CIVIL, ARCHITECTURAL & STRUCTURE - · PDF fileCIVIL, ARCHITECTURAL & STRUCTURE ... 2.4 OISD-STD-117 ... OISD - 163 (Process Control Room Safety) For Blast resistant Control room

VOLUME – V

CIVIL, ARCHITECTURAL & STRUCTURE

SPUR LINES OF CHAINSA – JHAJJAR PIPE LINE

0 10.11.2008

DESIGN BASIS/JOB SPECIFICATION/ STANDARD

SPECIFICATION/STANDARDS/ DRAWINGS/DATASHEET

REV. DATE

DOCUMENT No. REV-0 GAIL (INDIA) LTD NEW DELHI

LIST OF ATTACHMENTS

Page 1 of 1

Copyright GAIL – All rights reserved

INDEX--JOB SPECIFICATIONS

S.NO. DOCUMENT No. NO. OF PAGES

REV. TITLE

1 0001-01-09-02-001 38 0 Specification for Architectural Finishes.

2 0001-01-09-02-002 22 0 Standard specification for clean agent system

3 0001-01-09-02-003 9 0

Specific requirement for Geotechnical Investigations for pipeline laying and associated works tender

4 0001-01-09-02-004 4 0Job specific requirement for Civil- Strl. Works for pipeline laying and associated works

5 0001-01-09-02-005 15 0 Job Specification for packaged equipment inputs


LIST OF ATTCHMENTS STRUCTURALS

0001-01-11-11-001 Page 1 of 2


STRUCTURAL

STANDARD SPECIFICATIONS

Sl. No.

Specification No. No. Of Sheets

Rev Title

01 S-11-02-001 04 0 Technical Specification civil & structural works - General scope.

02 S-11-02-002 16 0 Technical Specification civil & structural works - Materials.

03 S-11-02-003 11 0 Technical Specification civil & structural works – Earthwork.

04 S-11-02-004 32 0 Technical Specification civil & structural works – Plain and Reinforced cement concrete.

05 S-11-02-005 7 0 Technical specification -civil & structural works - reinforced cement concrete in liquid retaining structures.

06 S-11-02-006 24 0 Technical Specification civil & structural works – Structural steel works.

07 S-11-02-007 12 0 Technical Specification civil & structural works – Miscellaneous steel works.

08 S-11-02-008 8 0 Technical Specification civil & structural works – Brick masonry.

09 S-11-02-009 9 0 Technical Specification civil & structural works – Stone masonry

10 S-11-02-010 5 0 Demolition & Dismantling11 S-11-02-011 8 0 Technical Specification civil &

structural works – Miscellaneous items.


LIST OF ATTCHMENTS STRUCTURALS

0001-01-11-11-001 Page 2 of 2


STRUCTURAL STANDARDS

Standard No. No. Of Sheets

Rev. Title

01 S-11-01-001 02 2 Flooring details for buildings02 S-11-01-002 07 4 Metal insert plates03 S-11-01-003 05 3 Standard lintels04 S-11-01-004 07 4 M.S.Anchor bolts05 S-11-01-005 10 5 Handrail06 S-11-01-006 6 4 Steel Stair07 S-11-01-007 6 3 Standard grating details08 S-11-01-008 3 2 Small operating platforms on

grade/RCC elevated structure09 S-11-01-009 4 2 Crossover10 S-11-01-010 17 2 Cable -Trench


LIST OF ATTCHMENTS ARCHITECTURAL

0001-01-09-11-001 Page 1 of 2


STANDARDS & STANDARD SPECIFICATIONS

STANDARDS DRAWINGS (ARCHITECTURALS)


REV. TITLE

1 S-10-01-001 4 0 Abbreviations and Legends

2 S-10-01-02 1 0 Cable crossing under road (PVC pipes)

3 S-10-01-003 1 0 Road curves and crossings

4 S-10-01-004 1 0 Standard section of storm water ditches.

5 S-10-01-005 3 0 Pipe culvert for storm water drainage

6 S-10-01-006 2 0 Box culvert type I, II, III & IV

7 S-10-01-007 1 0 Details of rungs for manholes, valve pits, tanks etc.

8 S-10-01-008 1 0 Std. Misc. Details for manholes

9 S-10-01-009 1 0 Concrete bedding and encasements for pipes.

10 S-10-01-010 1 0 Gully trap chamber11 S-10-01-011 1 0 Inspection chamber12 S-10-01-012 1 0 Septic tank (type-I, II & III)13 S-10-01-013 1 0 Details of soak pit14 S-10-01-014 1 0 Valve pit type-I for dia. 1.5”

15 S-10-01-015 10 Valve pit type-III for dia. 8” to

16”

16 S-10-01-016 10 Chequered plate details (for

masonry valve pit type-I, II III & IV)

17 S-10-01-017 10 Manholes type-I for depth 1m,

( 300mm)18 S-10-01-018 1 0 Details of neutralization pit

19 S-10-01-019 1 0 Std. detail of chain link fencing (with conc. post)

20 S-10-01-020 1 0 RCC pavement details.

21 S-10-01-021 1 0 Conc. Sliding sleeper cast-in-situ Type-II

22 S-10-01-022 1 0 Conc. Sliding sleeper cast-in-situ Type-III

23 S-10-01-023 1 0 Installation details of fire water


LIST OF ATTCHMENTS ARCHITECTURAL

0001-01-09-11-001 Page 2 of 2


hydrants, water monitor and foam/water monitor

24 S-10-01-024 1 0 Installation details of water monitor

25 S-10-01-025 1 0 Upflow Anaerobic filter26 S-10-01-026 1 0 Steel gate (for entrance)

27 S-10-01-027 1 0 Repeater Room at SV Station (without DG Rm.), sheet 7/7


ENGINEERING DESIGN BASIS(GENERAL CIVIL)

0001-01-10-03-001Page 1 of 9


ENGINEERING DESIGN BASIS (GENERAL CIVIL)

SPUR LINES OF CHAINSA JHAJJAR PIPE LINE



0001-01-10-03-001Page 2 of 9


CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 OVERALL PLOT PLAN

4.0 FENCING

5.0 SITE GRADING

6.0 ROADS & PAVEMENTS AND SITE FINISH

7.0 STORM WATER DRAINAGE

8.0 PITCHING

9.0 WATER SUPPLY

10.0 SEWERS & DISPOSAL

11.0 CONTROL ROOM SAFETY

12.0 FIRE PROTECTION SYSTEM



0001-01-10-03-001Page 3 of 9


1.0 SCOPE

1.1 This document covers engineering design basis for General Civil works such as site grading, fencing, roads, pavements, storm water drainage, water supply, waste collection & disposal system for Despatch terminal (DT), Sectionalising Valve (SV) stations, Intermediate Pigging stations (IP), Tap-off Points (TOP) etc.


2.1 Civil works & Roads: Indian Standards (IS) and Indian Road Congress (IRC) Codes

2.2 Water services: Manual on water supply and treatment (Published by Ministry of works and housing, Delhi)

2.3 Sanitary collection: Manual on sewerage and services sewage treatment. Published by Ministry of works and housing, Delhi)

2.4 OISD-STD-117 (Fire Protection Facilities for Petroleum Depots and Terminals and Pipeline installations). OISD-STD-118 (Layout for Oil and Gas Installation) OISD - 163 (Process Control Room Safety) For Blast resistant Control room

2.5 IS Codes for Fire Fighting Equipments.

2.6 NFPA Codes for Clean Agent and CO2 system.

2.7 IS codes for various civil works.

3.0 OVERALL PLOT PLAN

3.1 The Overall Plot Plan shall be developed based on good engineering practice & meeting requirement of statutory bodies.

3.2 Additionally the Overall Plot Plan shall also meet the requirement of OISD norms.

3.3 The various statutory approvals shall be obtained with the Owner’s assistance as and when required.

4.0 FENCING

4.1 Protection of land acquisition limit.



0001-01-10-03-001Page 4 of 9


4.1.1 Intermediate Pipeline installation coming on route i.e. SV, IP, and TOP etc.

- 1.5m high chain link fencing with additional 0.5m high barbed wire fencing over 0.5m high Brick masonry wall.

4.1.2 Receipt Terminal and Despatch Terminal

- 1.5m high chain link fencing (for installation within existing - installation) over 0.5m high Brick masonry wall. - 2m high chain link fencing with additional 0.5m high barbed wire fencing (for isolated installation) over 0.5m high Brick masonry wall.

5.0 SITE GRADING

5.1 All the tree roots and vegetation shall be grubbed up minimum 150 mm and removed from site.

5.2 The grading of the area shall be done by cutting and filling with the following:

a. Cutting area : Thoroughly rolled and compacted.

b. Filling area

- Other than Road: Compacted in layers not exceeding 30 cm. to achieve min.

- 90% of max. Dry density (conforming to Indian Standard (IS)-2720, Part-VII ).

- - For Roads: Compacted in layers not exceeding 20 cm. to achieve min. 90% of max. Dry density (conforming to IS:2720, part-VIII and GAIL standard specification no. 6-65-0018).

5.3 Plant Finished Grade Level (FGL):

5.3.1 New Site: To be kept 150 to 300mm above the nearby metalled road level and may vary as per site requirement for new stations/locations.

5.3.2 Existing sites: To be maintained same as FGL for existing stations.

5.4 Slope in graded areas

5.4.1 General site grading : 1 in 500



0001-01-10-03-001Page 5 of 9


5.4.2 During micro grading after completion of major construction (For road corridors) : 1 in 200

6.0 ROADS & PAVEMENTS AND SITE FINISH

6.1 ROADS

6.1.1 Road Width Location Road width i. Main Road and Access Road

a) All SV(s), IP(s) and TOP: 4.0 M wide bituminous road consisting of 3.0m wide carriage way and 0.5m wide shoulders on either side.

ii) Road inside Battery limit

a) All SV(s), IP(s) and TOP: 4.0m wide concrete road consisting of 3.0m wide carriage way and 0.5m wide shoulders on either side.

b) Receipt Terminal : 6.0 M wide concrete road consisting of 4.0m wide carriage way and 1.0m wide shoulders on either side.

iii) Foot path : 1.0 M wide of PCC

6.1.2 Camber : 1 in 50 (From road crown to edge of road)

6.1.3 Radius of curve : 8m / 12m / 15m

6.1.4 i) Bituminous Roads : Road shall be designed based on CBR (California Bearing Ratio) value of sub grade and msa for the proposed road as per IRC 37:2001

ii) Concrete Roads : Shall be designed as per IRC 58

6.1.5 Road finish : Bituminous carpet with seal coat / RCC

6.1.6 Finished road top level above FGL : 0.15 to 0.3 M

6.1.7 Road Gradient : 1 in 30 (in plain terrain)

: 1 in 20 (in hilly terrain)

6.2.0 PAVEMENTS

6.2.1 Material : Reinforced Cement Concrete (RCC)



0001-01-10-03-001Page 6 of 9


6.2.2 Pavement slope : 1 in 100

6.2.3 Type : Type-II( 150 mm thick RCC) as per GAIL Standard.

6.3.0 SITE FINISH

6.3.1 Site Finish shall be provided as follows:-

Site Finish Area

Concrete - Operating area & equipment area Asphalt - Road Approach to facilities - Footpath

7.0 STORM WATER DRAINAGE

7.1 Run off coefficient

Areas : Run-off coefficient

- Paved (Concrete)area : 1.0 - Bituminous : 0.9 - Compacted area : 0.7 - Open area : 0.4

7.2.0 Storm Water Drains

a. Type: Rectangular/trapezoidal type open drains.

b. Construction: Brick masonry with cement mortar

7.3.0 Culverts and Road Crossings

7.3.1 Pipe culverts: RCC pipes Class Non-pressure Class 3 (NP3) conforming to IS:458 (if clear cover over pipe is less than 600mm from road top, pipe shall be encased)

7.3.2 Box culverts : RCC construction

7.3.3 ERC/IRC crossings : Poly Vinyl Chloride (PVC) pipes Class 1 as per IS:4985 class embedded in concrete. Minimum pipe size 150 mm. (ERC/IRC - Electrical



0001-01-10-03-001Page 7 of 9


Instrumentation Road Crossing)

8.0 PITCHING

In filled up areas where level difference is more than 1.0m and upto 2.0mRR masonry pitching shall be provided on slopes for protection of earth against erosion and sliding all around station and approach road. The limit of pitching shall be within fenced area.

8.1 Side Slope : 1 in 1.5 (1 vertical : 1.5 horizontal)

8.2 Construction : 300 thk. RR masonry pitching 1:6 cement mortars at joints, flush pointing in 1:4 cement mortar

9.0 WATER SUPPLY

9.1.0 DRINKING WATER SYSTEM

(For Existing Terminal)

Drinking water system shall be extended by hooking up from existing drinking water system for drinking and toilet needs. Toilet shall be served from 1 Cu.m HDPE overhead water storage tank placed on top of the Control room / Sub-station building.

9.1.1 Rate of water supply : 135 lpcd (litres/per capita/day).

9.1.2 Source - To be extended from the existing drinking water network

9.1.3 System- Under ground main ring with Galvanized Iron (G.I.) pipes and fittings conforming to IS:1239 (Heavy).

9.1.4 Storage- Overhead HDPE water storage tank of Capacity 1.0 cu.m kept on individual building as per IS:12701

9.2.0 Water System (un-manned stations, i.e. SV and IP and isolated installation)

No Toilet facility and water supply system is considered for these stations.

10.0 SEWERS & DISPOSAL

10.1.0 General

10.1.1 Oily water sewer is not envisaged for any of the pipeline installation.



0001-01-10-03-001Page 8 of 9


10.1.2 Acidic waste collected from battery room of control building shall be neutralized by providing Neutralization Pit and neutralised water to be disposed in the nearest open storm water drains.

