istobal Twash 4TA6000 Civil Work And Installation

WASH TUNNEL

MOD. 4TA6000

Departamento de Formación V_07_14

TRANSLATED FROM THE ORIGINAL MANUAL

CIVIL WORK AND INSTALLATION

34GJ100B

ISTOBAL, S.A. Avda. Conde del Serrallo, 10 46250 L’Alcúdia (Valencia - España)
Teléfono 96 299 79 40 Fax [phone] E-mail: [e-mail] www.istobal.com

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34GJ100B

1. SAFETY 3

2. BUILDING SPECIFICATIONS 7

3. EXCAVATION PLAN 12

4. NO ENCLOSURE 14

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INDEX

2.1. Excavation work 7

2.2. Filling work and embankment 7

2.3. Bed 7

2.4. Reinforced concrete slab 8

2.5. Concrete specifications 9

2.6. Drainage gutters 10

2.7. Drainage piping 11

2.8. Rain gutters, with enclosure 11

3.1. No enclosure 12

3.2. With enclosure 13

4.1. Design measurements and sections 14

4.2. Electrical lines 16

4.3. Air and water lines 17

4.4. Dimensions 18

5. WITH ENCLOSURE MP 20

5.1. Design measurements and sections 20

5.2. Dimensions 22

5.3. Electrical lines 24

5.4. Air and water lines 25

6. WITH ENCLOSURE CM 26

6.1. Design measurements and sections 26

6.1. Adjoining bays 28

6.2. Dimensions 30

6.1. Electrical lines 32

6.1. Air and water lines 33

7. CONNECTION DETAILS 34

8. INSTALLATION 36

8.1. Service lines and pipes 36

8.2. Electrical data 38

8.3. Electrical distribution cabinet 39

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SAFE PRACTICE AND SAFETY RULES

To guarantee your safety, please cooperate with the company at all times and obey the safety rules detailed here
to help ensure that accidents are avoided. (Article 29. Safety at Work Act). The following list of obligations shall
be respected by all workers carrying out work whether directly employed by ISTOBAL or subcontracted.

SAFETY

• Please make proper use of the personal protection equipment provided.

• Follow the instructions of your superiors, and any indications given by the person responsible for the

facility.

• Keep tools and personal and collective protection equipment in good order. If you observe any deterioration

in them, advise your superior immediately.

• Keep the work site clean and tidy.

• Advise your superiors and colleagues of any danger or risk that you perceive on the facility. In case of

serious and imminent risk, do as indicated above while also ceasing to perform any activity which may add
to such risk.

PREVENTIVE MEASURES

ISTOBAL, S.A. personnel and workers subcontracted by the company are to take into account the following
preventive measures while carrying out work:

• Hand-held ladders are not permitted for performing jobs. For work where use of a scaffold is not physically

possible or where its use would be an added risk, a platform step ladder is to be used.

• If a certied scaffold is used, follow the manufacturer's assembly instructions closely. Make sure it is in

perfect condition before use. Do not place it near power lines. If the scaffold is moveable, put the brakes on
all the wheels and use securing bars to stop it moving unexpectedly. Do not move the scaffold with workers
on it. Do not leave tools or materials lying around on the scaffold.

• If a platform step ladder is used, it must only be used by duly trained and authorised personnel. Make sure

that it is used in accordance with the instructions supplied with it.

• All waste generated is to be collected and removed from the work area as and when it is generated. The

work area should be kept as clean as possible at all times.

• Make sure the work area is organised - do not leave materials and tools lying around as these could cause

accidents.

• When materials are being loaded and unloaded with winches / cranes; materials are being lifted; heavy parts

are being mounted, etc., make sure there are no workers underneath. Check this before starting to move
anything.

CONDUCT ON SITE

• Station your vehicle in designated parking zones. Turn off the engine. Parking is not permitted in classied

areas or where the vehicle would obstruct the passage of persons or vehicles.

• Inform the supervisor or person responsible for the facility of the presence of the vehicle and why it is

there.

CIVIL WORK AND INSTALLATION

• Before starting work, put up signs and cordon off the areas where you will be setting up equipment such as

winches, compressors, etc.

• After the work is completed, remove leftover waste from the work area, such as plastic, cardboard, wood,

etc.

• Collect your tools and other equipment.

• Inform the Supervisor or person responsible for the facility that the work is completed and what the situation

is now.

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SAFETY

PROTECTION EQUIPMENT

Personal and collective protection equipment used should be appropriate to the task, certied with the mark,
and display the corresponding inspection dates.

