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Outline Specifications
Revision 1.2
March 21 2014
2722 / Sto IV
21.03.2014
Estadio de Madrid – Roof Structure
Outline Specifications
II
Estadio de Madrid – Roof Structure
Outline Specifications
CONTENT
1 General ................................................... 1
1.1 Introduction ................................................ 1
1.2 Scope of work ............................................... 4
1.3 Geometry .................................................... 8
1.3.1 Final geometry of the structure ................................ 8
1.3.2 Deflections under environmental loading ........................ 9
1.3.3 Measurements / Surveys / Accuracy .............................. 9
1.4 Delimitation of the activities ............................. 16
1.5 Workshop drawings .......................................... 18
1.6 Measurements for Payments .................................. 18
1.7 Erection ................................................... 19
1.7.1 General ....................................................... 19
1.7.2 Accuracy assuring trial assembly .............................. 20
1.7.3 Erection of steelworks ........................................ 22
1.7.4 Erection of cable structure ................................... 22
1.7.5 Erection of membrane structure ................................ 23
1.7.6 Erection of the canopy ........................................ 23
1.8 Execution Class ............................................ 25
1.8.1 Failure Consequences Class [CC] as per EN 1990:2010 Table B.1 . 25
1.8.2 Category of operational demands (System Class) [SC] as per 1090-
2 Table B.1........................................................... 25
1.8.3 Category of Production [PC] as per 1090-2 Table B.2 ........... 25
1.8.4 Execution Class [EXC] as per EN 1090-2 Table B.3 .............. 25
2 Quality Control System ................................... 26
2.1 General .................................................... 26
2.2 Requirements for steelworks ................................ 26
2.3 Requirements for cable structure ........................... 26
2.4 Requirements for membrane structure ........................ 27
3 Metal materials .......................................... 28
3.1 General fabrication remarks ................................ 28
3.2 General structural steel remarks ........................... 28
3.3 Mild Steel/ Fine grain steel ............................... 29
3.4 Stainless Steel Plates ..................................... 30
3.5 Aluminium for Clamping Plates .............................. 30
3.6 Bolts and Rods ............................................. 30
3.7 Stainless Steel Bolts ...................................... 32
3.8 Friction Grip connections .................................. 33
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Estadio de Madrid – Roof Structure
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Outline Specifications
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Estadio de Madrid – Roof Structure
Outline Specifications
1 General
1.1 Introduction
Due to the sophisticated nature of the roof structure, the execution should
be undertaken by an experienced Contractor, which fulfils the following
criteria:
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Estadio de Madrid – Roof Structure
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Estadio de Madrid – Roof Structure
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Some key points of the design and execution of manufacture in the workshop
are:
• Machine-operated processing of the end plates of all compression
ring elements (i.e. upper chord/ lower chords) to secure the angles,
the length, the fit of the hole shapes, and the precision of the
cable connection boreholes is mandatory. The end plate thickness’
marked on the drawings are data applicable after milling. Respective
provisions to achieve that is in the responsibility of the
contractor.
• Trial assembly of five compression ring elements (over 10 axes) in
each case, together with the associated engineer's measurements and
CAD monitoring of the results. One segment can leave the factory
after the trial assembly. Two segments are to remain in position as
a reference for the next trial assembly. (see also erection drawing)
• Monitoring of manufacture in workshop:
The consultant may conduct, if necessary, extensive monitoring of
the manufacturing work. For this purpose, the contractor is grant
access to the manufacturing processes at any time. A suitable
workplace in the factory is to be made available. Quality assurance
and its documentation require the approval of the consultant.
• Possibilities of 3D-CAD in planning the workshop activities.
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The scope of the works and services for the contractors comprises the supply
and erection of the complete roof structure, including:
Steel structure incl. catwalks and all mechanical & electrical
provisions including bearings and supports
cable structure
membrane structure
cladding for canopy, compression ring and tension ring
roof drainage system
all temporary works for the roof including temporary support systems
for the trial assembly and the final erection of the compression ring
and catwalks
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The contractor has to adjust all details related to cables and cable
sockets considering the final diameter and socket geometry. The
stiffness of the cables considered in the structural analysis must be
maintained at any time
Workshop development of geometry of membrane panels including all
eccentricities and cutouts
Workshop design of membrane attachment details (i.e. clamp bar system,
clamp plates, link plates and edge cables and belts).
Workshop drawings of all membrane details, based on the structural
design and drawings provided by the client
Workshop 3D development of gutter details to ensure drainage as
designed.
Biaxial-testing of all membrane materials, to derive the stiffness
parameters and compensation values for the contractors design. The
contractor has to seek the approval of the client for the testing regime
and procedure.
Cutting pattern analysis and workshop drawings for all membrane panels,
based on the overall 3D-cable-steel-member-geometry supplied by the
client and finalized in he structural design. It is the task of the
roof contractor, to derive the final membrane geometry, including all
off sets and details. The contractor has to seek the approval of the
client for the final patterning prior to commencement of fabrication.
Planning for transportation and packing of membrane panels (i.e.
rolling fabric or fold plan).
Corrosion protection planning and design of all details. Including
corrosion tests by a third party institution
Workshop design of all fixations of installations (welded on, cast in
or bolted to primary steel structure)
Executive workshopdesign of dewatering layout and equipment
Executive workshopdesign of aluminium or coated steel plate cladding
As-built drawings, whereby the quality and quantity requirements of the
additional technical contract conditions are valid for all contracted
services
Maintenance proposal (intervals, important elements, service proposals,
specifications of cleaning detergents etc.)
Further works as described in the following chapters including
adjustment of all details to the finally chosen materials and details.
Final workshop design of catwalks and catwalk suspension based on the
assumptions made in the structural analysis document, limiting the dead
load to the there specified values.
All handrails and safety stainless steel cables within catwalk
including workshop design and drawing with approval by client.
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Included in the roof contract are all tests and surveys as defined in these
specifications.
The general architectural and structural design as well as layout of all
elements, members, materials and details shall not be changed. If required,
the contractor has to seek the approval of the client.
Changes and amendments are possible at any time through the client. Additional
planning of the other trades (for instance the reinforced concrete
construction) are to be obtained in due time from the contractor in
conjunction with its design requirements. This is to be taken into
consideration for construction approach and work shop design.
Should changes in weight or stiffness or other circumstances (for which the
contractor bears responsibility) make it necessary to reanalyse the roof
structure, bowl structure or foundations or as well details of the global
system, the contractor owes the client this calculation, including the fees
for review and, if necessary, expenses for reinforcement and reconstruction
measures.
The erection calculations for the steel, cable and membrane structure, the
analysis for all additional erection equipment (jacks, tie-down cables,
additional fixation in concrete structure, scaffolding, etc.), and all shop
drawings have to be done by the contractors. All calculations and drawings
have to be approved by the client and his consultants.
The contractor has to submit the following method statements; further
documents might be required at a later stage:
• Fabrication of compression ring including machining of head plates
• Trial assemblies for compression ring segments, maintaining required
accuracy
• Trial assembly of special details of support structure
• Survey of connection points at RC structure prior installation
• Erection sequences bearings, compression ring, canopy
• Erection sequence cables
• Manufacture, packing and transportation, installation sequence for
membrane including time stepped prestress procedure and connection
• Damage assessment of fabric
• Survey during erection, during cable lifting and as built (as
described later)
• Monthly surveys of foundation settlements from begin of installation
of CR to end of contract of roof contractor and liaison and hand
over to client’s surveyor for a further period of one year.
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1.3 Geometry
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Some governing values are given in service limit state (SLS), other values
can be taken from the structural analysis report. Downward deflections are
indicated (+), upward deflections are indicated (–). Detailed results can be
found in the structural analysis.
General
Prior to construction and until the final acceptance, the contractor has to
perform settling and deformation measurements which are required for the
precise spatial location of the construction and to verify their planned and
redundant implementation.
During the construction each and every sub contractor within the roof contract
has to handover the actual built geometry to the succeeding sub contractor.
The successor may verify on its own costs the hand over geometry. This
procedure shall happen at least:
The measurements are to be made especially before and after significant change
in load and internal forces. The progress of the installation and the
equipment is to be taken into account. Scaffolds and other temporary
structures have to be included in the measurements.
Measurement concept
The contractor has to present a measurement program for approval in good time
prior to beginning construction. The measurement program has to consider all
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The contractor owes the client the documentation of the measurements including
the comparison of the planned and actual measures in tabular and graphic form
for all stages described above.
The comparison is to contain influences from deviations of temperatures during
the measurement of the calculated deployment temperature.
The documentation is to be presented to the contracting party upon request
or upon completion of the individual building phase at the latest.
After conclusion of the construction measures the contractor has to hand over
to the client all the original documents developed for measurement in
connection with the erection and acceptance of the construction
(calculations, plans, coordinates and height indices, graphic analyses), in
binders and with the corresponding comments, without a claim for additional
remuneration.
Within the scope of the measurement of the roof structure especially the
location of the system joints of all radial cables (pin points), the canopy
anchorage (pin points) and the compression ring sections (centre point) are
in particular to be noted.
