Blackall Aerodrome Lighting Quotation

BLACKALL-TAMBO
REGIONAL COUNCIL

Quotation for:
Supply & Installation of
Lighting of Runway, Taxiway and Apron
Blackall Aerodrome

QUOTATIONS CLOSE AT 4.30PM, FRIDAY 29 AUGUST 2014

Blackall Tambo Regional Council
Supply & Installation of Lighting of Runway, Taxiway and Apron
Blackall Aerodrome

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CONDITIONS OF QUOTATION

1. The Tenderer shall state :-
(a) in the case of an individual, full Christian or given names, surname and address;
(b) in the case of a business name, the names and addresses of all proprietors and the
address of the principal place of business;
(c) in the case of a company, the full name of the company and the address of the
registered office of the company.

2. Every quotation shall be enclosed in a sealed envelope addressed to :-

The Chief Executive Officer
PO Box 21
BLACKALL Q 4472

and be endorsed on the front of the envelope :-

Quotation for Supply & Installation of Lighting of Runway, Taxiway and Apron - Blackall
Aerodrome

Documents required to be lodged must include:
Quotation Form
Completed Schedule of Prices
Completed Works Programme & Methodology Schedule

3. Quotations shall be lodged in the tender box in the office of Blackall Tambo Regional
Council, 6 Coronation Drive, Blackall before 4.30pm on Friday 29 August 2014.

Any quotation lodged after the above closing time shall not be considered unless there is
evidence satisfactory to Council that such quotation :-
(a) was delivered to a place nominated by Council for the closing of quotations, before
the specified closing time; or
(b) was despatched to a place nominated by Council in sufficient time before the
specified closing time for quotations to reach that place under normal circumstances
but was still in the course of delivery at the specified closing time.

Council at its discretion may reject a quotation delivered after the closing time for the receipt
of quotations no matter what the reason being for the late delivery.
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Franking machine stamps will not be accepted as proof of the date of posting of a tender
received after the specified closing time for the receipt of quotations.

4. Quotations may only be sent or transmitted direct to the office of Council by facsimile or
email with the prior approval of the Principal. No other forms of lodgement by electronic
means will be accepted. No guarantee as to the confidentiality of information can be given
for any quotations sent electronically to the Principal.

Quotations lodged by a Tenderer or Agent in facsimile form, in accordance with subclauses
(2) and (3), will be considered by Council.

5. Every quotation lodged shall contain a statement by the Tenderer that the quotation price is
fixed and no increase will be sought from or imposed on Blackall Tambo Regional Council,
except as varied with the approval of Council.

6. Tenderers shall show in the quotation the time within which the quotation will be fulfilled.

7. Council may accept the quotation that in view of all the circumstances appears to be the
most advantageous, or may decline to accept any quotation.

8. Canvassing of Councillors is prohibited and may lead to outright rejection of a quotation.
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QUOTATION FORM

NAME OF TENDERER: ...................................................................................

ADDRESS OF TENDERER: ...................................................................................

...................................................................................

ABN: ...................................................................................

Licence No.: ...................................................................................

QUOTATION AMOUNT: ...................................................................................
(GST inclusive)

DATE FOR COMPLETION: ...................................................................................

SIGNATURE OF TENDERER: ...................................................................................

DATE: ...................................................................................

SIGNATURE OF WITNESS: ...................................................................................

DATE: ...................................................................................

Note:
1. The quotation shall be a fixed price schedule of rates valid for 3 months from date of closing.
2. The quotation prices set out herein are fixed and no increase will be sought from or imposed
on Blackall Tambo Regional Council except as varied according to the specification
attached.
3. The lowest or any quotation will not necessarily be accepted.
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LIGHTING OF RUNWAY, TAXIWAY AND APRON - BLACKALL AERODROME
SCHEDULE OF PRICES
Item
No.
Description
Amount
$
1 Establishment on Site incl. Site Facilities
2 Project Management
3 Supply & Install Runway Switchboard
4 Supply & Install Runway Lights
5 Supply & Install Taxiway Lights
6 Supply & Install Apron Flood Lights
7 Supply & Install Illuminated Wind Direction Indicator
8 Supply & Install Runway Conduits incl. Trenching, Backfilling and Pits
9 Supply & Install Taxiway Conduits incl. Trenching, Backfilling and Pits
10 Supply & Install Runway Primary & Secondary Cables
11 Supply & Install Taxiway Primary & Secondary Cables
12 Testing & Commissioning of Installation incl. Ground Checks & Training
13 Cleanup of Site of Works
14 Spare Parts
15 Manuals
16 Additional Nominated Items Not Included Above:

SUB-TOTAL
GST (10%)
TOTAL

SIGNATURE OF TENDERER: ...................................................................................

DATE: ...................................................................................

SIGNATURE OF WITNESS: ...................................................................................

DATE: ...................................................................................
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COMPLIANCE WITH SUBMISSION REQUIREMENTS

The Tenderer shall provide hereunder an assessment of the compliance of the content of their
proposal with requirements contained in this Specification.

SIGNATURE OF TENDERER: ......................................................................................

DATE: ......................................................................................

SIGNATURE OF WITNESS: ......................................................................................

DATE: ......................................................................................
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COMPLIANCE WITH TECHNICAL REQUIREMENTS

The Tenderer shall state hereunder a detailed assessment of the compliance of their proposal with
technical performance requirements contained in this Specification.

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DATE: ......................................................................................


DATE: ......................................................................................
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WORKS PROGRAMME AND METHODOLOGY

The Tenderer shall state hereunder a detailed preliminary indication of their proposed works
schedule, including key milestone points, construction methodology and likely cash flow. A full works
programme in bar chart form shall be provided prior to the prestart meeting for the contract, with
such programme to be updated regularly as necessary.

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DATE: ......................................................................................


DATE: ......................................................................................
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QUOTATION INFORMATION

1. Information to be Supplied with Quotation

Complete all schedules attached to this quotation document (if any).

2. Fixed Price Quotation

The Quotation shall be a for a FIXED PRICE LUMP SUM. The Quotation shall NOT be
subject to variation on account of rise and fall of wage rates or materials prices. No
increase will be sought from or imposed on Blackall Tambo Regional Council except as
varied according to this specification.

3. Licensed Builders

The attention of Tenderers is drawn to the contents of the Building Services Authority Act.
Where required by the Act, Tenderers must tender in the name of the licensed builder(s)
under the Act. The signature of the Tenderer must be that of the licensed builder(s) or
authorised agent in which case a copy of the authority should be enclosed with the Tender.

4. Enquiries

Tenderers shall be deemed to have satisfied themselves of all aspects of the proposed
works and the contents of this quotation document prior to submission of their quotation.
Enquiries during the quotation period shall be directed to Bryan Payne of Brandon &
Associates, ph 46223799.
Councils Manager of Works, Les Edmistone, ph 46216600 mob 0427574298, will be
Principals Representative and Superintendent for the works.

5. Visit Site

The Contactor is requested to visit the site and determine the extent of proposed works prior
to submitting their quotation.
The site of works is at the Blackall Aerodrome, located at the end of Leek Street Blackall,
which extends in a south-westerly direction from the Landsborough Highway at the north-
western end of Blackall.
Access to the site during preparation of quotations shall be arranged via contact with
Councils Manager of Works.

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6. Discrepancies

Should a Tenderer find discrepancies in or omissions from the Specification, or be in doubt
as to their meaning, they shall at once notify the Superintendent and obtain a ruling on the
matter. The whole of the work shall be executed to the true intent of the Specification.

7. Permits and Approvals

Submit a Method of Working Plan (MOWP) to Council for forwarding to obtain CASA
approval for the project. The Contractor will be required to comply with conditions included
in such approval, including submission of required certificates of workmanship.
Written evidence of all other required permits and approvals shall be provided to Council
before commencement on site.

8. Workplace Health and Safety

The Contractor will be appointed the Principal Contractor in respect of the work which is the
subject of this contract in accordance with the provisions of the Act.
Where the word Owner appears in the Act, Owner shall be defined as the Principal
referred to in the Specification and/or General Conditions of Contract.
The initial completion and lodgement of the Notification and Payment Form and payment of
the Notification Fee shall be the responsibility of the Principal. The Contractor shall be
responsible for all other requirements under the Act, including completion and lodgement of
other forms, notices and work plans, use of appropriately trained and qualified staff and
payment of other fees.

9. Security

All work activities in the aerodrome precinct are subject to relevant aerodrome security
requirements, particularly where those activities may impact on the airside area and/or
facilities. Ensure the Works Programme and Methodology Schedule submitted contains
sufficient detail to facilitate early approval from Council for any activities affecting or
potentially affecting security. Work activities identified by Council as potentially affecting
security shall be undertaken in accordance with conditions of approval for those activities.

