46200 Petaling Jaya Selangor Darul Ehe Tel: 03-79678000, Fax: 08-79572895 TECHNICAL SPECIFICATION PRECAST PLINTH, BOLLARDS AND KERBS FOR COMPACT SUBSTATION (CSU) Specification No. | KEJ08460:2020 | Revision No. 0 Prepared by Harpreet Singh A/L S Singh Jurutera Utama (Project Design) ‘Asset Development Distribution Network, TNB Mohd Khalid Bin Othaman Jurutera Utama (Substation System Design) Engineering Services Distribution Network, TNB Approved by | TNB, Distribution Network Division Technical Committee Dated: 25 February 2020 Menjalanka\ Tugas Head (Asset Management) Distribution Network Division, TNB 4Technical Specification Precast Plinth, Bollards and Kerbs for Compact Substation (CSU) TENAGA NASIONAL Specification No. | KEJO8460:2020 Revision No- Page 1 OF 13 ‘Approved by ___| TNB, Disiributfon Network Di iston Technical Committee Dated 25 February 2020 1.0 INTRODUCTION ‘This specification for Precast CSU Plinth, Bollards and Kerbs (PPBK) is to be used for the installation and commissioning of Compact Substations (CSU). 2.0 SCOPE ‘This technical specification covers the design, material, construc inspection for PPBK. n, testing and product 3.0 NORMATIVE REFERENCES ‘This specification shall make reference to the following standards and TNB technical specifications unless otherwise stated. Standard Title BS 8110:Part 1 1997 ‘Structural Use Of Concrete | BS EN 12390-3:2019 ‘Testing Hardened Conerete: Compressive Strength MS 1462014 Grade 500 | TIO, T12, T16, High Tensile Reinforcement Steel Bar BS EN 10025 $275 ‘Structural Grade Steel With A Minimum Yield Strength of 275 Nimm? BS EN ISO 1461:2009 | Hot Dip Galvanized Coatings On Fabricated tron and Steel Articles. Specifications And Test MethodsTechnical Speciation & Precast Plinth, Bollards and Kerbs for Compact Substation (CSU) TENAGA NASIONAL Spaaciion No [ REVO 020 Reviion No Fage2OT “Approved by | TNB, Distbation Network Division Technfcal Commies Dated 25 Febrary 2020 4.0 FUNCTIONAL REQUIREMENTS: ‘The PPBK shall be suitable for the installation of CSU equipment. Below are the functional requirements of the all the components: Table I: CSU Precast Components and Functions Item] Component Funetion 1 | Precast Plinth ‘Conerete base support for CSU equipment 2 | Precast Bollard Concrete barrier to protect the CSU plinth from damage due to vehicular impact 3 | Precast Kerb ‘Conerete segments on the perimeter of CSU land to mark the boundary and also support the premix. 5.0 DESIGN AND CONSTRUCTION 5.1 Design of PBK a. The PPBK shall be made of reinforced concrete and shall achieve a concrete compressive strength of at least 30 MPa. b. The design drawings of the PPBK shall be endorsed by Civil & Structural Professional Engineer and submitted to TNB for approval. ©. The precast plinth shall be designed and manufactured as per the dra Appendix 1. The steel reinforcement drawing for the precast plinth, is as per drawing in Appendix 2. 4. The plinth shall be provided with slab covers fitted with mild steel angle frames and sinkable holders. The mild steel components shall be coated with hot dipped galvanizing. The plinth shall also be provided with weep holes for water drainage, e. The precast bollards shall be designed and manufactured as per the drawing in ‘Appendix 1. The bollards shall be of removable type fitted in concrete footings planted into the ground. f. The precast Kerbs shall be designed and manufactured as per the drawing in Appendix 1Technical Specification Precast Plinth, Bollards and Kerbs for Compact Substation (CSU) TENAGA NASIONAL Spastcton No. | KETORIGU020 Revision No FTO “Approved by | TNB, Disibuton Network Division Technical Comoe Date 25 Febrany 1020 5.2. Material and Sizing ‘The material and sizing of the PPBK components are shown in Table 2 below: Table 2: Material and Sizing of PPBK Components item] Components | Material Dimensions/Characteristies 1 | Precast Reinforced | 30 MPa compressive strength of concrete Plinth Concrete | High tensile steel reinforcement bars of sizes T10, T12, T16 Overall size: 6250mm (L) x 2550mm (W) x 1200mm (H) LY chamber: 1250mm (L) x 250mm (W) x 1200mm (H) HV chamber: 1000mrn (L) x 2550mm (W) x 1200mm (H) CSU chamber: 400mm (L) x 2000mm (W) x 120mm (#1) Slab cover: 180mm (L) x 205mm (W) x 50mm thick Duet ways: 180mm dia. x 36 nos. cable ducts Weep holes: 25mm dia. x 3 nos. weep holes 2 | Precast Reinforced | 30 MPa compressive strength of concrete Bollards Concrete} High tensile steel reinforcement bars of size T10 Bollard size: 150mm dia, x 100mm (L); Quantity=14 nos. Bollard footing size: 375mm (L) x 375mm (W) x 450mm (1H); Quantit Reflector sticker (50mm width) shall be provided that is 14 nos. water resistance, durable, strong reflectivity and shall stick permanently on the bollard. 