building structure by vibration isolators, which shall be purpose designed and selected to suit the machinery. Pipework connections to the machinery shall likewise incorporate purpose designed vibration isolations. Pipework shall generally be supported independent of machinery.

Vibration isolators shall be of an approved type and manufacture, and installed strictly in accordance with the manufacturer’s recommendations.

Pipework vibration compensators shall be as manufactured by Design Support Technology or equal and approved, and installed strictly in accordance with the manufacturer’s recommendations. All compensators shall be installed in accordance with BS 6129: Part 1 and shall be suitable for the pressure, temperature and fluid type being conveyed within the pipework system. Due consideration must be given to the internal pressure, and expansion and contraction of the pipework installation. Compensators shall be provided with correct mating and backing flanges and tie bolts. Compensators shall not be used to take up discrepancies in the alignment of pipework connections.

Noise and vibration level information, based upon octave band analysis, shall be submitted for all items of plant and equipment.

Supports for pipework shall include suitable isolators to limit transmission of vibration to the building structure.

3.18 Air Venting of Pipework

Full provisions shall be made for air venting of the systems, whether or not shown on the drawings.

Exposed air bottles, automatic vents and drip pipes where required shall be properly insulated to a standard matching the adjacent pipework.


Air vents shall be provided at all high points within the pipework system they are intended to vent.

Air bottles on pipework up to and including 80mm bore shall be manufactured from 50mm diameter pipe, 100mm diameter and over from 100mm diameter pipe. All shall be 250mm long with welded end caps and be complete with 8mm copper pipe brought down from the top of the air bottle to within reach of the appropriate floor levels and fitted with 8mm lockshield needle valve complete with key. The final vertical piece of vent pipework will be kept as short as possible.

All automatic air vents shall be installed where required or shown on the design drawings and shall have gunmetal bodies with not less than 15mm connections, copper or stainless steel floats, guides and non-corrodible needle valves. In all cases the air vent shall be protected by a lockshield pattern stop valve and the discharge from the air vent shall be 12mm copper pipe, which shall be run to discharge externally or over an agreed gulley, sump or other convenient position. Automatic air vents shall be complete with check valves to prevent air ingress to the system.

3.19 System Drain Down Requirements

Drain points shall be provided on all items of plant and equipment, at all low points of water services installations and also on the branch side of all main isolating valves and cocks whether or not shown on the drawings.

Drain points shall be fitted with a drain cock of gunmetal construction manufactured to the requirements of BS 2879: Table A complete with hose union and removable key.

Plant equipment or components supplied within the terms of the contract which are fitted with condensate trays, drains, overflows or discharge collection points, shall be provided with suitable drain pipes extended to the nearest gulley or drain, by an approved route. Condensate drip trays shall be provided with water seal trap of depth not less than twice the duct static pressure, on the outlet prior to the tundish. All drains which discharge into drainage pipe or stack shall be provided with an air break between the discharge from the equipment and an open tundish. The discharge from the tundish shall be trapped prior to entry into the drainage system.

3.20 Venting And Drainage, Pipe Gradients

Pipework systems shall be installed with continuous gradients to allow for air venting and/or drain down according to the service concerned. Gradients shall be


continuous over the entire length of the horizontal pipework to the following ‘fall’ ratio:-

Low temperature hot water/(Mains) 1mm in 240mmChilled water/condenser water

Hot and cold domestic water 1mm in 200mm

3.21 Dirt Pockets

Dirt pockets shall be installed at the base of all pipework risers. Dirt pockets shall be constructed as a full bore continuations of the riser being not less than 300mm long with gate valve and drain cock per permit flushing. Whilst dirt pockets shall be full pipe bore, the maximum size of gate valve shall be 50mm.

3.22 Protective Painting And Coverings

All ferrous material shall be primed where possible prior to installation and touched up insitu to the satisfaction of the Engineer. Associated brackets and supports may be primed before despatch to site but in any case must be primed before fixing of any structure. Materials to be primed shall first be thoroughly cleaned from scale, rust, dirt and grease etc. before applying one coat of heavy duty brushing quality zinc phosphate primer to an average dry coat thickness of 0.05mm.

In the case of galvanised pipework and fittings an etch primer shall be applied prior to the zinc phosphate primer.

Any damage received to a primed surface shall be made good by cleaning down to bare metal by wire brushing and painted with two coats of zinc phosphate primer. The whole steelwork installation shall then be painted with one further coat of zinc phosphate primer.

Primer shall be stored and applied strictly in accordance with the manufacturer’s instructions. All painting shall be carried out only on completely dry surfaces and the paintwork shall be left in sound condition.

3.23 Gas Equipment and Pipework

Gas pipework, equipment and systems shall comply fully with British Standard code of Practice CP 331: Part 3, BS 6400, the British gas Safety (Installation and Use) Regulations, the Gas Act 1972 and British Gas Publications and Specifications, in particular IM/16.


In the instance of this specification differing from the British Gas recommendations the higher standard shall be applied.

Any room containing gas equipment shall be ventilated in accordance with the requirements of British Gas and the relevant Local Authorities.

Gas distribution pipework within the building shall be fire protected and the space around ventilated to atmosphere to the satisfaction of the British Gas and the relevant Local Authorities.

All necessary vent pipework to items of gas equipment (i.e. meters, gas boosters etc.,) to vent the gas to atmosphere at high level away from opening windows and escape routes etc. shall be provided in order to conform to the recommendations of British Gas.

The installation of any anti-flame device to the termination points on vents shall also be included in order to comply with the requirements of British Gas and the Area Gas Authority.

3.24 Valves, Cocks, Strainers and Vents

3.24.1 General

The design intent drawings are generally indicative of the valves etc., required for a given system but in addition to intent those shown on the drawings sufficient valves and strainers shall be provided, as detailed below, to ensure that the following facilities will be available.

Regulations of low pressure, hot water means of commissioning valve sets. Isolation of low temperature hot water by gates valves.

Isolation and regulation of hot and cold water services by sluice valves on sizes 65mm and above and by gate valves for sizes up to and including 50mm for main service runs. Isolation and regulation shall be provided for ‘dead legs’ or final connection to each individual fitting on both hot and cold water services by a copper to copper servicing valve.

Isolation of gas services by gas cocks, ball valves and butterfly valves.

Isolation of oil service by gate valves.

Isolation of pressure of altitude gauges by gauge cocks.


Draining of system by plug cocks and hose unions.

Non-return valves shall be fitted where plant must operate on an automatic changeover basis or where flow reversal is to be avoided.

Valves and stopcocks shall be installed using mating flanges or screwed fittings, as applicable, manufactured from compatible non-corrosive materials to ensure that no electrolytic action occurs.

Flanged valves shall have flanges and mating flanges manufactured in accordance with BS 4504.

The following schedules and accompanying statements provide details of valves, strainers and stopcocks. Valve, stopcocks and other fittings used on a particular service shall be suitable for the temperatures, working pressures and for the nature of the fluid carried by the service.

Valves, strainers and stopcocks shall be as manufactured by the company, stated under each section, or equal and approved.

The various types of valves shall be, as far as is practicable, of the same manufacture and type to provide uniformity of appearance and to simplify maintenance.

3.24.2 Isolation Valves (LPHW)

Screwed gunmetal gate valves for sizes 15mm. to 50mm. and flanged cast iron gate valves for sizes 65mm. and above as follows:-

Maximum temperature 95°CMaximum pressure (gauge) 6 Bar

Size (mm) Type Class Manufacture Fig. No.15-50 Wedge Gate PN20

PN20PN20

CraneHNH TA

D15133X64

65-300 Wedge Gate PN16 PN16 PN16

CraneHNH TA

FM52M549S1500

Isolation Valves (LPHW)

Screwed bronzed ball valves for size 15mm. to 50mm. and cast iron butterfly valves size 65mm. and above as follows:-



Size (mm) Type Class Manufacture Fig. No.15-50 Ball PN20

PN25PN25

CraneHNH TA

D171 500100

65-300 Butterfly PN16 PN16 PN16

CraneHNH TA

F71435 940

3.24.3 Regulation Valve (LPHW)

Regulation of LPHW circuits shall be by means of commissioning valve sets.

Regulating valves and commissioning sets shall be fitted with Binder Twinlock test plugs.

Maximum temperature 95°C

Maximum pressure (gauge) 6Bar

Size (mm) Type Class Manufacture Fig. No.15-50 DRV PN20

PN20PN20

CraneHNH TA

D920 Series B CV1432/1332MD20

65-300 DRV PN16 PN16 PN16

CraneHNH TA

DM920 M733DR MDF2

15-50 Commissioning Set

PN20PN20PN20

CraneHNH TA

D941 SeriesB CV2432 MD41

65-300 Commissioning Set

PN16 PN16 PN16

CraneHNH TA

DMM940 CVM2733 MDF4


3.24.4 Chilled and Condenser Water Services

Specification as for LPHW as applicable for pressure condition.

3.24.5 Hot Water Service

Isolation on ‘dead legs’ or final connection to each individual fitting by service valves. Isolation and regulation of main service runs and in plant rooms by gate valves. Regulation valves shall be lockshield pattern.

Size (mm) Type Class Manufacture Fig. No.15-80 Wedge

GateSeries B PN20PN20

CraneHNH TA

D15133X64

100-300 Wedge Gate

PN16 PN16 PN16

CraneHNH TA

FM63 M5411750

15-54 Servicing Valve Ball Valve T Handle

Copper X Copper Copper X Copper

HNH

Ballofix

100CT

3.24.6 Cold Water Service

Specification up to and including 54mm as for Hot Water Service except that stopcocks in MCWS shall have loose jumper.

Size (mm) Type Class Manufacture Fig. No.65-300 CWS

(Sluice) BS 5163

PN16 PN16 PN16

PN16

CraneCraneHNH

TA

FM124(H/W)FM125(CAP)27 M599 Metal Seat and M589 Resilient Seat1201

3.24.7 Non Return Valves

Size (mm) Type Class Manufacture Fig. No.


15-50 All PN25 PN25 PN25

CraneHNH TA

D1384727

65-300 All PN16 PN16 PN16

CraneHNH TA

FM492 M651250

3.24.8 Gas Service

Gas Cocks, ball or butterfly valves as follows:-

Size (mm) Type Class Manufacture Fig. No.15-22 Cock Y.I.M. Ltd 20625-50 Ball PN16

PN16 PN25

Crane TA HNH

D195 ISICHR 100GBA


Crane TA HNH

P6ll32941


Crane TA HNH

F61232G 941G


Audco TA HNH

IBW32/32G970G

200-300 Butterfly valves shall be gear operated.

3.24.9 Oil Service

Size (mm) Type Class Manufacture Fig. No.15-100 Gate PN20

PN20 PN20

Crane HNH TA

D15133X64

Valves used on oil service shall have special packing, lubricants and be air tested to twice working pressure.

3.24.10 Drain Cocks


Drain cocks on pipework and equipment shall be as follows:-


Gland cocks shall only be used on closed circuits, to

the approval of the Local Water Authority.

3.24.11 Automatic Air Vents

Size (mm) Location Manufacture

Fig. No.

15 Screwed LPHW 7 Bar to 93C

Charles Winn

C2

3.24.12 Radiator Valves

Each radiator shall be installed complete with chromium plated lockshield valve and a chromium plated hand wheel isolation valve or thermostatic radiator valve as shown on the drawings.

The thermostatic radiator valves shall be as described elsewhere in this specification. The lockshield valves and isolation valves shall be as follows: -



Size (mm) Location Manufacture

Fig. No.

15-25 Pipework CraneHNH TA

D340371471

15-50 Dirt Pockets (see 3.21)

CraneHNH TA

D344 81HU 18HU

15-50 Equipment CraneHNH TA

D344 81HU 18HU

3.24.13 Ball valves

3.25 Valve Labels

Labels shall be supplied, and securely attached to the valves, which shall identify the valves in accordance with the valve schedules of numbers and operation, in plant rooms, ceiling voids and ducts.

3.26 Safety Valves and Boiler Fittings

Unless indicated elsewhere in equipment specification, all safety valves shall be as NABIC or equal and approved. Figure No. 42, to the size and set to discharge at the


Size (mm) Manufacture Fig. No.15-25 H W Straight

CraneHNH TA

D890CP 2407CP RVO Straight

15-25 H W Angle

CraneHNH TA

D880CP 2386CP RVO Angle

15-25 L S Straight

CraneHNH TA

D891CP 2407CPLS RVO/LS/ST

15-25 L S Angle

CraneHNH TA

D881CP 2386CPLS RVO F Angle

All Size (mm)

Description Manufacture.

