Manhole Specification

Document: MH_002_STD

Table of Contents

DOCUMENT CONTROL .............................................................................................................................................. 1 1. SCOPE ........................................................................................................................................................................ 1 2. PREAMBLE TO STANDARD SPECIFICATIONS FOR MANHOLES .................................................................................. 1 3.

Introduction ..................................................................................................................................................... 1 3.1

Works Description ............................................................................................................................................ 1 3.2

Contractor Camp Establishment ...................................................................................................................... 1 3.3

Location of Camp and Depot............................................................................................................................ 1 3.4

Management of the Environment.................................................................................................................... 1 3.5

Spoil Areas ........................................................................................................................................................ 2 3.6

Sanitary Facilities ............................................................................................................................................. 2 3.7

Site Conditions ................................................................................................................................................. 2 3.8

Site facilities ..................................................................................................................................................... 2 3.9

Stockpiling Material ......................................................................................................................................... 2 3.10

Existing services ............................................................................................................................................... 2 3.11

As-Built Documentation ................................................................................................................................... 2 3.12

3.12.1 Manholes .................................................................................................................................................................. 2

3.12.2 Duct Routes .............................................................................................................................................................. 2

3.12.3 Installation of indoor ducting ................................................................................................................................... 3

3.12.4 Installation of sub-ducts (mini and micro) ................................................................................................................ 3

Materials and Equipment ................................................................................................................................. 3 3.13

Codes of Practice .............................................................................................................................................. 3 3.14

Deviations and Variations ................................................................................................................................ 3 3.15

COMPLIANCE TO STANDARD SPECIFICATIONS AND REGULATIONS ......................................................................... 3 4. Specifications related to Civil Works and Construction and SANS referred to: ............................................... 3 4.1

ACCOMMODATION OF TRAFFIC (Local and Provincial) ............................................................................................ 4 5. METHODS AND PROCEDURES: MANHOLES .............................................................................................................. 5 6.

Overview .......................................................................................................................................................... 5 6.1

Site preparation ............................................................................................................................................... 5 6.2

Types of Manholes approved by The CoCT ...................................................................................................... 5 6.3

Installation Guide ............................................................................................................................................. 5 6.4

BRICK BUILT MANHOLES ........................................................................................................................................... 6 7. Standard Brick Built Manhole .......................................................................................................................... 6 7.1

7.1.1 Introduction .................................................................................................................................................................. 6

7.1.2 Design ........................................................................................................................................................................... 6

7.1.3 Slopes ............................................................................................................................................................................ 7

7.1.4 Manhole Alignment ...................................................................................................................................................... 7

7.1.5 Bricks ............................................................................................................................................................................. 7

7.1.6 Brick Alignment ............................................................................................................................................................. 8

7.1.7 Brick force ..................................................................................................................................................................... 9

7.1.8 Cement/Concrete ......................................................................................................................................................... 9

7.1.9 Sleeve Entries ................................................................................................................................................................ 9

7.1.10 Copings ..................................................................................................................................................................... 9

7.1.11 Roof Corrugated Iron Sheets .................................................................................................................................. 10

7.1.12 I-Beams ................................................................................................................................................................... 10

7.1.13 Angle iron ............................................................................................................................................................... 11

7.1.14 Construction of New Roof ...................................................................................................................................... 11

7.1.15 Brick Walls .............................................................................................................................................................. 12

7.1.16 Floor (Base) ............................................................................................................................................................. 12

7.1.17 Top Surface / Finishing ........................................................................................................................................... 13

7.1.18 Backfilling................................................................................................................................................................ 13

7.1.19 Manhole completion .............................................................................................................................................. 13

7.1.20 Brackets .................................................................................................................................................................. 14

7.1.21 Steps – Step irons (When required) ....................................................................................................................... 14

7.1.22 Reinstatement of Surrounding Walkways, Grass, Road and Other Surfaces ......................................................... 14

Non-standard Brick Built Manholes ............................................................................................................... 15 7.2

7.2.1 Overview ..................................................................................................................................................................... 15

7.2.2 Dimensions ................................................................................................................................................................. 15

7.2.3 Material....................................................................................................................................................................... 15

7.2.4 Retaining Walls ........................................................................................................................................................... 16

7.2.5 Manholes with chimney .............................................................................................................................................. 16

PREFABRICATED GRC MANHOLE ............................................................................................................................ 17 8. Dimensions ..................................................................................................................................................... 17 8.1

Installation Depth (1200mm manhole) .......................................................................................................... 18 8.2

Preferred Installation Method ....................................................................................................................... 18 8.3

Bedding .......................................................................................................................................................... 19 8.4

Backfilling ....................................................................................................................................................... 19 8.5

Completion ..................................................................................................................................................... 19 8.6

DCP TESTING ........................................................................................................................................................... 19 9. DISPOSAL OF MATERIAL.......................................................................................................................................... 20 10. MANHOLE COVERS ................................................................................................................................................. 20 11.

The D400 Ductile Iron MH Cover ................................................................................................................... 20 11.1

The 2A Polymer Concrete Manhole Cover ..................................................................................................... 21 11.2

The B125 Ductile Iron MH Cover .................................................................................................................... 21 11.3

INSTALLATION OF FDP (SPLICE DOMES) BRACKETS ................................................................................................ 22 12. MANHOLE LOCKS .................................................................................................................................................... 22 13. CONNECTOR BOX .................................................................................................................................................... 23 14. BOUNDARY BOX ...................................................................................................................................................... 23 15. HEALTH AND SAFETY ............................................................................................................................................... 24 16. PROTECTION OF THE WORKS .................................................................................................................................. 24 17. SHORING ................................................................................................................................................................. 24 18. ABBREVIATIONS ...................................................................................................................................................... 24 19. DEFINITIONS ........................................................................................................................................................... 25 20. REFERENCE DOCUMENTATION ............................................................................................................................... 25 21. MH INSTALLATION CHECKLIST ................................................................................................................................ 25 22. CONTRIBUTORS ....................................................................................................................................................... 26 23.

Manhole Specification: MH-001-STD

Model ID: Brick built manhole

by David Jacobs

1

SCOPE 2.