3 | Precast | Reinforced [30 MPa compressive strength of concrete Kerbs Concrete | Kerb size: 600mm (L) x 150mm (W) x 300mm (H); Quantity = 36 nos.Technical Specification Precast Plinth, Bollards and Kerbs for Compact Substation (CSU) Speciication No._[ KETO84602020 [Revision No. Paged OF 13 Approved by | TNB, Distribution Network Division Technical Commies Dated 25 February 2020 ‘The following are the allowable tolerances* for the above precast components: ‘Component Tolerances Precast Plinth Length: -13mm; 25mm Width: +/-19mm Thickness of wal Slab Thickness: 4.5mm; +25mm 3: 4.5mm; +25mm Precast Bollards Length: +-6mm Diameter: +/-6mm Precast Kerbs Length: ¥7-1.5mm Thickness: +/-1.5mm * Ref, Tolerance Manual for Precast and Pre-Stressed Concrete Construction ~ Precast/Pre- Stressed Institute, USA (2000). 53 Construetion a, Precast Plinth © Excavate pit of 6800mm (L) x 3100mm (W) x 1300mm (D) to accommodate the precast plinth. The related HIRADC on excavation shall be complied with. Lay and compact 200mm thick crusher run followed by a SOmm thick layer ofrriver sand atthe base of the excavated pit. Ensure that the finished surface of the compacted material is completely horizontal. ‘© Place the precast plinth in the pit using hoisting equipment of sufficient capacity. The related HIRADC on hosting shall be complied with, * Backfill and compact the excavated ground surrounding the plinth b. Precast Bollards * Excavate pit of $00mm (L) x 00mm (W) x 550mm (D) to accommodate each bollard footing. «Lay and compact 200mm thick crusher run followed by # 50mm thick layer of river sand atthe base of the excavated pit. Ensure that the finish surface of the compacted material is completely horizontal.Precast Plinth, Bollards and Kerbs for Compact Technical Specification ‘Substation (CSU) TENAGA NASIONAL ‘Specification No. KEIOR#60-2020 Revision No. Pages OF 13 “Approved by "TNB, Distribution Network Division Technical Committee Dated 25 February 2020 Place the precast bollard footing in the pit, backfill and compact the excavated ground surrounding the footing. ©. Precast Kerbs Excavate a trench of 300mm (W) x 150mm (D) throughout the perimeter of the CSU land, Spread cement mortar at the base of the trench and place the precast kerb footing in the pt, backfill and compact the excavated ground surrounding the footing. The joints between kerbs shall be sealed with cement mortar. d. Premix Excavate ground within the perimeter kerb to suitable level and lay 200mm thick erusher run. Lay and compact 60mm thick premix. The final level of the premix shall be 150mm below the precast plinth and match the top level of the precast kerb and bollard footing. ‘The slots on the CSU plinth in front ofthe LV ad HV component shall be filled with premi 6.0 INSPECTION AND TESTING 6.1 Product inspection / factory acceptance tests shall be carried out by TNB Quality Assurance Inspector (QAI) o appointed quality inspection agent before the PPBK is allowed to be delivered for site installation. 62 — Manufacturing Routine Test i, Routine tests shall be carried out by manufacturer on all products in the finished state or, where appropriate, during the manufacturing process to ensure compliance to the reference standard requirements.Technical Specification Precast Plinth, Bollards and Kerbs for Compact Substation (CSU) TENAGA NASIONAL ‘Speciffeatfon No. | KEI08460:2020 Revision No, Page OF 13 Approved by | TNB, Disiribuifon Network Division Technical Commitee Dated 25 February 2020 All test records will be kept safely and produced for inspection by TNB QAI during Product Inspection (PI). 63. Factory Acceptance Testing / Product Inspection (PI) Product inspection or factory acceptance tests shall be carried out on sample of PPBK, ‘The product inspection or factory acceptance tests that shall be made on the products are: ‘Visual inspection on PPBK construction and quality of finishing, Verification of the dimensions iii, Concrete Cube Test (BSEN 12390-3:2019 Compressive strength of test specimens) iv. Ready mix supplier, must be certified ISO 9001-2015 v. Steel Bar - Mill Cert MS 146:2014 Grade 500 (Specification for Hot Rolled Steel Bar) vi, Galvanizing test using ELCO meter Vii, Calibration report of equipment utilized for test and measurements 64. Thesampling rate for product inspection / factory acceptance tests and acceptance criteria shall refer to the latest TNB Quality Assurance Guidelines (Terma Serta Syarat Pengurusan dan Penguatkuasaan Jaminan Kualiti Produk, TNB) 7.0 QUALITY ASSURANCE AND CONTROL ‘The manufacturer is responsible to maintain all quality and test records for a minimum period of Five (5) years. TNB and /or its appointed agent reserve the right to inspect these records as and ‘when deemed necessary. 