15-50 Equilibrium type, BS1212 to suit mains pressurecomplete with copper ball

Charles Winn Ltd

65-300 Equilibrium Type Guest & Chrimes15 AI

25-50 Equilibrium type screwed

HNN Fig. 340

65-150 Equilibrium type flanged

HNH Fig.337

pressures indicated on the drawings. The valves and boiler fittings shall be provided in accordance with BS 759, BS 779, BS 853, BS 855, BS 1123, BS 5500 and BS 6759.

Safety valves for boilers, heating calorifiers and all pressure vessels shall be provided irrespective of whether shown on the drawings or not.

3.27 Strainers

These shall be of Spirax-Sarco Ltd, Crane or HNH manufacture, or equal and approved. Strainers shall be line size or as detailed on the drawings with a suitable and approved mesh size/performance. Strainers shall be suitable for the working pressure of the system to which they are installed.

Strainers shall be flanged on sizes of 65mm and over and shall be provided with drain facilities in the clean-out connection at the bottom of the body construction. Strainers shall be fitted with isolating valves upstream and downstream to facilitate maintenance.

3.28 Test Points, Gauges and Thermostat Pockets

Boilers shall have a minimum of a flow temperature gauge, a return temperature gauge and a pressure gauge. Storage water/water heat exchangers shall have flow and return temperature gauges on both primary and secondary sides with one pressure gauge on the secondary side.

Circulating pump shall have pressure gauges on both suction and delivery connections.

Each main branch circuit leaving a heat generator or heat exchanger plant room shall be fitted with a temperature gauge and pressure gauge on the flow and a Binder Twinlock test plug on the flow and return.

All temperature gauges shall comply with BS 5235, dial type mercury in steel, and shall be polished with removable brass pockets filled with conductive gel.

All pressure gauges shall comply with BS 1780: Part 2 and shall be complete with siphons and gauge cocks and shall have 10mm. connections. Siphons shall be of the same material as the pipework.

All capillary tubes to remote gauges shall be supported upon their entire length, including the final connection to the equipment, on PVC coated tray.


In order that the installations may be accurately balances and set to work, test plug points for temperatures and pressure tests shall be provided on flow and return connections to all items of equipment and around mixing valves.

Test plug points shall consist of connections made into the pipework and fitted with a Binder Twinlock test plug (Binder test points shall not be used on high pressure systems or steam). The test plugs shall be extended to the surface of any insulation applied to the pipework.

Temperature test pockets shall be located and be of sufficient depth as to ensure a true reading of the fluid temperature. Where the pipework size is below 42mm the pipework accommodating the test pockets shall be increased locally to 50mm so as not to affect the flow rate and response of the gauge/thermostat. Pockets shall be filled with mineral oil and the thermometers fixed so that the tails are truly subjected to the temperature of the fluid to be measured.

Except where gauges form part of a ‘packaged unit’ they shall be no less than 100mm diameter for mounting heights up to two metres from floor level and 150mm diameter above two metres.

The gauges and ancillaries shall be manufactured by Brannan Thermometers Ltd, or equal and approved, to the following reference numbers:-

Thermometers Vertical PatternAngle Pattern

Series 020 or 050 Series 935 or 065

Pressure Gauges Vertical Pattern Fig. No. 37-62 or37-92.

Siphons Vertical Ring

Angle ‘U’ Pattern

Fig. No. 39-015 or 39-017.Fig. No. 39-011 or

39-013Cocks Female Ends Fig. No. 39-001

3.29 Water Meters

Water meters shall be installed where specifically called for on the drawings/detailed Specification. Water meters shall provide a digital record of the total water flow (total m³) to pass through the meter to an accuracy of not less than +/- 2% and shall also be of a suitable pattern and size to pass the maximum design flow rate (m³/h).

Where the design maximum flow rate is less than 10m³/hr. then the meter shall be selected from the Kent PSM-T Pulse Unit range with the bore size in keeping with the maximum flow rate at a head loss of 3 metres water gauge. Floor flow rates


above 10m³/hr. then meters shall be selected from the Kent Helix 3000 PU10 Pulse Unit range in association with the recommended head loss at a continuous flow.

Type PSM-T water meters shall be complete with disc type non-return valves and connectors suitable for the pipeline material in which the meter is to be installed. Pulse output shall be supplied suitable for a Building Management System as specified elsewhere.

Type Helix 3000 shall be installed complete with Kent type H.S. strainer and isolation valves and suitable for remote readout by a Building Management System as specified elsewhere.

3.30 Fire Hydrants

Fire hydrants shall be to BS 750 type 2 hydrant. The hydrant shall have a cast iron body with bronze screw down valve. Inlet flange to be 80mm NP16 flange. Outlet connection 2½” BS round thread male and complete with drain connection from the body.


SECTION FOUR

DUCTWORK INSTALLATION


4.0 Ductwork Installation

4.01 General

The ductwork services installation shall follow the detail set out in the Form of Contract and accompanying documents including the design drawings. Ductwork installations and construction requirements shall be in accordance with the recommendations of the Heating and Ventilation Contractor’s Association publication of the following reference/title.

Sheet Metal Ductwork

DW/144Specification for Sheet Metal Ductwork Low, Medium and High Pressure/Velocity Air System.

DW142Specification for Sheet Metal Ductwork, Flat Oval low velocity sections only.

Plastic Ductwork

DW/151Specification for Plastic Ductwork.

Including all current amendments and addenda.

A copy of the ductwork specifications DW/144 and DW/151 shall be kept on site and shall be freely open for reference purposes as and when any situation demands.

The work shall be carried out by an Approved Specialist Ductwork Contractor. The Sub-Contractor shall advise the company name of the proposed specialist at Tender Stage. The Sub-Contractor will not be appointed without the provision of this information.

4.02 Installation and Shop Drawings

In all practical situations site dimensions shall be taken prior to the preparation of ductwork fabrication drawings. Before manufacture commences, copies of the fabrication drawings showing full details of fabrication, fittings and method of support shall be submitted for acceptance.

4.03 Standard and Quality of Work


The manufacture of all ductwork shall be to a high standard of construction and quality so as to provide a tidy aerodynamic, leak free installation conforming to the required Specification standards. Workmanship not meeting these requirements will be rejected and replaced at the installer’s expense without jeopardising the Contract Programme.

4.04 Materials

Unless stated otherwise on the design drawings all sheet metal ductwork shall be fabricated from hot-dipped galvanised sheet to BS 2989, Grade Z2, coating type G275. All cut edges and bare metals shall be cold galvanised i.e. coated with zinc-rich paint. The minimum thickness of sheet shall be 0.8mm. Sheet metal ductwork shall comply with DW/144. All square bends shall incorporate aerofoil section turning vanes of a proprietary manufacture, which together with the radius of ducts and splitter configurations shall conform to DW/144 Part 3.

Chemical extract ductwork shall be constructed from PVC ductwork and manufactured in accordance with specification DW/151 produced by the UK HVCA. The ductwork shall be erected by a specialist.

4.05 Circular/Flat Oval Ductwork

Circular and flat oval section sheet metal ductwork shall be spirally wound with branch ducts angled to suit the airflow direction or provided with an angled “throat” for similar purpose. Right-angled take off branches shall not normally be permitted without a practical reason.

4.06 Supports and Brackets

Ductwork and assisted equipment shall be adequately supported on purpose made hangers and/or brackets, and shall be positioned and spaced in relation to other ducts, piped services and to the building structure so as not to interfere with any other services and to allow for the required thickness of insulation.

The restriction on methods of fixing and locations of fixing detailed in Section Three shall be taken into account and shall equally apply to the ductwork services installations.

Under no circumstances shall stranded wire hangers be employed.

Within concealed areas, for sheet metal ductwork a hardwood insulator shall be provided between the support and the ductwork, in accordance with DW/144, Clause 19.6.1, Method 2, including vertical ducts supports.


Bolts, nuts, washers etc, used for support arrangements shall be provided with a non-corrosive finish such as cadmium plating, sheradising or galvanising as appropriate.

Sheet metal ductwork with exposed surfaces and associated metal flanges, brackets, drop rods and other components, whether galvanised or not, shall be primed after erection.

4.07 Joints and Sealants for Sheet Metal Ductwork

All Sheet Metal Ductwork Joints Shall Be Made Such That Joining Surfaces Shall Abut Together Or Overlap Tightly Without Distortion or aid gaps and shall be made air tight using sealing compound applied immediately prior to making the joint. Joints shall be tightened after the sealer is applied and the surplus cleaned off immediately.

Sealant should be of the liquid mastic type which permanently retain adhesion and elasticity throughout a temperature range of 0 degrees to 70 degrees C. The sealant should be applied with a brush or gun and shall completely seal the joint. The ductwork must not be pressurised until the sealant has cured.

The jointing between angle flanges can employ suitable gaskets or mastic sealant. The gasket should not be less than 3mm thick for ducts of up to 1500mm long side or 1250mm diameter, and not less than 4mm thick for larger ducts. Gaskets or sealant shall form a continuous seal between flanges and around the entire perimeter of the duct.

Before application of any sealing method all surfaces shall be thoroughly cleaned.

4.08 Manual Volume Control Dampers (VCD’s)

4.08.1 Location of Dampers

Volume control dampers shall be installed wherever shown on the design drawings and additionally at all branches carrying more than 0.25m³/s and particularly at: -

Main horizontal branch ducts, at the foot of distribution risers.

Branch ducts serving individual large air volume grilles/diffusers or groups of lesservolume grilles/diffusers regardless of volume control dampers forming an integral part of these grilles/diffusers.


Branch ducts serving terminal air conditioning units.

Construction of Dampers

Ductwork containing dampers shall be adequately constructed, true in section, and supported so as to allow damper blades to be adjusted for air volume without binding or jamming.

Manually operated dampers shall be provided with a locking wing nut or similar device enabling the damper blades to be secured in the desired position appropriate to the required air volume flow. The device shall provide a visual indication of the damper blade position.

Dampers shall be positioned within a duct system such that there is a length of straight duct downstream of the damper equivalent to 5 No duct diameters/duct widths. Damper blades when fully open shall be clear of any duct joint, which might impair the damper operation.

Vibration/rattling or similar movement of damper blades within the air stream will not be permitted.

Damper blades for sheet metal ducts shall be constructed of light gauge galvanised plate securely attached to the spindle and supported between bearings attached to the duct face. Bearings shall be of non-ferrous, nylon or full bearing construction positioned exactly central to the desired spindle position.

For plastic ductwork dampers shall be provided in accordance with DW/151 with the blades manufactured in the parent material with the spindles in stainless steel.

Multileaf Dampers

Dampers with single blades shall be appropriate to duct diameters/widths up to 150mm. Thereafter dampers shall be of the multi-leaf type. Multi-leaf damper blades shall be arranged to operate on an opposed blade principle unless required solely for isolation, in which case they may be arranged for parallel operation.

Damper blades shall not exceed 1200mm length and where dampers are required for greater length the damper sections shall be constructed with mullion bars so that the face area of the damper is split into more than one section as necessary. Provision shall be made for linkages to connect the multiple extended spindles and a suitable device indicating the damper position shall be provided on the outside of the damper section.

The dampers shall have double skin stainless steel aerofoil blades, and galvanised sheet steel enclosures suitable for quadrant or automatic operation as applicable.


These dampers shall be as manufactured by Waterloo Ozonair or equal and approved.

4.09 Automatic Control Dampers

Location of Dampers

In addition to those called for on the drawings to control the operation of the plant, automatic dampers shall be provided, operated by temperature sensors, smoke detectors etc, in accordance with the Bye-Laws and Regulations of the Local Authority, Fire Authority and all interested parties.

Construction Of Dampers (Automatic Control)

Duct sections housing dampers shall be rigid, adequately stiffened and supported so as not to distort the damper. Only proprietary automatic control damper sets shall be used, with known flow characteristics, the blades being opposed or parallel operation as required by the Engineer.

The dampers shall be of proprietary manufacture and of known/documented performance characteristics.

Details of the damper characteristics shall be submitted for approval prior to installation.

Control dampers shall be constructed in removable ductwork sections long enough to contain the damper blades when in the full open position.

Construction of dampers shall be to suit the relevant atmospheres being handled as defined herein.