All the anchoring elements for the roof structure will be installed at the
time when the spectator stand and the foundations are being constructed
(anchor plates).
The steel contractor is to record the positions of all the connecting points
prior manufacture to modify / adjust the workshop drawings to built geometry,
by carrying out his own dimensional checks and surveys. This includes
compensation due to creep, shrinkage and foundation settlements. The
deviations of theoretical and actual measured system points of the recording
of the positions have to be approved by the client and his consultants.
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- During the erection of the compression ring, each and every erected
segment is to be surveyed: Measurement of the cable connecting holes
and the bearing plate of the newly erected segment. During CR erection
on a weekly basis, during lifting and prestessing on a daily basis and
for all other stages on a monthly basis.
- After the completion of steel assembly: Survey of all cable connecting
holes, connecting holes of Canopy structure and bearings in the steel
structure (after removal of temporary structure)
- During prestressing of the roof structure: 4 surveys of the cable
structure shall be done (4 times 2x96 points)
- After the completion of cable assembly: Measurement of all cable
connecting points, connecting holes of Canopy structure (2x96 points
to be measured) and cable structure i.e. tension ring (96 points to be
measured). Additionally:
- After the completion of membrane assembly: Measurement of all system
points in the steel i.e. compression ring (96 points to be measured)
and cable structure i.e. inner tension ring (96 points to be measured).
Additionally: In four, by the project consultant defined axis all system
points of radial cable.
- Prior the erection of the Canopy structure: Measurement of all
connection points for the attachment of the secondary structure i.e.
out compression ring (2x96 points to be measured)
- After completion of the roof structure: Complete survey of the roof in
the points mentioned above and at the tip of the main canopy girders
(96 points to be measured).
The method of optical 3d survey on site must work within a range of + 2 mm.
Tape measurements must be within a range of +-0.5mm. The tapes have to be
calibrated to the ambient temperature during design (T = 8°C with 50N nominal
pull)
The stated survey must be carried out by a licensed surveyor acting on the
contractor's instructions and at the contractor's expense. The measurements
must not be impaired by uneven temperature distributions (resulting from
solar irradiation). This may make it necessary to carry out measurements at
night. In addition, survey work is required during the whole of the assembly
operations. These measurements are to be agreed upon with the client before
the start of the assembly work.
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The contractor is, on his own responsibility, to design long lasting targets,
determine, and affix in good time, all those targets on the structural
components which are required for measurement purposes. The locations of the
targets shall allow for ongoing measurements after completion thus additional
targets may be necessary for hidden locations behind cladding etc. The targets
require the agreement of the client.
The measurements of the trial assembly of the compression ring and geometrical
checks of all other elements (i.e. columns etc.) must be performed by a
licensed surveyor. The consultant is to be informed immediately of the results
and deviations of each section of the survey. All survey results have to be
evaluated by the contractor and to be submitted to the client and his
consultant for approval. The contractor is to introduce the 3d measurements
into a 3d DWG system to overlay original geometry requirement and existing
measurement and determine deviations immediately. This model is to be
submitted to the client after each modification.
The method of optical 3d survey at the fabrication facility must work within
a range of + 1 mm. The measurement of compression ring element length during
trial assembly must work within a tolerance of 1/20000. Tape measurements
must be within a range of +-0.5mm. The tapes have to be calibrated to the
ambient temperature considered during design (T = 8°C with 50N nominal pull)
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Achieving the tight tolerances specified is the vital part of the construction
work.
Note:
All described tolerances are to be seen globally and relative to the adjacent
system points. The following summary indicates the most important items:
Tolerances for materials shall comply with EN 1090 Tab. A.3 for Execution
class EXC as specified. This includes
EN 10029 Class B for plates
EN 10210 / EN 10219 for profiles
The added axial tolerance for any of the elements within the array of
elements shall not exceed a tolerance of + 10 mm. (This has to be
confirmed by means of the trial assembly!)
Straightness of lug plates, tubes and box sections: 0.05% of the system
length.
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Deviation from the global specified position of the tension bars, cast-in
parts or bearings:
max. deviation in vertical directions: +5 / -5 mm
max. deviation in horizontal directions: +10 / -10 mm
max. sum of deviations of two adjacent parts: +5 / -5 mm (all
directions)
These figures are to be considered for all parts of the bearings (refer
also to the chapter “Bearings”).
Also great precision is required when marking the connecting points for the
clamps.
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The accuracies required for the assembled and pre stressed final roof
structure are as follows:
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Steel structure
* Manufacture, corrosion protection, delivery and assembly of:
Support structure such as bearing elements and connecting base
plates
Compression ring
Canopy steel structure
Substructure for cladding elements compression ring and canopy
Canopy edge cladding (steel and aluminium)
Catwalks in compression ring
Provisions for drainage and lighting elements
Drainage utters for compression ring and canopy
* Manufacture, corrosion protection, and delivery of:
Crosslink, Catwalks tension ring, Flying struts
Substructure for tension ring cladding elements and
mechanical/electrical equipment
Cladding elements of tension ring (steel and aluminium)
Cable structure:
* Manufacture, corrosion protection, delivery and assembly of:
Primary cable structure
Castings
* Manufacture, delivery, and corrosion protection of:
edge cables for fabric
casting clamps for membrane connections
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* Assembly of:
Crosslink, Catwalk tension ring, flying struts
Substructure for tension ring cladding and
mechanical/electrical equipment
Cladding elements of the tension ring
Membrane structure:
* Manufacture, corrosion protection, delivery and assembly of:
Primary membrane structure incl. all clamping and connections
to cables
Upper and lower membrane of canopy
Compression ring cover membrane structure incl. all details
Tension ring cover membrane structure incl. all details
Closure flaps, manholes, water inlets, water deviators, gutter
boxes connected to the membrane
* Assembly of:
Edge cables
casting clamps for membrane connections
Drainage:
* Manufacture, delivery and assembly of:
Complete pressure drainage system for the tension ring
drainage of the main roof, including all inlets, horizontal
and down pipes, connection details to the steel/cable
structure suitable to the chosen system, flexible connections
at the joints between cable structure / compression ring and
roof / concrete structure. Including the calculation of the
complete system and final testing on site.
Connecting pipes of membrane outlets with the gutter in the
compression ring.
Downpipes for compression ring drainage of the main roof
Additional outlets with pipes and downpipes of the canopy over
the Peineta.
Mock-up for the outlet/collection pan for the “waterfall” at
the canopy.
Final outlet/collection pan for the “waterfall” at the canopy.
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All contractors shall prepare detailed workshop drawings for all structural
elements based on the final structural design drawings under the supervision
of an experienced professional Engineer. All workshop drawings have to be
sent to the client and the consultant for approval before fabrication
commences.
The approval includes the member sizes only, but excludes dimensions, cleats,
bolts, welds and gussets etc. The contractor shall allow 4 weeks for checking
and approval by the client, and shall also allow for any possible changes to
shop drawings.
Drawings for approval shall show the elements in their geometrical
configuration with their connecting elements. Single piece drawing will not
be approved. For complex geometries 3D models are necessary for approval.
Generic detail drawings with complex corrosion protection tasks shall be
verified at an early stage by a corrosion protection expert.
All the workshop drawings are to be drawn up in English and Spanish language
with metric measurements.
All steel elements are measured on metric tons basis and as described in the
technical drawings. No extra amount will be allowed for milling tolerances,
bolts, weld seams, cutting gloss or clippings. The cutting of the shaped and
sheet-metal butt joints into lengths, and the processing and manufacture of
those butt joints, together with the required connections and fastenings, are
to be included in the unit prices. There will be no special remuneration for
any assembly connections, assembly scaffolding or structural details, which
do not have to remain installed.
All cable elements will be measured by item, metric length from pin to pin
of sockets and metric tons given are as reference only.
Membrane roof cover will be measured on metric real area (m²) basis. Remaining
cuttings from patterning won’t be measured; employed material only will be
measured according to the client approved patterning layout, even if the
patterning layout preferred by the client results in higher cuttings.
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1.7 Erection
1.7.1 General
The proposed erection sequence should only help the contractor to price. The
total responsibility for the finally chosen erection procedures will remain
with the contractor, and may differ from the described proposal.
The erection procedure shall be in accordance with proposals submitted by
the Contractor and approved by the Consultant Engineer.
The Contractor shall inform the Client and his Consultant Engineer when
fabricated sections are ready for inspection prior to erection.
The Contractors have to prepare detailed erection drawings and erection
descriptions, which have to be issued and submitted to the Client and his
Consultant Engineer for approval.
For all erection steps of the structure, the temporary structural systems
have to be considered and all relevant structural calculations have to be
performed and submitted to the Client and his Consultant Engineer for
approval, but this approval shall in no way relieve the Contractor of his
responsibilities for the work under the contract.
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The built-up section of the top chord box will be fabricated with all
the lug plates and the head plates.
The accurate length and the angle at either side of the box will be
achieved by milling the head plates of the top chord in the workshop.