Personal protection equipment should give effective protection against the risks they are intended for. Such
equipment should not constitute a risk in itself nor cause unnecessary inconvenience. The equipment should:

• Respond to the conditions existing in the workplace.

• Take into account the anatomy, physiology, and state of health of the operator.

• Fit the bearer properly after the pertinent adjustments.

• Where multiple risks are involved which require several types of personal protection equipment to be

used together, they should be mutually compatible and maintain their level of efciency in relation to the

corresponding risk or risks.

PERSONAL PROTECTION EQUIPMENT

COMPULSORY PROTECTION

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Safety footwear.

Mechanical protection, waterproof, and with a dielectric

sole, anti-slip, and anti-perforation protection.

High visibility reective vest.

Safety helmet.

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Safety gloves.

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PERSONAL PROTECTION EQUIPMENT

OTHER PROTECTION DEPENDING ON THE WORK TO BE DONE

Tool belt.

OTHER PROTECTION DEPENDING ON THE WORK TO BE DONE

SAFETY

Safety harness.

For work at a height of 2 m. and above.

Back support belt.

For tasks which require unusual positions to be adopt­ed, or straining.

High impact safety goggles.

Use of drills, radial saws, etc.

CIVIL WORK AND INSTALLATION

Ear protection.

Use of drills, radial saws, etc.

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SAFETY

PERSONAL PROTECTION EQUIPMENT

Welding screens and masks with metal smoke lter.

Use of welding sets.

COLLECTIVE PROTECTION EQUIPMENT

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Safety tape and cones

To indicate and cordon off the work area.

No entry sign.
To prevent unauthorized access, and indicate the
need for PPE to be worn.

Portable re extinguisher.

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Fire blankets

For work generating heat (welding, radial saws,
etc.).

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BUILDING SPECIFICATIONS

2.1. Excavation work

Any vegetation will be cleared, and any elements or small infrastructures will be removed, should there be any.

The whole site will be cleared and the vegetation soil all over it will be removed.

Once the desired level has been reached, soil moisture and compaction will be checked.

2.2. Filling work and embankment

'Esplanade' or 'embankment' is the nished excavated area where the paving layers (bed and slab) will be

built.

The esplanade must be correctly compacted until it is totally even and homogeneous, which requires a number
of roller operations.

• Minimum esplanade type E1 (5 < CBR < 10)

If the esplanade needs to be formed or if the features of the existing plot are not suitable, these can be either
improved by means of stabilization, or replaced at an adequate depth by a bed with the right features.

• Materials to be used Features:

- Minimum: Adequate ground (as per PPTG PG3)

- Stones with max. diameter below 10 cm. Sieved with

sieve no. 200, 35% of weight.

- LL < 40

- Maximum density, normal Proctor test, 1.75 kg/dm3,

CBR>5

- Organic matter < 1%

- Soluble salts (including gypsum) < 0.2%

In the esplanade work and the subsequent bed, please bear in mind that the work to be done shall cover an

additional 3.0 m band parallel to the boundaries of the wash tunnel area so as to allow for drainage and for a

transition between the facility level and that of the adjoining areas.

2.3. Bed

Granular material layer between the esplanade and the slab, consisting of natural aggregates or aggregates

derived from quarry stone grinding or natural gravel, or clay/marl-free selected soils.

CIVIL WORK AND INSTALLATION

To be compacted in a single layer (15 cm course minimum) until 97% PM is reached.

• Type - Wet-mix macadam

• Thickness - See civil works ground plan.

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BUILDING SPECIFICATIONS

• Granulometry - Fractions going through the 0.08 sieve will be smaller than

• Compacted density - Over 100% of maximum density. Modied Proctor Test

2.4. Reinforced concrete slab

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half the fractions sieved with the 0.40 sieve. Measured by

weight.

- Maximum aggregate size will be smaller than half the

compacted layer.

- The fraction retained by Sieve 5 should at least have 50%

(weight) elements with two or more fracture surfaces.

- Abrasion measured by Los Angeles test should be lower

than A 30.

- The material must be non-plastic and the sand-content

equivalent must be over A 35.

- CBR > 80 for 100% compaction, Modied Proctor Test

density, even in singular project areas (edges, meeting
points, elements).

• Thickness - See civil works ground plan.

• Reinforcement - Electro-welded mesh AEH 500 (fyk=5100 Kp/cm2)

• Slopes - See civil works ground plan.

• Contraction joints - every 5.0 m

- width 4 mm

- depth 40 mm

• Expansion joints - every 25.0 m

- width 20 mm

- lled and sealed

• Finishing process - Spreading and compacting with concrete screeder.

- Surface smoothing by screeder.