For duct widths wider than 1200mm dampers will be constructed in multiple frames. The blades shall be opposed blade type as described for multi-leaf dampers.

All motor and thruster operating linkages shall be fitted with self-aligning swivel joints having provision for length adjustment.

4.10 Fire Dampers

4.10.1 General


Fire dampers shall be provided wherever ducts penetrate structural walls, floors, partitions etc forming fire barriers and shall meet the required resistance/fire rating and smoke penetration barrier as necessary to meet the requirements of the Building Regulations.

Damper blades when in the open position shall be retained completely clear of the air stream unless otherwise authorised.

Fire dampers shall be complete with installation frames and both fire dampers and installation frames shall comply with the Insurance Company, Fire Officer and Building Control Officer requirements in all respects, and every damper shall be tested and witnessed in operation as warranted by the Authorities concerned.

Fire dampers shall be equipped and suitable for operating with the specified damper release device, i.e. solenoid release, fusible link, frangible bulb, etc.

The approval of the Fire Authority and Building Control Officer shall be obtained for all dampers with sides over 100mm. and for multi-damper assemblies.

All dampers shall operate freely and close securely when released and shall be constructed to the standards of air tightness applying to the system in which they are installed.

All fire dampers shall be of stainless steel construction, all as manufactured by Waterloo Ozonair Ltd, or equal and approved.

Location

Fire dampers should be located within the thickness of the fire barrier. Where this is not possible, the section of ductwork between the damper and fire barrier shall have fire resistance equal to that of the damper itself, and the whole arrangement be installed, and be to the approval of the Fire Authority and Building Control Officer.

Fusible Links

Each fire damper shall be held in the open position by a fusible link (set to release at a temperature of 72°C), and all blades must be tensioned to ensure immediate closure on release of the link. In chlorine laden atmosphere the fire damper shall be held open by a frangible bulb operated mircoswitch.


4.11 Access Openings

4.11.1 General

Access panels shall be purpose made units and shall be rigidly framed and fitted with airtight covers secured with cam-fasteners or similar devices for the quick and easy removal and reinstatement of the panel. Self tapping screws shall not be permitted. Access panels shall be of dimensions to provide an opening in the duct face adequate for the intended purpose as listed below: -

Access for personnel allowing maintenance and replacement of plant items.

Access for routine maintenance, lubrication and adjustment of items not requiring full man access.

Access for inspection of items concealed in ductwork (e.g. automatic and manual dampers, fusible links, orifice plates, thermostats etc) and for cleaning.

Removable Access Covers

Access covers/openings shall be of dimensions appropriate to the size of the item to be inspected/maintained/removed from within the duct and to the size of the duct.

Generally openings shall not be less than 250mm square or as large as the duct will allow. Similarly openings shall not be greater than 400mm square without first having gained the engineer’s approval.

Access openings in the duct shall be adequately reinforced and sufficiently rigid to prevent distortion and accept the cover panels. A suitable sealing gasket shall be secured to the perimeter of the opening or cover panel using a suitable adhesive or similar fixing to obtain an airtight and permanent seal.

Access Openings in Insulated Ducts

Where ducts are to be thermally insulated the access doorframe shall be mounted on a shallow spigot equal to the insulation thickness such that the panel is not obstructed by the insulation and can be easily removed/replaced as necessary. Insulation shall be tidily finished level with the spigot face. The access panel shall be of proprietary type comprising of mineral wool insulation totally encapsulated by two skins of stainless steel. Access panel to be complete with galvanised sheet steel frame and as manufactured by Actionair or equal and approved.

Test Holes for Instruments


Test holes shall be provided wherever requested by the Engineer but normally at the outlets/inlets to major plant items and at major duct branches. After use test holes shall be sealed with suitable neoprene grommets or equal. Thermal insulation shall be cut back and formed neatly around each test hole; the vapour barrier shall remain continuous.

4.12 Vibration and Noise Insulation in Ductwork Installations

All machinery providing a possible source of vibration or noise shall be isolated such that noise/vibration is contained and prevented from travelling through structure or along ducts all within specified limits.

Vibration isolators of various types as applicable shall be supplied by an approved manufacturer.

Duct attenuators and acoustic louvers shall be purpose made and designed/installed to meet the required acoustic and airflow performance, as specified.

Attenuators shall be tested in accordance with BS 4718 and shall have acoustic infill material with a minimum rating of Class 1 for surface spread of flame as measured to BS 476: Part 7. The attenuator and infill material shall be suitable for the temperature, corrosive nature and moisture content of the air within the ductwork system and shall not degrade or erode within the maximum velocity range of the air movement through the attenuator.

Silencers splitters shall be designed and manufactured in aerofoil section to minimise air generated noise and turbulence.

Noise and vibration level information, together with attenuator insertion loses based on octave band analysis, shall be submitted for all items of plant equipment.

Ductwork supports shall be provided with suitable isolators where necessary to limit the transmission of vibration to the building structure.

4.13 Flexible Joints

Flexible joints shall be manufactured from materials suitable for the expected conditions of temperature, pressure, noise and fire protection specified.

For all rectangular duct connections, the flexible connection shall be held in position by a mating flange and matching flat iron frame. The flexible connection shall be sandwiched between the frames such that its metal edge is securely gripped.


On all low velocity circular spigots the flexible material is to be secured by a clipband with adjustable screw or toggle fittings. All medium and high velocity circular and flat oval ductwork and spigots shall be secured with heat shrink sleeves of an approved type, unless the application of heat would cause damage to the equipment to be connected, when flanged fittings shall be employed.

Flexible connections shall be fitted to suction and delivery connections to all fans, at expansion joints in building, or where described in the contract documents.

Flexible connections shall be manufactured from materials, which shall be flameproof and not able to support combustion. They shall also be vermin proof. For external applications the connections and flanges shall be constructed from rot proof materials secured with stainless steel flanges.

All flexible connections shall be to the approval of the relevant Local Authorities.

Backing flanges shall be not less than 3mm thick. Flexible joints shall be kept as short as practicable above a minimum length of 50mm. In no case shall flexible joints exceed 250mm in length.

Flexible joints shall be installed in a neat and tidy manner. Ductwork sections shall be properly and accurately aligned. Flexible joints shall not be used to take up miss-alignment. Sufficient ‘slack’ in the joint shall be allowed to enable free movement as required; the joint shall not be installed in a ‘drum skin’ manner.

4.14 Flexible Ductwork

Flexible ductwork may be used to make the final connection between air terminal units, diffusers etc. Maximum lengths of flexible ductwork shall be as agreed by the Engineer. Gross distortion, non-alignment or sagging will not be permitted. Where flexible ducts are to be insulated, this shall be achieved using a proprietary manufacture of “pre-insulated flexible ducting”.

Flexible ductwork on view to be colour matched to connecting ductwork/Architects colour requirements.

Flexible ductwork material shall be flame resistant, vermin proof and shall not support combustion. They shall also be to the approval of the appropriate Local Authority.

4.15 Builders Work Duct Connections


Ductwork connections to builders work shall incorporate a mild steel flange of dimensions appropriate to the duct size for fixing to a built in hardwood timber frame or similar builders work detail. A detail of the arrangement shall be provided by the Sub-Contractor for comment by the Engineer. Ductwork connections to a fire barrier wall shall however not incorporate combustible materials.

Joints between ductwork/flanges and hardwood frames/masonry shall be sealed using a suitable sealing gasket or waterproof mastic as appropriate.

4.16 Connections to External Louvres

Wherever practical, ductwork connections to external intake/discharge louvres shall be arranged such that the base plate of duct shall slope down towards the louvre thereby draining back any rainwater that enters through the louvre. The entire inside surface the duct shall be painted with a black bitumastic coating for a distance along the duct equivalent to the height of the louvre.

4.17 Roof Penetrations

All ductwork penetrating roof structures or terminating at roof intake/discharge cowls etc shall incorporate weatherproof flashing/collars arranged to prevent the entry of rainwater etc. down the external face of the ductwork. Flashings and collars shall be constructed from appropriate heavy gauge materials. Details shall be submitted to the Engineer for comment prior to installation.

4.18 Instrumentation and Control Equipment

All thermometers, thermostats, flow switches; manometers etc shall be installed in duct faces in accordance with the manufacturers’ instructions. Where thermal insulation is applied to the ductwork then instruments shall be provided with a suitable saddle. All instruments shall be located as shown on the design drawings or adjacent practical accepted position.

Manometers and filtometers shall have calibrated pressure ranges in keeping with the anticipated system pressure values.

4.19 Plastic Ductwork

All plastic ductwork shall be manufactured in accordance with the specification for Plastic Ductwork No DW/151 produced by the UK Heating and Ventilating Contractors’ Association and shall be supplied and erected by a ductwork specialist.


All chemical exhaust ductwork system unless otherwise indicated shall be constructed from UPVC ductwork. Plastic ductwork and all associated moulded or extruded sections, angles and fittings shall be unaffected by the range of substances conveyed and conditions indicated.

The Sub-contractor shall ensure that adequate expansion joints are incorporated within the ductwork systems to offset the temperature effects on the ductwork.

The Sub-contractor shall ensure that all plastic ductwork is ultra violet stabilised.

The Sub-contractor shall allow for pigmenting of external ductwork to a BS colour approved by the Engineer.

Longitudinal seams shall not be located at corners or in the bottom face of a rectangular duct or in the lower half of a circular duct.

Solvent cementing shall not be utilised as a jointing technique.

The ductwork shall be installed with a minimum of horizontal runs and where such runs are unavoidable they shall have an in-built slope towards a drainage point. Drainage points shall be provided at all low points of the extract system.

Leak proof covers shall be provided at regular intervals to permit inspection and cleaning of the entire internal surface of the system. The ductwork shall be suitably labelled at these points to indicate the nature of the hazard.

4.20 Ductwork Cleanliness

All new ductwork installations shall be undertaken in accordance with DW/TM2 Guide to Good Practice/Internal Cleanliness shall be to intermediate level included therein unless otherwise advised by the Engineer.

Where suitable protection is not provided and at the discretion of the Engineer, the Sub-Contractor shall undertake specialist cleaning of the ductwork at no expense to the contract.


SECTION FIVE

THERMAL INSULATION STANDARDS


5.0 Thermal Insulation Standards

5.01 General

The Contractor shall include for the supply, delivery and installation of all materials necessary for the thermal insulation of systems described in this Specification. The works shall be carried out by an approved Thermal Insulation Specialist, the Contractor shall advise the Engineer of the Company Name of the proposed specialist at Tender Stage.

The Thermal Insulation Specialist shall make himself fully acquainted with all the site conditions and programme of works and shall execute his works within such confines and programme.

All works shall be carried out by skilled and efficient operatives, the installation shall be of the highest order and in accordance with: -

BS 5422: 1977BS 3533BS 3927BS 5970: with all current amendments

Any works not of an acceptable standard to the Engineer shall be removed and replaced at no cost to the contract.

The thermal insulation works shall not be applied until the whole of the pipework and ductwork installations have been completed and tested.

Insulation materials and finishes shall be inherently proof against rotting, mould and fungal growth and attack by vermin, be non-hygroscopic and in all respects be suitable for continuous use throughout the range of operating temperatures and within the environment indicated.

Unless otherwise indicated, all thermal insulation materials used within any building shall meet the Class 0 requirements; document B2/3/4 Appendix A Paragraph A8. Smoke obscuration for the insulation shall not exceed 5% when the product is tested to BS 5111. When requested, evidence of fire classification, obtained from any approved testing laboratory, shall be provided by the Sub Contractor in order to confirm that the product complies with this Clause.

No materials containing CFC components shall be acceptable.


5.02 Scope Of Works

Pipework Systems

Unless indicated otherwise, the following components/transient distribution ways shall be thermally insulated and vapour sealed as directed: -

Chilled Water Pipework

Thermally Insulated and vapour sealed

Steam and Condense

Not Applicable

Hot Water Services (Domestic)

Thermally insulated.

Cold Water Services (Domestic)

Thermally insulated and vapour sealed

LPHW Heating

Thermally insulated.