Therefore the thickness of the head plates must have sufficient
milling allowance (minimum 5 mm either side) taking care of
inaccuracies during fabrication of the box.
Additionally the bolt holes and the cable connecting holes within the
head plates will be done CNC guided during the process of milling the
head plates at the workshop.
The top and bottom chords connecting struts and diagonals will be
fabricated separately.
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After erection of the concrete columns and after the above-mentioned survey,
the built-in components (bearings etc.) for the compression ring elements can
be installed.
After that the compression ring elements can be installed according the
erection drawings on temporary supports.
Element per element will be installed and connected to the prior installed
element by fixing the front plates with HSFG-bolts and connected to the
bearing. For controlled pre-tensioning of the HSFG-bolts a specified torque
will be required.
The cable structure will be laid out on protective elements on the ground or
on the stand superstructure the whole cable structure is pulled by heavy
lifting units, mounted on the compression ring, until the cable structure
reaches its final position, and can be anchored to the lug plate at the
compression ring.
Note:
The whole cable structure has to be pulled in 48 axes at the same time. A
simultaneous tensioning sequences is required.
Requirements:
surveying of all erection stages by controlling the system nodes,
heavy lifting equipment up to approx. 3000 kN capacity,
protection of all stand surfaces.
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During stressing of the cable structure the compression ring moves from its
erection geometry much closer to the dead load geometry. The compression ring
shortens and moves radially inwards, towards the soccer field. If the canopy
is installed at a different stage during the construction sequence as assumed
in the design project, this movement has to be compensated in the workshop
design of the canopy members.
The first step is the prefabrication of the main bodies of the radial girders.
Since there are only two different types it is recommended to built two jigs
to achieve maximum accuracy for these elements. Then the ring beams have to
be cut to length and the end details applied.
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All individual elements need corrosion protection and can then be transported
to the site. The bar connecting the main bodies of the radial girder and the
top chord of the compression ring is the last part which shall be produced
after survey of the as-built geometry of the compression ring.
On the site two adjacent radial girders starting at one expansion joint shall
be welded together with the ring beams between them. The preassembly yard
for the compression ring can be used. This ladder like element should be
temporarily braced and lifted into place.
The same principle should be applied for the next two radial girders leaving
the ring beams between these two “ladder” elements open. Similarly the third
ladder element can be installed before the geometry of all three ladder
elements is controlled and if necessary adjusted with the temporary bracings.
After that the remaining ring beams always in between two ladder elements
can be bolted in the air, the permanent bracing installed and the temporary
bracing removed.
After the installation of five radial blocks of the canopy one should start
with the next segment of the canopy. After verification of the geometry of
the second segment the girder along the joint between the first and second
segment can be installed. This helps to ensure that all joints are of equal
size and that any construction deviation can be distributed over more than
one joint.
Right after completion of one whole segment the top and bottom membrane, as
well as the front edge cladding, drainage, closure flaps, etc. can be
installed.
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1.8.2 Category of operational demands (System Class) [SC] as per 1090-2 Table
B.1
EXC 4
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2.1 General
A quality control system according to ISO 9000 - 9004 is mandatory. The full
quality documentation has to be submitted to the client.
The factory expert is to present acceptance test documents as per EN 10204 -
3.1/3.2 in respect of all the checks regarding geometry, weld seam tests,
castings, doubling tests, and corrosion-proofing.
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3 Metal materials
Provide in accordance with the stipulated codes. Properly mark and match mark
the material where field assembly is required. Sequence the shipments to
expedite erection and minimize the field handling of material.
Milling: Completely assemble and weld members before milling of surfaces. The
milling device is to be of appropriate capacity to obtain the requested
accuracy.
Welding: It is the steel contractor's task to plan suitable measures for
welding (e.g. shape of seam, seam preparation, heat treatment, welding
sequence, checking of seams, assembly). Welding sequence plans are to be
submitted for approval. Only experienced and qualified welders with
applicable certification will be allowed to weld. For special requirements
for welding (i.e. tubular sections, overhead positions, thick plates, high
grade material, welds of castings to mild steel, dynamic loaded welds etc.)
welders will have to be qualified in tests surveyed by an independent agency
in accordance to EN 10204 - 3.2. A suitable procedure is to be used to
demonstrate that the seams are free of cracks. The nature and extent of the
tests are to be agreed.
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As per EN 1090 cl. 5.3.4 the base material in the area of transversal tension
loading or welded stiffener plates must be quality class S1 for inner
inhomogeneity as per EN 10160.
In general the proof of the required Z quality remains with the contractor
due to the chosen manufacturing.
All stainless steel plates and sections are to be grade 1.4401 with S355 (fyk
= 355 N/mm²) unless stated otherwise. If cold drawn materials are not
available to achieve fyk = 355 N/mm² or if elements have to be welded 1.4462
has to be used instead. Stainless steel C Clips are to be made of grade 1.4401
or 1.4404 S355 (fyk = 355 N/mm²).
Minimum requirement for the powder coated aluminium (and not the raw material)
is fyk = 235 N/mm² as the minimum yield strength. This has to be considered
in the workshop design and final layout of the clamping bars.
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For all sets of screws (i.e. bolt, washers and nuts including lubrication)
the individual elements shall be of one single manufacture. Always two washers
are to be used in each set for grades 8.8 and 10.9, one on each side.
Manufacture, procurement and delivery are to be in an assembled set.
Threaded rods are hot-dip-galvanized bar sets 8.8 as per EN ISO 898-1 / DIN
976-1 galvanized at “normal temperature” as per EN ISO 10684 (avoid hydrogen
induced embrittlement). Rods need to be delivered to site as assembled set
with nuts and washers and with the required lubrication, demonstrating that
nut and thread are matching well (the nut must be rotatable by hand easily).
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EN EN E
14399-3 14399-3 AD
HR HR
EN EN AE
14399-7 14399-7 BE
EN EN CE
HR
14399-3 14399-3
HR H
EN EN
EN +
14399-7 14399-7
14399-6 suppl
EN EN
10. HV HV ier
14399-4 14399-4 10
9
EN EN
HVP
14399-8 14399-8
HR
EN EN
HRD
14399- HRC 14399-
10 10
Table: high strength bolts for prestressed bolted connections (type
A,B,C,D,E,AD,AE,BE,CE)
All stainless steel bolts, screws and washers are to be grade 1.4401 / 70
(fybk = 450 N/mm² fubk = 700 N/mm²) or of higher corrosion grade or higher
strength unless stated otherwise.
For pretensioned connections and clamps the actual tension forces achieved
while pretension the bolts using torque has to be tested. This applies to
all sets of screws in various arrangements used for pretensioning (screws in
nuts, in tapped holes, in blind taped holes etc.)
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All contact surfaces between the head plates of the compression ring are to
be machined, sandblasted and coated in accordance to EN 1090 to achieve a
minimum friction coefficient of class B (0.4). During transport and
installation these surfaces are to be protected properly. The achievement of
the mentioned friction coefficient is vital to the behaviour of the
compression ring as per the structural design, hence the method statement is
to be approved by the client prior to execution.
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Unless stated otherwise, pins with diameter > 50mm are to be secured using
cap plates. The cap plates need to be held in place using at least two bolts
grade 8.8 or 10.9 with washers 300HV (pre-stressed). Additionally high
strength loctite® or equivalent is to be applied. Bolts and washers shall be
hot dip galvanized and shall be delivered to site without grease application
and prepared for the use with loctite. Threads at pins shall be re-cut after
galvanization and prepared for application of loctite.
Pins with diameter < 50mm shall be secured using
A) unless stated otherwise: retaining rings similar to DIN 472 heavy duty
shape made of bronze CuSn8 material number 2.1030.34 with Re 600 Rm 720 MPa
together with appropriate hot dip galvanized support washers as per DIN 988.
The dimensions of the grooves for the retaining rings are to be met after
galvanization of the pins considering an oversize initial groove for the zinc
layer. Galvanization must follow EN ISO 10684 with centrifugation to remove
any surplus of zinc from the grooves. Pins, retaining rings and washers must
be delivered to site as preassembled units.
B) pin caps with a machined groove that fits to a machined up-stand at the
end of the pin. This is to provide a mechanical lock against any rotation
between pin and pin cap after assembly. The cap plates are held in place
using one bolt grade 8.8 or 10.9 (pre-stressed). Additionally high strength
loctite® or equivalent is to be applied.
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Tension rods shall be hot dip galvanized and of type 860 Pfeifer or
equivalent. Only approved and accredited systems of tension rods shall be
utilized. Steel grade S460 of specified diameter coated as per corrosion
specification with top coat RAL. The fork ends shall be "Pfeifer” fork ends
or equivalent.
Anchorage system
Single bar tendon system; unbonded tendons without free tendon duct with
permanent corrosion protection system are to be employed.
System according to current permission/ specification ETA-05/0123 type
DYWIDAG or ETA-05/0122 type SAS or equivalent. Only accredited and officially
approved systems can be proposed. Length of single bar tendons according to
structural drawings in accordance with the roof structural requirements.