10.1.3 For dry batteries no neutralisation pit is required because there is no acid leakage.

10.2.0 Types of Sewers and Disposal Method

10.2.1 Acidic and Alkali seer : Neutralization Pit (and neutralized water discharge to nearby open drain).

10.2.2 Sanitary sewer: From individual toilet block disposal by means of providing septic tank and soak pit combination or septic tank anaerobic upflow filter combination

10.3.0 Cover for sewer line

10.3.1 Minimum cover over sewer line shall be 600 mm

10.3.2 If cushion over sewer pipe is less than 1200mm under roads, sewer shall be encased in cement concrete.

10.4.0 Manholes

10.4.1 Type and construction of manhole: Brick masonry

10.5.0 Material of Construction for sewers

10.5.1 Acidic and Alkali sewer: High Density Polyethylene (HDPE) as per IS: 4984

10.5.2 Manhole for acid / alkali sewer shall be provided with Acid/Alkali proof lining.

10.5.3 Sanitary sewer

a. Toilet block upto Inspection chamber: Heavy cast iron (HCI) pipes as per IS: 1729

b. Gravity main & lateral:

RCC Pressure Class 1 (P1) as per IS: 458

11.0 CONTROL ROOM SAFETY

Control room shall be sized and designed meeting requirements of OISD-163



0001-01-10-03-001Page 9 of 9


(Process Control Room Safety)

12.0 FIRE PROTECTION SYSTEM

12.1 The Fire Protection facilities shall be provided meeting the minimum the requirements of TAC for insurance purposes.

12.2 Additionally the requirements of OISD 117 as applicable shall be provided.

12.3 Adequate number of capacity 4.5kg CO2 type and capacity 10kg dry chemical powder portable extinguisher of capacity shall be provided at all Despatch Station, Receipt Station, SV(s) and IP(s) stations as per IS:2190.

Despatch / Receipt Terminal

A) The Firewater network comprising of A93A class piping with hydrants and monitors shall be provided by extending from the existing Firewater network (if available).

B) Protection system inside control room shall be clean agent system.

SV & IP Stations and R

A) Carbon dioxide flooding system as per NFPA-12 shall be provided in new control rooms of unmanned stations

DOCUMENT NO. REV-0 GAIL (INDIA) LTD NEW DELHI

SPECIFICATIONS OF ARCHITECTURAL FINISHES

(ARCHITECTURE) 0001-01-09-02-001Page 1 of 38


GAIL (INDIA) LIMITED


(ARCHITECTURE)

SPUR LINES OF CHAINSA JHAJJAR PIPELINE





1.0 SPECIFICATION OF ARCHITECTURAL FINISHES

1.1 GENERAL

1.1.1 For any aspect of item not covered in the document, the contractor shall follow instructions of the engineer-in-charge and execute the work as per relevant I.S codes/ recommendations of approved manufacturer/ good engineering practice without any cost or time implication to owner.

1.1.2 All materials shall be of first quality conforming to the specifications & IS or equivalent with IS marks and shall be obtained from the approved Manufacturer. The Contractor shall get the materials approved by the Engineer - In - Charge before ordering & procurement. The Contractor shall furnish necessary certificates etc. as asked by the Engineer - In - Charge. Further to that he shall get the materials tested from approved test house if asked by the Engineers - In - Charge & submit the test certificate at his own cost for which no extra payment shall be made to him. The Engineer - In - Charge shall have the right to reject all or any of the materials intended to be used and such materials shall be immediately removed from the site by the Contractor at his own cost without any claim for compensation etc. due to such rejection.

1.1.3 Workmanship shall be to the satisfaction of the Engineer - In - Charge. The contractor shall follow the specifications, relevant Codes & Manufacturer's guidelines for achieving desired level of workmanship as per specification & good engineering practice. Any executed work not conforming to the specification or not to the satisfaction of the Engineer -In-Charge shall be rectified by the Contractor as directed by the Engineer -In-Charge. No extra payment shall be made to the Contractor for such rectification. The contractor shall use only first quality approved material for all items.

1.1.4 All specifications of various finishing items include construction supervision; supply of all materials, labours, tools, tackles, scaffoldings etc. and are applicable for all heights, locations etc.

1.1.5 For specifications of construction water, sand, cement, bricks/ stone, aggregates etc. reference shall be made to the Civil/ Structural specifications attached in the bid document.

1.1.6 All specialised items of work (e.g. Aluminium Doors and Windows, Waterproofing, Underdeck and Overdeck Insulation, Precoated roof sheeting/ cladding, False ceiling, False Flooring, Partitioning and Panelling etc.) shall be got executed by the Contractor only through authorised applicators/ sub contractors of approved manufacturer/ vendor. The contractor shall submit list of such authorised





applicators/ sub contractors for approval before execution of such items.

1.2 FLOOR FINISHING

Reference shall be made to the following Indian Standards for any further information etc. not covered in the specification. In case of any conflict/contradiction, provision of specification shall override.

IS: 4971 Recommendations for selection of Industrial floor finishes. IS: 2114 Code of practice for laying in situ terrazzo floor finish. IS: 1237 Specification for Cement concrete flooring tiles. IS: 777 Specification for glazed earthenware wall tiles. IS: 2571 Code of practice for laying in situ cement concrete flooring. IS: 4631 Code of practice for laying of epoxy resin floor toppings. IS: 1443 Code of practice for laying and finishing of cement concrete floor tiles IS: 5491 Code of practice for laying in situ granolithic concrete floor topping. IS: 4441 Code of practice for use of silicate type Chemical resistant mortars. IS: 4443 Code of practice for use of resin type chemical resistant mortar. IS: 1196 Code of practice for laying Bitumen Mastic flooring.

1.2.1 Cement Concrete Flooring Cement concrete flooring shall be laid in average 25mm thickness over sub base (as per structural drawings/ specifications) and shall generally conform to IS:2571. The flooring shall be laid in panels and shall consist of:-

(A) 25 mm thick base course of M-15 grade cement concrete (with 6mm and down size stone aggregate) laid on the sub-base in panels (each panel not exceeding 1 Sq. Mtr.in area) in desired shape and pattern. The panels shall be bound by 3x20mm PVC/ Stainless Steel/5x20mm glass strips’ panel dividers; fixed in position with their top at proper level maintaining the required levels, slopes, linearity etc. as required. Base course shall be laid in alternate panels. Before laying the base course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area shall be applied (brushed) over the prepared sub base surface. Cement concrete shall be placed in position and beaten with trowel, including tamping and finishing smooth. Finishing of the surface shall follow immediately after completion of laying of base. The bed for flooring shall be prepared either level or sloped as per drawings and as instructed by Engineer-in-charge.

(B) Neat cement @ 2.75Kg. per Sq. Mtr. mixed with water to form a thick slurry applied over the base course (when the concrete is green), spread over the surface, pressed twice by means of iron floats; once when the slurry is applied and second time when the cement starts setting. The junction of floor with wall plaster, cladding, skirtingshall be rounded off uniformly upto a radius of 25mm unless otherwise mentioned. Each finished portion of floor, on completion shall be kept wet with ponding for a





minimum period of 7 days.

1.2.2 Cement Concrete Granolithic Flooring 1.2.3 Cement concrete granolithic flooring shall be laid in overall 40mm/ 50mm

thickness over sub base (as per structural drawings/ specifications) and shall generally conform to IS:5491 in workmanship. The flooring shall be laid in panels and shall consist of :-

(A) 25mm/ 35mm thick base Course (Under layer) of M-15 grade Concrete (shall generally conform to Civil structural specifications) laid over sub base in panels (each panel not exceeding 1 Sq. Mtr.in area) in desired shape and pattern. The panels shall be bound by 3x30/40mm PVC/ Stainless Steel/ 4x30/40mm glass strips’ panel dividers; fixed in position with their top at proper level maintaining the required levels, slopes, linearity etc. as required. Base course shall be laid in alternate panels. Before laying the base course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area shall be applied (brushed) over the prepared sub base surface. The borders of the panels shall have mitred joints at the corners of the room and intermediate joints shall be in straight line with panel joints. Cement concrete shall be placed in position and beaten with trowel and finished smooth. Beating shall cease as soon as surface is found covered with cream of mortar. Necessary slope shall be provided.

(B) 15mm thick Wearing top layer of cement mortar 1:3 (1 cement: 3 course sand by volume) which shall be laid within 15 minutes of laying the first layer. The cement and aggregates for the top layer shall be mixed dry. After mixing, sufficient quantity of washed sand and water shall be added to make the mix plastic but not flowing. The top and bottom layer shall firmly grip together. The base course shall be free of excessive moisture before starting the floor finishing. Use of dry cement, cement sand mixture sprinkled on the surface to stiffen the concrete or absorb excessive moisture shall not be permitted.

(C) While the concrete is still green, cement @ 2.75 kg per Sq.M of floor area shall be mixed with water to form a thick slurry and spread over the surface. It shall be pressed twice by means of iron floats, once when the slurry is applied and second time when the cement starts setting. The junction of floor with wall plaster, cladding, skirting shall be rounded off uniformly upto a radius of 25mm unless otherwise mentioned.

Each finished portion of floor, on completion shall be kept wet with ponding for a minimum period of 7 days.

1.2.3 Heavy Duty Flooring Heavy duty Cement concrete flooring shall be laid in overall 50mm thickness over sub

base (as per structural drawings/ specifications); shall generally conform to IS:5491 in workmanship. The flooring shall be laid in panels and shall consist of :-





(A) Base Course (Under layer) 35mm thick of cement concrete (1 cement : 1.5 coarse sand : 3.5 stone aggregates of 10mm to 6mm size by volume) laid over sub base in panels (each panel not exceeding 1 Sq. Mtr.in area) in desired shape and pattern. The panels shall be bound by 3x40mm PVC/ Stainless Steel/ 4x40mm glass strips’ panel dividers; fixed in position with their top at proper level maintaining the required levels, slopes, linearity etc. as required. Base course shall be laid in alternate panels. Before laying the base course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area shall be applied (brushed) over the prepared sub base surface. The borders of the panels shall have mitred joints at the corners of the room and intermediate joints shall be in straight line with panel joints. Cement concrete shall be placed in position and beaten with trowel and finished smooth. Beating shall cease as soon as surface is found covered with cream of mortar. Necessary slope shall be provided.

(B) Wearing Top layer/ Finishing layer shall be of cement, hardener and stone aggregate mix of 15mm thickness laid over the base course. Unless otherwise mentioned, one part of approved quality hardener and four parts of cement by weight shall be mixed dry. This dry mixture shall be mixed with stone grit of 6mm and down size in the ratio of 1 hardener and cement mixture : 2 stone grit by volume Just enough water shall then be added to the mix.

The mixture so obtained shall then be laid on the base course within 2 to 4 hours of latter's laying. It shall be firmly pressed into bottom concrete so as to have a good bond with it. After the starting of initial setting, the surface shall be finished smooth and true with steel floats.

Each finished portion of floor, on completion shall be kept wet with ponding for minimum period of 7 days.

1.2.4 Cement Plaster Skirting 1.2.5 Cement plaster skirting shall be laid with cement mortar (1 cement:3 coarse sand by

volume) shall be of 6mm/ 12mm/ 18mm thickness. The surface on which the skirting is to be applied shall be prepared and skirting shall be laid. The junction between flooring and wall shall be rounded off to a radius of 25mm if not otherwise mentioned. While the mortar is still green, cement @ 2.75Kg per square metre shall be mixed with water to form a thick slurry and applied over the mortar. It shall be pressed twice by means of iron floats, once when the slurry is applied and second time when the cement starts setting. The flooring shall be cured for 7 days.

1.2.6 Terrazzo Tiles Flooring

Terrazzo tiles Flooring shall be laid in minimum 40mm overall thickness over sub base (as per structural drawings/ specifications); shall generally conform in all respects to IS-





1237. The tiles shall be precast hydraulically pressed (factory made) of minimum 22 mm thickness, made with 10mm down size stone aggregates, white & ordinary cement mix (1 white cement : 6 ordinary cement by volume) and pigments conforming to IS:2114. Table1. Pigments to be admixed with mortar or for grouting the joints shall conform to Table -1 of IS: 2114. The tiles shall be laid on a bed of 18mm thick cement mortar 1:4 (1 cement : 4 course sand by volume) for flooring and 1:3 (1 cement : 3 course sand by volume) for skirting (which shall normally be 125mm high unless specified otherwise) .The base on which tiles are to be laid shall be cleaned of all dust, dirt and properly wetted by applying neat cement slurry @ 2.75 kg. of cement per Sq.M. of area without allowing water pools. The tiles shall be laid on a bed of 18mm thick cement mortar 1:4 (1 cement : 4 course sand by volume) for flooring and 1:3 (1 cement : 3 course sand by volume) for skirting (which shall normally be 125mm high unless specified otherwise) .The base on which tiles are to be laid shall be cleaned of all dust, dirt and properly wetted by applying neat cement slurry @ 2.75 kg. of cement per Sq.M. of area without allowing water pools. Cut tiles of uniform sizes shall be laid along periphery, if necessary. Neat cement slurry @ 4.4 kg. of cement per Sq.M. shall be spread over the mortar bed for laying 20 tiles at a time. The tiles shall then be fixed in this grout one after the other, each tile being gently tapped and properly bedded in line and level. The joints shall not exceed 1.5mm in width. After the day's work, the excesscement slurry on top and the joints shall be cleaned with broom stick and washed before the slurry sets hard. Next day, the joints shall be filled with the cement grout to match the shade of the tile. Tiles along the periphery shall be continued by average 12 mm under the wall plaster, skirting or dado.

For skirting/ dado/ risers on the brick masonry wall, the joints shall be raked out to a depth of at least 15mm while the masonry is being laid. In case of concrete work, the surface shall be hauled and roughened with wire brushes. The wall surface shall be uniformly and evenly covered with backing of cement mortar 1:3 (1 cement : 3 coarse sand by volume) of minimum 12mm thickness. Before hardening of the cushioning mortar, back of each tile shall be covered with a neat layer of cement slurry @ 4.4 kg of cement per Sq.M. and edges with white cement with or without pigment to match the shade of tiles and the tiles then shall be pressed on the backing and tapped.