This document serves to define the:

Excavation for an installation of a Manhole

Procedure for constructing a Brick Built Manhole

Procedure for installing a drop-in prefabricated Manhole

Physical and design characteristics of the various types of prefabricated Manholes, Frames, Covers and Locks accepted for use by the CoCT

Reinstatement of surfaces after project completion

PREAMBLE TO STANDARD SPECIFICATIONS FOR MANHOLES 3.

Introduction 3.1

This standard, including all its reference documents, form part of the contract between the CoCT and the Contractor

This document is the standard specification for Manholes and covers the specific regulations for the construction of a manholes or the installation of duct(s) and Manhole equipment which all contractors will adhere to

These requirements are to be read in conjunction with documents mentioned and specifications and standards referred to

The term “Contractor” shall apply to the person, company, firm, partnership or any applicable entity appointed for the supply, installation, testing and commissioning (and/or maintenance thereof) of Manholes as specified by the Tender.

Works Description 3.2

This Specification describes how preparation, excavating, the constructing of Manholes, backfilling, the laying of underground ducts and the reinstatement of surfaces shall be done

The complete installation shall comply with the requirements of this specification. In the event of any deviation, the CoCT will decide whether the work shall be re-measured on site or whether re-measurement will be drafted on the standard drawing specifications within this document

A Route Supervisor will inspect the installation during progress and after the work has been completed. Deviations will be pointed out to the Contractor and these are to be remedied at the Contractor’s own expense. The Contractor will abide to the terms agreed to and will not be relieved of responsibility towards the expected agreements and standards

The Contractor will inform / notify the CoCT when the installation reaches important milestones of completion, e.g. before closing or sealing Manholes or resurfacing completed projects. This will aid the Route Supervisor to schedule his inspections in the best interest of all parties concerned.

Contractor Camp Establishment 3.3

When required:

The Contractor shall institute a camp and/or onsite office as determined by his own requirements

The location thereof shall be negotiated by the Contractor with the landowner(s) and relevant parties concerned for the provision of services such as electricity, water, portable sewage systems, etc.

Expenses accompanying costs for the camp and/or office establishment which may include generators, fuel, electricity and water consumption, portable sewage systems and any other expenses and rates associated with the establishment of the camp/office shall be financed by the Contractor.

Location of Camp and Depot 3.4

When required:

The Contractor shall submit to the Client his proposed siting and layout of all camps, stores, offices etc. within ten (10) days after acceptance of the contract

The Contractor shall make his own arrangements for the accommodation of all labour and comply with the requirements of the respective authorities. Only night watchmen shall be housed at the camp and depot

Control of access for construction plant onto the public roads shall be in accordance with the requirements of the relevant roads authority.

Management of the Environment 3.5

The Contractor shall adhere to the requirements of the Environment Management Plan

The Contractor shall observe the highest of safety measures in relation to camp establishment, works and construction, and any other activities which may have a negative impact on the environment

2

Spoil Areas 3.6

The onus is on the Contractor to find a suitable spoil site (off-site). Expenses attributed to the removal and transport shall not constitute an additional cost (other than itemised details specified in the bill of quantities).

Sanitary Facilities 3.7

The Contractor shall provide toilet facilities for all his employees and shall maintain them in a clean and hygienic state at all times.

Site Conditions 3.8

Parties applicable (Contractors, excavators and installers) are advised to visit the site and acquaint themselves with all local conditions prior to the execution of the work and installation of the Manhole(s). No claims from the Contractor which may arise from insufficient knowledge of the site and area conditions, the establishment and implementation of the tender, etc. will be considered after the submission and acceptance of quotes according to the tender agreement.

For installations where permission is required before the contractors visit or work on the site, affected parties will be required to arrange the necessary approval

The Contractor shall provide a foundational plan of execution which shall reflect a proposed sequence of strategies and activities encompassing the work for the contract. The foundational plan shall conform to the specification(s) provided.

Site facilities 3.9

Source of Water Supply

Water for construction purposes may be obtained by applying for a metered standpipe on the municipal mains bounding the site. The Contractor shall allow in his tender for all costs related to water supply for the Works.

Source of Power Supply

Where required, the Contractor shall arrange with the Electricity Department of the Local Authority for a supply for the Contract period. All supply costs shall be allowed for in the tender.

Stockpiling Material 3.10

The positions and method of stockpiling of material will be to the Route Supervisor’s approval. The safeguarding of construction material against theft or damage will solely be the Contractor's responsibility.

Existing services 3.11

The Contractor shall search and verify details, positions and levels of intersection points well in advance of undertaking related works to prevent any possible delays if such services are not as indicated or assumed. The onus is on the Contractor for continuity of construction activities by ensuring that location and arrangements for negotiation of all services occur well in advance

The underground services located inside and on the boundaries of the site consist of water mains, sewage pipelines, storm water lines, telecoms cables and HV and LV electricity cables

All identified pre-existing services that are damaged or disrupted by the Contractor shall be repaired by the Contractor or the relevant authority. All costs will be charged to the Contractor

The Contractor shall liaise in good time with the relevant authorities before working in the immediate vicinity of these services (however, CoCT to lead wayleave requirements).

As-Built Documentation 3.12

The Contractor shall provide detailed As-Built documentation for all construction and installation work. All digital photographs are to contain a date stamp and co-ordinates (or recorded dates and positioning). The document must contain at least the following information:

3.12.1 Manholes

Dimensions

Photographs inside, outside and of the cover (closed)

Surveyor GPS coordinates (accurate to 0.5m)

3.12.2 Duct Routes

Actual route followed (not straight line), accurate to within 1m

3

3.12.3 Installation of indoor ducting

Actual route followed (not straight line), including height from floor and distance from nearest walls

Digital photographs showing the installation

3.12.4 Installation of sub-ducts (mini and micro)

Distances installed

Type of duct used (7-way mini-duct, 12-way micro duct, 2-way micro-duct)

Materials and Equipment 3.13

All materials and equipment will conform to set standards in quality. Manufactured, performance related and the quality of equipment and materials utilised will conform to the appropriate test standards and requirements of the SABS and/or SANS where applicable

All materials and consumables must be pre-approved by the Technical Committee and form part of the Toolbox

Specifications for particular products such as ducts will be supplied on request

Codes of Practice 3.14

Where any reference is made to any standard specification or requirement of the CoCT in this document, the most updated revision will be deemed relevant and shall be adhered to.

