. COMPLIANCE STATEMENT .

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1 Scope Noted
This specification details the requirements for the design, manufacture, inspection, testing, delivery,
handling, marking and packing of Cold Pour Resin Joints for use on KAHRAMAA PILC and
XLPE cables on the low voltage Electricity Distribution System.

The specification relates to branch joints, with a single branch cable, of the mains or services type.
The joints shall be suitable for use with any combination of XLPE and PILC cables, i.e. XLPE/XLPE,
XLPE/PILC, PILC/XLPE, PILC/PILC.

The contents of this specification include reference to system parameters that the material shall be
rated to. In addition, this specification states the requirements of warranty, statement of compliance,
ISO certification, instructions on information to be supplied with the tender, storage and delivery.

2 References Noted
Where the requirements of this specification deviate from specifications referenced herein, this
specification shall take precedence unless otherwise stated. The referenced standards shall be the
latest version and/or KAHRAMAA reserves the right to follow the other version of the referred
standard.

Table 1: References

Document Ref. Description

IEC 60228 Conductors of insulated cables

Compression and mechanical connectors for power cables - Part 1-1: Test
methods and requirements for compression and mechanical connectors for
IEC 61238-1-1
power cables for rated voltages up to 1 kV (Um = 1,2 kV) tested on non-
insulated conductors
Specification for impregnated paper insulated lead sheathed or lead alloy
BS 6480
sheathed electric cables of rated voltages up to and including 33000V
Test methods and requirements for accessories for use on distribution cables of
BS EN 50393
rated voltage 0,6/1,0 (1,2) kV
Resin based reactive compounds used for electrical insulation. Specifications
IEC 60455-3-8
for individual materials. Sheet 8: Resins for cable accessories
Table 2: KAHRAMAA References

Document Ref. Description

KM-EPM-D-CBL-GENERAL Cables and Accessories General Requirements
KM-EPM-D-GEN-GENERAL General Requirements
KM-EPM-D-CBL_ACC- Shear Head Mechanical Connectors Size 16 to
CONNECTORS_16 mm2_TO_35 mm2 35mm2
KM-EPM-D-CBL_ACC- Shear Head Mechanical Connectors Size 70 to 120
CONNECTORS_70 mm2_TO_120 mm2 mm2

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KM-EPM-D-CBL_ACC- Shear Head Mechanical Connectors Size 185 to

CONNECTORS_185 mm2_TO_300 mm2 300 mm2
KM-EPM-D-CBL-0.4-XLPE-UGD-
LV XLPE Insulated Armoured Cables
Armoured

2.1 Alternative Codes and Standards Noted

The Bidder may propose alternative Codes and Standards provided it is proven that it gives an
equivalent degree of quality as the referenced Codes and Standards. Acceptability of any alternative
Codes or Standard is at the Discretion of KAHRAMAA.

3 System Parameters Noted

The LV cold pour resin joints covered by this specification shall be designed and rated for operation
under the system parameters as detailed in General Requirements document KM-EPM-D-GEN-
GENERAL and specific system parameters as provided in Table 3.

The LV cold pour resin joints shall be capable of satisfactory operation under a power supply system
frequency variation of +5% and voltage variation of ±10%.

Table 3: Specific System Parameters

Parameters Value

Uo: Rated Power Frequency Voltage between conductors and earth (kV) 0.6
U: Rated Power Frequency Voltage between conductors for which the
1.0
cable joint is designed (kV)
Rated Highest Withstand Voltage (kV) 1.2

Maximum Symmetrical Fault Level (kA) 44

The highest Fuse Rating (A) 400

4 Environmental Conditions Noted

The LV cable cold pour resin joints covered by this specification shall be designed and rated for
operation under the environmental conditions as detailed in General Requirements document KM-
EPM-D-GEN-GENERAL and KM-EPM-D-CBL-GENERAL.

5 LV Cold Pour Resin Joints

5.1 General Noted & Accepted
Low Voltage Cold Pour Resin joints include straight, branch, multi-service, transition and pot-end
joints. Resin cable joints shall be suitable for underground (direct burial), submersible, cable tray and
overhead cable jointing installations.

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The cable joint shall accommodate cross core jointing.

The cable joint shall provide waterproofing, mechanical protection, electrical protection, shall be
designed and manufactured to provide a complete moisture seal, and tested to meet the requirements
of the relevant standard listed in Section 2.

The continuous current rating and short circuit fault ratings of the joint shall be in accordance with the
appropriate cable specification.