10. Portable Long Service Leave Levy

The initial completion and lodgement of the Notification and Payment Form and payment of
the Levy shall be the responsibility of the Principal.
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All other requirements shall be the responsibility of the Contractor.

11. Supervision

The Contractor shall ensure work is supervised at all times by an appropriately qualified and
experienced person.

12. Licensed Persons

Only persons appropriately licensed shall supervise the particular trade aspect of work on
the project.

13. Insurance

Contract work insurance should be effected by the Contractor.

14. Electrical Power & Water Supply

The Contractor shall be responsible for arranging supply of electrical power and water as
required for the works.
Existing electrical power and water supply services to the Aerodrome may be used at no
cost but at the Contractors own liability.

15. Special Working Hours and Operations

The Contractor will be bound by any requirements of the approved Method of Working Plan,
Civil Aviation Safety Regulations and relevant security arrangements to remove themselves
from any location or all of the site of works when aircraft are landing, disembarking,
boarding and taking off. This will include both regulated passenger transport flights and all
other aircraft operations.
No constraints on working hours or operations additional to the above and those imposed by
relevant legislation will be applied by Council.

16. Time for Completion

Council has certain commitments in respect of the effective operation of the Blackall
Aerodrome.
An expedited construction programme, minimisation of disruption to operational
effectiveness, timely completion of critical elements and timely completion of the project as
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a whole are therefore of significant importance to Council in assessment of the most
suitable Contractor for this project.
Ensure the enclosed Works Programme and Methodology Schedule is completed in an
accurate and informative manner and submitted with the Schedule of Prices.
All work shall be completed prior to the agreed date for completion.
Failure to complete the works within the specified time (after allowance for approved
extensions) shall incur Liquidated Damages of Two Hundred Dollars ($200.00) per day or
part thereof.

17. Payment

Progress payments will be made at monthly intervals for completed items in accordance
with the Schedule of Prices and on satisfactory completion of all works.

18. Defects Liability

A defects liability period of twelve (12) months shall be applicable to work performed under
this quotation.
Retention money equivalent to five per cent (5%) of the final quotation amount, including
any variations, shall be held by Council pending successful completion of this period.
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JOB SPECIFICATION

1.0 Scope

The work to be performed under this quotation consists of design and installation of new
airside lighting to the Blackall Aerodrome as specified herein and as approved by Council.
The successful tenderer will be directly engaged by Council and will work as visitors under
control of ASIC red card client supplied personnel. Council will provide airside security
control during works where necessary for interaction with aerodrome operations. All costs
associated with conformance and safety requirement costs shall be borne by the Contractor.
All tenderers are required to submit a Method of Working Plan (MOWP) that outlines how
they will install all equipment during an operating aerodrome, including supply of temporary
equipment as required to maintain lighting operations during construction, and showing the
expected full duration of works.
The existing runway and taxiway lighting system must continue to operate outside working
hours.
The Contractors work methodology will require for temporary relocations and connections
of some lights to support continuous operating lighting system. The Contractor must allow
for all work associated with these temporary relocations, and this document does not detail
this work as it is up to the Contractor to provide this information via the MOWP.
It is imperative that prospective Contractors include in their tender submission how the
existing system will be maintained during all modifications.
All work shall be carried out in accordance with the Specification, Drawings and such details
and instructions as are issued by the Principals Representative and / or the Principal during
the progress of the work.
This Specification shall be read in conjunction with the drawings and tender schedules, all of
which are intended to be mutually explanatory. All work called for by the one even if not by
the other shall be fully executed.

2.0 Drawings

Project drawings are Ashburner Francis Drawing Nos. 12-3-075 E01-E06 inclusive Issue A.
Drawing No. Title
12-3-075 E01 Key Plan and Legend
12-3-075 E02 Lighting Layout Western End Sheet 1 of 3
12-3-075 E03 Lighting Layout Mid Section Sheet 2 of 3
12-3-075 E04 Lighting Layout Eastern End Sheet 3 of 3
12-3-075 E05 Runway Lighting Switchboard
12-3-075 E06 Lighting Control Schematic and Installation Details
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3.0 Works by the Principal

Work to be performed by the Principal shall include:
Liaison with CASA in relation to relevant approvals.

4.0 Extent of Works

Works to be completed includes but may not be limited to the following:
Contract administration, MOWP, time duration scheduling and reporting, all temporary
supply and installation of equipment to support MOWP, all works associated with
disconnection, removal or temporary rerouting of existing runway cables to support the
MOWP;
Provision of a safe isolation procedure for isolation of the existing lighting system when
working in proximity to the existing system;
Supply of all staff on site facilities including office, staff lunchroom and toilets;
The demolition and relocation of existing runway and taxiway lighting;
Supply and installation of new Runway, Taxiway and Apron Flood Lighting, complete
with all underground conduits, pits, runway cables, secondary cables, series isolation
transformers, above ground lights and inset lights as shown on the drawings;
Supply and installation of a new Illuminated Wind Direction Indicator, complete with all
underground conduits, pits and cables as shown on the drawings;
Design review from equipment supplier, with conformance statements for compliance to
MOS139;
Supply and installation of a new runway lighting switchboard for connection of new
equipment and commissioning assistance for the new and modified runway and taxiway
lighting;
Installation of above ground lighting emulsion spray aprons in locations as shown on the
drawings;
New Apron floodlighting, complete with cables, pits, poles and foundations;
Supply and installation of two apron floodlighting pushbuttons and cabling as shown on
the drawings;
Complete demolition and removal of all existing runway lighting (once the new lighting
system has been installed and commissioned) including conduits, pits, service markers,
lights, cables, etc.;
Supply and installation of trenching, conduits and pits and back filling for underground
cabling systems;
Cabling and cable support systems;
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Asphaltic Concrete (AC) cutting for secondary cable installation and AC coring for
installation of inset lights, complete with supply and installation of all required two pot
epoxy, backing rods and bitumastic fillers;
Under-boring of taxiways as shown on the drawings by specialist under-boring
contractor.
Termination and joining accessories;
Supply of all required runway and secondary cable, and any control cables;
Equipment supports and bracing;
Supply of foundations for Apron floodlighting poles;
Complete commissioning of the new system in accordance with CASA requirements,
including ground checks and a flight check. Refer to the latest relevant CASA Advisory
Circular for further requirements. The flight check must be carried out by CASA
approved pilot who holds a Letter of Competency from CASA to conduct flight checks of
aerodrome lighting systems;
Supply of Maintenance Manuals;
Supply of As-Installed Drawings;
Installation, testing and commissioning;
12 months warranty on installation works;
Training of Aerodrome Operations staff;
Maintenance during 12 months defects liability period.

Related work in connection with the Electrical Services (performed by other trades) includes
the following:
Site coordination for work scheduling with respect to asphalt overlay and how it will
interact with installation of above ground and inset lights;
Site coordination for work scheduling with respect to Terminal Building work to wire in
Airside Lighting to the new location of the Runway Lighting Switchboard.

5.0 Supply of Materials and Equipment

The Contractor shall be responsible for supply of all materials, tools and equipment
necessary for construction of the works.

6.0 Supply of Spares

The quotation price shall include supply of specified and/or nominated spares, for storage
by Council for future maintenance replacement.

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7.0 Closure of Access

The prior approval of Council must be sought should it be considered necessary for safety
or logistic purposes to close access adjoining the site of works, either temporarily or for the
duration of the works.

8.0 Services

Before commencement of any work on site, the Contractor shall verify the nature, location
and extent of all existing services, both above and below ground, within a 3 metre margin of
the construction perimeter.
The Contractor shall be responsible for the protection of all services, unless otherwise
approved by the Principal. Any damage which occurs to services required to be protected
during the quotation period shall be repaired at no cost to the Principal.

9.0 Excavation

Excavation must be sufficient for construction of footings. Excavated soil shall be disposed
of neatly. Excavated rocks and other surplus debris shall be removed from site or to
approved location.
Trenches where excavation in hard rock is necessary will be verified by the Principals
Representative prior to filling with concrete or backfilling as appropriate. An allowance over
and above the tendered amount will be negotiated for each trench in which hard rock needs
to be removed.