Deviations and Variations 3.15

All deviations and/or variations are to be issued by means of a written site instruction and presented to the Route Supervisor

All deviations and/or variations and/or additional work over the contract may be subjected to additional costing and a variation in quote submissions for payment (subject to approval prior to execution)

All variation quotes are to be submitted within 48 hours of request

COMPLIANCE TO STANDARD SPECIFICATIONS AND REGULATIONS 4.

All works performed will strictly comply and adhere with all regulations and protocol which includes:

The Occupational Health & Safety Act, 1993 (Act No. 85 of 1993)

Road Ordinance Act 19 of 1976 (in line with the TCT - Transport for Cape Town)

Aspects requiring special attention include:

Client health and safety requirements issued separately

Protection of existing services; especially live electrical cables

Safe utilization of plant and vehicles

Access route safety

Storage and stacking of materials

Good housekeeping and site tidiness

Methods applicable for labour based construction.

The Contractor’s safety plan and method statements shall be approved and a safety officer shall be appointed prior to the commencement of any activities.

Specifications related to Civil Works and Construction and SANS referred to: 4.1

SANS 10100 –1 2000 The Structural use of Concrete

SANS 50196-21 / SABS EN196-21 Testing of Cement

SANS 1200 A 1986 General

SANS 1200 C 1980 Site Clearance

SANS 1200 D 1990 Earthworks

SANS 1200 DB 1989 Earthworks (Pipe Trenches)

SANS 1200 DM 1981 Earthworks (Road, Subgrade)

SANS 1200 G Civil Engineering Construction – Concrete Structural

SANS 1200 GA Civil Engineering Construction – Concrete Small Works

SANS 58621/SABS SM 862-1 Concrete Tests and Slump Test

SANS 1200 LB 1983 Bedding (Pipes)

SANS 1200 LC 1981 Cable Ducts

SANS 1200 M 1996 Roads (General)

SANS 1200 MH 1996 Asphalt Base and Surfacing

SANS 1200 MJ 1984 Segmented paving

4

SANS 1200 MK 1983 Kerbing and Channelling

SANS 1200 F 1983 Standardized specification for civil engineering constr. Section F: Piling

SANS 50124 1994 Gully tops and manhole tops

SANS 558 Manholes for use in Systems National Building Regulations

Public Works 334 Development of Infrastructure on Dolomite

SABS 878 2004 Ready mix concrete

SABS 1294 Poly Manholes

Minerals Act, regulation 9.33.5

Environmental Management Act, Act 107 of 1998

Construction Regulations –Government Notice No. R1010 18 July 2003

All in-house procedures and regulations issued by local and other authorities who have jurisdiction over the contract

Manhole types will be designed and installed so that the physical, operational and maintenance characteristics will not degrade when exposed to the ecological conditions of South Africa (including recorded climate and weather conditions of the local area) and the expected environmental conditions (which includes traffic). The quality of the equipment used and the design and installation thereof will be to protect fibre connections and internal equipment from damage, theft and unauthorised access

Excavations as well as incomplete and completed installations will be according to expected standards and will adhere strictly to set guidelines – see Terms of Construction Regulations 2014. This is to observe public safety, property, equipment protection as well as Client and Network security

Open Manholes which constitute a hazard to pedestrians or traffic will at all times be adequately demarcated and barricaded to protect footpath and road users. The Contractor will also ensure that access to areas affected by the works is maintained at all times

Traffic Routing and accommodation shall conform to Chapter 13 of Volume 2 of the South African Road Sign Manual (SARTSM)

Work will not commence until all Wayleaves have been completed, approved and received by the parties concerned and relevant insurances are in place

When working on non-City roads, i.e.: N1, N2, etc. -the Contractor shall adhere to all specifications concerning excavation as well as road/pavement reinstatement in relation to any road authority applicable (such as SANRAL, the Western Cape Government, etc.).

ACCOMMODATION OF TRAFFIC (Local and Provincial) 5.

The Contractor shall ensure that all access routes which are affected by the Works and/or Temporary Works are kept in a safe condition for pedestrian and vehicular traffic

The Contractor shall organize his work so as to reduce the inconvenience to traffic to a minimum, and no public road shall be completely closed without prior approval

The Contractor shall provide and maintain in proper condition all necessary barricades, lights, warning signals and all direction signs necessary to enable traffic to flow in both directions. He shall provide flagmen at all deviations and/or obstructions

All signs shall be in all three local official languages (English, Afrikaans and Xhosa) and all traffic signs and control of traffic shall be in accordance with the South African Road Traffic Signs Manual

The Contractor shall liaise with and co-operate with the relevant Traffic authorities wherever the works affect existing roads. The Contractor shall sign an indemnity clearing the Local Authority, as applicable, from all liabilities in respect of any works on or adjacent to trafficked roads.

5

METHODS AND PROCEDURES: MANHOLES 6.

Overview 6.1

Works will include any one or more of the following:

Establishment on site

Accommodation of traffic (vehicle or pedestrian)

Excavations

Construction of manholes, including installation of copings, frames and covers

Installation of prefabricated manholes, including copings, frames and covers

Testing of Soil

Reinstatement of roads, sidewalks and private property

Site preparation 6.2

The Contractor must examine all plans, details and specifications received. Should any discrepancy be found on site, the discovery shall be brought to the Route Supervisor’s attention immediately

The felling or removal of trees, shrubs and plant materials may be necessary. Prior to starting this, the Contractor must gain written approval from the relevant authority and / or property owner

On private property, the property occupier is to be given a minimum of 24 hours’ notice prior to the commencement of work. Trenches and / or Manhole excavations on private property are not to be left open outside of normal working hours. Should this be unavoidable, the Contractor must undertake the necessary precautions to safeguard the incomplete work during the period. This includes establishing precautionary measures for public safety.