Ductwork System

Unless indicated otherwise, the following components/transient distribution ways shall be thermally insulated and vapour sealed as directed:-

Ducted Systems

Warm Air Ventilation Distribution Ductwork

Thermally Insulated

Air Conditioning Distribution Ductwork


Thermally Insulated

Fresh Air Intake Ducts to Plant

Thermally Insulated

Return Air

Thermally Insulated

Ductwork Exposed on Roof Ambient

Thermally Insulated

5.03 Materials

5.03.1 Pipework Systems

(i) Pipework Services Up To 120C

Insulation shall comprise of 35Kg/m minimum density CFC- free phenolic foam sections with factory applied reinforced aluminium foil facing.

The conductivity of insulation shall be a maximum 0.020 W/mC @ 10C mean. The insulation shall be Class ‘0’ rated to the Building Regulations, with or without facing. The bore face of sections shall be de-dusted and coated with a dust suppressant after manufacture.

The smoke obscuration of the insulant shall not exceed 5% when tested to BS 5111.

The insulation shall be Koolphen K as manufactured by Kooltherm Insulation Products Limited, or equal and approved.

(ii) Pipework Services Above 120C (excluding steam pipework)

The insulation shall comprise of 130/150Kg/m density mineral wool pipe sections with factory applied reinforcement aluminium foil facing. The conductivity of insulation shall be maximum 0.033 W/mC @ 10C mean.

The insulation shall be as manufactured by Pilkington Insulation Limited, or other equal and approved.


5.3.2 Ductwork Systems

(i) Ductwork – Rectangular

The insulation shall comprise 40Kg/m density CFC-free phenolic foam laminate with reinforcement aluminium foil facing bonded to core during manufacture.

The conductivity of laminate shall be maximum 0.018 W/mC @ 10C mean.

The laminate shall be Class ‘O’ rated to the Building Regulations – Approved Document B2/3/4 Appendix A paragraph A8.

The insulation shall be Ductphen–K as manufactured by Kooltherm Insulation Products Limited, or equal and approved.

(ii) Ductwork-Circular

The insulation shall comprise 35kg/m minimum density CFC-free phenolic foam sections with factory applied reinforced aluminum foil facing for ductwork up to 350mm. diameter. The insulation to ductwork in excess of 350mm diameter shall be 40kg/m density foil faced phenolic laminate, back slotted to accommodate the curvature of the ductwork. The insulation shall be Koolphem-K or Ductphen-K flatwrap as manufactured by Kooltherm Insulation Products Limited, or equal and approved.

(iii) Ductwork – Flat Oval

The rounded ends of ducting shall be insulated with 35kg/m minimum density CFC-free phenolic foam half sections with factory applied reinforced foil facing. The top and bottom of ducting shall be insulated with 40Kg/m density phenolic foam laminate. The insulation shall be Koolphen-K and Ductphen-K as manufactured by Koolthern Insulation Products Limited, or equal and approved.

5.04 Insulation Finishes

5.04.1 Pipework Systems

All pipework systems shall have insulation of the type required for the particular service and finished as detailed below:-

Service Ducts and Ceiling Voids


The insulation shall be supplied with a factory applied Class ‘0’ foil finish. All joints between sections of insulation shall be sealed with 50mm. wide self adhesive matching Class ‘0’ tape.

(ii) Internal and Exposed To View

Where indicated the insulation shall be wrapped with a 170g/m² canvas membrane, fully adhered to the surface of the insulation with (Chilseal CP50) adhesive. The canvas shall be stretched tight to eliminate any creases or wrinkles and overlapped onto itself by at least 75mm. along all joints. When the adhesion has fully dried, the outer surface of the canvas shall be treated with (Chilseal CP50) coating in accordance with the manufacturer’s instructions.

It is essential that the final finish is applied to a high standard. An additional paint finish shall be provided to an approval BS colour.

(iii) Internal in Plantrooms, Boilerhouses, etc

The insulation finish shall be as Clause 5.4.1 (i) above, but additionally finished with fabricated sheet aluminium casings for protection against mechanical damage.

External

All pipework insulation exposed to ambient conditions shall have a weatherproof coating of polyisobuthylene adhered to the insulating materials and bonded to it at all lap joints.

5.4.2 Ductwork System

All ductwork systems shall have insulation of the type required for the particular service and finished as detailed below:-

(i) Service Ducts and Ceiling Voids

The insulation shall be supplied with a factory applied Class ‘0’ foil finish. All joints in the foil jacket shall be sealed with 50mm. wide self-adhesive matching Class ‘0’ tape.

All exposed edges of the insulation and where the jacket is penetrated by insulation pins or other protrusions shall be sealed with (Chilbyl CP76) sealant or self adhesive tape.

Internal, Exposed to View where indicated, the insulation shall be wrapped with a 170g/m canvas membrane, fully adhered to the surface of the insulation with


(Chilseal CP50) adhesive. The canvas shall be stretched tight to eliminate any creases or wrinkles and overlapped onto itself by at least 75mm along all joints. When the adhesion has fully dried the outer surface of the canvas shall be treated with (Chilseal CP50) coating in accordance with the manufacturer’s instructions.

It is essential that the final finish is applied to a high standard. An additional paint finish shall be applied to an approved BS colour.

Internal In Plantroom

Where specifically detailed elsewhere in this Specification, the insulation finish shall be as Clause 5.4.1 (i) above, but additionally finished with fabricated sheet aluminium casings for protection against mechanical damage.

External

All ductwork insulation exposed to ambient conditions shall have a weatherproof coating of polyisobutylene adhered to the insulating material and boned to it at all lap joints.

5.05 Standards and Workmanship

5.05.1 Pipework Services

5.05.1.1 Pipework Services General

Adhesives, sealant and coatings shall be utilised in strict accordance with current recommendations of the supplier, particularly in respect of coverage, drying time, service temperature limits and method of application.

All pipework shall be insulated with preformed sections with factory applied Class ‘0’ foil finish. All joints in the foil jacket shall be sealed with 50mm. wide self-adhesive matching Class ‘0’ tape.

All bends, tees, flanges, valves, etc. shall be insulated with same materials as above, using oversized segments of preformed sectional insulation.

All rigid sections shall be concentric and be accurately matched for thickness, with no steps and undulations in the surface. No sections having damaged ends or edges shall be used.


Straight sections of insulation shall be applied in lengths up to 1.0m in half segment sections.

Bends and fittings shall be formed from mitred and trimmed sections, cut to ensure that a good contact with the surface to be insulated is made.

At all valves, fittings and pipeline equipment and at not more than 7.0m centres along any pipe line ends of the rigid sections shall be sealed off with a suitable mastic.

The insulation shall be neatly trimmed with a purpose made end caps at pump casings, flange joints, valves and strainers etc.

All pipework supports and brackets shall either be of tanalised softwood or other material approved by the Engineer. The aluminium foil insulated finish shall be continuous through the support and the joints sealed.

Under no circumstances shall pipes be married together with the insulating materials.

At termination points the insulation shall be trimmed with polished aluminium coiled end capping pieces secured over the aluminium covering with closed head pop rivets.

5.05.1.2 Pipework Conveying Chilled or Cold Water.

For pipework conveying chilled or cold water services a continuous vapour seal shall be provided and inserts shall be fitted between the pipe and the hanger brackets. The inserts shall have the same thermal properties and be incompressible and shall be approximately 100mm. long, the outer diameter being identical to that of the insulated pipe and the insulation finish shall be continued over the inserts and the finish shall be protected, by means of sheet metal hoops under the brackets, against movement of the pipe and/or hanger.

Care must be taken to ensure the integrity of the vapour seal is maintained on all cold water service and chilled water pipework insulation. Where any edge requiring vapour sealing is exposed, continuity shall be maintained by an application of (Chilbyl CP75) sealant.

Pipework Conveying Hot Water

Pipework conveying hot water shall be thermally insulated as detailed elsewhere, but vapour sealing shall not be required.


Generally, pipework conveying hot water shall be insulated only where concealed from view.

External Pipework

All pipework external to the building and exposed to ambient conditions shall be insulated as previously described and weatherproofed with 0.8mm reinforced polyisobutylene sheeting adhered to the insulation with 50mm end and edge caps solvent welded to shed water. Flanges, valves, etc., shall be insulated with oversized segments of sectional insulation and weatherproofed.

The polyisobutylene sheeting shall be run through the bracket support points to provide a continuous waterproof finish.

Where indicated on the drawings or elsewhere in this specification, pipework shall additionally be treated with electric trace heating protection for the prevention of frost with automatic sensors and controls.

Pipework Buried In Trenches And Covered With Selected Backfill (E.G. Sand Or Fine Gravel)

In these instances, heavy density (600kg/m³) pipe insulation shall be used in place of standard density. The insulation shall be finished with a protective covering of 100mm wide SERVIWRAP TISA pipe wrap tape spirally wrapped over the insulation with a 50% overlap or equal and approved finish.

Protection of Pipework Insulation within Plantrooms

Insulation to pipework services in plantrooms shall be protected against possible mechanical damage by fabricated sheet aluminium casings.

All pipework insulation shall be enclosed in pre-rolled stucco embossed aluminium cladding secured with aluminium bands at 450mm centres and at circumferential joints, all joints shall be overlapped by a minimum of 40mm.

The stucco enclosed aluminium cladding shall be 0.6mm thick on pipework up to 150mm. diameter, 0.8mm. thick on all pipework above 150mm diameter. Elbows, bends, tees, sets, etc. shall be enclosed in stucco finished aluminium cladding to match the pipework using segmented pieces or mitre bends where applicable.

The stucco embossed aluminium cladding shall be run through the bracket and support points.


All flanges and valves etc. in plantrooms shall be fitted with removable boxes constructed with 0.7mm thick aluminium sheeting lined with equivalent bonded insulation to the same thickness as that on the accompanying pipework. All flanges and valve boxes shall be secured with “quick release” clips. Flanges, valves, etc. on chilled and cold water lines shall have vapour sealing maintained by the application of a (Chilbyl CP76) sealant.

Ductwork Services

Ductwork Services General

All thermal insulation shall be securely fixed to ductwork where practicable with a full bed application of adhesives compatible with the insulation.

Insulation applied to ductwork, whose underside or standing side dimensions exceed 600mm, shall be mechanically attached to the duct surface with pre-bonded insulation pins and washers, the spacing of which shall be to a maximum of 300mm centres.

Adhesives, sealant and coatings shall be utilized in strict accordance with the current recommendations of the supplier, particularly in respect of coverage, drying time service temperature limits and method of application.

All rectangular ducting shall be insulated with slabs cut to fit on site so that the top and bottom slabs overlap the sides at all four corners of the duct. The insulation shall be adhered to the duct using (KP31) general purpose two-way contact adhesive. The insulation on the underside of the duct shall be additionally secured by means of pre-bonded insulation pins and washers spaced at 300mm centres.

All circular ducting up to 350mm diameter shall be insulated with factory applied foil faced sections. Above 350mm diameter, insulation shall comprise foil faced laminate, back slotted, to allow it to be fitted to the curvature of the duct. Insulation shall be fully bonded with KP31 adhesive.

All flat oval ducting shall be insulated with foil faced pre-formed half sections on the semi-circular sides. Top and bottom to be insulated with foil faced laminate. The insulation shall be bonded to the duct using KP31 general purpose two way contact adhesive. Inverted insulation to be additionally secured with pre-bonded insulation pins and washers spaced at 300mm centres.

Generally, all foil joints to the ductwork insulation and any protrusions throughout the facing shall be sealed with 100mm wide self adhesive aluminium foil tape. On circular ductwork, additional support to the insulation shall comprise circumferential bands of 100mm wide self adhesive foil tape applied at 300mm centres.


Ductwork supports for insulated ductwork shall be in accordance with DW 144 incorporating a rigid (tanalised softwood or similar) insulator between the support and the ductwork to the thickness of the insulation with insulation vapour seal being taken through the insulator support and not over the bracket

Ductwork Conveying Conditioned or Cooled Air

For ductwork conveying conditioned air a continuous vapour seal shall be provided and inserts shall be fitted between the ductwork and the hanger bracket. The inserts shall have the same thermal properties as the insulation and shall be incompressible. The insulation shall be taken up to the support inserts and sealed to the inserts. The vapour barrier shall be carried through the supports enclosing the inserts.

Thermal insulation properties shall be as indicated above in rigid slab form with the same application.

Insulation slabs shall have the aluminium reinforced backing specified herein. Matching self-adhesive tape shall be applied to all insulation joints to prevent ingress of moisture of capillary action. All penetrations for mechanical bonding to be sealed with CP76 to maintain the vapour barrier.

The insulation shall cover the flanges by means of increasing the general thickness of insulation to give at least 6mm cover at the flanges, where the insulation is 25mm thick.