10.0 Clean Up

The whole of the site shall be left in a neat and tidy condition on completion.
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TECHNICAL SPECIFICATION

SECTION 3 GENERAL REQUIREMENTS
3.1 GENERAL
This section outlines general requirements which are applicable to all sections of this
specification and the works.
3.2 STANDARDS AND REGULATIONS
Conform to the latest editions of all standards and regulations. The following standards and
regulations are always applicable:
AS/NZS 3000 Wiring Rules
State Workplace/Occupational Health and Safety Legislation
Electrical Safety Act and Regulations
Australian Government Civil Aviation Safety Authority Regulations and Standards
CASA Manual of Standards Part 139 Aerodromes. (MOS 139)
Electrical Safety Act and Regulation
All other relevant airport lighting standards within Australia
AS 3012 for Construction and Demolition Sites
AS 60529 for Degrees of Protection of Enclosures
AS/NZS 3017 for testing for safety of low voltage electrical systems
3.3 QUALITY OF MATERIALS AND WORKMANSHIP
All materials shall be new, of the best quality and of the class most suitable for the purpose
specified.
All equipment shall have a verified history of successful use in the commercial environment.
No prototype equipment will be accepted.
All work on the site shall be supervised by a competent tradesman supervisor who shall be
present on site when requested by the Principals Representative for all phases of the
project. A representative shall be nominated, who shall be present and responsible for the
day to day running of the project.
The entire electrical installation shall be executed by licensed, experienced tradesmen and
shall be completed in a neat and first-class tradesman-like manner to the satisfaction of the
Principals Representative and Principal.
3.4 UNIFORMITY
All fittings, accessories and equipment of the same type shall be of the same manufacture
and catalogue number.
3.5 WARRANTY
Provide manufacturers two year warranty on all components.
Note that outsourced items are required to provide a 2 year warranty from the sub-supplier
passed on to BTRC via this contract.
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The equipment supplier shall provide a priced option to provide an extended five year
warranty.
The tender documents shall include a warranty statement from the tenderer that details
what is included, and excluded for each individual different type of equipment, and the
warranted duration for this equipment.
Include copies of final warranty certificates in the data sheet and maintenance manuals.
Replacement lights and spare parts shall be available for a minimum of 7 years.
Provide 18 months warranty on installation and workmanship.
Include copies of warranties in the maintenance manuals.
3.6 SUBMISSIONS
3.6.1 Tender submission
Provide the following information with the tender:
Company profile
List of previous relevant projects, work history, with emphasis placed on offered
equipment
Reference sites and contact details. (include equipment supplied and value of the
project)
Quality Assurance Certification
Detailed warranty breakdown
Equipment brochures
Manufacturers technical specifications and data sheets
Type test reports, copies of relevant standards certification
Performance data
Suppliers spare parts listings with part numbers
Installation details etc. as required
Compliance statement for MOS 139
CV of site supervisor
CV for proposed commissioning engineer
Nominated CASA certifying pilot
Note that the dry sealed bases for the inset lighting will require an installation manual. This
manual shall be included in the above documentation.
3.6.2 Working drawings submission
Provide 2 copies of marked up A1 size prints using the original design drawings showing the
final set-out of all taxiway and runway lights, for approval to the BTRC site representative.
3.6.3 As-Installed drawings submission
Provide as-installed drawings at the end of the project. Show all existing and new conduit
sizes and numbers thereof on these drawings, using the electrical drawings as a basis.
Provide dimensions for critical equipment locations, or where items of equipment have
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changed location.
3.7 CERTIFICATION
Certify that the works have been installed to the requirements of all applicable rules and
regulations.
The contractors airside lighting supplier shall review the current design for compliance to
MOS 139 using their supplied equipment and shall provide a statement of compliance to
MOS 139. If required the supplier shall provide recommendations for modification at
tendering time to ensure this compliance.
3.8 HAZARD ASSESSMENT AND RISK MANAGEMENT
Comply with the requirements of the Workplace Health and Safety Act and Regulations with
respect to hazard identification and risk management.
Submit a Hazard Assessment and Risk Management Plan (HARMP) for the construction
phase of the works.
Provide a safe working isolation procedure, as part of the MOWP, for isolation of the
existing runway lighting system when working in close proximity to the existing cabling and
system equipment. Allow to trace all existing cabling using cable locators to assist with
identification of routes and extend of impact with new works.
The Principal will provide airside security control with ASIC red card authorised personnel.
The contractor shall allow for all costs associated with DAMP (Drug and Alcohol
management plan), training and testing of all their personnel to be able to work airside as a
visitor under these supervisors.
3.9 ELECTROMAGNETIC COMPATIBILITY
Ensure that the entire installation covered by this specification meets the Electromagnetic
Compatibility requirements of the Australian Communications and Media Authority.
3.10 SITE CONDITIONS AND PRECAUTIONS
The site will be occupied and operational for the duration of the contract.
Ensure that systems remain fully connected and operational at all times, except where
shutdowns are required.
Where shutdowns of systems are required:
They are to be in accordance with the MOWP of this contract;
Provide the Principals Representative written notification in accordance with the
MOWP in advance of the intended shutdown time;
Keep each shutdown time to a minimum;
For each shutdown, complete the works and ensure that the systems are fully
operational prior to leaving the site for the day. If any existing lights are removed
temporarily or permanently ensure that the remaining lights are still operating within
their defined maximum system requirements. Change MIT taps if necessary to reduce
runway lighting current to be within the same range as the original operating current of
the system before it was modified.
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Provide a safe working isolation procedure for isolation of the existing runway lighting
system when working close to the existing cabling and system equipment. Allow to
trace all existing cabling using cable locators to assist with identification of routes and
extend of impact with new works. Assist with any necessary fault finding and
recommissioning. Assist where necessary with any required relocation and rerouting or
installation of temporary cables.
Carry out the work in such a manner as to interfere as little as possible with other trades
and persons having access rights.
Ensure that normal access ways to buildings, runways and taxiways are unobstructed.
3.11 SETTING OUT
The positioning of equipment as shown on the Drawings is approximate and diagrammatic
only, and these Drawings shall not be used for exact setting out. Final locations of all
taxiway and runway lights shall be marked on the civil line marking drawings to ensure that
installed positions are correct. For conflicting information refer to the Principals
Representative for resolution.
The location of pits and lights will be pegged by survey for the Contractor by the Principals
Representative prior to works commencing on site.
3.12 DEMOLITION AND TEMPORARY SERVICES
Decommission, disconnect and remove from site all existing redundant electrical services
including pits, cables, conduits, etc. Do not burry redundant assets on site.
Provide temporary connections and interfaces as detailed on the drawings or as necessary
to support the works.
Provide temporary services to assist with the civil works methodology for completion of the
works. This may include temporary relocation and connection of lights and equipment for
displaced thresholds.
Discuss actual requirements with BTRC and provide all assistance as necessary to
complete
the construction. Note that the airport will be operating at all times during the construction
phase, and airport lighting must be operational at all times.
3.13 WORK ON EXISTING ELECTRICAL SERVICES
Comply with the requirements of Clause 1.9.3 of AS/NZS 3000:2007 for interfacing to
existing electrical services.
Amend existing electrical services as required during the construction to ensure continued
operation and integrity of existing electrical services.
Comply with AS 3012 when working on existing electrical systems.
3.14 INSTALLATION
Install equipment and services square and in line, plumb and at consistent mounting
heights.
Provide brackets, fixings and supports to manufacturers recommendations and as required.
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Organise reticulated services neatly and with applicable segregation.
Provide all access equipment and temporary lighting necessary for the installation of
electrical services.
3.15 CORROSION PROTECTION
All metallic materials and components shall be suitably protected against corrosion.
Bolts, screws, rivets etc. for external use shall be non-ferrous or stainless steel, or where
approved galvanised steel.
Brackets, plinths, rods etc. shall be hot dip galvanised after fabrication.
All steel sheets shall be corrosion protected by means of degreasing, priming and painting
as a minimum.
3.16 FINISHES
All equipment shall be painted unless the equipment material is chromium, anodised
aluminium, plastics, stainless steel or other non-ferrous metals.
Paint and paint application shall comply with AS/NZS 2311 and AS/NZS 2312.
Carry out all powder coating to AS3715.
3.17 ADHESIVES
Provide adhesives and sealants capable of transmitting imposed loads, sufficient to ensure
the rigidity of the assembly or the integrity of the joint and which will not cause
discolouration or lack of adhesion of finished surfaces.
3.18 FASTENERS
Provide masonry anchors, bolts, nuts, washers, screws, nails and plugs as required for
installation of electrical services.
Fastener materials, finishes and physical sizes shall be as appropriate for the loads, the
types of materials in contact with the fastener and the environment.
All fasteners shall be SS304 or hot dipped galvanised.
3.19 METALS
Provide metal sections and sheet as required for the electrical services.
Finish invisible joints by welding, brazing, soldering, grinding and buffing prior to application
of finishes such as galvanising or painting.
Repair galvanised or electroplated metals using two pack organic primer to AS/NZS 3750.9.
3.20 GENERAL LABELS
Provide labels to equipment as required for identification, operation and warnings.
Labels shall be non-ferrous metal or multi-coloured laminated plastic.
Labels shall be of proven longevity without significant deterioration.
Externally mounted labels shall be weather and corrosion resistant.
Fix labels using nuts and bolts or rivets. Externally mounted fixings shall be corrosion
resistant.
Warning labels shall be white lettering on red background with minimum 10 mm high
lettering.
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Minimum letter heights shall be 3mm.
Refer to the lighting section for specific requirements for runway and taxiway lighting labels.
3.21 OPERATION AND MAINTENANCE MANUALS
Provide Operation and Maintenance Manuals for all systems and components covered by
this specification. Include As-Installed documentation for the entire installation in these
manuals. As-installed locations of electrical works to include both new and existing works
that make up the systems operations on completion of contract works.
Provide three (3) copies of manuals and drawings neatly bound into A4 size hard cover ring
binders which are permanently labelled with the Project Name, Contract Description and
Subcontractors Name. Copies to be provided to the Principals Representative.
Include the following in each set of manuals:
Index
Brief description of the Electrical installation.
Copies of all test results, certificates and approvals.
Manufacturer's operating instructions and details of model numbers, serial numbers,
operating instructions, and manufacturer's guarantee certificate for equipment supplied.
Warranty certificates.
MOS 139 certificate and compliance statement.
Installation details.
Paper prints of all As-Installed Drawings as follows:
o As-Built drawings prepared using AutoCAD of all electrical layout drawings and
installation details. (Note that design drawings will be made available for this
purpose.)
o System schematic diagrams and schedules.
o The title block of each drawing amended to include the Subcontractor's name and
contact details, Subcontractor's drawing number and date of issue.
A CD-ROM, or approved equal medium, containing electronic copies of the manuals in
.doc format and all As-Installed drawings in AutoCAD .dwg format and .pdf format.
A recommended maintenance programme for all equipment installed based on
manufacturers requirements and specifications
A recommended list of spare parts.
Provide a draft set of the Operation and Maintenance Manuals to the Principals
Representative and Principal not less than 2 weeks before the date of actual completion
date of relevant milestones, for the purpose of review and comments.
Submit final sets of the Operation and Maintenance Manuals to the Principals
Representative not more than 2 weeks after the receipt of comments on the draft from the
Principals Representative and Principal.
Final contract payment will not be approved until satisfactory Operation and Maintenance
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Manuals have been received.
3.22 CLEAN UP
At completion clean all electrical equipment to as-new condition.
Remove all waste and debris on a continuous basis.
Ensure work site is completely free of Foreign Object Debris (FOD) on completion of each
work ship and on project completion.
3.23 TESTING AND COMMISSIONING
Fully test and commission the complete electrical installation prior to actual completion date.
Record all test results and submit for inspection to Principals Representative prior to actual
completion date.
Provide a commissioning engineer to assist with the commissioning of the complete system.
This engineer shall preferably be supplied from the equipment supplier and as such will be
fully conversant with the lighting equipment.
Provide personnel to assist the commissioning engineer as necessary to complete all works.
As this person will be on site for limited defined periods it is essential that his time is used
efficiently. Coordinate his arrival with completion of all works to ensure that time is not
wasted.
Completely commission the new system in accordance with CASA requirements, including
ground checks and a flight check. Refer to the latest relevant CASA Advisory Circular for
further requirements. The flight check must be carried out by CASA approved pilot who
holds a Letter of Competency from CASA to conduct flight checks of aerodrome lighting
systems.
3.24 TEST INSTRUMENT CALIBRATION
All test instruments shall have current calibration certificates. Certificates shall be shown to
the Principals Representative prior to commencement of each test. Certificate currency
shall be 12 months maximum.
3.25 INSPECTION AT ACTUAL COMPLETION DATE
Arrange for an Actual Completion Date Inspection by the Principals Representative. A
minimum of 10 working days notice shall be given.
Ensure that the installation is fully operable and practically completed before requesting an
inspection. The Principal has allowed for one only inspection at Practical Completion.
Should this inspection reveal that the installation is not fully operable or practically
completed and require further inspections, the cost of such further inspections will be
charged to the Contractor.
3.26 INSTRUCTIONS AND TRAINING
Provide skilled operators to instruct such persons as may be nominated by the Principals
Representative in the effective operation of all of the electrical systems in the installation.
Instructions shall not be given until completion of all tests and adjustments.
Conduct training at agreed times and locations and for durations commensurate with the
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complexity of the systems. Provide a training schedule to the Principals Representative for
approval.
3.27 MAINTENANCE AND WARRANTY DURING DEFECTS LIABILITY PERIOD
Carry out preventative maintenance on a regular schedule as prescribed by the equipment
manufacturer.
Promptly rectify all defects during the defects liability period. Attend site within 1 working day
of notification of non-critical defects. Attend site immediately to rectify critical defects. Critical
system defects shall be rectified immediately. Critical defects include those defects that will
mean the operation of the airside lighting system will be fail to meet operation requirements
as detailed in CASA Manual of Standards Part 139 outside the hours of 6am to 5pm within
12 hours of defect notification to the Contractor. Non-critical defects are those defects that
mean the system can still operate in accordance with CASA MOS 139 however require
action to minimise further defects or worsening of the defect into a critical defect within the
system.
Costs associated with the Principal arranging for a third party Electrical Contractor to attend
to critical defects due to the Contractors failure to attend site, within the mentioned
timeframes for the defect classification, will be borne by the Contractor under this contract.
3.28 METHOD OF WORKING PLAN
Submit a Method of Working Plan (MOWP) that outlines how the Contractor will install all
equipment during an operating aerodrome, including supply of temporary equipment as
required to maintain lighting operations during construction, and showing the expected full
duration of works.
Maintain and supplement this MOWP during the construction stage to add as necessary any
additional works necessary to complete the project.
Provide a time schedule to the Principal at tendering time, and then during construction
update and maintain this schedule on a weekly basis and review it and all works during the
weekly site meeting with Principals Representative.
Attend all site meetings and provide all necessary updates and documentation for site
meetings in compliance with the Principals requirements.
3.29 SITE FACILITIES
Provide site office, lunchroom, and toilet facilities for all on site personnel. Allow for supply,
installation and connection to Principal supplied electrical supply, at nominated location.
Toilets shall be portable type with no sewer connection.