Types of Manholes approved by The CoCT 6.3

There are different types of manholes available for deployment in the Approved Toolbox. Manholes currently approved by the CoCT are:

Brick Built Manhole

Cylindrical Prefabricated Manhole GRC Manhole

Installation Guide 6.4

Please see steps below:

Step 1 Examine Plans, details and specifications received

Step 2 At the specified location, erect Public Safety barriers and demarcate zones for public use

Step 3 Institute Pilot hole (test hole)

Step 4 Test soil and excavate MH cavity (which is aligned to the Trench or as per plan)

Step 5 Install Bedding (if required by soil conditions), level and compact

Step 6 Install or construct planned Manhole as per specified steps within this document

Step 7 Route Ducting from Trench into Manhole

Step 8 Backfill and compact opening between MH exterior walls and excavated ground, as per compact guidelines

Step 10 Install coping / frame

Step 11 Adjust Slack Brackets

Step 12 Install MH cover

Step 13 Clear debris and rubble from site

Step 14 Reinstate surfaces

Step 15 Once site inspection has been approved, remove barricades and excess waste materials

6

BRICK BUILT MANHOLES 7.

Standard Brick Built Manhole 7.1

7.1.1 Introduction

A Brick-built Manhole (BBM) is a manhole constructed (by hand) primarily from Bricks, Mortar and Cement. It is more durable than prefabricated designs and is the preferred type when installing a MH in a location that experiences a high volume of traffic, i.e. roads.

Fig. 1 Brick-built manhole

Generally, conditions on site will dictate the size and type of manhole required and what is most suitable – depending on the service requirements. The CoCT Fibre Planner will dictate which type of manhole is constructed in each case. This section of the document will cover standard sized manholes. For non-standard manholes, refer to 7.2

7.1.2 Design

To ensure Public and Traffic Safety on sidewalks, roads, pavements, etc. – it is essential that an even, level, non-protruding, ground-level Manhole cover is fitted. This is to minimise any possible risk to the damage and injury of vehicles, pedestrians, path or road users and the public in general. The MH frame and cover shall be at the same level as the surrounding area. The sizes mentioned below are the interior measurements from inner-wall to inner-wall as well as the floor to the surface.

There a three basic volume sizes listed in the points below. Should any difficulty encountered prevent the actual measurements from being achieved, the Route Supervisor is to be consulted.

800mm -the minimum internal distance between the walls is to be 800mm and the depth of the hole should not be less than 800mm from the base to the manhole cover. This results in internal dimensions of 800mmx800mmx800mm

1200mm -the minimum internal distance between the walls is to be 1200mm and the depth of the hole should not be less than 1200mm from the base to the manhole cover. This results in internal dimensions of 1200mmx1200mmx1200mm. The overall volume must not be less than 1.728m³. If it is unavoidable that one of the dimensions must be decreased, the other dimensions must be increased to maintain the volume at 1.728m³. No dimensions may be smaller than 800mm. All deviations from the norm must be approved in writing by the Fibre Planner and a site instruction issued accordingly.

1500mm -the minimum internal distance between the walls is to be 1500mm and the depth of the hole should not be less than 1500mm from the base to the manhole cover. This results in internal dimensions of 1500mmx1500mmx1500mm. The overall volume must not be less than 3.375m³. If it is unavoidable that one of the dimensions must be decreased, the other dimensions must be increased to maintain the volume at 3.375m³. No dimensions may be smaller than 800mm. All deviations from the norm must be approved in writing by the Fibre Planner and a site instruction issued accordingly.

1500mm MHs constructed for Switching Facilities are to incorporate a Sump Pump. The sump positioning is not to obstruct entry into the MH nor prohibit the sump pump from being installed in the MH. See Fig. 2 for the default placement and dimensions - situated close to the exit hole and as far away from services as possible, whether a permanent fixture or temporary sump installation.

7

Fig. 2 Sump Area (Bergstan)

7.1.3 Slopes

In an area comprising of a non-level terrain, the gradient or contour above ~16° (as per National Building Regulations in relation to walkways) of the ground may obstruct the regular design of a manhole. In this instance, a retaining wall / structural supporting fortification must be erected (site specific). The structure shall be non-slip and visible at ground level to aid in public safety. The National Building Regulations calls for

The retaining wall shall be constructed for MHs installed on sloping areas

The retaining wall shall have a double brick layer with semi-face clay bricks

Loffelstein blocks shall be used. This is site specific and to be determined by the Route Supervisor.

7.1.4 Manhole Alignment

Manholes shall be aligned with the Trench direction and routes. Manhole coping will also be installed with the sides parallel to kerbs, road endings, fence lines, etc. (not misaligned).

Fig. 3 OSP Route cut-through

7.1.5 Bricks

Burnt clay engineering (NFX) standard bricks must be used. To construct manholes the following shall apply:

The wall thickness shall be double brick (unless otherwise specified) and according to masonry standards with bagging finish inside.

8

7.1.6 Brick Alignment

The CoCT shall utilise either the Stretcher bond or the Flemish bond brick alignment. This will be determined by the Civil Engineer / Route Supervisor on site. In this document, illustrations shall revert to the Stretcher bond alignment as it is the default industry standard.

Fig. 4 Flemish Bond Alignment Fig. 5 Stretcher Bond Alignment

At no point shall Stack bond be accepted (see Fig.6 below).

Fig. 6 Bond Alignments

Fig. 7 Stretcher Brick Alignment

All Stretcher bond walls shall employ brick-force wiring (see 7.1.7 below).

9

7.1.7 Brick force

Every third layer of placed bricks shall have a 150mm brick force steel wired grid

The brick force shall be made of galvanised steel

The steel wire grid shall be placed within the cement between bricks (see Fig. 8)

Fig. 8 Brick Force installation per wall

7.1.8 Cement/Concrete

All cement must be in accordance with the specifications and standards of SABS 196-21 and SANS 50196-21 and shall at all times be subject to the approval of the CoCT

Concrete strength shall be at least 30Mpa.

7.1.9 Sleeve Entries

All BBMs must be constructed with sleeve entries (stubs) according to the following minimum specification:

All BBMs shall have a minimum of 2 x 110mm sleeve entry points on all 4 sides and must be cemented inside and outside, around the sleeve

The bottom of each sleeve entry point shall be 100mm above the MH base (staggered lay-out)

Sleeves are to be inserted at the side of the manhole wall face, NOT in the middle. The first sleeve must be installed 100mm from the side of the next (parallel) wall, and the following a maximum of 50mm further in. The Fibre Planner will dictate on the plan which side must be used (i.e. 100mm from the East or West wall, in the case of a North or South entry).