Additional length for tensioning process to be considered.
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Materials
1)It is noted explicitly that the demands specified hereunder are exceeding
the requirements given in EN 10340.
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General
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Mechanical characteristics
Tolerances
For the fabrication of the steel castings the tolerance grades according to
ISO 8062 (1997-08) apply. Required tolerance grade:
nominal dimensions > 25 mm: CT 11
nominal dimensions < 25 mm: CT 10
for cable grooves at least (all diameters): CT 8, unless specified
other
Specific demands may supersede the above mentioned classification and require
a higher accuracy. This will be indicated in the drawings.
Heat treatment
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Quality class
Quality class 1
Quality class 2
Quality class 3
The required higher quality class applies in the areas marked and with a
depth of min 30mm from the surface of the casting.
Figure: Areas of the casting and respective requirements for the quality
class (shown at a typical ring cable connector)
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3) For surfaces that are inaccessible for the magnetic particle inspection
(MT) a dye penetration test (PT) can be carried out.
4)Alternatively to the radiographic examination (RT) ultrasonic examination
(UT) can be carried out where technically applicable. A minimum of one piece
per geometry is to be tested by RT if the elements contain welding ends and
in case of non acceptable results of the UT. In case of results below the
acceptance criteria RT has to be used for the other pieces as well.
The testing methods chosen by the fabricator due to the specifications above
have to be specified in the testing schedule in advance, showing the entire
fabrication sequence and testing procedure. All fabrication steps, tests,
hold points and 3rd party inspections must be indicated in detail.
Any expenses for testing incurred by the foundry and 3rd party inspection are
to be included in the unit price. The same applies to the expenses for
material verification.
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Repairs
Before the agreed commissioning date, the fabricator has to check and confirm
the compliance with the stipulated dimensions in the acceptance certificate.
Unless specified otherwise, the ID-number given in the order and the material
no. have to be stamped at the position denoted in the order drawings. The
steel letters have to be rounded off.
The full documentation has to be handed over to the client who determines
the safe-keeping duration. The documentation has to include but is not limited
to
- ID-number and order number
- Material designation
- Heat number, ladle analysis, and melting process.
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Inspection (d) Visual inspection (e) Surface testing (f) Volume testing -
of welds inner defects
VT MT 3) UT
Magnetic particle Ultrasonic
inspection examination
Code EN 12454
BNIF-guideline Nr. EN ISO 17638 EN ISO 17640
359-01
Required - 3S1 for raw cast
grade surfaces EN ISO 23278 - level EN ISO 11666 level 1
- 3S2 for ground 1
surfaces
Scope 100% 100% 100%
Remarks Cracks are Cracks are
unacceptable unacceptable
table 3.12-1 Testing of Welds
3) For surfaces that are inaccessible for the magnetic particle inspection
(MT) a dye penetration test (PT) can be carried out.
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4 Corrosion protection
4.1 General
In general all smaller mild steel elements like membrane plates and built in
parts as well as pins, bolts and cast elements are to be hot-dip galvanized.
The galvanizing agency has to be internationally accredited and well
experienced with high grade steels and avoidance of hydrogen embrittlement.
Detailed description see below under coating.
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4.4 Miscellaneous
The colour shade of the last top coat in each case is described in detail in
the architectural drawings and is to be approved by the client. For this
purpose the contractor is, without receiving any special remuneration, to
produce sample areas which will be used to decide the final colour shade.
4.5 Coatings
CPS 02 Hot dip galvanized steelwork and plates with limited dimensions
Catwalk - and roof access (stair treads, ladders, suspensions etc.)
steel gratings and grids
tension rods
fixing systems for MEP - equipment and other provisions
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Coating system for steel constructions, excellent gloss and colour retention,
corrosion category C4 high durability.
In workshop
Surface preparation blast cleaning to Sa 2 1/2 of DIN EN ISO 12944 part 4
with sharp edged material, roughness acc. to ISO 8503/1 Type G Segment 2-3
Primer coat:
2-C-Epoxy- Zinc dust min 80% zinc in the dry film
Dry film thickness: 60 µm
Product: Interzinc 52 or eqv.
-grey-
Intermediate coat:
2-C- recoatable epoxy micaceous iron oxide intermediate coat
Dry film thickness: 130 µm
Product : Intergard 475 HS or eqv.
Colour shades acc. to RAL white
Top coat:
2-C- Acrylic -Polysiloxan - long time overcoatable top coat with excellent
color and gloss retention
Dry film thickness: 50 µm
Product : Interfine 878, or eqv.
Colour shades acc. to RAL, BS, MNS, Munsell or similar
On construction site
Repair of damages caused by transport /installation. Surface preparation to
PMa or PSt 2-3 of DIN EN ISO 12944 part 4
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-alu-
Edge Protection
All edges and welds shall be provided with an additional stripe coat of epoxy
MIO. The stripe coat shall cover the edge and weld and run 50 mm onto the
flat surface. The total dry film thickness on the stripe coated areas shall
be 400 microns. All right angle and sharp edges shall be broken and smoothened
with a minimum radius of 2mm.
Notes
Primer and intermediate coats to be applied in the shops with due cognisance
being taken of the over coating time requirements between the various coats.
Coating sequence as described.
Stripe coating to be carried out as described.
All site repairs to handling and erection damage shall be carried out as
described
Architectural coat to be applied on site after erection.
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All nuts and bolts to be patched with intermediate coat prior to the
application of the finishing coat.
All welds to be coated shall be blast cleaned to grade Sa 2½ to ISO 8501-1.
The surface quality of grade Sa 2½ to ISO 8501-1 shall be present immediately
prior to coating. If the surface has deteriorated between blast cleaning and
the time of coating it shall be re-blasted to Sa 2½ before coating.
The surface roughness after blast cleaning shall be according to ISO 8503/2-
G and as specified by the coating manufacturer for the particular primer to
be used. The coating manufacturer shall confirm in writing the value of
roughness.
Areas of damages and site welds shall be made good according to the defined
specifications.
The Contractor shall apply all coatings under shop conditions, on site and
in the fabrication shop or yard, in strict accordance with the manufacturer’s
instructions and recommendations. These detailed instructions and
recommendations shall be documented and submitted prior to approval of the
Contractor's proposal.
The coating manufacturer shall be present during coating application to ensure
materials are used in accordance with the instructions and recommendations.
Coating system for steelwork according to EN ISO 12944, Corrosive category
C-4, high durability (H)
Ensure by design that no metals, including alloys of the same base metal,
are placed together in a manner, combination, or location likely to give rise
to damage by electrolytic action or other corrosion. In particular, avoid
metal to metal contact between aluminium and metals other than an appropriate
alloy of stainless steel as per the recommendations of the material
manufacturer and to the approval of the Architect. Ensure that dissimilar
aluminium alloys in contact with each other are compatible with each other
or are isolated. Any other dissimilar materials are to be treated or protected
in such a manner as necessary to prevent corrosive action.
Isolation of dissimilar metal surfaces to prevent electrolytic action shall
be accomplished by materials that are impervious to moisture and non-
absorptive.
Aluminium surfaces in contact with mortar, concrete, fireproofing, plaster,
masonry, or absorptive materials of any kind shall be coated with an anti-
galvanic material, impervious to moisture.
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4.5.2 CPS 02 - Hot dip galvanized steelwork, plates, elements and castings
with limited dimensions:
In workshop
Surface Preparation: Sweep blast
Primer Coat:
hot dip galvanizing to ISO 1461:1999 or equivalent EN. Minimum layer thickness
85 µm or - limited to ring connectors and cast elements - with cable grooves
spraying galvanizing minimum layer thickness 1000 µm.
Intermediate Coat:
Intergard 475 HS or equivalent two component recoatable epoxy micaceous iron
oxide tie coat/intermediate coat dry film thickness 80 micron
Finishing Coat:
2-C Acrylic-Polysiloxane Interfine 878 or equivalent two component
polysiloxane finishing coat dry film thickness 60 micron
Notes
Cable contact surfaces / cable grooves will be zinc sprayed with 1mm thickness
to achieve friction coefficients and soft cable saddle beds.
The galvanized surface shall not be passivated.
Uncoated areas for renovation by the galvanizer shall not exceed 0,5% of the
total surface area of a component. Renovations at the galvanizing works shall
be done by zinc metal spraying. The zinc thickness shall be 30 micron greater
than the specified galvanizing zinc thickness.
The galvanized surface shall be sweep blasted prior to the intermediate coat
application.
The intermediate and finishing coats are to be applied in the shops with due
cognisance being taken of the over coating time requirements between the
intermediate and finishing coats.
Stripe coating to be carried out.
All site repairs to handling and erection damage shall be carried out as
follows:
Galvanizing to be repaired with either zinc metal spraying or epoxy zinc rich
paint. The zinc rich paint shall contain a minimum of 80% zinc in the dry
film and the thickness shall be 30 micron greater than the specified
galvanizing zinc thickness. The damaged area shall be thoroughly cleaned and
the repair coating shall overlap onto the surrounding sound zinc for a
distance of at least 50 mm.