SECTION 4 EQUIPMENT SUPPLY AND INSTALLATION
4.1 CONTRACTOR SUPPLIED AND INSTALLED ITEMS AND EQUIPMENT
Contractor supplied installed items and equipment shall include the following:
All elevated lighting fixtures
All inset threshold lighting fixtures
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Supply of inset dry type sealed bases, c/w alignment jigs
Supply of the new runway lighting switchboard
Supply of Apron floodlights, and associated conduits, pits, low voltage cabling, poles,
rag bolts and footing cages
Supply of Illuminated Wind Direction Indicator and associated conduits, pits, low voltage
cabling, pole, rag bolts and footing cage
Supply of all Primary runway cable
Supply of all Primary cable plug/socket connectors
Supply of Secondary extension cable
Supply of Secondary cable crimp connectors
Secondary 300mm long cable extension kits with moulded rubber plugs SIT end
Secondary 300mm long cable extension kits with moulded rubber plugs light fitting end
Installation instructions
Commissioning assistance
Supply of new 100 watt SITs for outer threshold lights
Supply of all 400mA and 700mA SITs for all lights. Note that alternative SITs may be
required to conform to the intensity requirement ration of MOS 139 with respect to
runway lighting versus taxiway lighting. Refer to drawings for details
Storage of all equipment
All conduits and pits to complete the works
Epoxy grout for inset lights
Sealant and filler for tarmac saw-cuts as shown on the drawings
Light surround emulsion sprays with compacted fill and white paint circles as shown on
the drawings
All ancillary cables, supports, fixings, labels, signs, bolting hardware, termination
accessories, lugs, terminals, glands, packers and items necessary to provide a
complete project
2 years warranty
Pricing option for 5 years warranty
Assistance with design verification
Commissioning and final CASA certification
Training
Spare parts
The above list of Contractor supplied equipment is not exhaustive and the Contractor shall
not use this list as such. It is the contractors responsibility to supply all equipment and
labour necessary to complete the project to construct a fully complete Airfield Ground
Lighting System.

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SECTION 5 LIGHTING
5.1 GENERAL
Supply and install all luminaires, lamps and lighting controls as scheduled, detailed and
specified and shown on the pricing schedule and drawings.
All LED lighting engines shall be natural colour for uniformity of spares and ability to
interchange LED lamps between lamps using different lens colours.
All offered runway and taxiway lighting shall be proprietary equipment purpose
manufactured for this application. All lighting offered shall have a proven track record in
other installations.
5.2 PRODUCTS
5.2.1 Luminaire Construction
Luminaires shall:
Be thermally designed to ensure optimum lamp operation and component operating
temperatures below recommended limits
Be rigid, true and symmetrical in construction
Have support and fixing mechanisms to suit the intended application
Have photometric performance equivalent to the published data
Be constructed of durable and corrosion resisting materials suitable for the installed
conditions and environment
Be complete with all required lamp holders, terminal blocks, fuses, control gear,
temperature rated cabling, reflectors, lamps, cable clamps, and fixings as required for
complete luminaires
Have SITs and lamps matched for optimum performance
Have purpose built low loss electronic controllers for LED lamps
Have C-Tick approval for EMC classification
Be provided with inset bases for inset lights , c/w all termination accessories, including
cable glands , connectors and links
Be provided with all necessary terminating equipment such as primary cable
connectors, heat shrink sleeving and ancillary crimp links and connectors as detailed in
the LED pricing schedule
Provide luminaires which are marked in accordance with AS 3137 for floodlights.
5.2.2 Pole Mounted Luminaires
Provide hot dip galvanised painted steel poles complete with rag bolt and cage assemblies,
component hatch secured with vandal-proof bolts, outreach arms, mounting spigots and
corrosion resistant fixings.
Foundations shall be of approved structural design for the installation conditions and
environment.