Unused sleeve entries shall be sealed with 110mm end caps or foam sealed

Sleeves shall be High Density Polyethylene (HDPE) sleeves with couplings (including rubbers/O-rings) between links

Sleeves shall be of 110 mm outer diameter

Sleeves must be cut back to a min. of 50 mm from wall (i.e. ducts must “stick out” into the manhole by 50mm, and not be cut flush with the wall)

7.1.10 Copings

Manholes either have a prefabricated concrete coping, or a coping that is cast onsite, as specified by the Fibre Planner.

See Appendix for dimensions of precast copings.

The following rules apply when casting a coping:

The coping must be cast together with the roof (slab) to ensure the there are no weak points between the coping and roof. The frame of the manhole must also be cast into the concrete coping

The frame will either be a polymer-concrete frame (2A) or a ductile iron frame (B125 or D400), as specified by the Fibre Planner.

Concrete must slope to the outside to prevent undercutting from water (site specific, determined by the Route Supervisor)

The coping is to be chamfered – to trim sharp edges, as per Route Supervisor

From coping parameter edge to frame: (300mm -Polymer or 150mm – Ductile Iron)

The coping must be at least 100mm to 150mm thick concrete at 30MPa

Wood float finish to prevent slipping

When the manhole is built on a pavement with brick surfacing, the copings must be level with the existing brick work

When the manhole is built in a road or pavement with tar surfacing, a ±30 mm gap must be left on the coping if it is on the pavement and a ±75mm gap must be left when in the roadway to allow tar reinstatement to be done.

When there is a fall in the ground level to one side the manhole frame must be adjusted to the grading of the ground

10

Fig. 9 Cast coping for tar surface Fig. 10 Cast coping for brick surface

Fig. 11 Cast coping (brick surface)

7.1.11 Roof Corrugated Iron Sheets

0.5mm Grade-A SANS approved corrugated iron sheets must be used for the roof (Fig. 12). The sheets must be cut to fit around the I-beams – as displayed in the illustrations below. Sheet sizes are to be determined by the Route Supervisor.

All I-Beams and angle iron must be painted with red oxide to prevent rust (slow down the oxidation process).

Fig. 12 & 13 Roof Corrugated Iron Sheets

7.1.12 I-Beams

I-beams shall be mounted as support structures for the MH frame and cover

I-beams shall offer maximum support and will not obstruct the MH cover or opening circumference

I-beam dimensions shall be 100 x 55mm with a wall thickness of ±5mm

I-beams shall be strong enough to tolerate weights of 13 tons for MHs on pavements, and 40 tons in driveways and roads (this includes the rooftop weight)

Where a frame can’t fit on walls, the frame must be supported with I-beams. The following should be used:

Pedestrian areas: 100 x 55 x 6 mm

Vehicular areas: 140 x 70 x 6 mm

11

Fig. 14 The I-Beams and corrugated iron roof sheets

7.1.13 Angle iron

Angle irons (40mm X 40mm) to be used on all brick-built manholes

4 X 10mm X 200mm round bars, bent in a V shape must be welded to the frame, to secure frame to the I-Beams

670mm angle irons must be installed between the I-Beams to support the corrugated iron sheets

Fig. 15 Angle-irons used to attach the frame to the I-Beam

7.1.14 Construction of New Roof

Fit cover and frame as per the following specifications where applicable:

In-situ and precast roofs

Fix to existing coping structures using chemical anchors

Drill 14 mm hole min. 100 mm into existing concrete slab

Use 12 mm threaded rod (150mm) cut at an angle (insertion point)

Use chemical anchor to fix rod permanently into concrete structure. Fig. 16

Min. 2 on opposite side of frame, with flat washer and nuts

Damage thread to prevent the removal of nut after installation

Welded support on I-beams / other steel fixtures

Treat all welded areas, to prevent oxidation. See Fig: 17

Fig. 16 Attaching the frame Fig. 17 Welding the frame in place

12

Fig. 18 The frame attached to the I beams

7.1.15 Brick Walls

All walls shall be constructed of solid baked clay bricks (see 7.1.5)

Mortar mixtures shall follow the 1 Workman’s Wheelbarrow (WW) Cement + 3 WW of sand ratio.

Bedding and vertical joints shall be 10-15mm thick

Inner dimensions shall comply with section 7.1.2 of this document

See 7.1.9 for information concerning Sleeve Entries

There will be no cavity (space) between walls

Wall to be constructed using double a brick wall (Fig. 19)

Fig. 19 Double wall construction

7.1.16 Floor (Base)

Floor dimensions shall be in accordance with the dimensions specified in 7.1.2

Floor thickness must be 150mm for manholes up to 1100mm deep and 200mm to manholes 1500mm deep

The floor base shall be level (in the 1500mm MH, where applicable, floor shall be sloped towards the Sump)

Concrete shall be 30MPa strength.

Fig. 20 1500mm Manhole Dimensions (Bergstan)

13

7.1.17 Top Surface / Finishing

Any completed manhole shall have the top surface flushed and levelled with the surrounding road/pavement

A corrugated sheet cut out made to cover the manhole shall be placed for Mortar fill (Ductile only)

8mm wire mesh shall be placed 50mm above the corrugated sheet in between the mortar to reinforce its structure, when required

The wire mesh shall be trimmed to the size of the coping and to the MH cover opening (with a 50mm clearance).

Fig. 21 Top surface

7.1.18 Backfilling

Backfill is the material installed above the compacted floor and between the brick walls and excavated earth to complete the refilling of the hole. The backfill should not in any way injure the ducts fitted to the MH from the trench

Backfill material shall consist of imported soil only. The contractor may use soil that has been excavated from the trench / MH for backfilling; however, any rocks, debris, organic material and objects are to be removed

Backfilling shall be compacted after every 100mm layer.