The tiles shall be corrected to proper planes with joints truly vertical in required pattern and butt jointed. The fixing shall be done from bottom upward. The top of skirting and dado shall be truly horizontal.

Grinding shall be commenced after the joints are properly set. Grinding shall be done by machines except for skirting and small areas. First grinding shall be done with Carborundum stones of 48 to 60 grade grit fitted in the machine. Water shall be properly used during grinding. When the chips show up and the floor has been uniformly rubbed, it shall be cleaned with water baring all pin holes. It shall then be covered with a thin coat of grey/white cement mixed with pigments to match with colour of the flooring. This grout shall be kept moist for a week. Thereafter the second





grinding shall be started with Carborundum stone of 120 grit. Grinding and curing shall follow again. Final grinding shall be with Carborundum of grade 220 to 350 grit using water in abundance. The floor shall be washed clean with water, oxalic acid powder shall then be dusted at 35 gms/sq. m. on the surface rubbed with machine fitted hessian bobs or rubbed hard with woolen rags. The floor shall then be washed clean and dried with a soft cloth or linen. If any tile is disturbed or damaged, it shall be refitted or replaced and properly jointed and polished.

1.2.6 Tile Work (Glazed/ Ceramic)

Glazed vitreous tiles shall conform to IS: 777. Ceramic tiles for flooring shall be matt finished and non slip type. All tiles shall be decorative type of approved shade, pattern, texture and design and of approved manufacturer. . The sizes of the ceramic tiles shall generally be 300x300x8mm for flooring and 100x200x6mm or 300x200x6mm for walls (dado). Pigments to be admixed with mortar for grouting the joints shall conform to Table -1 of IS: 2114. The tiles shall be laid over a coating of approved neoprene based adhesive (as per manufacturer’s specification) laid on base floor/ wall plaster. The joints of the tiles shall be flush pointed with cement paste (white cement and pigment conforming to IS:2114, Table-l) matching the shade of colours. The tile work shall be suitably cured.

1.2.7 Acid Resistant Tiles Flooring The tiles shall be vitrified ceramic tiles of approved size as per approved manufacturer’s specification and shall be homogeneous having following properties :-S.No. Property Values Norms 1 Water Absorptions ±0.5% ASTM C 3732 Scratch Resistance > 6 ASTM C 373 3 Chemical Resistance Unaffected ASTM C 650 4 Abrasion Resistance > 100 ASTM C 5015 Breaking strength 1400 kg/sq.cm ASTM C 648 6 Density > 2.0 Gm/CC

The base course for flooring shall be Cement Concrete flooring/ Cement Concrete granolithic flooring and for skirting/ dado it shall be Cement plaster and background surface shall be prepared as per clause no. 5.2 and IS:4443. Tiles shall be fixed on the prepared surface over a bitumen priming layer, bitumen mastic layer and resin type chemical resistant mortar. The bitumen shall conform to IS:702 and laying of bitumen mastic shall conform to 1S:1196. Joints shall be allowed to set for 24 hours. The floor shall then be washed as per manufacturer's specifications to totally remove all marks from tile surface.

1.2.7 Decorative vitrified porcelain flooring

1.2.8 The tiles shall be vitrified porcelain tiles , mirror polished ,of approved size as per





approved manufacturer’s specification and shall be homogeneous having properties similar to vitrified ceramic acid resistant tiles. The fixing of tiles shall be similar to ceramic tiles.

1.2.9 Kota Stone Finish

Kota Stone Flooring shall be laid in minimum 40mm overall thickness over sub base (as per structural drawings/ specifications). The Kota Stone slabs shall be of selected quality and shade, hard, sound, dense, homogenous in texture, free from cracks, decay, weathering and flakes. These shall be machine cut to the requisite size and thickness and chisel dressed. For flooring and skirting/ dado/ riser the thickness of the stone slabs shall be 25mm and 18mm respectively. Skirting shall normally be 125mm high unless specified otherwise.

The slabs shall have smooth top (exposed) face before being laid. Before starting the work, the contractor shall get the samples of slabs approved by Engineer-in-charge. Each slab shall be machine cut to the required size and shape and fine chisel dressed at all edges to full depth and machine rubbed to a smooth surface finish. All angles and edges of the slabs shall be true square and free from chippings giving a plane and smooth surface.

Preparation of base shall include making it rough, cleaning thoroughly and applying neat cement slurry @ 2.75 kg of cement per Sq.M. of area to receive the mortar. Cement mortar shall be 15mm thick !:6 (1 cement: 6 Coarse sand by volume) for flooring and 12mm thick 1:3 (1 cement: 6 Coarse sand by volume) for skirting. The mortar shall be laid for fixing one slab at a time. The slab shall be washed clean before laying. It shall be laid over cement mortar bedding on top, pressed, tapped gently to bring it in level. It shall be then lifted and laid aside. Top surface of the mortar then shall be corrected by adding fresh mortar at hollows and depressions. The mortar then shall be allowed to harden and cement slurry of honey like consistency @ 4.4.kg of cement per Sq. M shall be spread over the mortar. The edges of the slabs shall be buttered with white cement (with necessary pigment) grout to match the shade of the slabs. The slabs shall then be gently placed in position and tapped with wooden mallets till it is properly bedded in level. The joints shall be as fine as possible. Surplus cement on the surface of the slab shall be removed. The slabs in flooring shall continue for not less than 10 mm under the plaster/skirting. The finished surface shall be true to levels and slopes as instructed by the Engineer-in-Charge. The slabs shall be laid in patterns as per drawings and size shall not be less than 400 x 275mm, which shall be uniform. Cut size may be used along periphery as required. Curing, as required shall be done.

Preparation of base shall include making it rough, cleaning thoroughly and applying neat cement slurry @ 2.75 kg of cement per Sq.M. of area to receive the mortar. Cement mortar shall be 15mm thick !:6 (1 cement: 6 Coarse sand by volume) for flooring and 12mm thick 1:3 (1 cement: 6 Coarse sand by volume) for skirting. The





mortar shall be laid for fixing one slab at a time. The slab shall be washed clean before laying. It shall be laid over cement mortar bedding on top, pressed, tapped gently to bring it in level. It shall be then lifted and laid aside. Top surface of the mortar then shall be corrected by adding fresh mortar at hollows and depressions. The mortar then shall be allowed to harden and cement slurry of honey like consistency @ 4.4.kg of cement per Sq. M shall be spread over the mortar. The edges of the slabs shall be buttered with white cement (with necessary pigment) grout to match the shade of theslabs. The slabs shall then be gently placed in position and tapped with wooden mallets till it is properly bedded in level. The joints shall be as fine as possible. Surplus cement on the surface of the slab shall be removed. The slabs in flooring shall continue for not less than 10 mm under the plaster/skirting. The finished surface shall be true to levels and slopes as instructed by the Engineer-in-Charge. The slabs shall be laid in patterns as per drawings and size shall not be less than 400 x 275mm, which shall be uniform. Cut size may be used along periphery as required. Curing, as required shall be done. This grout shall be kept moist for a week. Thereafter the second grinding shall be started with Carborundum stone of 120 grit. Grinding and curing shall follow again. Final grinding shall be with Carborundum of grade 220 to 350 grit using water in abundance. The floor shall be washed clean with water, oxalic acid powder shall then be dusted at 35 gms/sq. m. on the surface rubbed with machine fitted hessian bobs or rubbed hard with woollen rags. The floor shall then be washed clean and dried with a soft cloth or linen. If any stone slab is disturbed or damaged, it shall be refitted or replaced and properly jointed and polished.

1.3 DOORS AND WINDOWS

Reference shall be made to the following Indian Standards for further information etc. not covered in the specification. In case of any conflict/contradiction the provisions of the specification shall override.

IS 6248 : Specifications for metal rolling shutters and rolling grill. IS 1081 : Code of practice for fixing and glazing of metal (steel and Aluminium) doors, windows and ventilators.

IS 4351 : Specifications for steel door frames. IS 1948 : Specifications for Aluminum doors, windows & ventilators. IS 1361 : Specifications for steel windows for Industrial buildings.

IS 1038 : Specifications for steel doors, windows and ventilators. IS 7452 : Specification for hot rolled steel sections for doors, windows

and ventilators. IS 2835 : Flat transparent sheet glass. IS 2553 : Safety glass.

1.3.1 Aluminum Glazed Doors, Windows And Ventilators Aluminium glazed doors/ windows/ ventilators shall be made of extruded tubular anodised ( 25 microns )/ electrostatically powder coated (min. 30





microns) Aluminium sections conforming to IS : 733 and IS : 1285 of “INDAL“ or approved equivalent manufacturer with 5.5mm thick transparent sheet glass conforming to IS : 2835 ( wt. : 7.2Kg/ Sq.M ) / 6.3 mm laminated safety glass conforming to I.S.: 2553 fixed with rubber lining or EPDM gasket and extruded anodised aluminum beading. Extruded aluminium sections used for various application shall have minimum weights as under.

A. Doors 1. For fixed frames I) Sides & Top members : 1.975 Kg/RM ii) Lock rail : 1.594 Kg/RM iii) Bottom rail : 3.495 Kg/RM 2. For shutter frame : 1.202 Kg/RM 3. Glazing clips ( beading ) : 0.182 Kg/RM

B. Window/Ventilator ]

1. For fixed frames : 0.639 Kg/RM 2. For shutter frame : 0.636 Kg/RM 3. Glazing clips ( beading ) : 0.165 Kg/RM 4. Coupling bars : 0.933 Kg/RM 5. Member for fixing the frame : 0.463 Kg/RM

The frames shall be fixed to masonry by means of Aluminum lugs fixed to the frame by counter sunk brass machine screws and grouted with M-15 grade concrete in minimum150 x 150 x 50 mm sized hole in the masonry. In case of RCC, the frames shall be fixed with 12mm dia dash fasteners in case of concrete. Any steel item coming in contact with Aluminum shall be galvanized.

Aluminum glazed doors shall be provided with cup pivots ( of aluminum alloy conforming to IS designation NS-4 of IS 737 and IS designation of A-5-M of IS : 617) riveted to outer and inner frames to permit to swing through an angle of 85 degree. Following hardware shall be provided for the doors.

1. Heavy duty & hydraulically operated double or single action adjustable door closer conforming to IS : 6315

2. 250mm and 150mm long, 10mm dia Aluminum tower bolts as per IS : 204 one each for each shutter.

3. Brass body 6 lever mortice lock as per IS : 2209

4. Aluminum door handle for each shutter for each side.





(Note : All Aluminium fittings/ fixtures shall be of same finish as that of door frame & shutter)

Side hung window shutters shall be fixed to the frame with Aluminum alloy friction hinges and shall be complete in all respects including accessories, fittings fixtures of same finish as that of window frame & shutter, handles of cast aluminum conforming to IS designation A-5-M of IS : 617 mounted on a handle plate riveted to opening frames, Aluminum Tower ,bolts, peg stays for ventilators etc. Wherever specified, decorative aluminium safety grills of approved design shall be provided which shall be screwed to the main frame.

1.3.2 Steel Doors Steel doors shall consist of :

(A) Pressed steel door frame of overall 125x 65mm size conforming to IS : 4351 and made of 16 SWG pressed steel sheet bent to required shape using bending machine to form solid/ true mitred edges/ corners, stiffened with 50 x 5mm thick MS flat spacers welded to the frame facing the wall/ column @ 600mm c/c maximum vertical spacing. The frame shall be fixed to the masonry by means of 300 x 25 x 6 mm thick MS hold fast welded to the spacer and grouted with M-15 concrete in minimum 350 x 100 x 100 mm sized hole in the masonry. In case of concrete, the frames shall be fixed by 96mm long, 12 mm dia metallic counter sunk type dash fasteners through the frame & spacers. Provision for hinges, locking arrangement and other hardware shall be provided in the frame by machine cutting of required size cutouts in the frame and welding/ screwing to 3 mm thick MS pad plates already welded over the cutout from behind. The frame shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and then finished with 2 or more coats of approved quality synthetic enamel paint of approved shade over a priming coat of approved red oxide zinc chromate primer/ approved shade electrostatically powder coated (minimum 30 microns). The hollow frame shall be packed with PCC to fill the cavity without gap.

(B) Pressed steel door shutter shall be made with 18 gauge steel sheets formed by machine bending in the form of hollow box ( overall 40mm thick ) welded at meeting of the sheets with pad plate of 3mm thick MS flat all along the perimeter. The shutter shall be braced with channel shaped 35mm wide horizontal stiffeners by folding 16 gauge MS sheets @ 500mm c/c fixed by flush riveting. 3mm thick MS pad plates shall be welded inside at required locations for fixing of hardware. The cavity inside shall be packed with rigid PU foam/ phenolic foam or glass wool insulation to fill into the box cavity without gap.

For double shutters, an MS angle ( 25x 45x 3mm thick ) shall be welded to one of the shutter providing a minimum 25mm wide rebate for the other shutter at the meeting point.





The shutters shall be fixed to the door frame by means of heavy duty MS butt hinges of 150mm size conforming to IS : 1341 @ 500mm c/c maximum. Each door shutter shall have following accessories.

1. Spring loaded pressure die cast zinc alloy door stopper.

2. Heavy duty, MS aldrop 400mm long for double shutter & 300mm long for single shutter.

3. 12mm dia, 300mm long pressure die cast zinc alloy handles on both sides.

4. 12mm dia, 250mm long MS tower bolt at top and 12 mm dia 150mm long at bottom.

5. 3- way spring loaded locking & latching system.

6. 150mm x 300mm Vision panel with 16 gauge MS beading bent to “ Z” shape & 4mm thick plain glass conforming to IS : 2853.