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- Mechanical oating once concrete is resistant enough

(helicopter, xed at propeller).

- Repeat previous operations as many times as necessary

until the desired nish is obtained. In our case, surface
nish must be non-slip.

- Curing by wax-based curing liquid (Bettocure-C).

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BUILDING SPECIFICATIONS

2.5. Concrete specications

The slab concrete's corrosion exposure class is “IIa” (normal reinforcement for high moisture conditions). It is

adequate for areas that are not by the sea. For other types of exposure, check regulations in force.

Concerning exposure relating to concrete degradation phenomena other than corrosion, the concrete is ero-

sion-classed, “E”.

If the area were affected by frost, no melting salts would be needed for the foreseen purpose. Designation

would be “H” (frost exposure, no salt de-icing).

• Denition - with compression HM-30 / B / 20 / IIa+E

- with frost risk: HM-30 / B / 20 / E+H

• Water/cement rate

- (Table 37.3.2.a EHE-08)

- Below 0.50 (Exposure class E)

• Minimum concrete strength - (Table 37.3.2.b EHE-08)

- 30 N/mm2

• Cement - Portland cement EN 197-1 CEM I 32.5 N (APPENDIX

4. Tables A.4.2 and A.4.5 CE Marking EHE-08

and Appendix I RD 956/2008 RC-08)

- (Table 37.3.2.a EHE-08)

- Minimum content 325 kg/m3. (Do not exceed maximum

cement content 375kg/m3.

• Consistency - Concrete slump test, base 6 to 9 cm.

- (Art. 31.5 EHE-08) Consistency SOFT

CIVIL WORK AND INSTALLATION

• Coating - (Art. 37.2.4.1 EHE-08)

- Without blinding concrete, minimum nominal coating

80 mm.

- With blinding concrete, nominal coating 4mm.

• Curing - (Art. 37.3.7 EHE-08)

- Prolonged curing, at least 50% above normal, that is,

10 days approximately in normal conditions.

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BUILDING SPECIFICATIONS

• Aggregates - (Art. 37.3.7 EHE-08)

• Additives - Waterproong liquid (Sika-1), 3% of cement weight.

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- Fine aggregates will be QUARTZ or a material with at

least the same hardness.

- Los Angeles coefcient for thick aggregates under 30.

- (Table 28.4.1.a. EHE-08)

- Thick aggregates: maximum % passing through sieve

0.063: 1.5 %.

- Fine aggregates: maximum % passing through sieve

0.063: 6 %.

- In case of frost risk (exposure class “F”), minimum

occluded air content 4.5%, as per UNE-EN 12350-7.

• Waterproong - (Art. 37.3.3 EHE-08)

- Concrete waterproong must be tested according to

UNE EN 12390-8, since the environmental exposure
class is “E”.

2.6. Drainage gutters

To be made on site using concrete with the same specications as the slab concrete and tting a prefabricated

PVC drainage gutter.

The gutters must be covered with perforated steel sheets seated on a 12 mm continuous prole on the gutter

edge.

• Width - 24 cm minimum.

• Depth - 19 cm minimum.

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• Slope - inner slope 1.0 % (minimum)

• Reinforcement - See civil works ground plan.

• Cover - Perforated steel sheet, thickness = 8 mm

- Dimensions: depending on gutter type (see details).

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BUILDING SPECIFICATIONS

2.7. Drainage piping

Gutter and central trap drainage is via a number of pipes that run along the boundaries of the wash tunnel.

The pipes are PVC, with connection boxes and pits at intersection points where necessary.

The pipework facilitates the drainage of water coming from the wash tunnel, taking it to the sludge settler,
where water treatment starts for water to be recycled and reused in new wash processes.

• Pipes - PVC 160 mm minimum diameter

• Slope - minimum 1.0%

• Connection pits - Perforated bricks, rendered and smoothed.

2.8. Rain gutters, with enclosure

Rain water is collected and channelled by separate gutters that run parallel to the drainage piping. As in the
previous case, the pipes are arranged on the sides of the wash tunnel.

For wash tunnels without an enclosure, rain water is collected together with that of the actual tunnel.

All pipes must be PVC, even the special parts.

Pipe slope should not be under 1.0%. Pipes must lean on a concrete or sand bed.

Couplings as per drawings, in connection boxes or pits built with bricks, rendered and smoothed. Pit dimen­sions are indicated in the corresponding drawings.

CIVIL WORK AND INSTALLATION

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EXCAVATION PLAN

3.1. No enclosure

3

L1 15640 17360 18990 20610

Z 755 790 820 855

22240

885

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Measurements in mm.