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5.2.3 Illuminated Wind Direction Indicator
Supply and install a new Illuminated Wind Direction Indicator.
An indicative location for the unit is shown on the drawings, however the exact final location
shall be as advised by the Principals Representative.
Provide an Illuminated Wind Direction Indicator that complies with Section 9.6 of the CASA
Manual of Standards Part 139.
Provide the unit complete with a hot dip galvanised painted steel pole with rag bolt and cage
assemblies, component hatch secured with vandal-proof bolts, outreach arms, mounting
spigots and corrosion resistant fixings.
Foundations shall be of approved structural design for the installation conditions and
environment.
5.3 INSTALLATION
5.3.1 General
Install luminaires in line, parallel, level, at the same mounting height, plumb and flush with
surrounding surfaces to drawing requirements.
Support luminaires using proprietary supports. Fix and secure luminaires to ensure
permanent mounting under service conditions. Provide a minimum of 2 fixings per luminaire
and more as required to avoid movement or distortion.
Primary and secondary cable joins shall only be via manufacturers approved connectors,
and joining systems. In all cases epoxy filled heat shrink shall be used to encase all
connections and provide a watertight join.
Install cables and SITs in accordance with the standard details shown on the drawings.
Install luminaires so that there are no light leaks.
Adjust lamp locations and aim luminaires to design specifications.
5.3.2 External Lighting
Maintain the required IP rating at cable entry and fixing points.
Provide cable entries to manufacturers recommendations to maintain weather or water proof
enclosure.
Provide in-situ concrete footings to structural design requirements for all post or pole
mounted floodlights. Exposed concrete shall be trowel finished and gaps between concrete
foundation and base plates shall be grouted and finished smooth.
Aim all external lighting systems to design specifications after sunset.
5.3.3 Runway and Taxiway Lighting Labelling
Each runway and taxiway light shall be provided with a SS 304 tag stamped with the
number as shown on the drawings.
Tags shall be 40 mm high and 40 mm long minimum, cut from 2 mm thick plate. Fix plates
to the top of each pit lid using fixings approved by the Principals Representative to suit in
service conditions, such as rivets or SS screws.
Tag lettering shall be 25 mm high.
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5.4 COMPLETION
Test and verify operation of all luminaires.
Program all lighting control systems.
Adjust all controls in conjunction with the Principals Representative and Principal for system
operation as required.
Clean all luminaires and diffusers to as-new condition.
Provide all necessary access equipment for luminaire and lighting controls commissioning.

SECTION 6 INSTALLATION REQUIREMENTS
6.1 GENERAL
Supply and install all required cables and cable support systems as detailed on the
drawings
6.2 QUALITY
6.2.1 Standards
Installation and selection to AS/NZS 3000, AS/NZS 3008.1.
Cables to AS/NZS 5000.1, 2 and AS/NZS 4961, YSVE 4005
Conduits to AS 2053 Series.
Fire and mechanical performance to AS/NZS 3013.
Testing to AS/NZS 3017.
6.3 PRODUCTS.
6.3.1 LV and HV Power Cables
Cables shall be multi-stranded copper conductor with PVC, XLPE insulation and sheath.
Cables shall be 0.6/1kV, V75 rated as a minimum standard.
Provide all cables and cable terminating accessories as shown in the pricing schedule. All
cables and accessories shall be proprietary type compliant with all MOS 139 standards.
Primary runway cable to AS/NZS 4961, YSVE 4005
Secondary extension cable to AS/NZS 5000.1, 2
Primary cable termination kits, c/w boots and special HV rated pins
Secondary cable extension kits
Secondary cable connection kits
Installation instructions
Jointing accessories, crimp links, epoxy filled heat shrink
Cables shall be colour coded as detailed in AS 3000:2007.
Minimum cables sizes shall be:
Lighting sub-circuits: 2.5 mm
2