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In workshop
Surface Preparation: Sweep blast
Primer Coat:
Hot dip galvanizing to ISO 1461:1999 - minimum layer thickness for castings:
85 µm
Intermediate Coat:
Intergard 475 HS or equivalent two component recoatable epoxy micaceous iron
oxide tie coat/intermediate coat, dry film thickness 80 micron
Finishing Coat:
2-C Acrylic-Polysiloxane Interfine 878 or equivalent two component
polysiloxane finishing coat
dry film thickness 60 micron
Notes
The galvanized surface shall not be passivated.
Uncoated areas for renovation by the galvanizer shall not exceed 0,5% of the
total surface area of a component. Renovations at the galvanizing works shall
be by zinc metal spraying. The zinc thickness shall be 30 micron greater than
the specified galvanizing zinc thickness.
The galvanized surface shall be sweep blasted as described prior to the
intermediate coat application.
The intermediate and finishing coats are to be applied in the shops with due
cognisance being taken of the over coating time requirements between the
intermediate and finishing coats.
Stripe coating to be carried out as described
All site repairs to handling and erection damage shall be carried out as
follows:
Galvanizing to be repaired with either zinc metal spraying or epoxy zinc rich
paint. The zinc rich paint shall contain a minimum of 80% zinc in the dry
film and the thickness shall be 30 micron greater than the specified
galvanizing zinc thickness. The damaged area shall be thoroughly cleaned and
the repair coating shall overlap onto the surrounding sound zinc for a
distance of at least 50 mm.
Intermediate and finishing coats to be repaired as described
All galvanized nuts and bolts to be patched with intermediate coat prior to
the application of the finishing coat.
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4.5.4 CPS 04 – Aluminium clamping plates and corner plates, clamping edges
and membrane details
Coating System:
Degrease and clean
Apply one coat of epoxy primer - 25 to 35 micron
Apply one coat of polyester powder coating – 60 to 70 micron (HWF-Powder
coating)
Application of primer and powder as per the proprietary powder coating methods
(method statement to be provided by contractor)
Notes:
The powder coating material as well as the applicator must have an GSB
approval; The qualification must be proved before application will take
place
Textured or ‘structured’ powder coatings will not be acceptable due to
variations in film thicknesses
Application methodology must ensure required mechanical properties of base
material after coating
Profiles to be degrease and cleaned
Damage to the coatings during installation and torquing of bolts shall be
carried out using a two component polyurethane acrylic coating as
recommended by the powder manufacturer in accordance with a customized
touch up instruction (to be provided by the contractor)
Temperature control and coating time control for temperature coatings
required to avoid loss of yield strength
Color shades acc. to Clients specification.
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4.5.5 CPS 05 - Pins, bolts, screws, flat washers and spring washers
All pins, bolts, screws, flat washers and spring washers shall be hot-dip
galvanized.
Hot dip galvanizing to be in accordance with ISO 1461, DIN 267
Minimum zinc thicknesses shall be as follows:
Articles of diameter less than 12 mm 45 micron
Articles of diameter of 12 mm or greater 60 micron
Articles of diameter of 40 mm or greater 85 micron
Painting (after installation and retensioning, if required)
Where the structures are painted (CPS 01) or galvanised and duplex coated
(CPS 02, 03), all nuts and bolts shall be degreased, and shall be fully coated
in accordance with the specification applicable to the structure or component.
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Finishing System:
DENSO Covercoat System or eq. with polyurethane finishing coats
The above described top coat shall be provided on the concrete exposed surface
for a distance of minimum 80 mm from the flange edge.
The edges shall receive additional protection as described.
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In workshop
Surface Preparation: blast clean to Sa 3 of DIN EN ISO 12944- 4 with sharp
edged material, roughness acc. to ISO 8503/1 Type G Segment 2-3
Primer Coat:
thermal spray zinc to DIN EN ISO 2063:2005. Minimum layer thickness:
160 m in general,
1000 m in the cable groove in contact to the cable.
Intermediate Coat:
Intercure 420 or equivalent two component epoxy micaceous iron
intermediate coat, dry film thickness 80 micron
Finishing Coat:
see CPS 01
dry film thickness 60 micron
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In workshop
Primer Coat
Interzinc 22 or equivalent ethyl based inorganic zinc silicate weldable
two component primer with qualified friction grip coefficient > 0.40.
dft 25-30 m.
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Surface Preparation: The surface shall be visually inspected for dust, oil,
rust spots and other substances. Note: Sand blasted surfaces may show defects
or errors in fabrication (e.g. welds) which otherwise would stay undetected.
In such case, the responsible inspectors should be immediately contacted.
The cleanliness of the surface shall be compared to the cleanliness degree
specified in the painting scheme. This comparison is done with the visual
samples of Standard SIS 05 5900 - 1967.
The rugosity profile shall be measured in 1 sq. meter of the surface, at the
start of the sand blasting, and this will be repeated at each 500 sq. m. or
fraction of equipment, and every time the sand or grit is changed.
In pipes, the rugosity shall be measured in 1 meter at the start of the
operation, and then every time the grit is changed.
The rugosity will be determined by the use of a “profile gauge”, making a
series of measurements, the average of which is the rugosity value.
The results of all these operations must be recorded. The rugosity profile
should vary between 40 and 75 mm. which is probably around 1/3 of the total
thickness of the dry film of the painting scheme.
Paint film should be checked for the following defects:
Runs
Blisters
Wrinkling
Cracks
Bubbles
Craters
Impregnation of grit
Flaking
Poor adherence
Adherence: The adherence test shall be done after the time for drying and
curing of the film, in accordance with ASTM Standard D-3359, with an X cut.
The minimum acceptable level will be 3A.
The test shall be performed in each 30 meters of piping, in each lot of
prefabricates pieces not larger than 30 m, and in each equipment.
For painting systems with primer of inorganic silicate base and thickness of
the dry film in each coat equal to or greater than 75 mm, the same test by
ASTM D-3359 with an X cut will be used, with minimum acceptable level 3A,
that is, removal of small dents up to 1.6 mm in any side along the cuts, to
determine the adherence.
The adhesive tape to be used in these tests shall have an adhesivity degree
of 40±2.8 g/mm2 (3M tape 810 or similar).
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5 Grout
To level the base points properly the volume between steel base plate and
concrete foundation socket is to be grouted if not directly cast in. The
grout touching surfaces need to be clean. The grouting procedure needs to
ensure that full contact is reached. No air bubbles shall be trapped. Exposed
grout surfaces are to be maintained with sufficient inclination in order to
drain water.
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6 Cable structure
6.1 General
For all cables, fully locked cables made from hot-dip-galvanised and galfan
coated wires are to be used.
The rated tensile strength of all the wires involved in the cable structure
must not exceed fu,k = 1570N/mm2 for the fully locked cables, and 1770 N/mm2
for the spiral strands where applicable.
The coils are to be so stored that they are protected against meteorological
and mechanical influences, and this also applies when they are being
transported. If the wires were not stranded on the premises of the wire
manufacturer, the attached plate must also state the wire manufacturer, the
cross-section, and the rated tensile strength.
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The tension test is to determine not only the tensile strength, but also the
breaking elongation. The latter must attain the following minimum values:
Bare wires:
3.5% min. when Lo = 10 x D or Lo = 11.3 x A0.5 (shaped wires)
Coated wires:
4.2% min. when Lo = 10 x D or Lo = 11.3 x A0.5 (shaped wires)
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When the dimensional accuracy is tested, the cross-sections are in each case
to be ascertained by two measurements of diameters, with one measurement
being vertically above the other. In shaped wires, the cross-section is
calculated from the measured weight by means of g=7.85kg/dm3.
The cables are to be manufactured from round and shaped wires of locked
design. The cross-section and structure are to be determined by the
contractor. They must include at least two layers of shaped wires. The
structure of the cables must allow for the planned angle of 20d through which
the cables are to be bent.
All the wires of the locked cables, with the exception of the two outer layers
of shaped wires, are to be thick-galvanised as per DIN 2078. The shaped wires
are to be given a galfan coat with a minimum weight of at least 300g/m².
The wires are to be given their galvanised coats by the hot-dip process. A
unilateral alloy of zinc and aluminium (5 weight %) is applied in a molten
state as a protective metal. As regards the galvanic coating, the
International Lead Zinc Research Organisation was granted a patent in 1984.
The client is to be informed of the structure of the cables in good time,
and that structure is to be agreed upon with him.
The modulus of elasticity of the cables must be E=160’000+5’000N/mm².
The lengths of twist of the cables are to be adapted to the modulus of
elasticity and to the angle through which the cables are planned to be turned.
The individual wire lengths are to be stranded alternately left-hand and
right-hand.
The cables must be good to bind together, i.e. the cable diameters of layers
located one above another must be so co-ordinated that no arches can form.
The inner corrosion-proofing to be given to the cables used in the cable
structure consists of an inner filling which has an active pigment (inorganic
zinc paint) and remains paste-like. The inner filling must be compatible both
with the zinc coating of the cables and with the galfan coating.