7.1.19 Manhole completion

All manholes are to be cleared of concrete and rubble after the completion of work

All labels to be turned face-up

All fibre to be correctly managed on slack brackets

All new manholes covers shall have manhole numbers stencilled with 50mm Helix Stencil with the appropriate manhole number as allocated by CoCT

Manhole number to be painted on cover with road marking paint (polymer = black paint and Ductile = white paint)

Manhole number to be painted on I-Beam with black road marking paint

All 110mm sleeves must be cut 50mm from the wall (i.e. the ducts stick out into the manhole by 50mm)

Slack brackets must be installed on all the walls of the manhole

Fig. 22 Cross sectional view of completed BB Manhole

All slack brackets must be installed in the middle of each manhole face

All beam filling must be done correctly: o Against the wall between the wall and the corrugated sheets o Between the I-Beams and the corrugated iron sheets

14

Fig. 23 Brackets and duct spacing Fig. 24 Correct installation of tube slack

Fig. 25 Manhole number painted on cover Fig. 26 Manhole number painted on I-beam

7.1.20 Brackets

The MH shall be equipped with brackets for storing cable slack:

The Cable Storage shall be hot dipped galvanised**

Brackets to be fixed with galvanised screws (75mm Coach screws)

Brackets to be evenly spaced to prevent/avoid unnecessary tension or sharp bends on optic fibre cables (see Fig. 24) **Currently, The CoCT Operations Department utilise a plastic variation of the bracket (see Fig. 23).

Fig. 27 The cable slack bracket

7.1.21 Steps – Step irons (When required)

Any MH deeper than 800mm shall be equipped with steps

Steps shall be placed at intervals of 300mm

CoCT Roads and Stormwater, Sanitation, etc. – utilise the standard cast-iron, plastic coated step-iron. This product shall be used.

7.1.22 Reinstatement of Surrounding Walkways, Grass, Road and Other Surfaces

Reinstatements must be replaced with like for like or better, unless previous reinstatement was non-existent or didn’t conform to the surroundings

Reinstatements shall be subjected to the Route Supervisor’s approval. Any reinstatement redone due to the Route Supervisor’s rejection of the restoration and resurfacing shall be at the contractor’s own expense.

Manholes (Team) Yes No N/A

Slack Managed correctly

Entry sleeves foamed, cut and painted (Sealed) as per specification

Ducts labelled as per specification

Slack brackets fixed as per specification

Manhole covers checked and tested

Manhole marked inside as per specification

Manhole cover marked as per specification

15

Fig. 28 Reinstatements for different types of surfaces

Non-standard Brick Built Manholes 7.2

7.2.1 Overview

This guideline is applicable for conditions where circumstances require non-standard manhole installations. The default Brick Built installation specification applies as per 7.1, however, the below specification is altered.

As mentioned in 7.1.1 conditions on site will dictate the size, design and type of manhole installation. Common examples of the special circumstances that require a non-standard manhole are:

Limited available space onsite

Hard rock sections found within the ground where a minimum depth of 1 metre cannot be reached

Conditions which require a larger manhole to be installed (such as services that cannot fit into a standard sized manhole)

Depth obstructions and other utility pathways which may necessitate the placement of a manhole below normal depth

Trench selections on a slope

Existing surfaces

RoW conditions

7.2.2 Dimensions

MHs shall be designed and built as per site conditions

Where other than standard sized manholes are required, one dimension shall be reduced at a time

Larger MHs are used to a limited extent and shall depend on the type of services at the site

The following dimensions shall apply:

Dimension Ideal / Standard Reduced MH Sizes

Minimum Maximum*

Length (mm) – excl. walls 1200 600 1500*

Width (mm) – excl. walls 1200 600 1500*

Depth (mm) – excl. base and cover 1200 600 1500*

Wall thickness (mm) Double brick approx. 220mm

Base thickness (mm) 150 150 200

7.2.3 Material

All MHs shall be built using clay bricks. Cement bricks are not acceptable. (See 7.1.5 Bricks)

All MHs shall have double brick layers (See 7.1.5 Bricks)

D400 Cover and Frame to be placed on this MH

I-beams and galvanised sheeting to be used

Strength:30MPa concrete mix

Hot dip galvanised steel slack brackets

16

7.2.4 Retaining Walls

A retaining wall shall be constructed for MHs installed on sloping areas

See 7.1.3 Slopes for information

7.2.5 Manholes with chimney

Floor base and manhole roof (chimney base) shall be 200mm thick reinforced concrete. Base must be cast in situ. Base need not be reinforced

Internal manhole wall thickness should be double brick (the chimney shall be single brick) and according to masonry standards with bagging finishing inside

Reinforced slabs shall be constructed offsite at supplier / contractor’s plant. See fig: 31 for lifting hooks. Y12 @ 100 c/c both ways 50mm cover bottom of slab

Trench to be dug at a gradient to allow for gentle fall of ducts into manhole.

Fig. 29 Sectional view of manhole with chimney

Fig. 30 Isometric view of Manhole with chimney

17

PREFABRICATED GRC MANHOLE 8.

Installing Prefabricated MHs is less time consuming compared to constructing a Brick built one. Prefabricated MHs are typically made in a controlled environment and exhibit high quality and uniformity. Because Prefabricated MHs are manufactured off site, during the installation process, there is a significant reduction in time, dust, noise and debris.

See Appendix at the end of this manual for additional dimensions.

All prefabricated manholes are cylindrical. Except in exceptional circumstances, both shall adhere to the same installation specification. The Prefabricated MH shall not be used in high traffic roads used by heavy vehicles.

Fig. 31 The GRC manhole Fig. 32 The GRC manhole cross-section

Dimensions 8.1

Fig. 33 GRC Manhole dimensions

18

Installation Depth (1200mm manhole) 8.2

Excavate for the Manhole depth of:

Frame & Cover 145mm or

Coping 150mm

Prefab Manhole 1200mm

Bedding 100mm

Preferred Installation Method 8.3

Regardless of the shape of the prefab MH, the below shall apply:

The Manhole shall be excavated to a depth of 1500mm to allow for the access of compaction equipment, as well as 100mm Bedding

Over –excavate the sides to allow for compaction equipment, allowing for sufficient space for compacting

The base of the excavation shall be a level, compacted surface (see 9.4 Bedding below)

Place the Prefab MH carefully into the excavation ensuring flush and proper seating before backfilling

Ensure that the Prefab MH duct entry holes align with trench/duct direction

Once the MH has been positioned correctly, insert the ducting from the trenches

Carefully seal the ducts to the entry points to prevent moisture from entering the MH

Unused Duct entries shall be sealed off with Duct caps (on the outside)

Once the ducts have been inserted and entry points sealed, proceed with backfilling in 300mm layers

Compacted backfilling is to be at least as strong as the surrounding virgin soil

Backfilling shall be to the top of the MH rendering the MH completely concealed

Fig. 34 Prefabricated manhole components

19

Fig. 35 & Fig. 36 GRC Manhole ducts and brackets

Bedding 8.4

Bedding material will constitute an even floor and consist of optimally compacted material 100mm deep.