The entire shutter including all accessories, fittings & fixtures etc. shall be painted with 2 or more coats of approved quality synthetic enamel paint of approved shade over a coat of approved quality red oxide zinc chromate primer/ approved shade electrostatically powder coated (minimum 30 microns)

1.3.3 Wooden Flush Doors

Flush doors shall consist of:-

(A) Pressed steel door frame of overall 125x 65mm size conforming to IS : 4351 and made of 16 SWG pressed steel sheet bent to required shape using bending machine to form solid/ true mitred edges/ corners, stiffened with 50 x 5mm thick MS flat spacers welded to the frame facing the wall/column @ 600mm c/c maximum vertical spacing. The frame shall be fixed to the masonry by means of 300 x 25 x 6 mm thick MS hold fast welded to the spacer and grouted with M-15 concrete in minimum 350 x 100 x 100 mm sized hole in the masonry. In case of concrete, the frames shall be fixed by 96mm long, 12 mm dia metallic counter sunk type dash fasteners through the frame & spacers. Provision for hinges, locking arrangement and other hardware shall be provided in the frame by machine cutting of required size cutouts in the frame and welding/ screwing to 3 mm thick MS pad plates already welded over the cutout from behind. The frame shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and then finished with 2 or more coats of approved quality synthetic enamel paint of approved





shade over a priming coat of approved red oxide zinc chromate primer/ approved shade electrostatically powder coated (minimum 30 microns).

The hollow frame shall be packed with PCC to fill the cavity without gap.

(B) Flush door shutters shall be factory made and overall 35mm thick consisting of solid core block board bonded with phenol formaldehyde synthetic resin conforming to IS : 848. The shutters shall be faced on both sides with 3 mm thick commercial plywood or teak veneering conforming to IS : 303, BS : 476 part-7. 35 x 20mm second class Teakwood lipping shall be provided all around the shutter by means of approved quality neoprene based adhesive and nailing @ 300mm (maximum). ). Commercial plywood along with the lipping shall be painted with 2 or more coats of approved quality & shade synthetic enamel paint over a coat of approved primer. Teakwood veneering along with lipping shall be French polished. The shutters shall be fixed to the frame by means of 125mm long MS butt hinges conforming to IS : 1341 @ 600mm c/c maximum

. Teakwood used for lipping, beading etc. shall be second class Indian teakwood (conforming to IS: 4021) of good quality, well seasoned and free from defects such as cracks, dead knots, sapwood etc. and shall be with no individual hard & sound knots more than 15 Sq.CM in area and the aggregate area of such knots not exceeding 2% of area of the piece. The wood shall be fairly closed grains having not less than 2 growth rings per Cm. Width in cross section.

Following hardware of approved quality and shade shall be provided in each shutter:-

1. Heavy duty, overhead hydraulically operated door closer conforming to IS : 3564.

2 . Anodised aluminum tower bolts as per IS : 204, 10mm dia 250mm long (at top) and 150mm long (at bottom), one each for each shutter on either side.

3. Brass body 6 lever mortice lock as per IS : 2209 including pair of handles of pressure die cast zinc alloy (satin finished )

4. 3mm thick plastic kick/push plate (150mm high at bottom for entire width & 200mm x 100mm at handle location).

5. Zinc alloy pressure die cast chromium plated spring loaded door stopper with heavy duty rubber shoes.

6. 150mm x 300mm Vision panel with of 4mm thick plain glass conforming to IS : 2853 fixed with second class Teakwood beading (not for toilet doors).

1.3.4 Steel Windows





Steel windows, ventilators shall in general conform to IS:1081/ IS:1038 and IS:7452. Rolled steel sections for the fabrication of steel windows, ventilators shall conform to IS:7452. Glass panels for glazing purpose shall be 4mm thick (wt. 7.2 kg/ Sq.M)/ 5.5mm thick transparent sheet glass conforming to IS: 2835/ 5.5mm thick wired glass conforming to IS:5437/ 5.5mm thick toughened glass conforming to IS:5437.The profile and type of windows, ventilators (glazed, partly glazed/ 1ouvred, side hung/ top hung/ fixed shutter, composite) shall be as per approved drawings.

The frames shall be constructed of sections cut to size and mitred. Corners shall be welded to form a fused welded joint. Process of welding shall be flash butt welding. The welded joints shall be grinded to square and flat edges. Where larger units are to be formed by coupling individual units, the mullions, transoms shall be bedded in mastic to ensure weather tightness.

Mastic shall be applied liberally to the channels of the outside frame sections before assembly, and the two units being coupled shall be drawn together tight with clamps, the mastic being squeezed out and cut off neatly when the units shall be screwed together tight. Where fixed glazing units are placed over openable units a push fit weather bar shall be provided. Before glazing, all opening parts shall be checked for their operational smoothness. The frame shall be completely cleaned and bedding putty shall be placed in the rebate before glazing. Glass then shall be cushioned into the bedding and shall be fronted with front putty in a manner so as to enable the painting to be done upto the sight line. The back putty oozing out over the glazing rebate shall be cut off square and smoothed down. For panels exceeding 600 x 300 mm in size, glass shall be secured by special glazing clips inserted in holes already provided in the steel sections, before applying the front putty.

For glazing of very large areas, rust proof steel beading with mitred corners shall be provided with screws @ 10 cm. from each corner and @ 20 cm. apart from each other. Putty shall be provided to the face of the bead in contact with glass, in addition to back putty. Side hung shutters shall be connected to the frame by means of friction hinges. The handle for side hung shutters shall be of pressed brass mounted on a steel handle plate welded to the opening shutter frame and shall not be removable easily after glazing. The handle shall have a two point nose which shall engage with a brass striking plate on the fixed frame in a slightly open as well as in a fixed position. In case of fixing with masonry, holes for fixing the lugs/hold fasts shall be cut at required locations. In case of concrete or stone, the frames shall be fixed by means of dash fasteners. In case of masonry, the lugs shall be grouted in the holes with cement concrete, M-15 Grade when fixing to steel work, mastic shall be applied to the sill of the opening and the unit shall be placed on it with the jambs and head buttered with mastic and the unit shall be fixed with special fixing dips or with nuts and bolts. All the steel surfaces shall be thoroughly cleaned free of rust, mill scale, dirt, oil etc. by sand and shot blasting and then painted with 2 or more coats of approved quality & shade





synthetic enamel paint over a coat of approved quality red oxide zinc chromate primer.

1.3.5.1 Steel Rolling Shutter

MS rolling shutters shall conform to IS : 6248 and shall be constructed with interlocking lath sections formed out of cold rolled 0.9mm thick, 80mm wide steel strips for shutter width upto 3.5 M , or 1.25mm thick, 80mm wide steel strips for shutter width beyond 3.5 M, jointless MS channel section of 3.15mm thickness for guide, MS girders & bottom rail, shutter suspension stud with pully & cage, top rolling springs, locking arrangement etc. all complete as per manufacturer’s approved drawings. The entire shutter including all accessories shall be painted with 2 or more coats of approved quality & shade synthetic enamel paint over a coat of approved quality red oxide zinc chromate primer. All the damaged surfaces of wall, columns, plastering etc. shall be made good.

Rolling shutters shall be mechanically operated type, when the size of the shutter exceeds 9 Sq.M and shall be complete with all accessories for mechanical operation as per approved manufacturer’s design & drawings. Wherever specified the Rolling shutters shall be electrically operated; complete with all accessories, electrical motor, cabling etc. as per approved manufacturer’s design and drawings

Wherever specified the Rolling shutters shall be grill type or partly grill & partly solid type or fully solid type depending on ventilation requirement.

1.4. PLASTERING

1.4.1 Plain Cement Plaster

Plain Cement plaster shall be provided in following thicknesses :

A. 12mm thick in 1:6 cement mortar for all plumb of the internal masonry walls & RCC Columns coming in line (flush) with this side of wall.

B. 15mm thick in 1:6 cement mortar for rough side of internal masonry walls RCC Columnscoming in line (flush) with this side of wall.

C. 18mm thick cement plaster in 1:6 cement mortar for all external surfaces as indicated. Wherever specified, the external plastering shall be with waterproof compound (cement

mortar mixed with approved acrylic waterproof compound @ 1 Kg. per 50 Kg. of cement).

D. 6mm thick in 1:4 cement mortar for all RCC ceiling, beam etc. However if the undulation in ceiling is beyond 6mm thick plaster, extra thickness of plaster shall be applied without any extra cost to give a smooth and fair surface to the satisfaction of Engineer-





In-Charge.

The plastering work shall include preparation of background surface which shall consist of cleaning of all dust, loose mortar droppings, traces of algae, efflorescence or any other foreign matter by water or by brushing, roughening up of smooth surfaces by wire brushing or hacking, trimming of projections whenever necessary. The surface shall be washed off and well wetted before applying the plaster. The plaster shall be kept wet for a period of 7 days. During this period the plaster shall be suitably protected from all damages at the contractor's expense by such means as approved by the Engineer-in-charge. The date of execution of plastering shall be marked on the plastering to ensure the proper duration of curing. The plastering shall include all scaffolding, damage rectification etc. complete.

1.4.2 Sand Face Plaster

1.4.3 Sand face plaster shall consist of 13mm thick 1:4 cement mortar ( 1 cement : 4 coarse sand by volume ) underlayer and top layer of 7mm thick 1:2 cement mortar ( 1 cement : 2 coarse sand by volume ) Preparation of background surface, workmanship, curing etc. shall be same as plain cement plaster. The first layer shall be started from top floor and carried downwards. Before the first layer hardens, surface of it shall be roughened up by edges of wooden tapers and close dents shall be made on the surface. The subsequent layer shall be applied over the first layer after the first layer has been allowed to set for 3-5 days depending on weather conditions. The surface shall not be allowed to dry during this period.

All the brick/stone masonry and RCC joints shall be provided with 20 gauge chicken wire mesh stretched tight and fixed with G.I. “U” type nails before plastering.20mm x 10mm grooves ( horizontal/ vertical ) shall be provided in perfect straight line & plumb in plastering as per drawings and instructions of Engineer- In - Charge.

Curing shall be started 24 hours after finishing the plaster. The plaster shall be kept wet for a period of 7 days. During this period the plaster shall be suitably protected from all damages at the contractor's expense by such means as approved by the Engineer-in-charge. The date of execution of plastering shall be marked on the plastering to ensure the proper duration of curing.

The plastering shall include all scaffolding, damage rectification etc. complete.

1.5 ROOF TREATMENT/ WATERPROOF COATING

1.5.1 Polyurethane (PU) Based Waterproofing The PU based roof treatment/ waterproofing-cum-terracing shall consist of:-





(A) The preparation of the surface shall include thorough cleaning of roof surface with a wire brush and removal of all foreign matter etc. Well defined cracks on the surface shall be cut to "V" section, cleaned and filled up with a paste of Polyurethane based crack filling compound and white cement in a ratio of 1:2.

(B) Application of one component urethane prepolymers based elestomeric membrane with Iso-cyanurate for rendering flame resistant characteristic.

The coating shall have physical features like high resistance to impact, abrasion and cracking, superior tensile strength (8 Kg/ Sq.Cm after 4 weeks at ambient temperature) and perfectly smooth, dust free glossy finish retained at least upto 3 years. It should also be resistant to acid, alkalies and have a very low water absorption rate (0.5 % maximum at ambient temperature after 7 days).

The one component system shall be in two or more coats of urethane based high solid content elastomeric membrane (having high viscosity to give a high build film) at approx. coverage of 0.5 kg per sq.m each coat. Before the membrane coatings a coat of urethane primer EMP at a coverage of 8 Sq.M per litre by brush shall be applied to achieve overall thickness of 1.5 mm (+ or -15%) as per ASTM C-836/898. Membrane coatings shall be applied after the priming coat is cured to a slightly tacky film (in 2-4 hours) but not later than 48 hours. If delay exceeds this, a fresh coat of urethane primer shall be applied. The second membrane coating shall be applied within 24 hours after the first coating becomes touch dry in 12 to 48 hours (in some conditions this might be delayed) of its application. Subsequent membrane coating, if required shall be applied similarly. Both primer and PU coatings shall be continued to be applied over parapet wall upto 150mm.

The PU coating shall be continued up the parapets/walls for a minimum of 150mm over the finished roof surface. It shall be continued into rain water pipes by at least 100mm. The final coat of PU when tacky shall be sprinkled with 300 micron layer of clean sand.

(C) Plain Cement Concrete screed laid to slope of 1:100 ( Steeper slopes shall be adopted for high rain fall regions) in 1:3:6 concrete mix. Minimum thickness of screed shall be

30mm at rain water outlet points. Screed shall be laid only after all the PU coatings are laid and fully cured and checked for the water tightness.

(D) Finishing protective layer of 25 mm thk. P.C.C.(1:2:4) in panels of maximum size 1200mm x 1200mm chequered finish with 24 SWG chicken wiremesh interposed in between finished smooth. The joints between panels shall be sealed with suitable urethane based elastomeric compound as per manufacturer’s specifications.

(E) Fillets of 75 mm radius with P.C.C. (1:2:4) at junctions of horizontal and vertical surfaces shall be provided and finished smooth.





(F) 450mm x 450mm khuras (rain water collecting pits) in 1:2:4 cement concrete at all outlets, levelled down by min. 25mm, finishing, curing etc. all complete.

(Note: The Contractor shall furnish 10 years performance guarantee for waterproofing.)

1.5.2 Polyurethane (PU) Based Overdeck Insulation with Waterproofing This shall consist of:-

(A) The preparation of the surface which shall include thorough cleaning of roof surface with a wire brush and removal of all foreign matter etc. Well defined cracks on the surface shall be cut to "V" section, cleaned and filled up with a paste of 2 component Polyurethane based crack filling compound and white cement in a ratio of 1:2.

(B) Application of a coat of urethane primer EMP at a coverage of 8 Sq.M per litre by brush.

(C) 50mm thick rigid polyurethane foam of density 40-45 Kg./ Cu. M. and thermal conductivity of 0.019 K cal/ M/ Hr/ C shall be sprayed over entire fully prepared R.C.C. slab as per approved manufacturer’s specifications.