Following pre-requisites (minimum but not limited to) must be ensured by the contractor prior to
installation of the cable joints, and they shall be mentioned clearly on the installation manual of kit
supplier:
Safe & secure working environment,
Jointers shall be well trained & KM certified for installation works and towards the system
voltage, the cable(s) involved and the type of accessories and methodology,
In order to prepare for the specific job, jointers shall be aware of the function of each of cable
joint components specified in the installation instruction/manual, as part of the instruction,
The complete cable joint kit shall be available at site with all components listed in the kit
content sheet which shall be part of the kit box,
Taking ultimate care to avoid any damage to the products, materials, tools & equipment
during the entire work period,
Adequate protective and safe environments/arrangements at the installation site,
A proper access to the terminations being installed and to the associated cables
Proper housekeeping to the installation area throughout the termination works,
Clean, dry and protected storage for accessory components, cleaning materials, other
consumables and working tools during the termination work,
Minimum possible water accumulation around the work site
Proper shelter from the rain, wind, sand storm etc.
Proper daylight and/or artificial lighting,
Prior to work start, jointers shall check that the end seals are intact. The cut cable shall be
ensured so that the conductor and other components are dry,
Dimensions indicated in the installation instruction/manual shall be verified to confirm that
joints, the working pit and exposed part of the cable are perfectly matching. in case there is
mismatch/contradiction, the work shall not be proceeded further,
Cables to be jointed perfectly straight and positioned to ensure that the cable joint(s) will be
installed properly,
be done in accordance with installation
instruction.

No work on cable preparation and jointing shall begin until the installer is confident that all parts and
materials are available and are the correct type and size to complete the installation. These shall be

rejected. Any required special installation tools shall be checked to ensure that they are correct for the
intended application and are in good working order.

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5.2 Joint Design Noted

Cable Joint types shall be classified according to the types of cable used, i.e.

TYPE A : XLPE to XLPE

TYPE B : PILC to PILC

TYPE C : XLPE to PILC and vice versa

The level of design, engineering and quality of manufacture shall ensure for a reliable service life of
at least 40 years.

Joint kits shall be delivered with all required components to produce a complete cable joint including
mechanical connectors to suit specified conductor. Those components shall be listed with quantities
of each item on the paper named Kit Content Sheet. That paper (kit content sheet) shall be included in
each package box with clear indication about components inside and stating their name, size, length,
quantity, etc. of each component.

Main components for the cable joints are:

Joint shell as per clause 5.5,

Four (4) mechanical connectors with shear head bolt type as per IEC 61238-1 class A for all
type of joints (Type A, B and C),
Four (4) PVC shrouds/covers over connectors which will make joint function safe even if the
connectors are touching each other or with joint shell,
Galvanized steel back-up ring and drive clip for armoured cables,
Silicone grease (if applicable),
Earth continuity for PILC cable shall be by solderless technique using roll spring and by this
the need for plumbing shall be eliminated.
Copper earth braid with cross section that shall be capable of the same level of short circuit
tolerance as the armour of the associated cable,
Tubular sleeves in four pieces for 4 cores.
Tubular sleeves in four pieces for connectors.
Constant force springs two pieces,
PVC tape,
Jointing instruction in Arabic and English, Please refer to attached deviation schedule
All other components required to complete the joint installation as per manufacturer's design
to properly install the joint shall be included in the package box.
The connectors shall be mechanical connectors with shear head bolt type as per IEC 61238-1 class A
and fully in accordance with specifications indicated in Table 2.

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5.3 Conductors and Metallic Screen / Armour Connections Noted

These shall comprise of:

a. Copper earth braid with cross section that shall be capable of the same level of short circuit
tolerance as the armour of the associated cable for electrical protection of the cable cores, over
the full length of the joint, with suitable arrangements for connection to the armour and, where
appropriate, the lead sheath of the cable(s).
b. Constant force springs which shall connect the metallic armour (in case XLPE cables) or the lead
sheath (in case of PILC cables) of the cable(s).
The type of bonding will be specific to the type of joint, whether Type A, Type B or Type C.
Bonding to the lead sheath shall be by solderless technique using roll spring and by this the need
for plumbing shall be eliminated.

Bonding to the armour shall be by mechanical means. This shall comprise a support ring, placed
under the armour, a piece of tinned copper braid over the armour and two suitable worm drive
clips per bond.

The bond and its connections shall be capable of the same level of short circuit tolerance as the
armour of the associated cable, this requirement relating to the cable which has the highest such
value.