The dosing of the inner filling is to be such that the last two layers will
get no inner filling. The total amount of inner filling is to be established
to provide the full corrosion protection.
The cables are to be marked at the places where it is planned that clamps
and saddles are to be connected, and also at the positions of the cable heads.
They are also to be given a straight surface line.
The anchorage in cable heads by means of hot sweating using redistilled zinc
alloys of the "Zamak" type as per DIN 1743 is to be carried out in accordance
with DIN 3092.
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Factory records of the serial designations for the manufactured cable batches
and for the individual cable lengths into which they are cut up are to be
kept and submitted to the customer.
General
The section on quality controls on the wires applies analogously here. The
following tests of the cables are required and to be carried out in accordance
to the related codes.
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Accuracy requirements
Volume:
All cable types and diameters
In order to achieve the expected structural behavior and redundancy of the
structure it is mandatory to achieve the defined condition of prestress and
geometry with high precision and as per design intend. Provisions for
adjustments on site are not foreseen and not in line with the design intend
except for elements stated explicitly. The cable manufacture, marking and
cutting subsequently must provide highest precision.
- Cable Length:
The overall length of a cable must be correct within a tolerance of 1:10'000
(0.01%)
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- Cable Marks:
Cable Marks on the surface of the cables are required in order to allow
precise assembly of connectors and cable clamps. The individual marking for
clamps on the carrying cables must be carried out with a tolerance of less
than 2 mm. Adding up of deviations along the cable must be avoided.
- Cable Diameter:
Tolerances of the cable diameter of Fully Locked Cables must be less than
±1% and must be considered during workshop design.
When cutting the cables into lengths, the contractor is to ascertain the
overall amount of the extension, taking into account the test results.
Temperature influences are to be included here.
All the cables are to be cut into lengths using, for the cutting into lengths,
a force which has been determined by the Contractor and is to be agreed upon
with the consultants. This force is to correspond approximately to the force
of the cable in the supporting framework under dead load.
The exact cable lengths must be calculated by the assembly planner after
receiving the results of the tests performed on the premises of the cable
supplier or at a testing establishment. The relevant cable forces and
coordinates of the cable system points will be supplied by the Consultants
responsible for the final design.
Using the system points supplied, the extended cable length can be calculated
in its final state. The free length of cable, or the distance between the
bolt axes, results from the geometrical dimensions of the anchoring cables
and is taken into account accordingly in the calculation.
Using the extended cable length and the force resulting from the calculation
of the supporting framework, the non-extended length of the cables can now
be calculated. For this purpose, the modulus of elasticity ascertained in
the test is employed.
The force relating to the cutting into lengths is not equal to the force
arising in the supporting framework. The extension of the cable is therefore,
on the basis of the non-extended length, calculated using the above-mentioned
force relating to the cutting into lengths. In addition to the elastic change
in the shape of the cable, there is also a creeping (plastic) change in the
shape. This permanent change in shape (0.2 - 0.5o/oo) is measured by long
term test or by submitting comparable test results, and is included in the
calculation of the final points which are to be marked; that is, when the
cables are cut into lengths and marked, the length used for this purpose is
reduced by the extent of the expected creeping change in the shape.
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The cables are to be marked with the designations stated in the contractor's
drawing, and are to be in coils, sufficiently protected.
A plate is to be attached to them giving the following details: information
on the manufacturer's factory, cross-section, and length. The plate is also
to bear the quality controller's acceptance stamp. The quality controller is
to place a lead seal on the wire by which the attached plate is made fast.
Even at the time when the cables are loaded on to the vehicle at the
manufacturer's factory, care is to be taken that they will, during transport,
be supported well enough not to be damaged. The same applies to any
intermediate storage at the manufacturer's factory.
Any such major damage to the coating as results from transport and assembly
is to be avoided, as it would be detrimental to the purpose for which the
cables are to be used. Smaller areas of damage (with any individual area
measuring no more than 1cm²) are - using inorganic zinc paint or sprayed-on
galvanization - to be immediately repaired in such a way that the original
corrosion-proofness factor of the zinc layer is restored.
6.5.1 Material
For all cable sockets and for the ring connectors cast steel of the quality
GS 18 is to be used. Specifications see section “Cast steel”. The socket
system shall be accredited and approved by a third party institution. For
clamp covers and hanger clamps S460 N/M is preferred.
6.5.2 Fabrication
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Each bolt of the cable clamps and clamp covers has to be pre-tensioned to
the given, nominal value by means of appropriate and calibrated tools (e.g.
electric or hydraulic torque wrench). In order to compensate the loss of pre-
stress due to material creep, cable contraction, etc., each bolt has to be
re-tightened another three times, means four times in total. Between one and
the next tensioning step a minimum holding time of 4 hours must be maintained.
Unless indicated otherwise, the last tightening sequence must be carried out
after the assembly of the cable structure is completed and the cable is
prestressed to permanent condition.
Each bolt head must be marked individually and distinctively after each
tensioning step. The different steps should be identified by different kinds
of markings. In addition the entire pre-tensioning procedure has to be
recorded in tabled form, indicating the applied torque moment, the used tool,
date and time. For all four steps the pre-tensioning has to be conducted in
crosswise sequence.
The used tools (torque wrenches) must comply with DIN EN 1090-2, 8.5 regarding
calibration, maintenance, etc.
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7 Membrane structure
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The coated material must be flame retardant, and be of class BS476 Part 6,
class 0 (or eq. class B1 as per DIN 4102 or eq. ASTM E 108 class A).
A certificate must be enclosed with the tender.
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The stiffness values shall be derived using the test method standard MSAJ/M-
02-1995 established by the membrane structure association of Japan.
The upper layer of the Canopy (material type 20) shows only little double
curvature in some areas. For the crucial ponding analysis additional values
for different stress ratios in warp and fill directions were derived from
the material properties of the Chukoh Skytop FGT 800 material (see structural
report for details). The contractor shall proof by a 1:1 load test of one
canopy panel that the chosen membrane material shows sufficient stiffness. A
frame shall be built for the most unfavourable membrane panel geometry of
the canopy with a stiffness that is comparable to the stiffness in the real
canopy structure. The membrane shall be connected to the frame in the same
way as in the actual structure. A snow load shall be simulated and the
deformed geometry is to be surveyed. Three different snow load patterns shall
be tested in accordance with the designer. The test shall verify the proper
drainage of the panel in the loaded condition. Stress/ strain curves or
equivalent shall be provided for the chosen material for different warp:fill
load ratios in addition to the uniaxial stiffness described above.
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The joint between one membrane and the next consists of a welded seam of 75mm
width. All welds are slightly to be tensioned to line up weld marks during
welding and to prevent weld shrinkage or uneven welds. The edges of the
electrode must be rounded.
During welding the integrity of the coating material shall be maintained to
prevent exposed fibres. Connections of single layer to double layer are to
be made as a three layer weld!
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vs 70
n
for random samples must be less than 0.12.
A total of 5 strip tension tests on test bodies 100 mm in width. The average
value n70 and the standard deviation s70 are to be ascertained from the
breaking loads of these tests. The value Z70 = n70 -2.0 x s70 must be greater
than the permitted Z70 = 87 kN/m. The tests are to be carried out in fill
direction.
In addition, the variation coefficient
70
vs 70
n
for random samples must be less than 0.12.
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v s 23
n
for random samples must be less than 0.12.
vs 70
n
for random samples must be less than 0.12.
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vs 23
n
for random samples must be less than 0.12.
vs 70
n
for random samples must be less than 0.12.
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vs 23
n
for random samples must be less than 0.12.
vs 23
n
for random samples must be less than 0.12.
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v s 23
n
for random samples must be less than 0.12.
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Joint line detail between main and triangle membrane – Material 20 in membrane
cuff and reinforced
Before cloth manufacture begins, the contractor is to demonstrate, by means
of tests performed on sample bodies, that this detailed structure fulfils
the requirements stated below. It is the responsibility of the successful
contractor to set up the geometry corresponding to membrane joint line detail
which is to be constructed. All details of this test need to be defined in
detail in conjunction with the client and his engineer.
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The coated material must be flame retardant, and be of class B1 as per DIN
4102. (A certificate must be enclosed with the tender.)
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- Biaxial wide panel tear test (European Design Guide for Tensile Surface
Structures A3.1 / A4.2.6)
- Adhesive strength (DIN 53357)
- Character of surface / coating.
- Breaking strength after crease fold ASTM D 4851 (-97):
The joint between one membrane mesh and the next consists of a welded seam
of 75mm width. All welds are slightly to be tensioned to line up weld marks
during welding and to prevent weld shrinkage or uneven welds.
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The clamping edge is to be build using the continuous base material through
the whole detail. Weld width 70mm.
vs 23
n
for random samples must be less than 0.12.
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Material 20:
Test group 13 Set A : T = 23°C
A total of 5 strip tension tests on test bodies 100 mm in width. The average
value n23 and the standard deviation s23 are to be ascertained from the
breaking loads of these tests. The value Z23 = n23 -2.0 x s23 must be greater
than the permitted Z23 = 134 kN/m. The tests are to be carried out in warp
direction.