The Route Supervisor will determine whether the material is too dry or if it requires moisture. Under no circumstances shall material which is saturated with water be used for Bedding or Backfill.

Bedding shall consist of virgin soil (site specific).

Backfilling 8.5

Backfill material shall consist of virgin soil. The contractor may use soil that has been excavated for the MH for Backfilling, however, any rocks, debris et al are to be removed.

Completion 8.6

During the compacting of Bedding and Backfill material, the contractor will exercise care to ensure that Manhole chamber, ducts and duct joints are not harmed or disturbed in any way.

Please refer to The Specification for Civil Works and Construction (installation of Underground Telecommunications Plant) document for additional specifications in relation to tamping tools (hand compacters), reinstatement of surfaces, etc.

Once the MH has been installed and completely sealed, the dome(s) may be installed and splicing of fibres may be implemented.

Fig. 37 Manhole completion

DCP TESTING 9.

DCP testing will be done up to 700mm deep from the surface. Testing will be done in manhole corners away from the ducts. The compaction standard will comply with DCP specifications (DCP-001-SPE).

20

DISPOSAL OF MATERIAL 10.

Excess material, waste and pollution are to be removed from the site. No material shall spoil the area, during and after the installation in accordance with SANS 10263-0 (2010).

The Contractor will deploy an alternate off-site accommodation for the waste material. The Contractor will be held responsible for observing and adhering to by-laws, regulations and operational standards and requirements of the relevant local authorities concerning fire and for any injury to persons and damage to property. The Contractor shall indemnify the Client (CoCT) against all claims for damages and injuries arising from this source.

MANHOLE COVERS 11.

The City intends to build many manholes as access points for the outside plant fibre network. MH Covers must be installed in accordance with the manufacturer’s instructions. All covers shall be equipped with a locking mechanism.

The manholes covers sealing the manholes must comply with the following specifications:

The cover must be supplied with a frame into which it fits snugly

The cover must form a watertight seal with the frame

The cover must have a locking mechanism which requires a special key to open

The cover must bear the logo of the City of Cape Town as well as the words, “City of Cape Town Optic Fibre” (Fig: 39)

The fibre planner will specify which cover and frame shall be fitted to each manhole

See Annexure A for specifications relating to MH Covers.

The D400 Ductile Iron MH Cover 11.1

The D400 Ductile Iron manhole cover is a heavy duty lid (and frame). The lid is fitted with lock assembly. The cover shall be SABS approved and be able to withstand 400kN of downward pressure.

Fig. 38 The D400 Ductile Iron Manhole Cover

Fig. 39 - D400 Ductile Manhole Cover

21

The 2A Polymer Concrete Manhole Cover 11.2

The 2A frame and cover are lightweight polymer resin products. The lid is fitted with lock assembly and can withstand 135kN of pressure. The 2A Polymer cover comes fitted with the Prefab MH as a unit.

The 2A MH cover and frame must be manufactured from a polymer concrete material

The installed 2A cover must be heavy duty and able to withstand 135kN of force

The outer diameter of the cover must be 600mm

The inner diameter of the frame must be ≥ 540mm

The frame must be no thicker than 140mm

Fig. 40 2A Polymer Concrete Manhole Cover

The B125 Ductile Iron MH Cover 11.3

The B125 Ductile Iron manhole cover is a heavy duty lid (and frame). The lid is fitted with lock assembly. The cover shall be SABS approved and be able to withstand 125kN of downward pressure.

Fig. 41 - B125 Cover fitted with lock

22

Fig. 42 B125 Ductile Manhole Cover

INSTALLATION OF FDP (SPLICE DOMES) BRACKETS 12.

Splice Domes are to be mounted firmly onto the preinstalled mountings (see 7.1.18)

Domes will be located beneath the Brackets

Brackets will made from Galvanised steel

Brackets shall be hot dipped galvanised

Fig. 43 Dome bracket

MANHOLE LOCKS 13.

Manhole covers are to be secured using the standard plastic and steel lock mechanisms (the Green Lock). Older covers may use different locking mechanisms and these should be retrofitted with the standard Green lock. Should the design of the cover prohibit the Green lock from being fitted, the cover should be changed to accommodate the approved locking mechanism. The frame will not be altered in this regard.

Currently, The CoCT uses 2 types of Green locks: B (for Polymer Concrete MH Covers) and C (for the Ductile Iron MH Covers). The only difference between the two designs is the length. Type C is 50mm longer to accommodate the dimensions of the Ductile Iron MH Cover.

Fig. 44 The City manhole lock

23

CONNECTOR BOX 14.

A Connector Box shall be installed in planned Manholes to aid with tidiness and the control of fibre routing. The box shall be firmly secured on a galvanised mounting rack as low to the manhole base and ducts as possible (to prevent the exceeding of specified duct, cable and fibre bend ranges).

The Connector Box:

Shall contain 7-Way and 12-Way ducts only

Shall be installed with the side grommets parallel to manhole duct entries

Shall have minimal cable slack within to prevent access to cables

Ducts shall be snipped internally as close to the grommets as possible to allow for cable bend radius (max of 20mm)

Side grommets shall aid in the continuous flow of ducts between manhole entry points

Top grommets shall be for diverting cables to domes, etc.

Fig. 45 & Fig. 46 Connector Box

BOUNDARY BOX 15.