Power sub-circuits: 4 mm
2

Submains: 6 mm
2

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Select cable sizes to comply with volt drop, short circuit and earth fault / touch voltage
requirements of AS 3000.
Cable lugs shall be of the correct size and material for the conductor.
6.3.2 Conduits
All conduits shall:
Be 20mm minimum diameter;
Be installed so that conductors are only drawn into conduit at equipment positions.
Be fitted with a sealed cap to prevent the ingress of moisture or obstructions entering
the conduit;
Be fitted with expansion joints when conduit runs between slabs of concrete deliberately
separated for thermal movement;
Be positioned with a minimum of 25mm of cover within concrete structures.
All conduits and ducts shall be used and installed in accordance with the requirements of
AS/NZS 3000.
Surface mounted conduits shall be rigid non-metallic conduits complying with AS/NZS2053
and shall be fastened at intervals not exceeding 900mm using double sided saddles and
fixed to approval. Corrugated PVC conduit shall not be used.
Flexible conduits complying with AS/NZS2053 shall be used for connection to free standing
equipment. Corrugated PVC conduit shall not be used.
Provide flexible conduit only as required for final connection of cables to equipment which is
subject to movement or vibration. Flexible conduit shall be anaconda range metal sheathed
flexible PVC served type liquid-tight or equivalent. Corrugated PVC conduit shall not be
used.
Conduits shall be laid in straight and symmetrical lines with easy sets or bends. Bends or
sets shall be made without altering the section of the conduit.
Large sweep bends shall be used for all conduits rising to lighting pits.
Join PVC conduits in accordance with the manufacturers instructions using the
recommended jointing cement.
Conduits concealed in floor slabs shall be rigid non-metallic complying with AS/NZS2053
and, where installed in screeds and chases, shall be secured at intervals not exceeding
1800mm with approved fixings. Conduit stub-ups through concrete surfaces and
foundations shall be adequately braced to prevent shifting during pouring and shall be
adequately plugged to prevent ingress of dirt.
Conduit fittings shall be of the same material and finish as the conduit.
Ensure that conduits are correctly stored for UV protection before installation.
6.3.3 Cable Pits
Install cable pits for underground wiring, generally in the locations shown on the drawings.
Large cable pull-in pits shall be of the size and type as noted on the drawings.,
Lighting pits shall be Carson 910 series HDPE, 300 diameter with locking lid.
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6.4 INSTALLATION
6.4.1 Cables and Cable Supports Generally
Install low voltage cables in accordance with AS/NZS 3000:2007 and in particular all of
Section 3 Selection and Installation of Wiring Systems.
All wiring shall be fully supported along the entire route length.
Cables and wiring for separate systems shall be run separately and on separate cable
support systems or in segregated sections of the same support system.
Low voltage cable sizes shown on the drawings are based on installation methods to avoid
derating in accordance with AS 3008.1. Increase cable sizes as required when cables are
installed in a manner requiring a derating factor to be applied.
All cables shall be installed in a manner which enables easy removal and rewiring.
All wiring shall be installed on the loop-in system with connections made at equipment or
accessories.
Ensure minimum bending radius requirements for all cable types are maintained at all times.
For cables run in conduit use draw wires to pull in cable groups from point to point. Fill
conduit to a maximum of 75% of the capacity noted in AS/NZS 3000.
Run all wiring systems grouped, tied or enclosed, square and parallel. Do not use adhesive
fixing for cable support systems.
Install cables in a manner that does not damage the cable during installation.
Any noted Spare Mains are to have 6mm nylon draw wire installed within the conduits for
future hauling of cables. Draw wires shall be fixed to the caps at the ends of these conduits
at the pit locations on Spare Mains.
6.4.2 Mains and Submains
Run in conduits or on cable support systems.
Terminate using cable lugs and crimping tool.
Use suitable glands when entering equipment or assemblies.
Identify cables at both ends using stamped tags or similar.
All gaps and / or voids / holes shall be plugged / capped on completion of works. Any spare
holes, voids, gaps shall be plugged / capped. Where impractical, expandable foam shall be
used to provide a complete seal to voids, holes / gaps. The exception to this requirement is
holes, gaps or voids that are required for ventilation purposes.
6.4.3 Fire and Mechanical Protection
Where required, install cables and cable support systems with fire and mechanical
protection (WS rating) to AS/NZS 3013.
6.4.4 Underground Wiring Systems - General
Supply and install a system of underground conduits for the Airside Lighting System as
shown on the drawings.
Conduits have been sized to allow for the installation of Submains or circuits in one (1)
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conduit only. Remaining conduits shall be left spare and termed Spare Mains. The use of
conduits shall be confirmed on site before cables are pulled in.
All joints shall be glued using gap filling adhesive to manufacturer's specification.
Spare conduits shall be capped.
6.4.5 Setting Out
The underground conduit system shall be set out generally in accordance with the routes
After setting out the proposed conduit system routes and locating of cable pits, obtain
approval from the Principals Representative before commencing work.
The finished levels to the top of cable pits shall be to suit finished runway/taxiway levels on
site. Liaise with the Principals Representative to ensure that the correct levels are obtained
before installation of pits commences.
Pits or conduits which are installed at incorrect levels shall be repositioned at no extra cost.
6.4.6 Excavation
Locate all existing underground services on site which are in the vicinity of proposed
excavation. Any damage to underground services shall be repaired to the satisfaction of the
Principals Representative at no extra cost to the Principal.
6.4.7 Underground Conduits
Underground 415V/240V wiring shall be installed in a Category `A' system in heavy duty
rigid plain conduit of insulating material to AS/NZS 2053, colour orange.
All LV conduits shall have 600mm minimum cover unless specified otherwise or shown on
the drawings. All trenching to be 450mm nominal width, 600mm maximum width.
The trench shall be cleared of all rocks and other sharp materials and the conduits laid on
50mm thick bed of selected sand.
Before backfilling, the conduits shall be covered with a further 50mm layer of sand. A PVC
"Electrical" marker tape (complete with tracer wire) shall be buried in the trench over the
entire length of the cable route above the conduit.
Provide for all excavation, spoil removal from site, rock excavation, bedding, backfilling and
reinstatement for all underground cabling and pit construction as part of this contract.
Cables shall not be installed direct buried.
Record the route of underground systems prior to backfilling.
Provide nylon draw wires in all Spare Mains.
6.4.8 Backfilling
Backfilling shall not be carried out without the approval of the Principals Representative.
After approval of the bedding and laying of conduits, backfilling shall be carried out.
Generally, backfilling shall be carried out using the excavated material but in special
instances, such as under pavements, backfill shall consist entirely of approved material
such as stabilised backfill (lean mix concrete), and the costs thereof shall be included in the
tender price.
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Backfill shall be compacted in 150mm layers by watering and ramming or other approved
method, care being taken not to dislodge conduits. All surplus backfilling shall be removed
from the site or disposed of to Principals Representatives directions on site.
The intent of this requirement is so that there cannot be any more than 25mm settling in any
runway or taxiway area after backfilling. If more than this amount of settling is found in any
location it will be the Contractors responsibility to correct this settling at no cost to the
Principal.
6.4.9 Pit Drainage
The complete pit and conduit system shall be drained as specified below.
Concrete benching / grout benching shall be provided in base of pits with a fall to ensure full
drainage of pits. Conduit penetrations through pit walls shall be fully sealed to approval of
Principals Representative .
The conduit system shall be provided with falls to pits to suit the finished contour levels, and
pits located in the lowest points of the system shall be drained.
Drains shall be 90mm slotted PVC drain pipes through rubble pits. 90mm PVC drain pipes
(unslotted) shall connect the conduit system to the rubble pit drainage system.
Drains are to discharged into rubble drains.
Rubble drains shall be 600mm wide x 1000mm deep located clear of the Runway strip at
locations as generally noted on the drawings. Drains shall be lined with Geofabrics Filter-
Wrap all around and backfilled with 50mm rock ballast. Bed slotted PVC pipe in 200mm
rock under. Trench length to be 6m min length. Grade trench at min 1:200 longitudinal
grade.
Conduit fall from pits to start of rubble drain to be min 1:200 longitudinally. Finish rubble
drain nom. 200mm from finished surface level and complete application of filter wrap.
Backfill last 200mm with clean general fill and topsoil and grass and maintain until
establishment. Stake rubble drains with nom 50mm x 50mm white timber posts drive min
1000mm into ground.
Survey of site to provide as-built locations of all rubble drains and PVC drain lines to rubble
drains. Invert levels to be included in as-built information.
6.4.10 Route Markers
Separate route markers shall be supplied and installed for each service as applicable.
The method of marking the route of services shall be either Alternative 1 or Alternative 2
noted below. Only Alternative 1 or Alternative 2 shall be used. A combination of Alternative
1 or Alternative 2 shall not be allowed.
Alternative 1
Markers shall be set in the ground at finished surface levels, directly above the underground
conduits and shall be provided as follows:
30 metre intervals on straight runs
at all changes in direction
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one (1) metre approximately from the point of entry of conduits into buildings
at all conduit stubs directly above terminal point of the conduit.
Markers shall be 300 x 300 x 300 deep cast concrete blocks. An engraved brass marker
plate 150 x 150 shall be fixed to the block to indicate type of service and direction of
underground conduit run.
Alternative 2
A proprietary service route marker system may be installed by the Contractor that is
completely located below ground with no ground surface markers present and that is able to
be activated / excited by an electronic handheld service marker locator / detector by field
staff to determine the location of the underground service being traced and for marking by
field staff as required from time to time.
Such a proprietary system shall be maintenance free, reliable and be able to be traced from
ground surface when installed in the service trench depth noted on the design drawings.
The design life and maintenance requirements of such a proprietary system shall be
detailed by the Contractor in the Operation and Maintenance manuals described in Section
3.22 of this specification.
Prior to commencement of construction, the Contractor shall seek the Principals
Representatives approval in written form for the proprietary system to be used.
6.4.11 Reinstatement of Existing Surfaces
Existing surfaces shall be reinstated to their original condition to the Principals
Representatives approval.
Mass concrete aprons shall be provided in accordance with the details on the drawings for
taxiway pit, and other selected locations.
Provide peaked lids over cable support systems where run exposed to sunlight and/or rain.
Provide cable protection where cables enter or leave cable support systems.
Separate low voltage power cables by distances sufficient to avoid derating in accordance
with AS/NZS 3008.1 Table 23.
6.4.12 Boring
Engage a suitably qualified specialist contractor for all underground boring works.
Confirmation of drilling method to be provided to the Principals Representative for approval
prior to works commencing on site. Drilling methods and work method statements for same
are to ensure no settlement / shrinkage occurs at the under bore locations on site.
6.5 COMPLETION
Carry out all tests as detailed in AS/NZS 3000 Section 8 Verification.
Use AS/NZS 3017 Electrical Installations Testing and Inspection Guidelines as the basis
for test procedures.
Record all test results and include in the Operations and Maintenance manuals.