8.0 WARRANTY ‘The PPBK shall have a warranty of minimum 1 year from delivery date against any defect in ‘material or workman: ‘The warranty period requit ay be revised and will be specified in tender document.‘Technical Specific: Precast Plinth, Bollards and Kerbs for Compact Substation (CSU) TENAGA NASIONAL ‘Specification No, | KETOR4G0:2020 Revision No. Page 7 OF 13 ‘Approved by TNB, Disiributfon Network Division Technical Committee Duted 25 February 2020 TECHNICAL SCHEDULE (To be completed by tenderers) NO. DESCRIPTION OFFER Yes!No 10 | Precast Plinth, Bollards, Kerbs (PPBK) Design TI |The design drawings and dimension of the PPBK endorsed by | Professional Civil &Struetural Engineer for TNB approval 12 | The precast plinth shall be designed and manufactared as per the approved drawing. The plinth shall be provided with concrete slab covers fitted with mild steel angle frames and sinkable holders. The mild stee] components shall be hot dipped galvanized. The plinth shall also be provided with weep holes for water drainag; 13 | The precast bollards shall be designed and manufactured as per the approved drawing. The bollards shall be of removable type fited in conerete footings planted into the ground. Ta | The precast Kerbs shall be designed and manufactured as per the approved drawing. The kerbs shall be planted 150mm into the ground and joints between kerbs shall be sealed with cement mortar 2.0 | PPBK Construction 2 | Supplier shall have ISO 9001: 2015, Quality Management System Certification 22 _| The Coniractor shall submit a Method Statement and HIRADC for TNB approval prior to commencement of the works 13.0 | Inspection & Testing 7 “3 | Manufacturing routine fests shall be carried out by manufacturer on all products in the finished state or, where appropriate, during the ‘manufacturing process to ensure compliance to the reference standardTechnical Specification Precast Plinth, Bollards and Kerbs for Compact Sutstation (CSU) TENAGA NASIONAL | Specification No. | KEJ08460:2020 ‘Revision No. Page 8 OF 13 ‘Approved by | TNB, Distebatton NeOWOrK Division Teshnlcal Commies Dated 25 February 2020 NO. DESCRIPTION OFFER Yes/No. requirements. All test records will be Kept salely and produced Tor inspection by TNB QAI during Product Inspection (PD). 32 | Product inspection or factory acceptance tests shall be carried out on sample of products in the finished state. The product inspection or factory acceptance tests that shall be made on the products are; ‘© Visual inspection on PPBK construction and quality of finishing + Verification ofthe dimensions ‘© Concrete Cube Test (BSEN 12390-3:2019 Compressive strength) ‘© Ready mix supplier, must be certified ISO 9001:2015 ‘© Stee! Bar - Mill Cert MS 146:2014 Grade 500 (Specification for Hot Rolled Steel Bar) © Galvanizing test using ELCO meter ‘+ Calibration report of equipment utilized for test and measurements 33 | The sampling rate for product inspection / factory acceptance tests and acceptance criteria shall refer to the latest TNB Quality Assurance Guidelines “4.0 | Quality Assurance & Control [ar | The manufacturer fora minimum period of five (5) years. TNB and /or its appointed agent Tesponsible to maintain all quality and test records reserve the right to inspect these records as and when deems necessary, 0 | Warranty The PPBK shall have a warranty of minimum | year from delivery date against any defect in material or workmanship. The warranty period required may be revised and will be specified in tender document.Precast Plinth, Bollards and Kerbs for Compact Substation (CSU) NAGA NASIONAL Speciation No. [ KEV0B4602020 Revision No Fase VOT ‘Approved by "ENB, Distribution Network Division Technical Committee Dated 25 February 2020 Architectural Drawings for Precast CSU Plinth, Bollards and Kerb‘Technical Specification G Precast Plinth, Bollards and Kerbs for Compact Substation (CSU) TENAGA NASIONAL Specification No. | KEV0#460:2020 Revision No. Page 10 OF 15, ‘Approved by | TNB, Distribution Network Division Technical Committee Dated 25 February 2020 APPENDIX 2: Steel Reinforcement Drawings for Precast CSU Plinth