(D) One component urethane prepolymers based elastomeric membrane having physical features like high resistance to impact, abrasion and cracking, superior tensile strength (8 Kg/ Sq.Cm after 4 weeks at ambient temperature) and perfectly smooth, dust free glossy finish retained at least upto 3 years. It should also be resistant to acid, alkalies and have a very low water absorption rate (0.5 % maximum at ambient temperature after 7 days). The one component system shall be in two or more coats of urethane based high solid content elastomeric membrane (having high viscosity to give a high build film) at approx. coverage of 0.5 kg per Sq.M each coat. coatings to achieve overall thickness (Primer + Membrane coatings) of 1.5 mm (+ or - 15%) as per ASTM C-836/898. Membrane coatings shall be applied after the priming coat is cured to a slightly tacky film (in 2-4 hours) but not later than 48 hours. If delay exceeds this, a fresh coat of urethane primer shall be applied. The second membrane coating shall be applied within 24 hours after the first coating becomes touch dry in 12 to 48 hours (in some conditions this might be delayed) of its application. Subsequent membrane coating, if required shall be

applied similarly. Both primer and PU coatings shall be continued to be applied over parapet wall upto 150mm. Each coat shall be allowed to dry for minimum 12 hours before applying next coat. Care shall be taken for quick application after mixing the 2 pack primer in view of short pot life of the mix and shall be fully consumed within the stipulated period as per





Manufacturer's specification (maximum 60 minutes at 30 deg.C) The PU coating shall be continued up the parapets/walls for a minimum of 150mm over the finished roof surface. It shall be continued into rain water pipes by at least 100mm. The final coat of PU when tacky shall be sprinkled with 300 micron layer of clean sand.

(E) Plain Cement Concrete screed laid to slope of 1:100 ( Steeper slopes shall be adopted for high rain fall regions) in 1:3:6 concrete mix. Minimum thickness of screed shall be 30mm at rain water outlet points. Screed shall be laid only after all the PU coatings are laid and fully cured and checked for the water tightness.

(F) Finishing protective layer of 25 mm thk. P.C.C.(1:2:4) in panels of maximum size 1200mm x 1200mm chequered finish with 24 SWG chicken wiremesh interposed in between finished smooth. The joints between panels shall be sealed with suitable urethane based elastomeric compound as per manufacturer’s specifications.

(G) Fillets of 75 mm radius with P.C.C. (1:2:4) at junctions of horizontal and vertical surfaces shall be provided and finished smooth.

(H) 450mm x 450mm khuras (rain water collecting pits) in 1:2:4 cement concrete at all outlets, levelled down by min. 25mm, finishing, curing etc. all complete.

(Note: The Contractor shall furnish 10 years performance guarantee for overdeck Insulation and waterproofing.)

1.5.3 APP Bituminous membrane Water proofing

Material:

The water proofing membrane shall have a non-woven polyester membrane coated on both side with APP (Atactic polypropylene) modified bitumen. It shall have a Black finish with a very thin polyethylene foil on both sides It shall be in rolls of 1x10m for continuous laying on large lengths. When installed, it shall form an impervious, flexible blanket, which accepts normal structural movement without breaking or cracking.

Workmanship:

a) Preparation of surface:

The roof surface (or screed) shall be thoroughly cleaned with a wire brush and all foreign matter etc. shall be removed. Well-defined cracks on the surfaces shall be cut to a ‘V’ section, cleaned and filled up flush with a paste of filling compound and cement in the ratio of 1:2. The finished surface shall be perfectly dry and any dampness should be allowed to evaporate.

b) Laying:





The membrane shall be laid on the perfectly dry prepared surface by torching-on method with a gas torch. All joints shall have an overlap of 75mm which shall be torch sealed. The overlap shall be done in a manner, which does not hinder water flow along the roof slope. The membrane shall be finished with bituminous base aluminium paint.

The waterproofing shall be continued up to the parapet/wall for a minimum of 600mm over the finished roof surface. It shall be continued into rain water pipes by at least 100mm.

c) Cement Screed:

Plain cement concrete (1:2:4) of 25mm min. thickness with 24 SWG chicken wire mesh shall be laid to slope in panels not exceeding 6 m.sq. area per panel over the roof slab. The joints between panels shall be raked out neatly (after stipulated curing period) to a min. 6mm x 6mm V-groove and filled up with an approved quality sealant compound. Drain outlet shall be provided for all spouts/ rain water pipes by suitable rounding, filling and sloping of PCC. At the junction of the roof and parapet or any other vertical surface, a fillet of 75mm radius shall be formed in cement mortar (1 cement: 4 coarse sand).

The finished work shall be measured in M.Sq of area for the purpose of payment.

A guarantee of 10 years shall be provided by the manufacturer against the performance of the finished waterproof coating.

1.6 WHITE/ COLOUR WASHING, PAINTING, POLISHING ETC. Reference shall be made to the following Indian Standards for further information etc. not covered in the specification. In case of conflict/ contradictions provisions of the specification shall override. IS : 6278: Code of practice for white washing and colour washing. IS : 2395: Code of practice for painting concrete, masonry and plaster surfaces. IS : 712: Specification for building limes. IS : 55: Specification for Ultramarine blue for paints. IS : 63: Specification for whiting for paint and putty. IS : 5411: Specification for plastic Emulsion paint for interior use. IS : 2338: Code of practice for finishing of wood, and wood based materials. IS : 5410: Cement paint, colour as required. IS 2524: Code of practice for painting non ferrous metals in buildings. IS 384: Brushes, paints and varnishes, flat. IS 486: Brushes, sash, tool, for paints and varnishes. IS 110: Ready mixed paint, brushing, grey filler enamels for use over primers. IS 426: Paste filler for colour coats. IS 345: Wood filler, transparent liquid. IS 3585: Ready mixed paint, aluminium brushing priming water resistant for wood work. IS 426 : Paste filler for colour coats. IS 106: Ready mixed paint, brushing, priming for enamels, for use on metals.





All materials required for the execution of painting work shall be obtained direct from approved manufacturers and shall be brought to the site in makers drums, bags etc. with seals unbroken. In case of ready mixed paints, thinning if necessary, the brand of thinner shall be as per recommendations of the manufacturer. Paint shall be applied by brushing or spraying. Spray machine used may be of high pressure type or low pressure depending on the nature and location of work. The paint containers, when not used shall be kept close and free from air. After the finishing of work, the adjacent surfaces not intended to be washed/ distempered/painted/polished, shall be thoroughly cleaned of all paint patches and shall be finished in accordance with surface finishing of such surfaces.

1.6.1 White/ Colour Washing

White washing in general shall conform to IS:6278. Scaffolding shall be erected for white washing in such a way that no part of the scaffolding shall rest against the surface to be white/ colour washed. The surface shall be thoroughly cleaned of all dirt, dust, mortar dropping and other foreign matter before white wash is to be applied. Surfaces already white/colour washed shall be broomed down to remove all dust, dirt, loose scales of lime wash or other foreign matters. All damaged portions of the surface plaster shall be removed to full depth of plaster in rectangular patches and plastered again after raking the joints in masonry properly. Such portions shall be wetted and allowed to dry before any operation. All holes, cracks, patches etc. not exceeding 0.1 sq. m. in area shall be made good with material similar to that of the surface. Surfaces affected by efflorescence, moss, fungi, algae, lichen etc. shall be treated in accordance with IS: 2395. The fat lime conforming to IS: 712 shall be slaked at site and shall be mixed and stirred with about 5 litres of water for 1 kg. of unslaked lime to make thin cream. This shall be allowed to stand for a period of 24 hours and then shall be screened through a clean coarse cloth. 4 kg of gum dissolved in hot water shall be added to each cubic metre of lime cream. Approved quality ultramarine blue (for white wash) conforming to IS: 55 @ 3 gram per kg. of lime shall be added to the solution. The whole solution shall be stirred thoroughly before use. For colour washing sufficient quantity of colour wash enough for the complete job shall be prepared in one operation to avoid any difference in colour. Mineral colours of approved shade and quality not affected by lime shall be added to the white wash solution in proportions as directed by Engineer-in-charge. Solid lumps etc. in the colour powder shall be ground to fine powder, sieved and mixed evenly and thoroughly to the white wash solution. White/ colour wash shall be applied with "MOONJ" brush to the in minimum 3 number of coats. The operation for each coat shall consist of stroke of the brush from the top to down wards, another from the down to upwards over the first stroke, similarly one stroke horizontally from right and another stroke from the left. Each coat shall be allowed to dry before the next coat is applied. The white washing





on ceiling should be done prior to that on walls. Surfaces of doors, windows, floors etc. shall be protected from being splashed upon. Such surfaces shall be cleaned of white/ colour wash splashes.

1.6.2 Oil Bound Distempering The oil bound distempering work shall consist of:-(A)Preparation of surface:-

The surface shall be thoroughly brushed free from dust, dirt, grease, mortar droppings, other foreign matter and shall be made smooth by sand papering. In case of distempering over existing distempered surface, the existing distempering shall be scrapped by steel scrappers leaving a clean surface. All nails shall be removed. Pitting in plaster shall be made good with Plaster of Paris mixed with distemper of colour to be used. The surface then shall be rubbed down again with a fine grade sand paper and made smooth. A coat of distemper shall be applied over the patches. The surface shall be allowed to dry thoroughly. The surface affected by moss, fungus, algae, efflorescence shall be treated in accordance with IS: 2395. Any uneveness shall be made good by applying putty made of Plaster of Paris mixed with water including filling up the undulation and then sand papering the same after it is dry. Scaffolding wherever required shall be erected in such a way that no part of the scaffolding shall rest against the surface to be painted.

(B) The primer coat:-The primer coat shall be alkali resistant primer or distemper primer and shall be of the same manufacture as oil bound distemper.

(C) Base preparation:-After the Primer coat, the base preparation shall include applying two or more coatings of oil based putty in paste form made from chalk powder mixed with linseed oil, white zinc, varnish etc. as per manufacturer’s recommendations. After each coat of putty, sandpapering of the surfaces shall be done.

(D) Application of Distemper:-After the base preparation coats have dried, the surface shall be lightly sand papered and dusted off avoiding rubbing off of the primer coat. The distemper shall conform to IS: 428 and shall be diluted with water or any other prescribed thinner recommended by the manufacturer. Minimum two coats of distemper shall be applied with brushes in horizontal strokes followed by immediate vertical strokes which together shall constitute one coat. The subsequent coats shall be applied after at least 24 hours between consecutive coats to permit proper drying of the preceding coat. The finished surface shall be even and uniform without patches, brush marks drops etc. Application of a coat in each room shall be finished in one operation.14 cm double bristled distemper brushes shall be used. After each days work brushes shall be thoroughly washed in hot water with soap solution and hung





down to dry.

Surfaces of doors, windows, floors etc. shall be protected from being splashed upon. Such surfaces shall be cleaned of distemper splashes.

1.6.2 Plastic Emulsion Paint

The Plastic Emulsion paint work shall consist of:-(A) Preparation of surface:-

The surface shall be thoroughly brushed free from dust, dirt, grease, mortar droppings, other foreign matter and shall be made smooth by sand papering. In case of plastic emulsion paint work over existing distempered/ emulsioned surface, the existing distempering/ emulsion shall be scrapped by steel scrappers leaving a clean surface. All nails shall be removed. Pitting in plaster shall be made good with ‘plaster of Paris’ mixed with plastic emulsion of colour to be used. The surface then shall be rubbed down again with a fine grade sand paper and made smooth. A coat of plastic emulsion shall be applied over the patches. The surface shall be allowed to dry thoroughly. The surface affected by moss, fungus, algae, efflorescence shall be treated in accordance with IS: 2395. Any unevenness shall be made good by applying putty made of ‘plaster of Paris’ mixed with water including filling up the undulation and then sand papering the same after it is dry. Scaffolding wherever required shall be erected in such a way that no part of the scaffolding shall rest against the surface to be painted.

(B) The primer coat:- The primer coat shall be alkali resistant primer or emulsion primer and shall be of

the same manufacture as plastic emulsion paint.

(C) Base preparation:- After the Primer coat, the base preparation shall include applying two or more

coatings of oil based putty in paste form made from chalk powder mixed with linseed oil, white zinc, varnish etc. as per manufacturer’s recommendations. After each coat of putty, sandpapering of the surfaces shall be done.

(D) Application of Plastic Emulsion Paint :- After the base preparation coats have dried, the surface shall be lightly sand

papered and dusted off avoiding rubbing off of the primer coat. The plastic emulsion paint shall conform to IS: 5411 (Part- I) and shall be diluted prescribed thinner recommended by the manufacturer. Minimum two coats of plastic emulsion paint shall be applied with brushes in horizontal strokes followed by immediate vertical strokes which together shall constitute one coat. The subsequent coats shall be applied after at least 24 hours between consecutive coats to permit proper drying of the preceding coat. The finished surface shall be even and uniform without patches,





brush marks drops etc. Application of a coat in each room shall be finished in one operation.14 cm double bristled distemper brushes shall be used. After each days work brushes shall be thoroughly washed in hot water with soap solution and hung down to dry. Surfaces of doors, windows, floors etc. shall be protected from being splashed upon. Such surfaces shall be cleaned of splashes.

1.6.4 Plaster of Paris Punning Plaster of Paris punning shall be applied over roughened plastered surfaces. Superior quality Plaster of Paris of approved make shall be mixed with water to obtain paste like consistency and shall be applied on walls, ceiling etc. in sufficient thickness to give an absolutely smooth, plumb and straight surfaces.

1.6.5 Waterproof Cement Paint Scaffolding shall be erected for white washing. The surface shall be thoroughly cleaned of all dirt, dust, mortar dropping and other foreign matter before white wash is to be applied. Surfaces already white/colour washed shall be broomed down to remove all dust, dirt, loose scales of lime wash or other foreign matters.