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SECTION 7 SWITCHBOARD
7.1 GENERAL
This section covers the supply of the Runway Lighting Switchboard. Provide a new runway
switchboard complete with all required accessories and equipment as detailed in this
specification and on the drawings.
7.1.1 Standards and Rules
The design of the Runway Lighting Switchboard shall be in accordance with requirements
of:
AS3439.1 Low Voltage switchboards
AS/NZS 3000 Wiring Rules
Australian Government Civil Aviation Safety authority
CASA Manual of Standards Part 139 - Aerodromes (MOS 139)
All other relevant airport lighting standards within Australia
The local supply authority
7.1.2 Design
The switchboards shall be designed for the following conditions:
Supply: 415V, 50 Hz 3 Phase 4 Wire
Fault Level: As shown on the drawings
Earthing: MEN System
Form of Segregation:
Switchboards Form 2B to AS3439.1
Degree of Protection:
External Switchboards Minimum IP56 to AS1939
7.1.3 System Fault Level and Protection
The system fault level applicable to the electrical installation shall be as specified herein or
nominated on the drawings.
All equipment connected to the system shall be of a design and type providing safe
operation at the fault level specified.
All protection devices, including relays, fuses, circuit breakers and the like shall be graded to
size, calibrated and set to ensure limitation, minimisation and localising of any resulting
overload or short circuit fault occurring in the system.
Provide copies of Test Certificates with the Tender for all switchgear and busbar systems or
alternatively, the manufacturer's published data, provided it:
Nominates the Test Certificate Number
Specifies the Test Authority
Indicates the nature and limitation of the tests conducted on the equipment
7.1.4 Drawings
Before construction of a Switchboard is commenced, drawings shall be submitted to the
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Principals Representative for review. Three (3) copies of the detail drawings of each
Switchboard shall be submitted. The drawings shall clearly indicate the arrangement of
components, the clearance between components and terminals, etc., the type of equipment
and the construction of the Board.
The drawings shall include:
General arrangement
Busbar details and connection
Schematic Diagrams including metering and protection circuits.
Any review of drawings by the Principal shall in no way relieve the manufacturer of their
obligations under other sections of the specification.
7.1.5 Tests and Inspections
The switchboards shall be routine tested, as specified for partially type tested assemblies,
before delivery to site.
A final inspection shall be carried out by the Principals Representative before delivery to
site.
7.1.6 Spare Space
The space required for future circuit breakers and equipment shall be as shown on the
drawings.
7. 2 CONSTRUCTION
7.2.1 General
Switchboards shall be metal clad, totally enclosed, dustproof or weatherproof type of
construction as specified herein or nominated on the drawings, of approved manufacture.
The Switchboards shall be of the front access type and contain the types of switches, fuses,
circuit breakers, number of poles and equipment as specified herein and shown on the
drawings.
Particular attention shall be made in the design of the Switchboards to ensure satisfactory
handling into position on Site during construction and that the Switchboard is designed to
suit the installation requirements and the available space.
Switchboard mounting shall be as specified herein.
Switchboards shall be manufactured from 1.6mm minimum CRCQ sheet steel pressed or
rolled to shape. All joints shall be neatly welded and finished flush with the adjacent
surfaces by grinding and/or machining. Joints shall not be located on a corner and all bare
edges shall be lipped. Structural members and bracing where necessary shall be welded or
bolted to the frame.
7.2.2 Doors and Covers
Doors and covers shall be provided with a right angle return on all sides, and fitted with a
continuous resilient sealing rubber gasket fixed on a metal retaining frame with
nonhygroscopic adhesive.
Doors shall be hung on substantial corrosion resistant hinges and fitted with chrome plated
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lockable door handles, operating a latching system into slots at top and bottom. All
mechanisms shall be cadmium plated.
All switchboard locks shall be keyed alike. Locks shall be Lowe and Fletcher No.92268 or
approved alternative. Two keys suitably labelled shall be provided for each switchboard.
The width of a single door shall not exceed 750mm with a door swing of at least 90 degrees.
Covers shall be fixed to frames using at least 4 fixings, held captive in the cover, and
provided with nylon washers. Cover edges shall be rested on the cubicle body or on
mullions.
Covers shall be provided with corrosion resistant D type handles.
7.2.3 Equipment Mounting Panels
Proprietary escutcheon plates shall be provided for each control panel for mounting of all
equipment.
Panels shall be sized to suit the weight of mounted equipment, and provided with angle or
plate supports bolted or welded to enclosure sides.
All cut-outs for panel mounted equipment shall be neatly made and additional supports shall
be provided where necessary to avoid panel distortion.
Escutcheon plates shall be provided with neat circuit breaker toggle cut-outs allowing
interchangeability of 1, 2, and 3 pole circuit breakers. Cut-outs shall also be provided for
future circuit breakers and fitted with black clip-in type in-fill panels.
Escutcheon plates shall be held in position with chromium plated captive type knurled thumb
screws. Where such panels are greater than 1 m
2
in area they shall be hinged.
Corrosion resistant lifting handles or knobs shall be provided.
7.2.4 Cable Entries
Provision for cable entries shall be made in the top and bottom or rear of the switchboard.
Sufficient clear space shall be provided within each enclosure, next to cable entries, to allow
incoming and outgoing cables and wiring to be neatly run and terminated without undue
bunching or sharp bends.
Removable gland plates fitted with gaskets shall be provided. Cable entries shall be sealed
with non-setting mastic after installation of the cables.
Provision shall be made for suitably fixing cables within the cable zones. This shall be in the
form of a cable tray, slotted PVC cable duct, or approved cable cleats. Adequate provision
for future cabling shall be made.
Connections to fuse units and circuit breakers shall be shrouded to allow future cabling to
be installed without the need to isolate the board.
7.2.5 Earthing
All metal parts of the switchboard and associated equipment shall be effectively bonded to
the protective earth conductor.
All earthing conductors shall be made strictly in accordance with AS3000.

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7.2.6 Mounting
Wall mounted switchboards shall have adequately reinforced bolt fixing holes. Recessed or
semi-recessed assemblies shall be provided with angle trims of the same material and finish
as the enclosure.
Floor mounted switchboards shall be provided with a 75mm X 40mm X 6mm galvanised MS
channel plinth, with toe-out profile. The channel shall form a continuous box section around
the base of the switchboard.
7.2.7 Finishing of Metalwork
Switchboards shall be etch primed followed by one (1) coat of undercoat and finished
externally with two (2) coats of high gloss enamel, colour as advised by the Principals
Representative, and internally with one (1) coat of high gloss enamel, white.
7.3 BUSBARS
7.3.1 General
Busbar assemblies shall be provided to the ratings shown on the Schematic Diagram.
Busbars shall be solid copper, of rectangular section with radiused edges, and sized and
supported to withstand the specified fault level.
The neutral busbar shall be rated to match the neutral conductor current carrying capacity.
The minimum size busbar shall be 13mm X 3mm copper.
Busbar assemblies shall be used to connect the incoming isolator to all outgoing circuit
breakers. The use of flexible cable in lieu of busbar assemblies is not acceptable unless
nominated on the tender drawings, and written acceptance provided.
7.3.2 Phase Sequence
For main busbars and connections to switching devices, set out phase sequence for phases
A, B, and C from left to right, top to bottom, and back to front when viewed from the front of
the assembly.
7.3.3 Colour Coding
Active conductors: Red, white, and blue respectively for A, B, and C phase.
Neutral busbar: Black.
7.3.4 Busbar Insulation
Active and neutral busbars shall be insulated with 660V grade insulation of appropriate
colour for their entire length.
7.3.5 Connections
Adequate provision shall be made for connection of cables by means of cable lugs or screw
type tunnel terminals. The number of connections shall correspond to the number of initial
and future circuits, and shall be numbered to correspond with the circuit numbers. Pre-drill
the main circuit supply busbar for future extensions, and extend busbar droppers into future
functional unit locations.
7.3.6 Jointing
All connections shall be bolted or clamped in an approved manner using cadmium plated
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high tensile steel bolts, washers and lock nuts or nuts with locking tabs.
7.4 AIR CIRCUIT BREAKERS
7.4.1 Rating
Air circuit breakers having a rated short circuit breaking capacity at least equal to the fault
level at the incoming terminals of the assembly shall be provided as shown on the
Schematic Diagram.
Alternatively, where current limiting protection is provided, or where rating and interrupting
capacities permit, circuit breakers may be moulded case types, to comply with AS 3111 or
AS/NZS 60898.1, having a minimum interrupting capacity of 6kA.
7.4.2 Mounting
Circuit breakers shall be mounted on a standard mounting chassis of approved manufacture
securely fastened to a channel fixed to the back of the Switchboard enclosure.
Construction of the circuit breaker assembly shall be such that a double or triple pole circuit
breaker can be replaced by three (3) single pole circuit breakers and vice versa, without
modification to the busbar assembly.
Cabling zones 125mm wide (minimum) shall be provided between the rows of circuit
breakers. Additionally, a minimum distance of 125mm for cabling shall be provided between
circuit breakers and the top, bottom and sides of the Switchboard cabinet. Circuit breakers
shall be numbered with push-in circular disk type numbers in the appropriate phase colours
fixed to the escutcheon plate. Circuit breakers shall be further numbered within the
Switchboard to correspond to the numbers on the escutcheon.
Circuit breakers controlling heaters shall be grouped together and labelled "HEATERS" in
4mm high letters engraved in "Red on White" Traffolyte.
Provide circuit breakers of NHP, ABB , Merlin Gerin manufacture.
7.4.3 Residual Current Devices
Provide combined residual current device (RCD)/circuit breakers for power circuits where
Provide RCD/circuit breakers which comply with AS 3190 or AS/NZS 61009, and which
have a rated residual operating current of 30 mA unless noted otherwise.
Provide combined RCD/circuit breakers which are of the same manufacture and which
attach to the same chassis as the standard circuit breakers.
Where combined RCD/circuit breakers use more than one pole for each protected pole,
increase the number of poles on the switchboard chassis to ensure that the specified
amount of spare space is provided and ensure the cupboard space provided will accept
such an increase.
7. 5 MAINS ISOLATION TRANSFORMER (MIT)
The kVA size of the MIT shown on the drawings shall be fully checked and confirmed by the
switchboard designer, and any size adjustment made in accordance with standard design
practice when allowing for cable losses and lighting load, plus a future spare capacity factor
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of 20%. The responsibility for correct and final sizing of the MIT lies fully with the
switchboard manufacturer, and shall be confirmed in the switchboard workshop drawings.
The new mains multi-tap isolation transformer shall be purpose constructed by a reputable
transformer manufacturer. Transformers shall conform to all current CASA requirements.
Manufacturers details shall be included in the tender documents.
Transformer secondary output shall be constant at 6.6 Amps in line with CASA runway
lighting requirements. Transformers shall be enclosed in painted sheet steel enclosures,
with internal connection terminals on connection plates, purpose built for Runway lighting
application. Taps shall be as follows:
0V, 400V, 420V, 440V input voltage taps
0V, 80V, 796V, 955V 1114V 1273V 1432V 1591V output taps
Tenders shall provide full technical specifications for MITs, in the form of data sheets,
showing all losses, efficiencies, ratings, winding ratios, current and voltage levels at each
tap.
Transformers shall be rated to withstand 10% overload continuously.
7.6 ENCLOSURE WIRING
All Wiring shall be adequately tied, run neatly and enclosed in cable ducts. Ducts shall have
perforated sides with split tops for cable access to individual terminals and shall be fitted
with lids. Ducts shall have a minimum spare capacity of 25% over and above the allowance
for future equipment shown on the drawings or specified herein.
Enclosure PVC slotted cable ducting shall be rated to withstand 70 degree ambient
temperature.
Where insufficient space is available within junction boxes to fit cable ducts, wires shall be
neatly loomed using cable ties.
Ducts as detailed above shall be provided adjacent to each row of equipment for outgoing
circuit wiring and shall extend the full width or height of the cabinet.
The duct cover shall be fixed such that it cannot be installed on a different duct.
The cross sectional area of the plastic duct shall be sufficient to accommodate all outgoing
circuit cables in accordance with the wiring regulations, and the requirements of this
specification with regard to spare space.
Plastic Duct shall be mounted far enough from top or bottom of control gear to allow easy
removal for service and to remove and install associated wiring.
Low voltage internal wiring shall be insulated (0.6/1kV grade) with V75 PVC insulation.
The control and instrumentation wiring shall be of adequate size, a minimum of 1.0 mm
2