Thermal vapour sealed ductwork insulation shall have foil vapour barrier finish as detailed.

Any exposed edges of insulation or penetration of the vapour barrier shall be sealed with sealant or self adhesive tape.

The insulation shall be carefully formed around access openings, damper arms, test holes etc. to give adequate access whilst maintaining the vapour seal and providing protection from mechanical damage.

Fresh Air Intake Ducts

Fresh air intake ducts shall be insulated and vapour sealed as described for cooled air above, Clause 5.5.2.2.

Return Air Ductwork

Return air ductwork shall be insulated as Clause 5.5.2.1


External Ductwork

The ductwork shall be insulated in accordance with preceding Clauses.

The insulation shall be enclosed in 0.8mm polyisobutylene sheeting with 50mm end and edge caps solvent welded, to shed water.

The polyisobutylene sheeting shall be run through the bracket support points to provide a continuous waterproof finish.

The top sides of rectangular ductwork shall be insulation fitted to falls to ensure shedding of water.

5.06 Insulation Thickness

Pipework Services

Declared Thermal Conductivity W/m°C of Insulating Material Closed Cell Phenolic Foam 0.02W/m°C @ 20.0°C.

Pipe Size Chilled LTHW HWS Domestic Services(mm) Water Htg. CWS MWS

Minimum Thickness of Insulation (mm)

15 20 20 20 20 2020 25 20 20 20 2025 25 20 20 20 2032 25 25 25 20 2040 25 25 25 20 2025 25 25 20 2065 30 25 30 20 2080 30 25 30 20 30100 30 30 30 20 20125 30 30 30 20 20150 35 30 30 20 20200 35 35 35250 35 35 35300 35 35 35Flat Surfaces 40 35 35 25 25+ Vessels


N.B: Phenolic foam shall not be used in services operating above 120°C.

Ductwork Services

The thickness of the insulation sections shall comply with the following table at a declared K value of 0.018W/m°C at a mean of 10°C:-_______________________________________________________________ Difference In Temperature Between Air Temperature Within Duct and Ambient Air_______________________________________________________________

10°C 25°C 50°C

25 30 40__________________________________________________________

Insulation thickness (mm)

5.07 Thermal Insulation of Heat Exchanger Cylinders and Buffer Tanks

Heat exchangers, hot water cylinders, calorifiers and buffer tanks shall be insulated with 50mm thick slotted foil faced laminate, preformed sections or rigid slabs with factory applied Class ‘O’ foil faced finished as appropriate. All corners and straight butt joints shall be sealed with self adhesive matching Class ‘O’ tape, 100mm wide.

The insulation shall be to the thickness indicated.

The equipment shall be covered with 0.8mm stucco enclosed aluminium cladding.

5.08 Internal And External Water Storage Tanks

Internal and external water storage tanks shall be provided pre-insulated.

5.09 Painting of Equipment, Steelwork And Exposed Pipework in Plantrooms, Boiler Houses and Major Service Ducts

5.09.1 All exposed steelwork, flange joints, cast iron or steel valves, fittings, brackets, etc shall be thoroughly wire brushed and painted one coat of red oxide based metal primer to BS 2524 followed by one coat of heat resistant black gloss paint to BS 4800 except for fire fighting systems which shall have a finishing coat of red gloss paint in accordance with BS 1710.


5.09.2 All exposed pipework shall be thoroughly wire brushed and painted with three coats of heat resistant paint to BS colour code, after being wire brushed and primed with one coat of zinc phosphate primer to an average dry coat thickness of 0.05mm.

5.09.3 All exposed gunmetal valves, fittings, etc shall be thoroughly cleaned and polished on completion of all painting and prior to handover.

5.10 Contract Identification

All plant, equipment, insulation, exposed pipework and exposed ductwork shall be identified by colour code/safety indicated and basic colour bands to BS 171.

The safety colour and colour indication bands shall be 160mm wide. The identification shall be at centres of not more than 6 metres, and adjacent to all valves, items of plant, changes in direction at both sides where pipework passes through walls, floors, etc, and all service access points.

The bands shall be of the “Flo-Code” type as manufactured by Flo-Code Ltd, 2 Dell Road, Stoneleigh, Epsom, Surrey, KT17 2ND, or equal and approved. The label shall incorporate the following information:-

Colour Code Pipe ContentsFunction/Source of SupplyFlow DirectionPipe SizeSafety Colour

The Contractor shall make use of the manufacturer to prepare a manuscript layout for incorporation into the manuals and supply the tape, together with test labels printed from the prepared manuscript.



SECTION SIX

TESTING AND COMMISSIONING


6.0 Testing and Commissioning

6.01 General Requirements

The Contractor shall include and be responsible for the setting up, testing, commissioning, balancing and putting to work the whole of the installation as indicated on the Contract Drawings and as described in this Specification.

The Contractor shall include in his Tender for employing the services of a firm of independent Specialist Commissioning Engineers for the full and final commissioning and measurement of all the air and water systems installed in the Contract.

The commissioning procedures and methods of measurement shall be carried out in accordance with the relevant current CIBSE codes of Practice for commissioning: -

A - Air Distribution

B - Boiler Plant

C - Automatic Control

R - Refrigeration

W - Water Distribution

A full set of the relevant Codes shall be kept permanently on site and the Commissioning Engineers shall be fully conversant with methods outlined in the Codes.

The Contractor shall make due allowance, for obtaining the services of the automatic controls Specialist Commissioning Engineers to commission the automatic control systems supplied by them, and for carrying out any interim visits as called for in this Specification. The Sub-Contractor shall be responsible for co-coordinating all the above specialists and attending on them and giving adequate notice of the date of his intention to carry out any test. All necessary pre-commissioning checks shall have been carried out prior to any tests.

The Contractor shall give three full day’s notice of his intention to offer a section of pipework/installation for testing, and/or commissioning, using a pro-forma similar to that appended to the end of this section.

The Engineer shall witness all testing and commissioning on the agreed date and in the event of the works being incomplete and causing a postponement of the various commissioning exercises then the Contractor shall be responsible for all costs


associated with the re-co-ordination and returning to site of the various Specialist Commissioning Engineers and the Engineer shall have the right to deduct from the Sub-Contract sum all reasonable costs incurred by him for attending and witnessing the re-commissioning at this later date.

The Contractor shall allow for and provide all assistance and appliances for testing and commissioning in sections during the progress of the contract where necessary to comply with the Main Contractor’s Master Programme and for final testing and commissioning.

In the event of sectional testing, the Contractor shall allow for and provide, fix and adequately support all necessary temporary blanked ends and plugs etc to facilitate the sectional test and remove them on satisfactory completion of the test.

6.02 Pipework Testing, Commissioning and Regulation

The Contractor shall ensure that all pipelines are clean and shall flush out any debris, obstructions or superfluous matter to the satisfaction of the Engineer before any sectional or full tests are applied and upon completion of the Contract.

All water pipework systems shall then be slowly filled to exclude all air and hydraulically tested to a pressure of 4 bar (60 psi gauge). This test pressure shall then be maintained without further pumping and without measurable pressure loss for a period of two hours after which time the system will be deemed to be satisfactory and watertight. The Contractor shall locate and remedy all defects revealed by the test. Screwed joints, which prove defective, shall be removed and made good. Welded joints shall be lightly hammer tested during the period of the test and if any leaks occur that portion of the weld shall be cut out and made good by re-welding.

The Contractor shall subsequently re-test until a satisfactory holding time of two hours is achieved.

Any items of equipment or air eliminators etc. not suitable for this test pressure shall be removed and the connection plugged before the test pressure is applied.

Generally the procedures adopted shall be in accordance with both Guidance Note GS4 “Safety in Pressure Testing” published by the Health and Safety Executive and the HVCA Guide to Good Practice for Site Pressure Testing of Pipework, reference TR/6.

6.03 Ductwork Testing, Commissioning and Regulation


All air systems shall be tested, commissioned and regulated to ensure that they operate with the correct performance, temperature, pressure and flow rate in accordance with the Specification and drawings.

All air handling equipment and air system plant components shall be measured and tested for pressure differential and flow rate to ensure that the installation and manufactured components comply with published and specified data.

The measurement of velocity within a ductwork installation, to determine volume flow shall, unless stated otherwise, be carried out in accordance with BS 1042.

6.04 Ductwork Air Leakage Testing

Air leakage tests shall be carried out in accordance with DW/144 and DW/143. The maximum rates shall be as Table 17 of DW/143. The systems shall be tested as medium pressure system Class B at 500Pa.

The results of the leakage tests shall be submitted in the manner indicated on the Specimen Test Sheet in DW/143. The measurement of the ducts under test shall be carried out and recorded at the time of the test.

6.05 Refrigeration Installation

Refrigeration installations shall be tested and commissioned strictly in accordance with the parameters and procedures set out in CIBSE Commissioning Code and BS 4434: Part 1.

The maximum working pressure, as defined in BS 4434, shall be obtained from the relevant refrigeration equipment manufacturer/supplier. The values of normal operating pressures, pressure limited devices, relief devices and test pressures shall be as defined in BS 4434.

6.06 Gas Installation

Gas installation shall be tested and commissioned in accordance with British Gas recommendations, BS CP 331, BS 6400 and British Gas Publications IM/2, IM/5 and IM/6.

The pressure test shall be carried out at twice the maximum working pressure of 5 kN/m², whichever is the greater.

6.07 Equipment And Commissioning Certificate, Schedules And Drawings

The design data for items of plant and equipment is generally as summarised on the design drawings and in the Specification.


Equipment and commissioning schedules shall be completed and submitted during commissioning, indicating the design conditions, site test readings and observations.

Schematic drawings of all systems shall be provided detailing the design data and locations of all measurements and tests. These drawings in conjunction with the schedules shall provide a complete record of design and test data for all sections of the various systems.

Upon completion of final balancing and commissioning of the systems, the test results shall be submitted in duplicate for approval.

The Contractor shall allow for providing all the necessary attendance and assistance to the Specialist Commissioning Engineers in the preparation of the required commissioning reports for items of plant, equipment and systems.

6.08 Pre-Commissioning Cleaning and Sterilisation of Pipework Systems

Following satisfactory completion of testing and prior to final commissioning, each water system shall be run for a period of time necessary to attain maximum working temperature and then for a further period of four hours.

The whole installation of each system shall be drained down completely, all filters removed and cleaned and all low points cleared of any sludge or scale, which may have collected there.

The flushing out of every system, shall be continued on the above basis, until all low points and filter strainers remain clean to the satisfaction of the Engineer.

The systems shall then be re-filled and vented using clean water prior to commencing the pre-commissioned cleaning.

An approved water treatment specialist shall be employed to carry out the pre-commissioning cleaning of all water systems in the works.

The right is reserved to instruct the removal of up to ten sections of the pipework installation and to have them inspected and examined.

If the test and inspection should prove that the cleaning is to the required standard, the Employer will pay the costs incurred in removing, testing and replacing the sections of the installation. If, however, the test and inspection show that the cleaning is below standard and incomplete, no costs or fees incurred by the tests shall be borne by the Employer: -


If any result suggests that cleaning the whole installation or system is incomplete, the pre-commissioning cleaning shall be continued until the witnessing is to the satisfaction of the Engineer. The right is reserved to deduct from the Contract Price all reasonable expenses incurred by the Engineer in attending the repetition of the witnessing.

Immediately upon completion and approval of the pre-commissioning cleaning, the water treatment of all systems shall be carried out as described elsewhere in the Specification.

An approved Water Treatment Specialist shall be employed to carry out the sterilization and chlorination of all new domestic hot and cold water installations, and existing installations where alternations have been made, including incoming and rising mains, tanks and tank cold water down services.

The sterilization and chlorination shall be carried out in accordance with BS CP 310 (BS 6700) with a minimum concentration of 50 mg/litre circulated for three hours and an independent testing laboratory shall be employed to certify that water from each system is free from any bacterial contamination.

A further set of tests shall be carried out during the Defects Liability Period to ensure any “hide out” of bacteria due to latent contamination is not present.

If the tests provide the presence of bacteria, the re-chlorination of any or all systems shall be undertaken at no extra cost.

All sterilization, chlorination and pre-commissioning cleaning shall be carried out in accordance with the requirements of HTM 2040 Control of Legionella in a Health Care Premises.