Scaffolding, Preparation of Surface shall be same as white wash. The surface so prepared shall be thoroughly wetted with clean water before the paint is applied. Waterproof cement paint of approved make shall be mixed with water and stirred to obtain a thick paste which shall then be diluted to brushable consistency. The proportion of mixture shall be as per manufacturer's recommendation. The paint shall be mixed in such quantity which can be used up within an hour of mixing to avoid setting and thickening of the paint.

The surface shall be treated with minimum two coats of waterproof cement paint. No less than 24 hours shall be allowed between two coats and subsequent coats shall be applied only after the preceding coat has become hard to resist marking by subsequent brushing.

The finished surface shall be even and uniform in shade without patches, brush marks, paint drops etc. Cement paints shall be applied with a brush with relatively short stiff hog or fibre bristles.

Curing shall be started after the paint has hardened. Curing shall be done by sprinkling with water two or three times a day. This shall be done between coats and for at least two days following the final coat.

1.6.6 Water Repellant Finish It shall be a coating of silicon/ acrylic based Water Repellant finish (as per approved manufacturer’s specifications) to be applied on walls. All the cracks shall be filled with white cement and pigment to match. Before that the surface shall be cleaned





of all dust, dirt etc. by rigorous brushing. The coating shall be applied evenly with brush including curing, drying the coated surfaces for 24 hours etc. all complete as per approved manufacturer’s specifications and recommendations.

1.6.7 Painting of Wood Surfaces (Synthetic Enamel Paint) Preparation of wood surface shall conform to IS: 2338 (Part-1) in general. All woodwork shall be dry and free from any foreign matter. Nails shall be punched well below the surface. The surface shall be smoothened off with abrasive paper used across the grain prior to painting, with the grain prior to the staining. Any knots, resinous, or bluish sap wood, cutting out of which is not justified shall be covered with red lead conforming to IS: 103. Plywood and block board shall be treated in the same manner as for wood work. Particle boards surface shall be filled with a thin brushable filler and finished as for solid wood. Painting of wood surfaces shall consist of:-

(A) Priming Priming shall be in accordance with IS :2338 (Part I and II). Dirt or any other extraneous material on the surface shall be removed and the priming shall be applied by brushing. Priming shall be done on all exposed and unexposed surfaces. Unless specified otherwise all joinery work intended to be painted shall receive at least 2 coats of primer. Type of primer shall be in accordance with Table-1 and Table-2 of IS: 2338 (Part-II).

(B)Stopping and Filling

Stopping and filling shall be done after priming. Stopping shall be made to the consistency of stiff paste and shall be used to fill holes and cracks. Filler shall be used to level up slight irregularities of the surface. Filler shall be applied with a putty knife and subsequently rubbed down to a level surface with abrasive paper. The filler coat shall be allowed to fully flatten and harden before subsequent coat is applied.

(C) Application of Undercoat Under coat shall be applied after the surface has been primed, stopped and filled, and rubbed down to a smooth surface. Under coat may be brushed or sprayed. After drying the coat shall be carefully rubbed down and wiped clean before the next coat is applied. The type of undercoat shall be depending upon the finishing and in accordance with Table 1 and Table-2 of IS: 2338 (Part II).

(D) Finishing

The finishing paint shall be two or more coats of synthetic enamel paint and shall be applied either by the brush or by spraying to give a uniform, smooth and glossy finish. Reference shall be made to the Table-1 and Table-2 of IS: 2338 (Part-II)





1.6.8 Polishing of Wooden Surfaces (Application of Clear Finishes) For the application of clear finishes, the following procedures shall generally be adopted in accordance with IS: 2338 (Part-I)

(A) Filling Fillers shall be applied to prevent the excessive penetration of the finish to the surface for obtaining a smooth finish. Fillers shall be conforming to IS: 345. Fillers shall be heavily applied to the wood surface by hand, using hessian or juterag across the grain. It shall be rubbed when still wet to get better penetration. After 5-10 minutes it shall be wiped off by hand across the grain followed by a light wipe with the grain. The filled surface shall be dried preferably over night and smoothened with abrasive paper.

(B) Preparation of Wood for Staining Surface intended for staining shall be kept scrupulously clean and free from greasy finger marks. It shall be prepared by careful smoothing with fine abrasive paper used in the direction of the grain. Small cracks/nail holes shall be stopped with plastic wood/fine plaster of Paris. The stopping shall be rubbed down with fine abrasive paper when hard and touched with a thinned knotting before staining. In case of oil staining stopping shall be done after staining using tinted putty or wood filler.

(C) Staining Spirit stains are solutions of spirit soluble dyes in Industrial methylated spirit. Oil stains are solutions of oil soluble dyes in linseed oil, but, usually consist of insoluble, semi-transparent pigments ground in linseed oil and thinned with turpentine or other solvent. Stains shall be applied by brushing, and wiping or by spraying. The stain shall be so thinned that it can be applied fairly, liberally without over staining and over lapping.

(D) Sealing A suitable sealer shall be applied on the filled and sanded surface to prevent absorption by the wood of the succeeding coats of finish and to seal stain and filler and thus preclude their bleeding into the finish coat. Sealer may be sprayed on taking care not to flood the surface and it shall be allowed to dry hard. When fully dry the surface shall be sanded taking care not to cut through at corners and edges. Dust shall be blown off and surface wiped with a clean rag.

(E) Finishing The stained surface shall be varnished, wax-polished or French polished as required after it is dried. Varnishing of wood and wood based material shall be in accordance with IS: 2338 (Part-I). Surfaces to be Varnished shall be prepared to produce a smooth, dry and matt





surface and all dust and dirt shall be removed from the surface.

The Varnish shall be applied liberally with a brush and spread evenly over a portion of the surface with short light strokes to avoid frothing. It shall be allowed to flow out while the next section is being laid in. Excess Varnish shall be scraped out of the brush and then the first section be crossed, re- crossed and laid off lightly. The Varnish, once it has begun to set, shall not be retouched. In case of any mistake, the Varnish shall be removed and the work shall be started afresh.

Where two coats of varnish are applied, the first coat shall be a hard drying under coating or flatting varnish which shall be allowed to dry hard and then be flatted down before applying the finishing coat. Sufficient time shall be allowed in between two coats. When flat varnishing is used for finishing, a preparatory coat of hard drying undercoating of flatting varnish shall first be applied and shall be allowed to harden thoroughly. It shall then be lightly rubbed down before the flat varnish is applied. On larger areas, the flat varnish shall be applied rapidly, and the edges of each patch applied shall not be allowed to set, but shall be followed up whilst in free working conditions.

French polish shall conform to IS :348. Suitable pigments shall be added to get the required colour. The surface to be French polished shall be rubbed down to smoothness with sand paper and shall be well dusted. Pores in the surface shall be filled up with fillers. A pad of woolen cloth covered by a fine cloth shall be used to apply the finish. The pad shall be moistened with polish and rubbed hard on the surface in a series of overlapping circles applying the polish sparingly but uniformly over the entire area to give an even surface. A trace of linseed oil may be used on the face of the pad for the purpose. The surface shall be allowed to dry and the remaining coats applied in the same way. To finish off, the pad shall be covered with a fresh piece of clean fine cloth, slightly damped with methylated spirit and rubbed lightly and quickly with circular motions. The finished surface shall have a uniform texture and high gloss.

1.6.9 Painting of Steel and Other Metal Surface Reference shall be made to IS :2524 and IS:1447. The surface, before painting, shall be cleaned of all rust, scale, dirt and other foreign matter with wire brushes, steel wool, scrappers, sand paper etc. The surface shallthen be wiped finally with mineral turpentine which shall then be removed of grease etc. The surface then shall be allowed to dry. In case of GI surface, surface so prepared shall be treated with Mordant solution (5 litre for about 100 sq.m.) by rubbing the solution generously with brush. After about half an hour, the surface if required shall be retouched and washed down thoroughly with clean cold water and allowed to dry.





Approved quality primer and paint in specified numbers of coats shall be applied as per manufacturer's recommendations either by brushing or spraying. Each subsequent coat shall be applied only after the preceding coat has dried.

1.6.10 Textured Coating The textured coating shall consist of twin pack fine grade wall coating system;with fine grade silica granules/ dry flakes made of special grade of china clay / granite type flakes of ‘Heritage’ or equivalent in approved shade and texture; mixed in-situ with100% acrylic polymer bonding agent. The textured coating shallbe applied over plastered surfaces. The granules/ flakes etc., bonding material, mixing, method of application surface preperation etc. all shall be as per manufacturer’s recommendations and specifications.

1.7 ROOFING

Reference shall be made to the following Indian Standards for information etc. not covered in the specification. In case of any conflict/contradiction, provisions of specification shall override.

IS 277: Galvanized steel sheet (plain & corrugated) IS 730: Hook bolts for corrugated sheet roofing. IS 1728: Specification for sheet metal rain water pipes upto 100 mm nom. size gutters, fittings and accessories. The roof slope shall be as specified and in general not pitched flatter then 1:5. The normal pitch if not specified shall be 1:2. Materials shall be supplied by approved manufacturer. The items supplied shall be free from cracks, chipped edges or corners or other damages. Storage and safety precautions shall be taken to avoid damage to the accessories.

1.7.1 Precoated Galvanised Steel Sheet Roofing/ Cladding The base metal of the roofing shall be Cold rolled in high tensile Galvalume Steel of 550 MPA yield stress conforming to IS:513, IS:14246 and ASTM A446 Grade E. The substrate shall have hot dip metallic coating of aluminium- zinc alloy (150 grams per sq. mtr. total on both sides, coating class AZ150 as per per ASTM A792). The bottom unexposed surface shall then be coated with alkyd backer of minimum 7 microns. Top exposed surface shall have SMP (Silicon Modified Polyester) paint system Minimum 20 microns top coat applied over 5 microns primer with additional coating of Fluropolymer (PVF2) paint system (for coastal areas only) over and above the top coating. The top coat shall be in specified colour. The precoated galvalume steel sheets shall meet the following performance standards

Pencil Hardness : F minimum Formability : 2-3 t





Specular Glass (60 deg) : 20- 35% (ASTM D523) Impact Resistance : Greater than 10J Salt spray test : 750 hours QUV-Wealterometer Test : 1000 light hours Humidity Test : 1000 hours Temperature Resistance : 100_C Fire performance : Class I

The SMP coated steel sheet in standard colour under normal well washed conditions of exposure shall not show any cracking, flaking or peeling of paint film for at least 10 years. Colour change during service, determined according to ASTM D2244 should not exceed 5E hunter lab units on light colours.

The profiles shall have a depth of not less than 28mm and pitch of 190mm. Overall sheet thickness shall be minimum 0.50mm. Minimum weight of the sheet shall be 5.2 kg/ Sq.M

All roofing accessories like ridge, gutters, north light curves etc. shall be fabricated out of precoated sheet of same thickness (as for roof sheeting) and as per manufacturer’sspecifications. Metallic Fasteners and Fixing accessories shall be corrosion proof (polyester polymer coated). Self drilling screws/ fasteners with integral washers and EPDM seals, and nylon colour caps and joint sealants shall be provided for fixing of sheets as per approved manufacturer’s specifications. Non metallic fasteners shall be of neoprene. Sealants shall be natural cure type and of cold setting variety. Wind ties shall be of 40 mm x 6 mm flat iron section and other size as specified. These shall be fixed at the two eaves end of the sheet. Fixing shall be done with the same loose bolts which secure sheets to the purlins. Slot holes shall be cut in the wind ties to allow for temperature variations. The wind ties shall be painted with two or more coats of synthetic enamel paint of same shade as that of sheeting over a coat of approved primer.

1.7.2 C.I. Rain Water Pipes C.I. rain water pipes shall be 100mm dia or 150mm dia (as specified/ indicated in drawings); shall bends, Tees, other accessories (as per approved manufacturer’s specifications) and shall be jointed with spurn yarn and cement mortar 1:2 (1 cement: 2 fine sand by volume). Embedded rain water pipes shall be suitably embedded/ encased in masonry/ cement concrete (M-15) with nominal reinforcement.

1.7.3 P.V.C. Rain Water Pipes PVC rain water pipes shall be 110mm dia (O.D.) or 160mm dia (O.D.) as specified/ indicated in drawings; of 6 Kg./ sq. cm. pressure rating. The pipes shall be provided complete with necessary clamps, connections, bends, Tees, other accessories (as per approved manufacturer’s specifications) and shall be jointed with approved quality bonding solution. Embedded rain water pipes shall be suitably embedded/ encased in





masonry/ cement concrete (M-15) with nominal reinforcement.

1.8 SANITARY FITTINGS AND FIXTURES

Reference shall be made to the following Indian Standards for any further information etc. not covered in the specification. In case of any conflict/contradiction provisions of specification shall override.

IS-2556 : Specification for Vitreous Sanitary appliances (Vitreous-China, Part 1-15). 1S-774 : Specification for Flushing Cistern for Water Closets and Urinals. IS-781 : Specification for Cast copper alloy screw down bib taps and stop valves for water services. IS-2064 : Code of Practice for Selection, Installation and Maintenance of Sanitary appliances.

All glazed earthen ware shall be of approved make, colour and of one piece construction. All metallic fixtures like taps, stop cocks, soap holders etc. shall be CP brass and approved make. All wall fittings shall be fixed with nylon sleeve and CP brass screws and washers.

1.8.1 Indian Type Water Closet Squatting Pan shall be 550mm x 440mm Orissa Pan conforming to IS: 2556 Part-IIIwithintegrated footrests. The closet shall be fixed in the floor with 150 mm thick sand cushion and shall be connected with 100 mm dia CI `S' or `P' trap. The closet shall also be fitted with 10litres valve less syphonic type glazed earthenware flushing cistern, conforming to IS: 774, and complete with all accessories like 15 mm dia. PVC inlet connection pipe 450mm long (with 15mm dia CP Brass stop cock and brass union), PVC ball valves, C.P Brass handle,telescopic 32 mm dia GI telescopic flushing pipe with union, 15 mm dia GI overflow pipe with mosquito proof net and fixed with glazed earthenware cover.