In addition, the variation coefficient
23
v s23
n
for random samples must be less than 0.12.
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Material 20:
Test group 14 Set A: T = 23°C
A total of 5 strip tension tests on test bodies 100 mm in width. The average
value n23 and the standard deviation s23 are to be ascertained from the
breaking loads of these tests. The value Z23 = n23 -2.0 x s23 must be greater
than the permitted Z23 = 108 kN/m. The tests are to be carried out in fill
direction.
In addition, the variation coefficient
23
v s23
n
for random samples must be less than 0.12.
Material 50:
Test group 15 Set A : T = 23°C
A total of 5 strip tension tests on test bodies 100 mm in width. The average
value n23 and the standard deviation s23 are to be ascertained from the
breaking loads of these tests. The value Z23 = n23 -2.0 x s23 must be greater
than the permitted Z23 = 116 kN/m. The tests are to be carried out in warp
direction.
In addition, the variation coefficient
23
v s23
n
for random samples must be less than 0.12.
Material 50:
Test group 16 Set A : T = 23°C
A total of 5 strip tension tests on test bodies 100 mm in width. The average
value n23 and the standard deviation s23 are to be ascertained from the
breaking loads of these tests. The value Z23 = n23 -2.0 x s23 must be greater
than the permitted Z23 = 86 kN/m. The tests are to be carried out in fill
direction.
In addition, the variation coefficient
23
v s23
n
for random samples must be less than 0.12.
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Material 70:
Test group 75 Set A: T = 23°C
A total of 5 strip tension tests on test bodies 100 mm in width. The average
value n23 and the standard deviation s23 are to be ascertained from the
breaking loads of these tests. The value Z23 = n23 -2.0 x s23 must be greater
than the permitted Z23 = 95 kN/m. The tests are to be carried out in fill
direction.
In addition, the variation coefficient
23
v s23
n
for random samples must be less than 0.12.
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4 No. Standard Clamping detail (various angles) incl. closure flaps (Main
roof and Canopy)
2 No. membrane cuffs
2 No. Joint line detail incl. clamp and cables
2 No. Gutter detail incl. steel gutter, cables, drainage, closure flaps and
sealants (Main roof and Canopy)
2 No. Butterfly detail incl. cables, closure flaps and sealants
2 No. Compression Ring Cover membrane lower clamping detail incl. clamps,
turnbuckle, belt and welds etc.
2 No. Lower Canopy Cover membrane clamping detail incl. clamps and closure
flaps
The cut out areas are strengthened by attaching one additional membrane layer.
Membrane reinforcements joining onto a cable cuff require reinforcing of the
cuff itself too.
The closure flaps are to be design thoroughly by the contractor. The general
layout is given in the technical drawings. The closure flap has to maintain
watertight at all times. The flaps have to be accessible and withstand all
environmental impacts. Lateral movements are to be taken and buffeting has
to be avoided.
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7.9 Drainage
7.10 Manhole
The clamp bar system and all other membrane details shall be of the highest
technical standards and satisfy the highest architectural demands. All
details shall be maintenance free in respect of the corrosion protection for
the life span of the membrane. The proposed system shall be verified by using
a corrosion test by an independent institute. If the test is not satisfactory
to the client, another corrosion protection methodology shall be proposed and
tested until approval. The test shall include all materials of the final
chosen system (cable, plastic inlay sleeve with bitumous layer, stainless
steel, straps, bolt and washer system, coated aluminium clamps. etc.) The
clamp bar system shall not weaken the membrane strength.
The aluminium clamp bar system shall be manufactured in accordance with DIN
4113 / DIN 1725 T1 the required material strength is to be chosen satisfying
the structural requirements or as stated in the specifications and drawings.
All bolts, washers and nuts and fixings are to be made of stainless steel.
The clamping edges touching the membrane need to be rounded of using r = 3
mm or greater. Corner plates shall be made of stainless steel or aluminium.
The radial clamp bar system has to carry tangential forces.
An approximate axial force of 100 kN (SLS) may be used for the design of the
clamp bar system. The final force is to be determined by the contractor during
the final workshop form finding and patterning procedure. Further design
forces are provided in the global analysis.
Further all clamp bar systems are to extend 3.5 mm per metre clamp bar length
using elongated holes at the end connection only. It is the responsibility
of the specialist contractor to carry out the final calculations and design
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to the forces and membrane stress levels provided. Detailed force printouts
and axial forces will be issued on request. The design calculation have to
be submitted to client and his design engineer prior to fabrication.
The clamp bar system has to be connected by link plates at upper and lower
face of the clamping profile. (stainless steel chain link plates). As many
kilometres of clamps will be necessary for the projects, tests shall prove
the integrity of the final chosen system.
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The shear angle resulting out of cloth width and length on each cloth has to
be limited to 2 degree. The shear angle can be derived using the European
Design Guide for Tensile Surface structures chapter 8.1 (8/3)
The contractor will determine the correct cut of the membrane. The contractor
is to determine, by means of tests for each cloth production unit, the
characteristic values which relate to the biaxial expansion behaviour of the
membrane and are required in order to ascertain cutting pattern of the
membrane. The load – time curves used for the biaxial tests have to submitted
to the structural engineer for approval. Further proposals for decompensation
need to be submitted to the structural engineer for approval.
The patterning model should incorporate the exact geometry reflected in the
3D analysis model and all the relevant the detail drawings. Mayor cut out
areas for detailing need to be incorporated. Drawings defining the system
points of the pattering model have to submitted to the structural engineer
for approval.
The mesh size of the form finding model needs to reflect the complexity of
the geometry and curvature. No mesh size shall be bigger than 1m diagonal
length. The joint line area between the main fabric, the triangle membrane
itself and the area of lens shaped double cables joining the two fabrics
shall be meshed much denser to reflect the complex geometry and curvatures.
For patterning the soft support of cables and cable deflections this needs
to be incorporated in detail. The connection onto the tension ring cable need
to be considered pretensioning the respective cable with the set pretensioning
force and set length on elastic basis and the correct stiffness.
The forces introduced by the suspended radial catwalk will affect the membrane
shape and the shape of the tension rings. These effects are subject to the
weight of services and will need to be considered. Therefore the contactor
will determine the weight of services accurately at a very early design stage
in order to proceed with the cable geometry and patterning.
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7.14 Tolerances
All fabric panels shall be checked for correct geometry prior to packing.
The control measurements need to be done under the same climate conditions
under which the panel was fabricated. The measurements for the main membrane
panels (main roof and canopy) are to be done on at least four location along
the fill direction and two locations in warp direction.
At least four measurements are to be done on each triangle membrane panel.
Each cover membrane needs to be measured at two locations in fill direction
and every 5m in warp direction.
The control measurements need to recorded and made available to the client
and his consultant within three working days on request.
The contractor shall propose a procedure describing how to achieve accurate
control measurements on all panels. Further the achievable tolerances for
manufacture of the panels itself and for the control measurement shall be
enclosed with the tender documents.
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For each material a test bed with 30 strip samples and 2 biaxial samples is
to be set up for the purpose - as part of the supervision of the building
work - of obtaining information on the particular current state of the
membrane material and the current strength of the seam.
The strip samples used for this purpose are approx. 100 mm wide and 900 mm
long. The strip samples are to be manufactured with parallel threads. They
contain a seam running across their longitudinal direction. The samples are
loaded with a creep-generating permanent load corresponding to the pre-
tension in the building structure. In the test bed, the samples are at an
bed is to be placed in
such a way that the atmospheric load on the samples approximately corresponds
to that on the actual building.
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8 Bearings
To minimise the bearing and column sizes high strength bearings are to be
used, which require high strength concrete columns.
The height levels for the top of concrete indicated in the drawings depend
on bearing type and manufacturer and type of casting in procedure. If
necessary the steelwork connecting the compression ring chords and the bearing
has to be adjusted during workshop design to accommodate for the chosen
bearing.
Special manufacturing techniques will be required for the cast in plates into
the column heads to achieve the following tolerances. The tolerances for the
cast in plates are + 5mm in height, + 0.5 degree in all elevations. The
maximum dislocation of the bolt holes sideways of + 3mm of horizontal fixed
bearings and + 10mm for horizontally free bearings.
The constant low friction of the used sliding material has to be confirmed
by long term tests of an independent testing institute with the following
conditions:
- average contact pressure p = 60N/mm²
- Constant sliding velocity 15mm/s
- Accumulated sliding path 50km
The maximum sliding coefficient during the test is µ < 3% with –35°C.
Characteristic pressure of the sliding material fk = 180N/mm²
The bearings are to be protected using expansion bellows covering the complete
contact surface of the bearing.
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9 Stainless steel
All stainless steel plates and sections to be grade 1.4401 S355 (f yk = 355
N/mm²) unless stated otherwise.
Stainless steel C Clips to be made of grade 1.4401 or 1.4404 S355 (fyk = 355
N/mm²).