The manufacturer shall at time of tender provide documentary proof of the short circuit
performance, in the form of test certificates or test reports in compliance with BS EN 50393, and
independently authenticated.

c. Connectors:
Mechanical connectors to be used for all the type of branch joints and each joint shall be supplied
with 4 shear head mechanical connectors as per IEC 61238-1 class A of the size appropriate to
the stated range of cable sizes in the Bill of Quantities.
d. The joints shall be suitable for colour to colour jointing.

5.4 Resin

5.4.1 General Noted

The Resin shall be Cold Pour Type high quality, high strength, non-toxic and shall consist of a two-
part mix, of either epoxy, polyurethane or acrylic materials. It will form the primary and secondary
insulant and provide protection against ingress of moisture and provide mechanical strength.

It shall be quick and easy mix and low viscosity resin and shall be supplied in a single pouch with a
separator. The silver resin pouches shall be provided. It shall be possible to transfer the mix directly
and easily to the joint shell.

Supplying of Resin and Hardener shall be in a pouch with a separator. The Components shall be
capable of mixing without exposure to the air, and without contact with the Jointers hands. The shelf
life of the resin shall be indicated by manufacturer and shall be at least 2 years when stored as per

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The Resin shall have been manufactured within 3 months at the time of delivery.

The resin, when cured shall be hard, and shall maintain excellent adhesion to all cable components.
Curing reaction shall not be sensitive to moisture. It shall be capable of withstanding a wide
temperature range, typically 10°C to 100°C in service.

When cured, the joint shall have excellent electrical and mechanical properties that does not allow
ingress of moisture.

The volume content of the resin kits shall be compatible with the requirements of the joints.

The Resin shall not cause any safety hazard.

The user wishes to maintain a high rate of turnover of stocks of resin. For this reason, it is preferred
that a minimum number of resin kit package sizes will be made available, compatible with the range
of joint shells supplied. Performance of the resin shall be in compliance with IEC 60455-3-8. The
manufacturer shall be obliged, at time of tender, to produce test certificates or test reports duly
authenticated by independent authority.

5.4.2 Tests on Resin Noted

Performance tests on Resin shall be in accordance with the latest version of standard IEC 60455-3-8
and as provided below:

a. tests on individual components prior to mixing,

b. tests on reactive compound just after mixing (ready to use),
c. tests on cured compound,
d. tests on cured compound after pre-treatment (thermal, humidity, water etc.).
Sequence of tests shall be as per IEC 60455-3-8, clause 5.4.

Test report shall include but not limited to the following data:

a. resin designation and identification,

b. lot number or other identification,
c. confirmation of marking and labelling according to the material safety data sheet (MSDS),
d. test results,
e. major test parameters, including conditioning and calibration, if any,
f. processing conditions used to reactive compound,
g. copy of the technical data sheet (TDS) and material safety data sheets (MSDS).

5.5 Joint shell Noted

The joint shell shall be of a split outer case vacuum formed from a suitable material. Foam strips shall
be provided to seal all shell mating surfaces, and adequate mechanical means shall be provided to
hold the sections together until the filled resin has cured and by ensuring there is no leakage while
curing.

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The shell shall be designed to give a minimum clearance between joint connections and shell inner
surface of 10mm.

The shells shall be embossed with the legend "ENA, QATAR", and a legend indicating range taking
capability of the joint.

The joint shells shall be in compliance with BS EN 50393.

Joints shell minimum inner length (I/L) and joints shell minimum inner cylindrical diameter (I/D) are
given in Clause 5.7.

5.6 Joint Accessories Noted

Each joint shall be equipped with all accessories listed in Section 5.1 necessary to complete the joint.

5.7 Size and Shell Dimensions of Branch Joints Noted

Dimensions of joints shell and cables are given in Table 4, with tolerance of +/-5% towards size
(length & ID) of shell design.

Table 4: Sizes and Shell Dimensions of Branch Joints

Joint Type Main Cable Size Service Cable Size I/L (mm) I/D (mm) Type

1. 300-185 300-185 1000 220 Group 1

2. 300-185 120-70 900 210 Group 2

3. 300-185 35-16 820 180 Group 3

4. 120-70 120-70 780 185 Group 4

5. 35-16 35-16 710 160 Group 5

5.8 Cable Types and Standard Sizes Noted

This list may be taken to apply both to PILC and XLPE insulated cables.