The cistern shall be fixed on MS brackets at a minimum height of 2150 mm from top of pan.

All exposed metallic surface shall be painted with two coats of synthetic enamel paint ofapproved quality over a coat of red oxide zinc chromate primer (primer is not required for GI pipes). One number heavy grade approved quality CP Brass bib cock conforming to IS: 781 (with necessary connections) shall be provided with each WC.

The work shall include providing and fixing water-closet and flushing cistern with allaccessories, breaking wall and floors and making good the same, all inlet and outletconnections of cistern and water closet, finishing of solder joints, painting and testing of





all connections etc. complete.

1.8.2 Wash Down (European) Type Water Closet Wash down water closet shall be of pattern-1 conforming to IS:2556 Part-II. Water Closet shall be of one piece construction, double trap syphonic type. This shall be fixed with plastic seat and cover as per IS:2548 of approved make and colour, fixed with CP brass hinges and rubber buffers and an integral 100 mm dia 'S' or 'P' trap with antisyphonage vent horn. A low level earthenware cistern conforming to IS:774 of about 10 litres capacity, with 15mm dia PVC inlet pipe (with 15mm dia CP Brass stop cock) and brass union with wiped solder joint, internal overflow arrangement, 40 mm dia CP brass flushing pipe. CI or MS supporting brackets shall be fixed with the water closet. The closet shall be fixed firmly in the floor with matching cement mortar. All exposed metallic surfaces shall be painted with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer.

The clearance between top of pan and bottom of cistern shall not exceed 300 mm. One number heavy grade approved quality CP Brass bib cock conforming to IS: 781 (with necessary connections); one number approved quality CP Brass Toilet paper holder (fixed to wall with wooden cleats, CP Brass screws) shall be provided with each WC. The work shall include providing and fixing of all fittings, breaking floors and wall, making good the same, making inlet and outlet connection to the cistern and the closet, testing of joints, painting the exposed metallic surface with two coats of synthetic enamel paint over a coat of primer etc. complete.

1.8.3 Urinals Half stall type urinal shall be of size 610mm x 400mm x 380mm and conforming to IS:2556 Part VI. Urinals shall be of single piece construction with integral flushing box rim. These shall be mounted on walls. The flushing inlet pipe shall be of CP brass 15 mm dia and wast pipe 32 mm dia GI, 750 mm long shall be embedded in wall. Necessary unions and CP bottle trap shall be provided in the waste line. Rawl plugs with CP brass screws shall be used for fixing the urinal. Fixing shall ensure that no liquid is left over in the pan after flushing. Unless otherwise indicated height above finished floors shall be 600 mm.

Urinals shall be connected to glazed earthenware automatic flushing glazed earthenware cisterns either individually, or in groups. Where individually connected to flushing cistern, the cistern capacity shall be 5 litres. For two urinals, one cistern of 10 litres capacity and for three urinals, one cistern of 15 litres, capacity shall be provided.

Cistern inlet shall be 15 mm dia PVC pipe with brass union. Outlet pipe from cistern shall be 25mm CP brass main, with 15 mm CP distributor pipe of sufficient lengths to reach each bowl. Where individual cisterns are provided the outlet shall be of 15 mm CP brass. The work shall include urinals inlet and outlet pipes, flushing cistern, breaking and





making good the walls and flooring, making inlet and outlet connections including all related G.I. piping work (embedded in wall), painting exposed brackets and exposed metallic parts with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer etc. all complete.

All The Urinals shall be separated by Marble partitions (of minimum 19mm thick WhiteMakrana/ White Ambaji/ Abu Green marble slabs; each partition in one piece) of minimum size 1000mm x 600mm or Granite partitions . These partitions shall be inserted upto 100mm depth in the wall and fixed with cement mortar 1:3 (1 cement ; 3 coarse sand by volume) and suitable sized M.S. Channel (embedded in wall with grouting) at bottom. The M.S. Channel at bottom shall be finished with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer.

1.8.4 Wash Basins

This shall be flat back wash basin (with require number of tap holes and conforming to IS: 2556 Part-IV) with anti splash rims on three sides, of size 550mm x 400mm size. Wash basins shall be of one piece construction including a combined overflow having an area of not less than 5 Sq. cm. shall be provided in the front or back of the bowl and it shall be so designed as to facilitate cleaning of the overflow. This shall be fitted on CI or MS brackets. Brackets shall conform to IS: 775. The brackets shall be given two coats of synthetic enamel paint or aluminium paint, over a coat of approved primer. Each wash basin shall be provided with 15mm dia CP brass pillar cock of approved make, rubber plug with CP brass chain, 32mm CP Waste fitting of standard pattern with 32mm dia G.I. pipe, CP Brass bottle trap, CP Brass 15mm dia stop cock etc. complete with all related accessories, fittings and fixtures. The wall side shall be fixed well flushed with the plaster or wall and the joint if any, shall be properly stopped with an elastomeric sealant. The top of rim of the wash basin shall be fixed at 800 mm above finished floor level, unless otherwise specified.

The work shall include provision and fixing of wash basin with all accessories, providing stop cocks and pillar cocks, breaking and making good walls, fixing and making inlet and outlet connections for stop cock, pillar cock and waste pipe, providing & fixing MS brackets painted with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer etc. complete

Following fixtures of approved quality shall be provided for each Wash Basin.

1. Mirror: Round edged Mirror of 5.5mm thick (minimum size of 400mm x 550mm) plain glass with 6mm thick AC sheet backing, beveled edged.

2. Glass Shelf: 600mm x 120mm x 4mm thick Glass shelf with CP brass bracket & guard rails; fixed on wall.





3. Towel Rail: Chromium plated brass towel rail of 20mm dia, 600mm length & 1.25mm thickness.

4. Liquid soap container: Chromium plated Liquid soap container.

All the fixtures shall be fixed to the wall at identified locations with wooden cleats and CP Brass screws including cutting walls, making good the same etc. complete.

1.9 FALSE CEILING, FALSE FLOORING, PARTITIONING, WALL PANELLING,UNDERDECK INSULATION ETC.

1.9.1 Aluminium Lineal False Ceiling Aluminium lineal false ceiling shall consist of:-

(A) Panel Carriers:-These shall be roll- formed out of coated steel/ 0.95mm thick aluminium alloy; 32mm wide and 39mm deep with cut-outs to hold panels in a module of 90mm/ 100mm; all complete as per manufacturer’s standard details and specifications. When two or more carriers are to be joined, they shall be joined together by means of carrier splices which will clip on to holes in the sides of the carriers and hold them firmly in place while maintaining the required module. The carriers shall be suspended from roof by 4mm dia. galvanised steel wire rod hangers, with height adjustment springs of stainless steel. Hangers shall be fixed to roof by “J” hooks and nylon inserts. Edge profiles shall be “L” shaped roll- formed out of 0.6mm aluminium alloy with coating.

(B) Panels:-Panels shall be 84mm wide, 16mm deep, roll formed out of 0.5mm aluminium alloy 5050 or 3005. The aluminium panels shall be chromatised and stove enamelled (coil coated) on both sides in approved shade. Panels shall be factory cut in lengths upto 5 metres to suit site dimensions. As per air- conditioning requirements, for return air, (wherever required) perforated panels shall be used, which shall have 2mm dia holes at 5mm centre to centre staggered in uniform pattern and symmetrically located in the middle of the panel face. The ceiling shall be erected in continuous manner as per approved manufacturer’s recommendations, specifications etc. The false ceiling shall have perfect levels, linearity etc. as required. Necessary cut outs for Electrical, AC and other fixtures shall be provided as per drawing and in co- ordination with relevant construction activities.

1.9.2 Aluminium Planks/ Tiles False Ceiling

This false ceiling system shall consist of:-(A) Panel carriers:-These shall be rows of 0.5mm thick galvanised steel clip in profiles of size 40mm x





20mm. These shall be suspended from roof structure by means of G.I. suspension angles, ceiling brackets and hold on clamps @ maximum 1200mm c/c all complete as per approved manufacturer’s specifications.

(B) Aluminium Tiles:-Aluminium Ceiling Tiles shall be 600mm x 600mm manufactured out of 0.7mm thick aluminium alloy AA3105, chromatised and stove enamelled (coil coated) with square edges produced on advanced equipments. Exposed side of the tile shall have 20 micron (minimum) coil coated polyester finish and 5 micron back coat of Alklyd primer. The short sides of each plank shall be raised and pipped and stopped to ensure positive engagement into the spring clip- in profiles, and shall allow for demounting of individual planks.

1.9.3 Cavity (False) Flooring (with Particle Board)

This False flooring system shall consist of (A) Pedestal base plate made of galvanized Mild steel and shall be of 100 mm x

100mm size and 8mm thick.

(B) Pedestal stud 30 mm dia made of galvanized mild steel seamless pipe and having threads at top and bottom for attaching the top head attachment and fixing to base plate.

(C) Top head attachments made of pressure die cast aluminium alloy of shape and thickness as per drawing; and shall be provided with check nuts at bottom portion for attaching the top head threads in the stud allowing for adjustment upto 25mm up & down.

(D) Channel stringers made of galvanized, machine cut, cold rolled mild steel channels of size 40 mm x 40 mm and 3.15 mm thickness.

(E) Floor panels of size 610 mm x 610 mm in general and of 35 mm thickness; made of unveneered, 3 layer flat pressed, teakwood particle board (conforming to IS :3087 bonded with BWP type phenolformaldehyde synthetic resin conforming IS: 848 and categorised as class-I for `Surfaces of very low flame

spread' as per IS-1642); finished on the underneath side with 0.05mm thick Aluminium foil turned up and extended by minimum 12mm along the perimeter; finished on top with 2mm thick antistatic type PVC tiles/ high pressure laminate and along four sides with hard PVC lipping as per drawing. 12mm x 12mm x 75mm long, 2mm thick Aluminium channel cleats shall be provided on middle of four sides of the panels for lateral stability. False flooring pattern shall be as per approved drawing. Pedestal base plates shall be fixed to the base floor by 6mm dia, 40mm long dash fasteners as per the grid. The pedestal stud locations shall ensure the grid work as per flooring pattern which in general shall be of 610 mm x 610 mm dimension. The length of the pedestal studs shall be such that clear cavity between false flooring and base flooring is of





desired depth. The top head attachments shall be inserted into the studs and shall be adjusted to obtain proper level of the finished floor panels by means of the adjustment nuts. Stringer channels then shall be fitted onto the top heads in position to form the supporting grid work for the floor panels checking the level once again by adjusting the nut position if necessary. Now the check nut shall be finally tightened to secure the final level. Floor panels as specified shall be placed over the stringer channels. Each floor panel shall be marked with positional numbering on the underneath. The finished floor panels shall be perfectly levelled, aligned without any gaps in between the panels. Each individual panel shall be removable for the purpose of maintenance of the cavity. Necessary cut-outs shall be made in the panels for cable routing, control panel fixation etc. as per drawing. Necessary ramps, slopes, steps etc. shall be also provided for as per drawing. Around a control panel/ rack, the residual space left out shall be filled up with cut panels of uniform size as required to fully close the gap between the adjacent full panel and the control panel base channel. In this case the part floor panel shall extend upto the full width of the base channel and the cut size shall be determined accordingly. An additional row of jack pedestals shall be provided along the cut out on which the edge of the floor panel shall rest and over which the base channel of control panel shall be placed. It shall not directly rest on the jack head pedestal or grid channels.

1.9.4 Phenolic Foam Underdeck Insulation:-Phenolic Foam Underdeck insulation shall be of rigid slab of 25mm thickness and approx. 1000mm x 500mm size as specified and shall conform to IS: 13204. It shall

have density of 32 kg / M3 and K Value 0.016 KCal/hr M deg.C as per BS 4370, Part

2. The insulation shall be classified as ` Non Combustible ' as per BS 476, part 5 and ‘Class I’ for surface spread of flame as per BS 476 ,part 7. It shall be prelaminated on both sides with kraft paper. The entire soffit of slab and beams shall be thoroughly cleaned. Bituminous primer or zinc chromate primer shall be applied evenly @ 0.5 kg/m2 over the entire surface. Hot bitumen or CPRX adhesive shall then be applied on the insulation panel @ 1.5 kg/Sq.M. The panels shall be pressed in position and further secured by dash fasteners.

The underdeck insulation shall be fixed only after all fixtures like hooks, clamps, cleats etc. for light fixtures, ducts etc. have been fixed in the ceiling.

1.9.5 Polyisocyanurate Foam Underdeck Insulation Polyisocyanurate foam (PIR) shall be rigid slabs of size 1000 x 1500mm and thickness of 30mm conforming to IS:12436 having density not less than 32 kg./ Cu. M., thermal conductivity (K- value) not more than 0.023 w/mk measured at 10 deg.