6.09 Instruments Used in Testing

The instruments used during the commissioning and testing shall have been re-calibrated by the manufacturer prior to carrying out any measurements on site.

Manufacturer’s instructions relating to test instruments shall be strictly adhered to.

Written documentation shall be submitted, from the instrument manufacturers, confirming the accuracy of the instruments and its serial number in order to demonstrate that the instruments being used are bonafide and capable of registering to the degree of accuracy acceptable.

Manufacturers of plant who put forward their own test figures for inclusion shall also state, in writing, the type of instruments used to obtain the figures quoted.


6.10 Underground Mains: Pigging

Underground mains shall be “pigged out” by the introduction into the mains, prior to filling and testing, of a 30mm polyurethane “pig”.

The pig shall be inserted into the open ended main and shall initially be approximately one and a half times the internal diameter of the main before being compressed manually into the main.

A compressor shall be connected to the main behind the pig to force it down the main until it is expelled from the opposite open end completely removing any foreign matter. The compressor shall be capable of developing a pressure of 10.5 Bar with an air quantity of 0.22 cubic metres/second.

Branch mains shall be pigged prior to main runs and the smaller pigs and foreign bodies deposited in the main runs shall be removed when the latter are pigged.

Any open-end mains or branch mains connected to the main or branch mains being pigged shall be blanked off.

All “pigging out” shall be carried out during the presence of the Engineer.

6.11 Automatic Control Systems

Current wiring diagrams for all electrical equipment associated with the plants being commissioned, including motor control circuit details and inter-lock arrangements, shall be obtained from the relevant manufacturers prior to commissioning on site.

All commissioning and testing shall be included as called for elsewhere in this Specification.

6.12 Systems Witnessing and Proving

Prior to Practical Completion of the Building, the Mechanical Contractor shall be responsible for the proving of all the Mechanical Services to the Client’s Representative; which will generally take the form of: -

Proving of the Control System including alarm simulation tests.Proving airflow rates.Recording and proving noise levels in all roomsChecking and proving of air velocities from supply air diffusers.


The Mechanical Contractor shall provide all necessary equipment and personnel (including 2-way radios) to undertake the aforementioned and shall advise the Engineer 1 weeks prior to proving and witnessing.

Upon completion of the proving and witnessing, the Mechanical Contractor shall provide full training of occupants on the complete Mechanical Services Installation, with Manufacturer’s Technical Staff also attending for the minimum: -

Controls

Comfort CoolingHeating SystemsDomestic SystemsVentilation Systems

6.13 Test Certificates

The following test certificates shall be the minimum required for the systems installed in addition to those itemised elsewhere in this specification.

Gas pipework pressure test certificate.

LPHW heating pipework pressure test certificate.

Hot/cold/mains water pipework pressure test certificate.

HVAC controls system commissioning test certificate.

External underground pipework pressure test certificate.

Cleaning and Chlorination Certificate.

DHWS and Cold Water bacteriological examination certificate.

Ductwork leakage test certificate.


SECTION SEVEN

RECORD DRAWINGS AND USER MANUALS


7.0 Record Drawings and User Manuals

7.01 Operation and Maintenance Manual

On completion the contractor is required to provide an energy logbook this shall be in accordance with L2B of the building regulations. The energy logbook shall be based on CIBSE document TM 31 using the CIBSE standard template and shall be supplied in both hard copy and software on CD ROM.

A water quality risk assessment and logbook shall be handed to the Engineer prior to handover this shall be in full compliance with L8 [2000] and must be provided in hard and electronic copies. The water quality risk assessment and log book can complied and supplied from one of the following water quality hygiene companies: Maxigiene Environmental services 12 Green Drive Thornton Cleveleys Lancs FY5 1LQ Tel : 0125 825987 H20 Chemicals Ltd Unit 18 Coney Park Harrogate Road Yeadon Leeds LS19 7XS Tel: 0113 250 3445 Activate 8 Bank Chambers 67 Deardengate Haslingdon Lancs BB4 5SN Tel: 01706 210210

The contractor shall prepare an operating and maintenance manual, which shall give a step by step guide to the daily running and maintenance requirements of the complete installation. The “As Fitted” drawings shall be provided in AutoCAD format to release LT2004. The operating and maintenance information including drawings shall be provided on


CD-ROM. All text documents are to be in editable PDF format via Adobe acrobat or similar. The contractor shall submit to the Engineer a draft copy of the manual for comments prior to practical completion. The contractor shall then update the manual to incorporate the Engineer’s comments and provide two copies of the manual two weeks after practical completion. The manuals shall also be presented within a black ring binder (A4 size) having full clear pockets to the front and spine, and a strong 4 D-ring mechanism fitted to the back cover. The information is to be stored in open top polypropylene pockets with punched reinforcing strip. Each section shall be divided up using durable polypropylene numbered index sheets, with matching contents page. The information contained within comprehensive O&M manuals can be grouped into the following areas: how to use the manual emergency information contractual and legal information systems description and design intent asset list/equipment scheduleparts identification and recommended spares spares policycommissioning dataoperation maintenance fault finding lubrication modification information disposal instructions manufacturers manufacturers’ literatureindex of plans and drawings This following provides a description of the required contents for each of the requirements.

How to use the Manual


This initial section is a guide to the contents, structure and layout of the manual it shall enable the reader to comprehend the scope and purpose of the manual and to easily identify where specific information can be obtained.

Emergency Information For quick reference, this should be located at the front or back of the manual and should include: the procedure for dealing with specific emergencies the names, addresses, telephone and fax numbers of appropriate.contacts during the daytime and night time in the case of a fire, leaks, breakdowns, injuries, building shutdown etc. Arrangements for public holidays should also be included.the location of fire fighting equipment, rising mains and hydrants details of known hazards within the building.photographs of important control panels under normal operating conditions

Contractual and Legal Information This section shall contain: details of ownership/leases and the address of the installation details of local and public authority consents.details of design team, consultants, installation contractors and associated subcontractors.start date for installation, date of practical completion and expiry date for the defects liability period.space to record details of work carried out by the installation contractor during the defects liability period.details of warranties for plant and systems including expiry dates, addresses and telephone numbers.test certificates, examination reports, safety and fire certificates a statement of any known feature or operational characteristic of the plant or system installed which may produce a hazard.any known hazard against which protection can be provided. Systems Description and Design Intent This shall provide a description of each engineering system installed in addition to details of the design intent and assumptions made. The areas covered shall include: reasons for selecting particular plant/systems i.e. the design basis.system location and what it serves.


what the system depends upon in order to function assumptions about the number of people in a space, compartmentalisation of space etc.the anticipated usage of heat producing equipment and the comfort criteria which provide the basis for settings on equipment controlling environmental systems.limitations/flexibility of the environmental systems in accommodating change.monitoring/metering systems incorporated in the services installation and the regime intended for recording results.plant operational efficiency (quoted by manufacturer, as commissioned and results of subsequent monitoring).original energy targets together with building occupation hours as agreed in the design brief.the control allowed to the individual over his/her immediate environment and how this is intended to fit in with the general centralised control system.the provision for natural ventilation and the role of management and the individual to ensure it is used effectively.an energy management plan to accommodate the above points. anticipated life of key plant/systems and recycling plans.

Asset List/Equipment Schedule The type, model number, serial number and capacity of all major component items within the system should be listed, together with the names of their respective manufacturers or supplies.

7.02 Demonstrations & Training

The Contractor shall be responsible for providing a full system demonstration to both Employer and the Engineer to allow satisfactorily operation of the equipment.

The level of training to the designated staff shall be sufficient to satisfy their site needs to enable safe operation and maintenance of the equipment.


SECTION EIGHT

CONTROL PANEL STANDARDS AND CONTROLS INSTALLATION


8.0 Controls and Control Panel Installation

8.01 General

The Contractor shall be responsible for the modifications to the control system and shall demonstrate the ability of the systems to fulfil the design criteria as set out elsewhere in this Specification.

The specialist controls manufacturer shall be responsible for the interpretation of the design intent, set out in the Specification and drawings, into the operational control installation.

8.02 Scope of Works

The contractor shall include for the modifications to the existing control panel to allow for the removal of control of 1No boiler, all chilled water plant equipment, the replacement of hot water cylinder and replacement of the ventilation system humidifier.

Local power supplies and all control wiring to each item of plant shall be provided by the Controls Specialist where required. The Controls Specialist shall provide all interfaces necessary for the item plant to be controlled by the control system.

Scope of Works is as follows: -

Modifications to 1No. existing control panel to include the following Removal of 1No. existing boiler (Boiler no. 2) Removal of 1No. redundant air cooled chiller Removal of 2No. redundant chilled water pumps Removal of 1No. redundant chilled water pressurisation unit Removal of 1No. AHU cooling coil Replacement of 2No. heating pumps Replacement of 2No. hws pumps Replacement of 1No. gas solenoid valve Modification for new 1No. humidifier

Supply and engineering of field mounted equipment.All associated electrical wiring from the control panel outwards to provide a full working controls system.Commissioning, Demonstration and Training of the complete project.Provision of control schematics and controls description prior to installation.Provision of 3No. copies of the operating and maintenance manuals including installed control schematics on AutoCAD LT2000 format.


Drawings detailing all electrical loading of plant and equipment associated with the works and manufacturer's drawings of all electric and electronic works associated with the contract shall be prepared and submitted.

The drawings shall be in the form of single line schematic diagrams and comprehensive wiring diagrams, clearly showing the location and functions of each component with the manufacturer's figure number or other identifying symbol, and noted to show the components specified. Manufacturer's ‘typical wiring diagrams’ are not acceptable. Field and panel wiring shall be identified with cable type, number of cores, cross sectional area etc.

For each item of plant the protective device type and rating shall be indicated and additionally for each starter, the thermal relay or overload range of setting shall be indicated. Run-on timers shall be identified fully described their function and set-point.

Any items of wiring which are to be provided by others shall be designated clearly on the drawings. Any such indication will not be acceptable as justification of incorrect interpretation of the specification.

The voltage, starting current, running current and duty in kW and shall be clearly marked against each motor and all associated components shall be suitable for all conditions resulting from this data.

The voltage, current and normal status of all electrical components shall be clearly marked, together with particular requirements for size and type of wiring and number of cores.

All control panel terminations shall be identified separately by numbers, and all fuse and contractors shall be clearly marked with the required ratings and settings.

Four copies of the electrical wiring diagrams complete with electrical and control equipment details and four copies of the control panel fascia layout drawings shall be submitted for comment.

Upon receiving comments, six copies of the finalised drawings and details shall be provided for distribution through the Contract.

8.03 Testing, Supervision, Commissioning And Proving


The Contractor shall be fully responsible for the correct location and functioning of the control equipment and shall include for his own and the control manufacturer’s supervisory service to carry out the following:-

To identify and locate the control equipment and advise on the correct method of installation.

To discuss with and advise all parties on the correct method of wiring and connecting the equipment.

To check that the equipment has been correctly installed.

To check that the electrical wiring has been correctly installed and connected, including electrical continuity test by the control manufacturer upon completion of the wiring installation.

Pre-commission control equipment at testing and balancing stage of each plant.

To commission the installation and to issue, in triplicate, a certificate of commissioning, which must be complete with all control equipment settings. The certificate shall not be issued nor the system accepted until the system has been demonstrated in full operation to indicate the various control actions and the satisfaction of the design conditions to the acceptance of the Engineer. The Contractor shall allow for the provision of two way radio communications over the period of the demonstration.

Instruct the Client’s staff in the running and maintenance of the controls installation.


8.04 Controls Description

The controls operation should be as dictated by the original control installation.The AHU is controlled by an individual dedicated controller.

Frost Protection

When the plant is not operating the internal temperatures shall be monitored. If the internal temperature drops to below 12°C when the plant is de-energised the boiler plant and associated pumps shall be energised to raise the internal temperature to above 20°C before de-energising.

Fire Shutdown

In the event of a fire detection the controls shall be arranged to shut down all of the mechanical plant.


SECTION NINE

HEALTH AND SAFETY


9.0 Health and Safety

The Contractor shall ensure complete compliance with all health, safety and welfare legislation and requirements of the land.

The Engineer may issue instructions requiring the dismissal from the works any person who gives cause or causes the breach of any health, safety or welfare requirements.

The Contractor shall comply with the requirements of Health and Safety Policies operated by the Employer, details of which are available on request. The Contractor will be expected to obtain copies of the relevant Health and Safety Policy document from the Employer and ensure all site operatives are aware of the requirements and their responsibilities in this regard.