(32/.0.20) rating, multi-stranded flexible copper conductors, PVC V75 Grade. The minimum
size for power cables shall be 2.5 mm
2
. Each control wire shall terminate with a pin crimp.
Wires shall be colour coded as follows:
240V control active - brown
240V control neutral - black
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ELV active or DC positive - white
ELV neutral or DC negative - grey
Earth - green-yellow
Wiring on (or to) all equipment, doors or hinged panels shall be arranged in a manner that
prevents any strain or chaffing of the wiring over the full travel of the door or panel.
Flexible wiring shall be used across such hinged or removable sections. Wiring shall not rest
on busbars or metal edges.
All cable cores shall be of sufficient length at each termination to allow a fresh connection to
be made.
The correct size and type of screwdriver shall be used for making terminal block
connections.
Push fit terminals shall not be used. All terminals shall be single screw type, single height,
minimum size 2.5 mm of Weidmuller, Sprecher and Schuh, or similar approved
manufacture.
Double deck terminal blocks shall not be used.
Terminal strips shall be provided within enclosures and equipment for control cable
terminations.
Terminal strips shall be provided with the number of terminals required to allow one
termination per terminal.
Provide protective covers and warning labels over all outgoing power connections within
enclosures. This shall comprise a Perspex cover mounted on stand-offs, fitted with a
Danger high voltage label.
Each terminal shall be identified with a number using permanent clip-on non-flammable
terminal markers with black characters on a white background.
7.7 CABLE FERRULES
The cores of all cables shall be continuity checked, and numbered with white engraved
ferrules with black numbers to correspond to the relevant termination diagrams and
equipment drawings. Wrap around adhesive markers are not acceptable. The Contractor
shall ensure that the component numbers of the identifier are aligned that the identifier is
clearly visible.
Ferrules shall be of a sleeve type which will not slip off the ends of the cables.
The overall cable shall also be labelled with approved tags and identifying references.
All cables and wiring shall be identified at each end where they are connected apparatus or
terminal strips using ferrules similar to Legrand Starfix, or Grafoplast. Spare cores shall be
labelled accordingly.
Cables shall be labelled using Critchley or Grafoplast labelling systems.
7.8 MAIN SWITCHES
7.8.1 Main Isolator
All switchboards shall be provided with lockable, fault making, load breaking, flush panel
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mounted main isolators as shown on the drawings.
7.9 AUXILIARY EQUIPMENT
7.9.1 General
Auxiliary equipment including time switches and contactors controlling equipment shall be
incorporated within the Switchboard.
All equipment shall be readily accessible for adjustment without the removal or opening of
the escutcheons. Time switches, etc. shall protrude through the escutcheon.
7.9.2 Contactors
Contactors shall be mounted within the Switchboard and labelled accordingly.
Contactors shall be a minimum of single pole 30 amp (or as indicated on drawings), and
shall be of Schneider or NHP manufacture.
7.9.3 Photo-Electric Switch
Supply and install a Photo Electric (PE) Switch to control external lighting as shown on the
Schematic Diagram.
Provide additional Future CCR PE switches and wire these switches to relays in the control
system for future integration of the PAPI CCR.
7.10 TRANSIENT PROTECTION
7.10.1 Surge Diverters
Supply and install shunt connected Metal Oxide Varistor (MOV) based surge diverters for
each phase on the line side of incoming functional units as shown on the drawings.
Provide protection fuses for the surge diverters in accordance with the manufacturers
recommendations.
Provide surge diverters in the following locations:
Switchboard incoming supply
Runway lighting outgoing circuit
Provide Novaris surge diverters, type SDN3 100-275, 3 phase & N AND N-E 100 kA rated,
for the incoming switchboard supply point.
Provide Novaris surge diverters, type SDH 100-2000 high voltage 100kA 2000 volt rated
fuse base mounted surge diverters for the runway circuit on each leg of the circuit.
Install the surge diverters in accordance with the manufacturers instructions.
7.10.2 Maximum Demand Ammeters
Maximum demand ammeters with reset controls shall be provided as shown on the
Schematic Diagram. Meters shall be 100mm square pattern type with a 270o concentric
scale.
Meters and CT's shall be of a type and accuracy for compliance with MOS 139.
7.10.3 Fuses
Fuses for use in main current carrying circuits shall be high rupturing capacity cartridge
type, suitable for the fault level at the assembly, and which discriminate with other protective
equipment.
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Instrument fuses shall be HRC cartridge type of appropriate rating, mounted in a moulded
plastic carrier with a moulded plastic fuse base.
HRC fuses shall be of the same manufacture throughout the entire installation.
Three (3) spare fuses of each type and rating used in the installation shall be supplied and
stored in a suitable enclosure within the Switchboard.
7.11 MARKING
7.11.1 General
Clearly label all equipment in accordance with regulations and to indicate function.
Provide labels including control and circuit equipment ratings, functional units, notices for
operational and maintenance personnel, incoming and outgoing circuit rating. Provide labels
fixed to access panels, doors, covers, and escutcheon panels, and internal equipment,
indicating the relevant section and component. Blank panels shall be provided for future
circuits.
All labels shall be machine engraved Traffolyte or equivalent, screw fixed with nickel plated
brass metal thread screws.
Prior to engraving the labels, a label schedule shall be submitted to the Principals
Representative for review.
7.11.2 Minimum Lettering Heights
Main Assembly Designation: 15mm
Distribution Assembly Designation: 10mm
Main Switches: 10mm
Outgoing Functional Units: 8mm
Other labels including equipment labels within cabinets: 4mm
7.11.3 Label Colours
Labels for main switches shall be red-on-white; circuit breakers controlling emergency
lights white-on-red; others shall be black-on-white.
7.11.4 Circuit Schedule
Provide a typed circuit schedule on the inside of the door of each switchboard in a suitable
metal frame (minimum dimensions 150mm x 150mm), protected by a clear plastic cover.
The schedule shall describe mains, submains and final sub-circuits. Circuit numbers on the
schedule shall match the pole numbers on the circuit breakers and the schedule shall
clearly describe the circuit, rating, phase and cable size.
7.11.5 Single Line Diagram
Provide a laminated copy of the "As Installed" Single Line Diagram for the Switchboard and
mount it on the inside the cubicle.
7.12 COMPLETION
Adjust, set and program all adjustable or programmable equipment.
Carry out all required site tests.
Clean all assemblies and remove all waste to as new condition.
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Energise assemblies in accordance with Workplace Health & Safety and company quality
assurance procedures.
Provide copies of wiring diagrams and airside lighting system / network layout on inside face
of airside lighting switchboard for operational and maintenance staff reference.
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SAMPLE PHOTOGRAPHS
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AERIAL VIEW OF BLACKALL AERODROME LOCATION

COMPOSITE VIEW OF RUNWAY / CROSS-STRIP / TAXIWAY

COMPOSITE VIEW OF APRON / AERO CLUB ACCESS
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EXISTING RUNWAY LIGHTING FIXTURES

EXISTING WINDSOCK
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DRAWINGS

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