Following cable sizes are to be considered:

2 Core: 16 sq.mm
4 Core: 16 sq.mm, 35 sq.mm, 70 sq.mm, 120, sq.mm, 185 sq.mm and 300 sq.mm

PILC Cables: 4 Core, stranded shaped copper conductors, paper insulated, lead sheathed, double
steel tape armour, bedding and PVC over sheathed to BS 6480. Neutral shall be composed of same
size as that of power core. Armour is bonded to lead sheath.

XLPE Cables: According to KAHRAMAA specification ref. no KM-EPM-D-CBL-0.4-XLPE-UGD-

Armoured, low voltage, XLPE insulated, multicore and single core and armoured cables. The armour
will be used to provide consumer with earth terminal.

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6 Inspection, Testing and Delivery

6.1 Inspection, Testing and Audit Noted
Inspection, Testing and Auditing shall be in all means as per clause 9.1 of CBL General
Requirements KM-EPM-D-CBL-GENERAL

6.2 Type Tests Compliance Noted

For the joints specified herein, Type Testing is required to be undertaken as specified below, along
with a minimal set of routine factory testing.

Manufacturer shall carry out type tests in accordance with the latest version of BS EN 50393:2015
standards. Tests shall take place at an internationally recognised testing station, or in manufacturer
own laboratories, witnessed and certified by an internationally recognised and KAHRAMAA
accepted certification body/laboratory.

Bidder shall submit certified copies of type test certificates covering proposed joint to be supplied.
Type tests certificates/reports may be considered acceptable if they are in compliance with the
relevant International Standards and the following:

a) The certified type test report shall not be older than 10 years and there shall not be change in
design, source of raw material and all other relevant material of the type tested and offered
joints.
b) Type tested cable joint shall be of equal voltage designation.
c) Same factory location and same manufacturing process of the type tested and offered joints,
d) Same raw material of the type tested and offered joints.
e) Fully compliance with range of approval as per clause 6.1 of BS EN 50393:2015.
Where items of a similar design to that previously tested are offered, consideration may be given to
accepting previous Type Test reports. Bidders are requested to substantiate their claims of equivalent
Type Test performance with written engineering evaluation, where full Type Test documentation is
not submitted for each of the items offered. Such evaluation must provide all relevant details such that
KAHRAMAA can establish the validity of existing Type Tests.

KAHRAMAA may request repeat of Type Tests to prove compliance to this technical specification
where the materials used in the equipment offered and/or the manufacturing process and/or the place
of manufacture or the referenced International Standards have changed since the equipment was
originally type tested, the Bidder shall submit for approval type test procedures and schedules for
performance of the same.

6.2.1 Electrical Type Tests Noted

Electrical tests shall be in accordance with the latest version of standard of BS EN 50393:2015, as
follows:

Impulse voltage withstand at ambient temperature as per BS EN 50393:2015 clause 8.2,

AC voltage withstand (in air) as per BS EN 50393:2015 clause 8.3,

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Insulation resistance (in air) as per BS EN 50393:2015 clause 8.4,

Impact at ambient temperature as per BS EN 50393:2015 clause 8.5,
Insulation resistance (immersed) as per BS EN 50393:2015 clause 8.4,
Heating cycle in air as per BS EN 50393:2015 clause 8.6,
Heating cycle in water as per BS EN 50393:2015 clause 8.6,
Insulation resistance (immersed) as per BS EN 50393:2015 clause 8.4,
AC voltage withstand (immersed) as per BS EN 50393:2015 clause 8.3,
Insulation resistance (immersed) as per BS EN 50393:2015 clause 8.4
Examination as per BS EN 50393:2015 clause 8.8,
Screen short-circuit as per BS EN 50393:2015 clause 8.9.

6.3 Routine Factory Tests Noted

These tests shall be carried out in accordance with the requirements of respective standard to which
cable joints are offered.

All material tests shall be performed as per respective standard to verify the quality of material
requirements. Manufacturer shall provide records of all routine factory tests performed on the
equipment supplied before shipment.

The following tests shall be performed as a minimum:

Dimensional checking as a minimum on 10% of the number of joints to be dispatched,

Physical inspection of the packing, availability of kit content sheet, shipping marks etc. shall
be verified and documented on 100% joints.
The bidder shall include with his bid a list of all routine factory tests to be undertaken on the proposed
equipment to be supplied.

6.4 Pre-Delivery Testing and Inspection Please refer to attached deviation schedule
Pre-Delivery, Testing and Inspection shall be in all means as per clause 9.4 of CBL General
Requirements KM-EPM-D-CBL-GENERAL.