The Construction (Design and Management) Regulations 2007 apply to this project.

A pre-construction Health and Safety Plan has been prepared and included with the Main Contract Tender documents.


SECTION TEN

PARTICULAR MECHANICAL SERVICE REQUIREMENTS


10.0 PARTICULAR MECHANICAL SERVICES REQUIREMENTS

10.01 General

This specification shall be read in conjunction with the contract drawings to cover the following scope of works for the design, manufacture, supply, co-ordination, installation, testing, commissioning and 12 months defects of the mechanical services installations.

10.01.1 Requirements

The works include the refurbishment of mechanical services within the four storey building, Compass House in Camberley.

The redundant mechanical installations of the building shall be stripped out and removed from site. However any further mechanical systems found during the strip out works that are redundant shall also be stripped out.

The works to the building will include the installation of all associated controls, pumps, heaters, water heaters, fans grilles etc to provide fully functioning systems.

The Contractor shall include for a site visit by an engineer to fully check the installation at the following intervals: after hand over, 6 months and 12 months. The engineer shall check every aspect of the installation to ensure that the system is functioning correctly. The Contractor shall include for all the relevant specialists to return to the site at the same time to check the relevant equipment i.e. controls, heat pumps etc.

The proposed works will be carried out during the following times depending on occupation of the areas being worked in:

Occupied spaces* – To be worked on out of hoursUnoccupied spaces* – To be worked on during normal hours

*(refer to schedule of occupation)

Floor OccupancyGround Floor – Suite 1 UnoccupiedGround Floor – Suite 2 UnoccupiedFirst Floor UnoccupiedSecond Floor OccupiedThird Floor Unoccupied


During normal hours office suites will be occupied so provision for working at weekends and at times/in offices to suite the occupier will need to be made by the Contractor.

Builders Work

The Contractor shall include for all items of builders work necessary for the installation of the mechanical services. This shall include for new holes, making good, lifting equipment, access equipment etc.

The entire building services installation shall be supplied, installed, tested & commissioned, provided with O&M documentation, Client Training and warranted against defect design and workmanship.


10.02 Scope of Works

The scope of works shall be as detailed on the following drawings and as detailed with the specification:-

Proposed Heat Pump System – Ground Floor 261/M/01Proposed Heat Pump System – First Floor 261/M/02Proposed Heat Pump System – Second Floor 261/M/03Proposed Heat Pump System – Third Floor 261/M/04Proposed Heat Pump System – Roof Level 261/M/05Proposed Ventilation Modifications – Ground Floor 261/M/06Proposed Ventilation Modifications – First Floor 261/M/07Proposed Ventilation Modifications – Second Floor 261/M/08Proposed Ventilation Modifications – Third Floor 261/M/09Existing Mechanical Services – Plant Room LayoutStrip Out Drawing 261/M/10Proposed Mechanical Services – Proposed InstallationPlant Room 261/M/11Existing Mechanical and Electrical Services – Ground Floor 261/ME/01Existing Mechanical and Electrical Services – First Floor 261/ME/02Existing Mechanical and Electrical Services – Second Floor 261/ME/03Existing Mechanical and Electrical Services – Third Floor 261/ME/04

The new installation shall consist of the following items of equipment: -

New VRV heat recovery heat pumps, condensers and ancillariesReplacement cold water storage tankReplacement hot water calorifierNew pipework connections/modifications to existing pipework for LTHW heating and domestic water systemsReplacement heating and hws pumpsModifications to the existing Flue InstallationModifications to the ventilation systemInstallation of replacement humidifierInstallation of new gas supply pipework to boilersStripping out redundant mechanical and electrical systems.Thermal insulation to new and existing services where modifications have taken placeModifications to automatic controls – see section 8.Any modifications to the existing electrical equipment/layout to enable installation of the new equipment.‘As Fitted’ drawings and O&M for new and existing installations to the requirements of Section 7.Fully commission all systems to Section 6.


All builders work/Access equipment.


10.03 Removal of Existing Services

The Contractor shall include in his tender all costs for the stripping out and removal of the following:-

Existing chilled water plant including roof top mounted air cooled chiller, 2No. chilled water pumps, chilled water pressurisation unit and associated pipework throughout plant room and buildingRedundant LTHW heating services including 1No. boiler & 2No. heating pumpsRedundant Domestic hot and cold services including 3No. tanks and 1No. calorifier and 2No. hws pumps.Redundant F&E tank.Redundant gas pipework serving boilers.Existing humidifier.

The Contractor shall visit site prior to submission of his tender to enable him to tender this element of works. No variations to the contract will be undertaken due to lack of knowledge of the existing systems.

Any holes in walls etc left by the removal of the existing systems shall be made good to the satisfaction of the Engineer.

The Contractor shall not isolate any section of any existing service unless the time and date of the isolation has been previously agreed in writing by the Client’s representative.

10.04 Heat Pump Installation

The contractor shall employ the services of a refrigerant contractor (list of contractors detailed in main Bill) to supply, install and commission a variable refrigerant volume system and a one to one heat pump system as indicated on the tender drawings.

All the systems shall be as manufactured by Mitsubishi Electric Ltd.

All the equipment shall be as manufactured by Mitsubishi Electric.

The equipment shall be installed and commissioned by a Mitsubishi Electric Diamond Business Solution Partner to provide a 7 year guarantee.

All interconnecting control wiring shall be provided.


Pipe sizes shall be design by the refrigeration specialist sub-contractor including the condensate drainage pipework. The refrigeration specialist sub-contractor shall also include for drainage lift pumps were required to ensure that the condensate system operates correctly.

All pipework shall be insulated using "Armaflex" Class "0" foil back and clearly identified.

The specialist shall make final connections from switched spur to cassette and external isolators to condensers.

The installation shall be backed by the manufacturers (Mitsubishi) 7-year warranty.

10.04.1 Air Conditioning Installation Specification - "R2" Series Systems

A Specialist Contractor shall supply, install, commission and demonstrate a Variable Refrigerant volume Heat Recovery Heat pump system, as manufactured by Mitsubishi Electric. Their R2 Series Standard System using R410A refrigerant.

The Air Conditioning Installation shall be installed as indicated on the Tender drawings and detailed within the specification.

10.04.2 In Room Units

Ceiling Mounted Units

Each cassette unit shall have ultra low noise fans and be complete with long life washable filters. Condensate lifting pumps shall be provided with each of the ceiling mounted units.

Units shall be installed in the positions identified on the contract drawings.

REF MODEL SUPPLY AIR DISCHARGE M3/S

HEATING COOLING FAN SPEED

ELECSUPPLY

FUSE RATING

QUANTITY

VRF-01 PLFY-P40VCM-E2

0.15 5.0 kW 4.3 kW MEDIUM SINGLE PHASE

6HRC A 56



6HRC A 10




6HRC A 3



6HRC A 2

10.04.3 BC Controllers

The refrigeration contractor shall install and commission Master BC Controllers and Slave BC Controllers as manufactured by Mitsubishi Electric, which shall be installed in the locations indicated on the contract drawings.

REF MODEL NO. OF CONNECTIONS

POWER INPUT / kW

ELECTRICAL SUPPLY

FUSE RATING

RUNNING CURRENT

BC-GF1 CMB-P1016V-GA1(Master)

16 H-0.312 / C 0.312

220V-240V 1PH 50Hz

6HRC A H-1.3A / C-1.3A

BC-GF2 CMB-P108V-GA1(Master)

8 H-0.161 / C 0.161

220V-240V 1PH 50Hz

6HRC A H-0.68A / C-0.68A

BC-1F1 CMB-P1016V-GA1(Master)

16 H-0.312 / C 0.312

220V-240V 1PH 50Hz

6HRC A H-1.3A / C-1.3A

BC-1F2 CMB-P1016V-HB1(Slave)

16 H-0.301 / C 0.301

220V-240V 1PH 50Hz

6HRC A H-1.26A / C-1.26A


16 H-0.312 / C 0.312

220V-240V 1PH 50Hz

6HRC A H-1.3A / C-1.3A

BC-2F2 CMB-P1016V-HB1(Slave)

16 H-0.301 / C 0.301

220V-240V 1PH 50Hz

6HRC A H-1.26A / C-1.26A


16 H-0.312 / C 0.312

220V-240V 1PH 50Hz

6HRC A H-1.3A / C-1.3A

10.04.4 System Controllers

Each suit/floor’s VRV systems shall be controlled via 1No. Mitsubishi AT50 controller per floor which shall be located in the location on the contract drawings.

In addition to the above, the contractor shall install a standard hard wired wall mounted controller per zone identified on the contract drawings that shall provide the following level of minimum control:-

Operating times


Temperature ControlFan SpeedFault Indication

Locations to be agreed on site.

The contractor shall include for the full commissioning of the controls to the requirement of the end user and demonstrations of the controls to the end users at a time to suit the end users.

10.04.5 VRV Condensing Units

The refrigeration contractor shall install and commission VRV condensers which shall be installed in the locations indicated on the contract drawing. The contractor shall include for any cranage necessary to install the condensers.

The compressor shall be scroll type, complete with inverter control to allow capacity variation between 16% and 100% of rated output.

Frequency conversion shall be between 30Hz and 90Hz.

The compressor shall be mounted on resilient rubber mounts in order to minimise both noise and vibration, complete with acoustic lagging.

The units shall have a maximum noise level of NC45 at 3 metres.

The units shall be complete with low noise fans each with independent speed control to ensure stable refrigerant conditions.

The outdoor units shall be controlled via a micro-electronic control board offering full diagnostic and fault information, both at the unit and via electronic transfer to the controller.

REF MODEL HEATING COOLING ELECTRICAL SUPPLY

FUSE RATING

STARTING CURRENT

RUNNING CURRENT

GF-1 PURY-P500YSJM-A

54.8kW 51.5kW 415V 3PH 50Hz

20HRC A / 20HRC A

8A / 8A H-23.3A / C-22.9A

GF-2 PURY-P20YSJM-A

25.0kW 21.3kW 415V 3PH 50Hz

20HRC A 8A H-8.7A / C-8.0A

1F PURY-P700YSJM-A

76.6kW 73.6kW 415V 3PH 50Hz

40HRC A / 25HRC A

8A / 8A H-34.5A/C-37.0A

2F PURY-P750YSJM-A

82.7kW 78.2kW 415V 3PH 50Hz

40HRC A / 32HRC A

8A / 8A H-371A/C-40.9A


3F PURY-P500YSJM-A

54.8kW 51.5kW 415V 3PH 50Hz

20HRC A / 20HRC A

8A / 8A H-23.3A / C-22.9A

10.04.6 Air Conditioning Installation Specification - "M" Series Systems

A Specialist Contractor shall supply, install, commission and demonstrate a Heat pump system, as manufactured by Mitsubishi Electric. Their Mr Slim System using R410A refrigerant.

The Air Conditioning Installation shall be installed as indicated on the Tender drawings and detailed within the specification.

10.04.7 In Room Units

Concealed Ducted Units

Each unit shall have ultra low noise fans and be complete with long life washable filters. Condensate lifting pumps shall be provided with each of the concealed ducted units.

Units shall be installed in the positions identified on the contract drawings.

REF MODEL SUPPLY AIR DISCHARGE M3/S

HEATING COOLING FAN SPEED

ELECSUPPLY

FUSE RATING

QUANTITY

VRF-05 PEAD-RP60JAQ


6HRC A 1

10.04.8 System Controllers

Each suit/floor’s VRV systems shall be controlled via 1No. Mitsubishi AT50 controller per floor which shall be located in the location on the contract drawings.

In addition to the above, the contractor shall install a standard hard wired wall mounted controller per zone identified on the contract drawings that shall provide the following level of minimum control:-

Operating timesTemperature ControlFan SpeedFault Indication


Locations to be agreed on site.

The contractor shall include for the full commissioning of the controls to the requirement of the end user and demonstrations of the controls to the end users at a time to suit the end users.

10.04.9 VRV Condensing Units

The refrigeration contractor shall install and commission a heat pump condenser which shall be installed in the location indicated on the contract drawing. The contractor shall include for any cranage necessary to install the condensers.

The compressor shall be scroll type, complete with inverter control to allow capacity variation between 16% and 100% of rated output.

Frequency conversion shall be between 30Hz and 90Hz.

The compressor shall be mounted on resilient rubber mounts in order to minimise both noise and vibration, complete with acoustic lagging.