All stainless steel bolts, screws and washers to be grade 1.4401 / 70 (fybk =
450 N/mm² fubk = 700 N/mm²) or of higher corrosion grade or higher strength
unless stated otherwise.
For pretensioned connections and clamps the actual tension forces achieved
while pretensioing the bolts using torque has to be tested. This applies to
all sets of screws in various arrangements used for pretensioning (screws in
nuts, in tapped holes, in blind taped holes etc.).
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10 Aluminium
10.1 General
There will be some Alumnium parts used in the cladding of the Canopy edge,
compression ring and tension ring. No major load bearing elements are made
of Aluminium.
The drawings show general concepts for the cladding parts based on approved
products. The successful contractor is encouraged to modify the cladding
elements to their specific products without altering the general appearance.
The changes and detailing have to be approved by the client prior to
production.
A mock-up for the following elements shall be presented prior to manufacture
of the cladding elements:
- Canopy edge (minimum 2m segment including substructure, drainage gutter
and a typical joint)
- Cladding of upper and lower tension ring (minimum 1 m segment of each)
- Aluminium Lamellas between tension rings (one small segment, approx.
3.5 x 4 m, including lamellas, two support struts and all visible fixing
elements; the inclination of the lamellas needs to be adjustable)
For the outer surface of the cladding solid aluminium sheets are preferred
(e.g. Novelis FF2 or equivalent). The contractor is encouraged to study
economic alternatives like composite aluminium (e.g. Alucobond or
equivalent), honeycomp aluminium (e.g. Alucore or equivalent) or corrugated
aluminium sheets (the outer surface shall be as smooth as possible, upstands
like in standard Kalzip or equivalent systems are not desired). The contractor
has to adjust all the connection details, edge details, etc. to the chosen
system and present it to the client for approval.
The chosen systems need a technical approval issued by an accredited European
agency and comply with codes described below.
All surfaces shall be flat and the individual sheets shall be mounted
constraint free by the means of bolts or rivets with a soft (plastic)
interlayer to allow thermal expansion. The bolts/rivet alignment shall be
uniform and as unobtrusive as possible. Gaps between the sheets shall be
parallel and smooth (free of displacements). Since the outer edge of the
Canopy is a twisted surface small displacements between adjacent sheets are
acceptable (< 5 mm). The surface quality between the different panels
The contact between steel and aluminium is to be avoided by using appropriate
interlayer.
Welding of aluminium, especially on site, shall be avoided. If the contractor
chooses to weld the aluminium, it is his responsibility to chose a proper
alloy, which is weldable, and compensate for the strength reduction in the
heat affected zone in his design.
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10.2 Materials
All aluminium componenets used for cladding, substructure, etc. shall comply
at least with all relevant national and international standards, especially
with the following (if nothing else is stated on the drawings or structural
description):
o UNE 38350,
o UNE 38337,
o UNE EN 573-1, -2, -3 and –4,
o UNE EN 515,
o UNE EN 485-1,
o UNE EN 754-1, -2 and –7,
o UNE EN 755-1, -2 and –7,
o UNE EN 485-2, -3 and –4,
o UNE EN 508-2,
o UNE EN 1559-1 and –2,
o UNE EN 1706
o UNE EN 12020-2.
For the connection between aluminium elements all relevant international and
national codes need to be fulfilled, in particular:
o UNE EN 439
o UNE EN 14532-3.
Facade elements need to fulfull all relevant national and international codes,
in particular:
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o UNE EN 10025-1
o UNE EN 1461.
For the connection between aluminium and steel elements all relevant
international and national codes need to be fulfilled, in particular:
All galvanized elements used for the cladding need to comply with all national
and international standard, in particular with:
o UNE EN 1461,
o DIN 50976 y
o DIN 267-10.
Anodized surfaces
The surfaces shall be continuous, uniform and without shine on the exterior
face sheet. Different samples of the proposed surface treatment shall be
provided for approval by the client and the architect prior to any surface
treatment works. The samples should also sufficiently represent the texture
variations that can be expected from the anodization process.
The surface shall show sufficient resistance against abrasion.
A temporary protection during transport and installation shall be provided.
If there is a danger of damage after installation this protection needs to
be in place until the construction work in the relevant area are completely
finished. Reparing of damaged pieces is not allowed. All damaged pieces must
be replaced by new elements.
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Coated surfaces
Maintenance
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The workshop design of the cladding elements must be coordinated with the
workshop design of the steel and cable contractor. The cladding contractor
has to work with the final 3d cable geometry. He also has to consider that
the workshop drawings show the unstressed geometry of the steel/cable
structure, while the cladding elements have to be mounted to the dead load
geometry which might differ. Any change in the connection details between
cladding and main structure needs to be incoprareted in the workshop design
of the steel/cable contractor.
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11 Drainage
11.1 General
PERFORMANCE OBJECTIVES
The rainwater from the flat roof outlets located at roof level will be
collected and discharged to the below ground drainage system by a symphonic
rainwater systems (e.g. the Geberit Ltd. Pluvia Syphonic or equivalent) in
full compliance with BBA Certificate No. 92/2729 or an Spanish equivalent.
The installer will design and install all rainwater pipework including all
rainwater outlets and connections to drain. The installer should note that
the specification should be strictly adhered to and the installer must ensure
that all other designers are aware of particular technical requirements such
as syphon breaks etc.
DESIGN PARAMETERS
The design calculation software should be dedicated to the pipe and fittings,
type of manufacturer used within the system and comply with BBA Certificate
No. 92/2796.
Calculations must be provided by the installer, containing the following
information and within the specified limits:-Pipe Size 40 to 315mm diameters.
Negative Pressure: Not to exceed -800mm/bar on pipe sizes up to 160mm and
not to exceed -450m/bar on pipe sizes 200 and above, unless PN 4 grade pipe
is used when –800mm/bar is acceptable.
Water/Air Mixture: Not below 60% water volume.
Velocity: Not below 1 0.7 metre/sec
Roof outlets will operate at their maximum capacity with a retained head of
40mm or less in accordance with CEN.
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SYSTEM DESCRIPTION
MATERIALS
INSTALLATIONS
The syphonic rainwater system will be installed only by the designers approved
installers.
All pipe and fitting joints including the joint to the outlet will be fusion
welded either electro sleeve coupling or butt weld.
All bends, unless otherwise specified to be 45o.
Horizontal pipes in excess of 1m in length must be fastened by means of a
purpose made pipe bracket to a square rail immediately above the pipe. Fixed
points will be provided at 5m intervals by a means of a welded sleeve on the
pipe and a purpose made bracket between the sleeve and the square rail.
Intermediate sliding supports to fasten the pipe to the rail will be at the
following intervals:
Pipe 40mm to 75mm diameter 0.8m.
Pipe 90mm diameter and above 10 x overall pipe diameter.
The rail to be fixed to the roof structure at maximum intervals of 2.5m.
The installer should allow for some secondary bracketing as a result of the
height from fixing rail to roof structure. The installer is advised to visit
site to survey the proposed routes.
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Where pipes pass through fire compartment walls, floors and ceilings provide
and install an intumescent firesleeve having an appropriate Agrement
Certificate or third party test report.
The firesleeves shall have a fire rating compatible with the wall, floor and
cavity barrier to which it is fitted. The firesleeves will be fitted in full
compliance with the manufacturers requirements.
PROTECTION
When the horizontal high level pipework is being installed at high level,
the installer will be responsible for providing a suitable working platform
for the installation of the rainwater pipework.
WORKING DRAWINGS
The installer will submit working drawings to the engineer showing sizes,
routing, invert levels, points of access, connection to drain and outlets
prior to commencing installation works. Drawings will be as produced by a
draughtsman using a computer aided draughting or equal.
Two copies of the working drawings will be issued to the Site Engineer.
RECORD DRAWINGS
The installer will keep a set of working drawings on site marked-up to show
"as installed" routes, sizes, access locations, invert levels etc. On
completing the installation the installer will incorporate the alterations
onto their working drawings using computer aided draughting and issue to the
Client via the engineer.
It should be noted that the installation would not be deemed complete until
the record drawings and where necessary revised calculations have been issued
and accepted.
The installer will issue four bound copies of Operating and Maintenance
manuals for the rainwater disposal system to include the following as minimum:
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It should be noted that the installation would not be deemed complete until
the Operating and Maintenance Manuals have been issued and accepted.
TESTING
The drainage contract includes all fixation elements to the main steel /
concrete structure. Refer also to the Bill of Quantities for items to be
considered.
At the transition between roof and concrete structure funnels are introduced
into the concrete to catch the water from the roof. A mock-up and test of
this element shall verify the dimensions of the funnel and outlet.
The Canopy is drained via free falling water at three points. A mock-up and
test shall verify the proposed dimension but also allow to judge the visual
appearance of the falling water. It is anticipated to create a rather uniform
wall of water with a defined width in contrast to a very local beam of water.
All requirements for the Syphonic Drainage System apply accordingly to the
Gravitiy drainage.
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