The Boundary box:

Shall contain 7-Way ducts only

Location shall be marked with a paved concrete slab (Route Marker Stone) indicating the serial number of the box

Shall have no slack within

Shall have side grommets which aid in the continuous flow of ducts between entry points

To be used from OSP to Customer Building

May be installed with a 100mm thick coping (site specific) for stability in certain areas.

Fig. 47 Boundary Box

24

16. HEALTH AND SAFETY

The Contractor is responsible for ensuring that the manhole is barricaded (at least 1m high) properly with orangenetting for the duration of the work

Barricading must remain in place at all times

Appropriate signage must be used where necessary to direct traffic and pedestrians passing by.

All excavated soil must be inside the barricaded area

The Contractor will submit a complete Health & Safety file according to the requirements of the City and prior tocommencement of work, subject to the approval of the City of Cape Town

The Health and Safety file must be properly maintained at all times and be readily available on site

The Contractor shall enter into an agreement with the CoCT and sign a mandatory 37.2 Agreement, signed by allrelevant parties

Toolbox talks must be done daily prior to commencement of work and be recorded on a register to be placed in theHealth & Safety file

The Contractor shall ensure that all workers are inducted on site prior to commencing their work

All personnel working on or visiting the site will wear suitable personal protective equipment (PPE)

The Contractor shall, furthermore, adhere to all provisions of the Occupational Health & Safety Act, 1993 (Act No. 85of 1993) at all times

17. PROTECTION OF THE WORKS

The Contractor shall protect the Works properly and shall so arrange his operations that no danger and the leastpossible inconvenience are caused to the public and to vehicle and pedestrian traffic. For this purpose shall, inter alia,provide and maintain sufficient Temporary Works, road signs, lights barricades, fencing and guarding as may benecessary or required by any act or statutory authority

All operations required in connection with execution and completion of the Works and Temporary Works shall, as faras the provisions of the Contract permit, not unnecessarily or in an improper manner encroach upon the use of publicroads or upon access to private property, and the Contractor hereby indemnifies the City against any claims,demands, damage and legal costs that may arise in this regard

The Contractor shall be deemed to have allowed in his prices for all such obligations except in as far as provision ismade in the Pricing Data for payment in respect of specific items to these obligations

Minor material, HDPE pipe and optical fibre cables must be stored away from direct sunlight.

18. SHORING

Due to possible sandy or waterlogged conditions, provision for shoring in locations where there is a danger of the sides of theexcavated hole collapsing shall be implemented. The Supervisor must determine where shoring is required and allow therefor in schedule. The strength of shoring must be adequate for site conditions.

Fig. 48 Shoring example

ABBREVIATIONS 19.

BBM : Brick Built Manhole

MH : Manhole

DCP : Dynamic Cone Penetrometer

SABS : South African Bureau of Standards

25

SANS : South African National Standard

CoCT : City of Cape Town

PW : Public Works

FDP : Fibre Distribution Point

kN : Kilo Newton (a measure of force. 1kN = 1000N)

DEFINITIONS 20.

Manhole - a covered opening in a floor, pavement, street, or other surface that allows a person to enter. Often referred to as a chamber, it is an access point to an underground structure or to concealed equipment.

Manhole Cover - a flush fitted lid which covers the Manhole and the contents within

Precast Concrete - a construction product produced by casting concrete in a reusable mould (or form) which is then cured in a controlled environment and transported to the construction site (or storage) and fitted into place. In contrast, standard concrete is poured into site-specific forms and cured on site

Glass Fibre Reinforced Concrete (GRC) – a material consisting of high-strength glass fibre embedded in a cementitious matrix. In this form, both fibres and matrix retain their physical and chemical identities, while offering a synergism: a combination of properties that cannot be achieved with either of the components acting alone

Contract - the agreement made in terms of the Form of Offer and Acceptance and such amendments or additions to the contract as may be agreed in writing between the parties

Trench - a deep furrow or ditch excavated into the ground, primarily used for fortification (protection) and concealment.

OSP (Outside Plant) - all of the physical routes, ducting, manholes and supporting structure and any associated hardware located between a demarcation point in a switching facility and a demarcation point in another switching facility or Client premises.

Demarcation Point - the point where the switched network ends and connects with the client’s on-premises wiring. It is the dividing line which determines who is responsible for installation and maintenance of wiring and equipment, i.e. the Client or the CoCT

As-Built - documentation describing the actual work done consequent to a Works Authorisation. This information may include geo-spatial co-ordinates and levels; descriptions of the installed equipment (including splicing diagrams); and test result, (viz. results of duct integrity, Optic Fibre OTDR tests)

REFERENCE DOCUMENTATION 21.

All documentation stipulated hereunder form part of this specification.

CWC-0001-STD - Civil Works and Construction

TT -0001-SPE - Trench Tape Specification

DCP-0001-SPE - DCP testing Specification

SARTSM - South African Road Sign Manual

SANS 1200 - Standardised Spec for Civil Engineering Constr.

Construction Drawings- For Works to be completed by the Contractor

Occupational Health & Safety Act, 1993 (Act No. 85 of 1993)

MH INSTALLATION CHECKLIST 22.

Description Y N

Description Y N

1. Was construction performed within the way leave permission?

9. Was the depth of the MH to specification?

2. Was the type and method of reinstatement approved by the Route Supervisor?

10. Was the bedding placed to the specified depth at the bottom of the Manhole?

3. Were all works performed according to the Traffic Management Standards?

11. Was duct/s placement correct, and covered to the specified depth with a protective layer?

4. Were all works performed according to the OHS & construction regulations?

12. Were duct openings sealed properly?

26

CONTRIBUTORS 23.

Sybrand Brink, Paul Atkinson, Fredel van As, Will Nieman, Reg Hite Garth de Villiers, Cedric Stevens, Christo Dreyer, Carl Gallant, Francois Badenhorst, Henning Pretorius, Ralph Cameron (Bergstan), C Botha (Bergstan).

Document End.

5. Were all works performed according to the Local Authority Safety Specifications?

13. Were the ducts checked to ensure that they were not twisted?

6. Was the MH fitted on a level even floor? 14. Was the backfilling compacted?

7. Was the MH bed clean and free of excavated materials?

15. Were all road markings reinstated correctly?

8. Was the MH bed flat, with a square bottom? 16. According to the spec, are DCP tests available?