6.5 Identification and Packaging Comply

All components of the cold resin joint shall be clearly marked with the manufacturer's name and
reference numbers. The marking shall not damage the unit, when applied or during its lifetime and it
shall be done before coating the adhesive onto the component.

Electrically conducting components shall be marked 'conducting' clearly and permanently.

Components shall be supplied as a complete joint kit. Each kit shall have clear unique identification
permanent printed thick label showing unique code/serial number, suppliers name/make,
manufacturing year, batch reference, voltage and cable size, as minimum information. This referred

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permanent printed thick label shall be provided by the manufacturer which shall be fixed/used while
installation for each joint for KAHRAMAA future reference.

Components supplied with adhesive coatings shall have means to prevent the coated surfaces from
adhering to each other.

Packing shall protect the components against damage during shipment and handling up to installation
site.

Packaging shall be designed to protect ingress of moisture and mechanical damage. The Kits shall be
packed in usable (not perishable) material to permit unpacking for inspection after shipping and be
suitable for re-packing for later usage. The packaging shall be also designed to provide easy and
perfect unpacking and re-packing during inspection. The repacked material shall protect ingress of
moisture and mechanical damage.

Each complete joint kit shall be stored within a shipment crate in a manner that ensures no damage
will occur during shipment. Each shipment crate shall be made of strong wooden material. The
shipment crates shall be transported and shipped in a moisture proof, seaworthy container in
accordance with international standards.

Each joint kit shall contain a comprehensive jointing instruction giving all relevant dimensions and
instructions for making the joint in Arabic and English.

The name of the manufacturer shall also be embossed on the shell in addition to the embossing with
the KAHRAMAA standard legends.

Each hard box shall be labelled with the following information:

Joint/accessories catalogue number,

Purchase order number/tender,
Contract number/scheme,
Manufacturer's name and country of origin,
Month and Year of manufacture,
Date of expire if applicable.

6.6 Warranty Comply

For general prequalification approval, warranty shall be 5 years from commissioning date only.

The manufacturer shall warranty the cable joints against all defects arising out of faulty design or
manufacturing or defective material for a minimum period of 4 years from the date of commissioning
or 5 years from the date of delivery whichever comes earlier. Equipment that fails within this
warranty period shall be replaced by the manufacturer at no cost to KAHRAMAA. The replacement
unit shall be supplied immediately with KAHRAMAA approved and successful design which is
identical to the supplied unit unless improvements were made. The root cause of failure shall be
determined and report shall be submitted to KAHRAMAA detailing the defect.

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6.7 Storage and Handling Comply

The joint components shall be capable of being stored without deterioration within the temperature
range -10°C to +50°C and to meet the environmental conditions specified in KM-EPM-D-GEN-
GENERAL and KM-EPM-D-CBL-GENERAL.

Joints and all associate material shall be stored properly indoor considering the environmental
conditions mentioned here above. The stacking pile height shall also be mentioned by the
manufacturer on the box itself.

The joints components shall be capable to withstand possible temperature increases above the
mentioned level during short term storage in transportation/transit before final storage without
incurring any damage.

Components or materials (including but not limited to pre-moulded, pre-stretched and heat shrinkable
tubes/sleeves) shall have no shelf life limitation and no special storage condition in given temperature
limits.

Non-metallic parts (grease, solvents, mastic tapes, etc) shall be with defined shelf life with no less
than 3 years from the date of delivery.

The shelf life of the resin shall not be less than 2 years from the date of manufacturing.

The validity of specific item which is not in line with the general expiry date of the complete kit shall
be mentioned separately over the item's packing itself (like any liquid, gel, tape etc.). The validity
must be in line with environmental conditions or otherwise specified.

7 Comply

shall be in all means as per clause 10 of CBL General Requirements

KM-EPM-D-CBL-GENERAL.

8 Tender Information
8.1 Tender Submission Requirements Comply
Bidder shall submit documents as instructed in clause 11.1 of CBL General Requirements KM-EPM-
D-CBL-GENERAL.

8.2 Statement of Compliance and Deviation Schedule Noted

Bidder shall submit Statement of Compliance as instructed in clause 11.2 of CBL General
Requirements KM-EPM-D-CBL-GENERAL.

8.3 Outsourcing Restrictions Comply

Outsourcing Restrictions shall be in all means as per requirements in clause 11.3 of CBL General
Requirements KM-EPM-D-CBL-GENERAL.

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9 Appendices

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