The units shall have a maximum noise level of NC45 at 3 metres.

The units shall be complete with low noise fans each with independent speed control to ensure stable refrigerant conditions.

The outdoor units shall be controlled via a micro-electronic control board offering full diagnostic and fault information, both at the unit and via electronic transfer to the controller.

REF MODEL HEATING COOLING ELECTRICAL SUPPLY

FUSE RATING

STARTING CURRENT

RUNNING CURRENT

GF-3 PUHZ-ZRP60VHA

5.95kW 5.5kW 220V-240V 1PH 50Hz

25HRC A 5 H-9.78A / C-8.68A

10.04.10 General Installation Specification

All necessary control wiring, refrigeration pipework and insulation, branch pipes, joint pipe sets, condensate pipework, sundries etc, will be installed to form a complete installation.


10.04.11 External Condenser Frame

The contractor shall include for all external condenser units to be mounted on Bigfoot frame system to ensure all condensers are level.

The Bigfoot frame shall be manufactured and supplied by Big Foot Systems Ltd, Tel 01323 844 355.

10.04.12 Controls Wiring

All Interconnecting control wiring between all Mitsubishi indoor units, outdoor units and all Mitsubishi controllers shall be supplied by the refrigeration contractor. Control wiring shall be co-ordinated with all other engineering services. All controls wiring shall be run in cabling tray and conduit.

10.04.13 Equipment Power Supplies

Power supplies to all equipment shall be installed by Electrical Sub-Contractor. Installations shall be carried out using load information and wiring diagrams as detailed in the specification.

10.04.14 Refrigeration Pipework

Refrigeration pipework between the various heat pump units shall be installed as described in the Specification and detailed on the Tender drawings.

All refrigeration pipework shall be routed in a neat and workmanlike manner, fully co-coordinated with all other services contained within the building, as indicated on the contract drawings.

The refrigeration pipe runs shall be graded as necessary to ensure the return of the oil to the compressor crankcase and drainage of condensation.

The refrigeration shall be soft copper to B.S.2871:Part 2. All refrigeration pipework shall be "dehydrated for refrigerant use" and shall be marked as such. Fittings shall be manufactured from copper or suitable corrosion free resisting alloy for copper. All pipework shall be adequately bracketed throughout using suitable for vertical routing of refrigeration pipework. Brackets shall not be more than 1.5m centres in all runs. All external refrigerant pipework runs shall be on cable tray. Internal


refrigerant pipework runs that are visible shall be in plastic trunking provided and installed by the Refrigeration Contractor.

Pipework shall be reamed after cutting and shall be free from burrs, scales and other defects, and shall be thoroughly cleaned before installation. At all times during installation the pipework shall have end capped except when actual joining is taken place and all pipework shall be sealed prior to installation.

Dry nitrogen shall be purged through the pipework whenever a brazing operation is being carried out to prevent any formation of oxides with the pipework. When brazing adjacent to valves etc., precautions shall be taken to prevent the heat distorting valve seats or similar by wrapping components with a damp rag to absorb heat.

Refrigerant pipework shall be installed shall allow easy recovery and topping up of refrigerant.

All joints shall be made in accordance with the manufacturer’s recommendations using only their recommended fluxes, solders, jointing compounds, etc and left clean after completion.

Refrigerant mains external to the building structure shall be double wrapped with Denso tape by the refrigeration machinery contractor during installation after the proper commissioning procedures have been completed.

Where exposed, pipework shall be supported with polished cast gunmetal built in clips.

Pipework installed in service ducts, ceiling voids, or together with other pipework shall be supported by gunmetal munzen rings from the common angle or channel iron supports.

All pipes shall be supported at not more than the following intervals; -

Size of Pipe (mm) Interval for Supports (mm) 15 1200 22 1200 28 1500 35 2000 42 2000 54 2000 67 2000 76 2000

Where pipes pass through walls, floors etc sleeve pipes shall be provided.


Upon completion of the pipework installation the system shall be pressure tested in accordance with the Mitsubishi Guide. After the pressure testing and dehydration of the system, the system shall be charged with the required amount of refrigerant.

10.04.15 Refrigerant Pipework Insulation

The refrigerant pipework insulation shall be either Armaflex Class "O" or Insutube Class "O", with a minimum wall thickness of 13mm. The insulation shall have a thermal conductivity of 0.03 W/mk at 0°C to DIN 52613.

10.04.16 Condensate Drains

Condensate drains from all indoor cassette units are to be pumped drains, routed as indicated on the tender drawings.

Each cassette unit shall incorporate a condensate pump and this pump shall be complete with condensate sump. The condensate pump shall be wired to interface with the cooling unit it serves and fail safe shall be operable to prevent the fan unit operating in the event of pump failure.

Where gravity drainage is proposed, the pipework shall be copper as detailed elsewhere within this specification.

Where pumped drainage is utilised, the pipework shall be PVC vinyl braided flexible hose with a minimum wall thickness of 1.9mm from the pump to copper main condensate drain. All connections to cassette units are to be 1-1/4” (32mm).

All drainage shall be leak and gravity tested on completion of the installation, including condensate pumps and certified by the Main Contractor as been tested.

All condensate mains shall be thermally insulated.

10.5 Ventilation System

10.5.1 General

The mechanical ventilation system provides supply and extract ventilation via packaged air handling unit located in the roof level plant room. The air is passed through the distribution system, consisting of a range of sheet metal ductwork, into and out of the building.


The ventilation system is controlled by the independent AHU controls.

The contractor shall include for the modifications indicated on the contract drawings to the existing ventilation system in addition to the full rebalancing of the existing system.

10.5.2 Dampers

Fire/smoke dampers shall be provided in ductwork where it passes through all fire/smoke barriers (riser walls) and on a floor by floor basis. Access panels shall be located adjacent to each fire/smoke damper. Any ductwork passing through a plantroom wall shall be complete with fire dampers.

Fire dampers are to be located in ductwork passing through any fire blankets, the dampers shall be complete frames supported from the buildings structure. Access panels shall be installed in the ductwork adjacent fire dampers to enable the dampers to be reset.

Volume control dampers (VCD's) shall be provided to all branches and sub branches to enable complete balancing of the ventilation system to be achieved. All VCD's shall be located in an accessible location.

10.5.35 Vibration

All mechanical services, plant and equipment are to be suitably isolated from the building structure in order to prevent the transmission of vibration. The Contractor shall comply with the guidance on the satisfactory magnitude of building vibration with respect to human response given in BS 6472.

Vibration limits are as follows: Plant rooms on occupied floors 0.015 m/s2

Plant rooms above and below occupied floor levels 0.050 m/s2

Remote plant rooms 0.100 m/s2

10.5.4 Acoustics

All plant and equipment shall be securely fixed to a solid ‘builderswork’ base, with anti vibration supports and fixings to ensure the plant is entirely isolated from structure.

Approval shall be sought from the Project Manager and Structural Engineer regarding support requirements for plant, with provision of full details for all


required openings and trimmings, etc, to allow the appropriate Structural design to be undertaken. No major item of equipment shall be mounted and no cuts or holes formed in the building fabric without gaining the approval of the Project Manager/Structural engineer.

The contractor will be responsible for the provision of any supports required to accommodate the proposed plant.

All secondary support systems for the Mechanical services plant shall be supplied and installed by the Contractor and be subject to the approval of the project Structural Engineer and Architect.

10.5.5 Ductwork

Acoustic flexible ductwork shall be installed where fixed ductwork connects to all the plenums, diffusers and grille units, and shall be independently supported to ensure constant diameter. The insulation shall also be suitably vapour sealed at each point of connection.

Acoustic flexible ductwork shall be perforated synthetic inner tube, vinyl coated steel spiral, surrounded by insulated layer of glass fibre, covered by an outer layer of metalised firm reinforcement with glass fibre.

Sound Attenuation:-63 125 250 500 1K 2K 4K 8K11 15 16 18 19 25 17 15

10.5.6 Grilles, Diffusers and Louvres

Extract grilles and supply diffusers and extract louvres shall be installed as required. New grilles and diffusers shall match the existing.

All diffusers, grilles, louvres and volume control dampers shall not exceed the noise ratings quoted within the CIBSE guides.

All the supply diffusers and extract grilles shall be complete with plenum boxes which shall be lined with black acoustic foam.

The contractor shall include for all necessary builders work to install the louvres including weather sealing.


Final connections shall be made in flexible ductwork to square diffusers. In each case the diffuser shall be separately supported. The maximum length of flexible ductwork shall be restricted to 300mm,

All grilles shall be supplied in a BS colour to be specified by the project manager.

Ref Brand Type Model Size AirflowS1 GDL Perforated Diffuser – 4

WayB661R+6C 600x600

S2 GDL Perforated Diffuser – 4 Way

B661R+2C 600x600

E1 GDL Perforated Diffuser B6E1R+6C 600x600E2 GDL Perforated Diffuser B6E1R+2C 600x600

10.06 Domestic Water System

10.06.1 Hot Water Heaters

The Contractor shall supply, install and commission a hot and cold-water installation which shall comply with all statutory and local authority regulations.

The hot water shall be via an unvented indirect cylinder, manufactured and supplied by Zip Heaters (UK) Ltd.

Unvented Indirect Hot Water Cylinder

Location Roof Level PlantroomModel Zip Aquaflo II AF4180Nominal Capacity 180LElement Rating @ 240v 1x3kWNotes C/W unvented kit & stat

All pipework shall be routed in a neat, logical and workmanlike manner, fully co-ordinated with all other services contained within the building.

Unit to be finished in factory fitted insulation on all 4No. square sides.

10.06.2 Cold Water Storage Tank

The contractor shall supply, install and commission a cold water storage tank. The water storage tank will be installed in accordance with the manufacturers recommendation.


Cold Water Storage Tank (Two Piece)

Specification

Model - GRP Sectional Water Storage Tank – Internally Flanged BaseCentral dividing wall to allow for cleaning Raised ball valve chamber

Dimensions - 2000 x 1000 x 1000mm highNo. of compartments - 2No.Nominal capacity - 2000 litres

The cold water storage tank shall be manufactured by the following company:-

Balmoral TanksBalmoral Park,Loirston,Aberdeen,AB12 3GYTel 0208 665 4100

10.7 Pumps

The contractor shall provide, install and commission the following circulating pumps as manufactured by Grundfos (or equal and approved).

All the pumps shall be complete with pump flex connections and anti-vibrations mounts to isolate the pumps from the building structure.

Pump Ref P1 (Drawing no. 261/M/11)

Circuit Primary Heating Location PlantroomModel MAGNA3 65-150 FDuty 3.57 L/s @ 100kPaElectrical Supply Single Phase Comments To be complete with anti-vibration mountings.

Pump Ref P2 (Drawing no. 261/M/11)


Circuit DHW Primary Location PlantroomModel MAGNA 32-60 NDuty 0.45 L/s @ 46.2kPaElectrical Supply Single Phase Comments To be complete with anti-vibration mountings.

Existing pipework to be modified to suite new pumps.

10.08 Flue Installation

The Contractor shall include for the modifications to the existing flue system to allow for the removal of 1No. existing boiler.

10.09 Humidifier Installation

The Contractor shall supply, install and commission a new electrode boiler steam humidifier serving the ventilation system. The humidifier shall be installed in accordance with the manufacturers recommendations.

Specification

Model - JS Humidifiers Condair CP3-25 Electrode Boiler Steam Humidifier

Dimensions - 569 x 667 x 350mm highNo. of units - 1No.Power - 18.8kWPower Supply - 400VACCurrent - 27.1AOperating Weight (empty) - 28kgOperating Weight (filled) - 65kg

The unit shall be complete to provide a fully functioning system including lances etc

10.09 AHU & Ductwork Cleaning

The Contractor shall include for cleaning the existing AHU and supply and extract ductwork that is being retained and reused as part of the proposed works.

The ductwork cleaning shall be carried out in accordance with the latest HVCA maintenance requirements and also the HVCA TR/19.


The Contractor shall include for installation of access doors to enable the cleaning of the ductwork.

10.10 Contingency Sum

The Contractor shall include a contingency sum of £10,000.00 (Ten Thousand Pounds) to be expended by the engineer in whole or part as required.


288 M Spec Rev T1

Documents

pipework installation313

contract documents101

copper pipework joints453

return of documents101

property of documents101

safety valves

pipe sleeves513

construction programme242