C. The slabs shall be covered on one side with glass fibre tissue/ Aluminium foil having 50mm overlap. The insulation shall be classified as ‘Non Combustible’ as per BS 476, part 5 and ‘Class I’ for surface spread of flame as per BS 476, part 7. First, holes in R.C.C. slab/ beam shall be drilled and nylon rawl plugs of size 8 x 25mm shall be inserted (5 nos. for each slab- One each at 4 corners and one at center). Entire R.C.C surface shall be thoroughly cleaned of all dust, dirt and loose particles by wire brushing. Then a coat of bituminous primer @ 0.5 Litres/ Sq.M. shall be applied to bare R.C.C. surface and allowed it to dry. After the primer has dried, hot blow grade bitumen of 85/25 grade or cold adhesive CPRX shall be applied on R.C.C. surface and to the two surface of each PIR panel and shall be pressed in position while the bitumen is still tacky. The PIR panels shall be secured in position with the help of G.I. screws (No. 8 x 75mm long) fixed into rawl plugs and G.I washers 25mm dia. Facing side of the panels shall be the one covered with fibre tissue/ Aluminium foil. The overlaps shall be covered with approved quality sealing compound (MAS-94 or equivalent). Chicken wire mesh 24G x 19mm shall then be fixed to G.I screws and tightened with lacing wire. The underdeck insulation shall be fixed only after all fixtures like hooks, clamps, cleats etc. for light fixtures, ducts etc. have been fixed in the ceiling

1.10 MISCELLANEOUS ITEMS 1.10.1 M.S. Pipe Handrail

The M.S. Pipe handrail shall consist of 25mm M.S. square balusters (one on each step; similar spacing for horizontal portions) with 40mm x 40mm x 6mm M.S flat shoe welded at bottom of baluster; embedded into floor/ steps and grouted with M-15 grade concrete in a cut out of 100mm x 100mm x 150mm size block. 32mm dia N.B. (Medium) M.S. pipe handrail shall be welded to balusters at top. The entire railing and balusters shall be painted with two or more coats of synthetic enamel paint over a coat of approved quality red oxide zinc chromate primer. All embedded metallic portions shall be provided with primer.

1.10.2 Steel Entrance Gate Steel entrance gate shall be made of MC-75 frame all round, 20mm square M.S bars welded to frame @ 100mm c/c vertically. A 500mm high (continuous along the width of the gate) hollow box made of 2mm thick M.S. Sheet welded by means of 12mm square M.S bars to 20mm vertical square M.S bars of the gate shall be provided. The gate shall be fixed to R.C.C. columns by means of 20mm dia M.S bolt (with 40mm dia, 3mm thick M.S washer) threaded through 2 nos. 75mm x 75mm x 6mm M.S. angle cleats (one welded to peripheral MC-75 frame of the gate and the other fixed to R.C.C. column by means of 25mm x 3mm x 200mm long M.S. holdfast). At bottom towards R.C.C. column the gate shall be mounted on floor by means of special pivot arrangement comprising of 25mm square bar rounded at bottom (fixed to gate by means of 2 nos. 6mmx 60mm x 100mm M.S. flats welded to gate frame from side) to form pivot and moving on 50mm x 50mm x 50mm M.S. section (with 22mm dia x 20mm deep slot) embedded in floor. The gates shall also





be provided with 75mm dia, 25mm thk. M.S. wheel with ball bearing fixed to bottom of the gate frame by means of 20mm dia bolt and 50mm wide 6mm thick M.S. clamp. The gate shall swing on 50mm x 50mm x 6mm M.S. Tee embedded in floor along its route curve. The gate shall be complete with all fittings and fixtures like locking arrangement, M.S. heavy duty aldrop etc. Entire gate with all fittings and fixtures shall be finished with two or more coats of synthetic enamel paint of approved make and shade over a coat of approved primer. All hidden metallic parts shall be provided primed.

1.10.3 Transformer Gates/ Fencing Transformer gates/ fencing shall be made of 50mm x 50mm x 6mm M.S. Angle frame, 50mm x 50mm x 6mm M.S. Tee stiffeners, 50mm x 50mm x 8mm welded mesh fixed to the frame by 20mm x 3mm M.S. flat beading. The gate/ fencing shall be fixed to the masonry/ R.C.C. by M.S. hinge arrangement (consisting of 65mm x 65mm x 6mm M.S. angle, bolt, washers etc.) with M..S. holdfast grouted with M-15 concrete block. The gate shall have M.S. pivot arrangement (ensuring smooth operation of the gate), one heavy duty 450mm long M.S. aldrop, heavy duty M.S. tower bolts etc. complete. The entire gate/ fencing with fittings/ fixtures/ accessories shall be finished with two or more coats of synthetic enamel paint of approved make and shade over a coat of approved red oxide zinc chromate primer. All embedded metallic parts shall be provided with primer.

1.10.4 Plinth Protection (Without Drain) The plinth protection (all round the buildings- without drain) shall consist of a layer (150mm thick) of compacted sand and over that 100mm thick M-15 grade concrete top layer laid to slope. The top concrete layer shall be trowel finished, cured etc. complete. The work also includes carrying out the necessary excavation, disposal of surplus earthwork etc.

1.10.5 Cinder Filling All the sunken R.C.C slabs of Toilets etc. shall be provided with cinder filling comprising of:-(A) Plastering the R.C.C. slab top, sides etc. with 18mm thick cement plaster 1:6 (1

cement : 6 sand by volume) mixed with approved waterproof compound @3% of cement by weight and finishing with a floating coat of neat cement slurry @ 2.75 kg. per Sq.M, finishing, curing etc. The work includes preparation of base surface as described in ‘Plastering’ item.

(B) Filling with Cinder concrete 1:10 (1 cement : 10 cinder of 12mm and down grade) including consolidating, finishing, curing etc. complete.

1.10.6 Sealing of Expansion Joints All expansion joints (25mm wide) of the building shall be sealed with premium grade Silicon sealant (‘SILPRUF’ of ‘GE Silicons’ or equivalent) consisting of the following:-

(A) The surfaces over which it is to be applied shall be totally dried and cleaned of





all dirt, oils, mortar droppings, all loose material etc. by vigorous wire brushing and wherever necessary by grinding and blast cleaning (sand or water).

(B) A backup material or joint filler tapes (as per approved manufacturer’s specifications) shall be fixed in the expansion joint.

(C) A coat of primer as per approved manufacturer’s specifications (specially developed for use with Silicon sealant material) shall then be applied over the surface.

(D) Silicon sealant shall be applied by means of ‘cartridge- type’ caul gun, either hand or air pressure activated. The sealant shall be applied in a continuous operation, horizontally in one direction and vertically from bottom to top of joint opening. The sealant shall be applied in excess so that a positive pressure adequate to properly fill and seal the joint is created. The sealant shall be struck with light pressure to spread the material against the back up material and the joint surfaces properly. The sealant shall be tooled to slightly concave surface. As the work progresses, the excessive sealant shall be removed. The masking tape shall be removed immediately after tooling. The sealant shall be cured as per approved manufacturer’s recommendations.

Entire work shall be carried out as per as per approved manufacturer’s specifications and recommendations.

1.10.7 Anti Termite Coating All woodwork (frames, panels etc. including hidden/ embedded portions of wooden members shall be provided with anti- termite coatings of approved quality aldrine- chlorinated phenol compound conforming to IS:401. Three or more coats as required @ 3 Sq. Mtr. per coat per Kg. covering capacity shall be applied before applying the finishing (painting, polishing, lamination etc. as specified) coats.


DRAWING/DOCUMENT REQUIREDFOR OWNER




SPURLINES OF CHAINSA-JHAJJAR PIPELINE PROJECT

DRAWING / DOCUMENT REQUIRED BY OWNER

(ARCHITECTURE)





VENDOR DRAWING AND DOCUMENT REQUIREMENT

The following Data marked “X” shall be furnished by Vendor

S. No.

Description With Bid

After Job award

For Review

For Information

Final in Book Form

1 2 3 4 5 6

1. Vendor drawing/ documents submission schedule

X X

2. GA & equipment lay-out of buildings/ sheds indicating sizing of internal spaces

X

3. Preliminary Architectural Drawings of the buildings in accordance with bid indicating Plans, Sections & Elevations & Architectural treatment. Such preliminary dwgs shall be prepared after finalisation of sizes & layout of the required spaces/ areas/ rooms and review of the same PMC.

X X

4. Construction drawings of all the Buildings/ Sheds. Construction Drawings shall contain the following. These drawings shall be prepared incorporating comments etc. on the preliminary Dwgs. 1. Plan of all levels, Terrace Plan, Key Plan.

X X

2. Sections as required for complete understanding of the Design & Construction

X X

3. Elevations of all sides. X X 4. Door/Window details. X X 5. False ceiling/ flooring details & layouts

X X

6. Schedule of Architectural Finishes X X 7. Architectural details as required.

X

8. Any other Dwg as required for X X





complete understanding of the Design & Construction.

5. Specification of materials not covered under bid document.

X X

6. Documents/ Drawings for Statutory Approval in accordance with the statutory requirement

X X

7. As-built drawings X X

8. List of all Sub - vendors / authorized applicators to be engaged for execution of various specialized items (like Aluminium Doors and Windows, Waterproofing / Insulation, False ceiling/ Flooring, Partitioning etc.

X

DOCUMENT DISTRIBUTION SCHEDULE

1. Documents listed under column 4 are to be submitted in 8 copies (6 copies to consultant, 2 copies to owner).

2. Documents listed under column 5 are to be submitted in 8 copies (6 copies to consultant, 2 copies to owner).

3. Documents listed in column 6 are to be submitted as hard bound indexed book for design calculations and AFC drawings in requisite number of copies as mentioned elsewhere in tender. (Electronic files of all final drawings & documents shall be furnished in CD-ROMs (5 sets for GAIL).


SPECIFIC REQUIREMENT PIPELINE LAYING TENDER

(GENERAL CIVIL) 0001-01-10-02-001Page 1 of 5


GAIL (India) LIMITED

SPURELIENS ON CHAINSA-JHAJJAR PIPELINE PROJECT

SPECIFIC REQUIREMENT PIPELINE LAYING TENDER (GENERAL CIVIL)

PIPELINE LAYING TENDER





1.0 SPECIFIC REQUIREMENTS :

1.1.0 CLEAN AGENT FIRE EXTINGUISHING SYSTEM FOR CONTROL ROOM / BUILDING/ POTA CABIN AT RECEIPT TERMINALS :

1.1.1 Design, engineering, supply, installation, erection, fabrication, testing & commissioning, Guaranteeing of auto-operated (with manual override) Clean Agent fire extinguishing system (fixed installation) along with complete fire detection, alarm and flooding of Clean Agent system for the fire protection of Telecom room, control Room & UPS Room of control room building at Despatch & Receipt Termianl as per Specs. No. (Specification for Clean Agent System), NFPA-2001 (latest edition) and electrical specifications enclosed in the tender including submitting of design basis, design calculations, general arrangement, detailed drawings, operation philosophy for review / approval of GAIL prior to any assembly, installation / construction, revising and incorporating the comments if any on the above documents/drawings without any extra cost including supply of all related materials but not limited to main fire alarm panel, Clean Agent fire protection panel, detectors, response indicators, exit signs, electronic horn, break glass type manual call point, junction boxes, mandatory spares such as cylinders, cylinder valve assembly, nozzles etc. all complete as per NFPA-2001, codes, standards, specifications, drawings, documents and direction of Engineer-in-Charge. Electrical specs. on fire alarm and detection system shall form part of overall scope. Main battery of Clean Agent filled cylinders along with 100% standby agent filled cylinders shall be provided. All Clean Agent cylinders shall be seamless. Additional quantity of Clean Agent in addition to main shall be provided to compensate for leakage which will take place from the openings such as doors / windows / exhaust fan openings / louvers etc. All equipments used for Clean Agent fixed system such as cylinders / valves/ nozzles/ manifolds/ directional valves etc. shall be FM/UL/VDS/LPC listed for the intended use. Clean Agent cylinders along with cylinder valves shall be CCE approved. Approved software shall be used by the contractor for design of Clean Agent system. The protection shall be provided for Telecom room, control Room & UPS Room and the system shall be designed as a high pressure Clean Agent system at 21degree centigrade temperature. The system shall be designed for the largest risk volume of Control Room building. For each risk (room), combined volume of false floor + main room + false ceiling shall be considered for calculating the total single largest risk volume. Full Clean Agent discharge test shall also be performed by the contractor for the smallest risk volume. The sub vendor, for Clean Agent system executing the job should have designed and executed at least one such job of similar nature in the past three years. The contractor shall furnish proper certification of the same from the sub-vendor along with the bids.

1.2.1 GENERAL

(i) In case of conflict between GAIL spec. & NFPA-2001 (latest edition), NFPA 2001 provisions shall govern.





(ii) For acceptance of the system, GAIL or its authorized representative shall be considered as authority having jurisdiction.

2.0 SPECIFIC REQUIREMENT ON ENGINEERING BY CONTRACTOR

2.1 The construction shall be done as per the drawings prepared by the contractor and reviewed / approved by GAIIL during the course of execution. The schedule of submission of various drawings and documents as listed below.

2.2 The drawings / documents submitted by the contractor shall be reviewed by GAIL. During such review, certain modifications may be suggested in the drawings/documents. The contractor shall incorporate all such modifications without any extra cost and time. GAIL may review and offer comments/suggestions on the layout, schemes, designs and drawings as prepared by the contractor and the bidder shall adhere to such comments/suggestions and revise/redo these design/drawings accordingly, and incorporate the same in the construction without any extra cost and time, maintaining the original time schedule. However, reviewing of design, drawings is not obligatory on the part of GAIL/and complete correctness/soundness of the design/drawings and their execution at site shall be the sole responsibility of the contractor irrespective of the fact whether the same has been reviewed/approved by GAIL or not. Any defect observed during commissioning and operating the system shall be rectified by the contractor by carrying out the necessary modification.

2.3 Successful Bidder shall be required to present documentation of all proposed design, installation and testing procedures for review and approval by GAIL. This shall be done at least 45 days prior to the commencement of relevant phase of activity. The fabrication/construction shall commence only after GAIL review/approval has been obtained. This report shall contain the design assumptions, calculations, materials specifications and details of construction.

2.4 Minimum six sets of each document/drawings shall be submitted during any submission. For design calculations three sets are required for submission by the contractor.

2.5 The contractor shall incorporate the comment (without any cost and time effect) if any, on documents and resubmit the same for GAIL ’s review.

2.6 Preparation of drawing, scheme and other documents for obtaining statutory approval as per rules & regulations from central/state government and other statutory authorities, arranging inspection of work by the authorities at appropriate times, necessary co-ordination, all liaison work shall be included in the scope of this tender, within the quoted rates.





2.7 The cost of work involved in preparation of document in line with the State/Government and other statutory authorities for obtaining the approval shall deemed to be included in the lump sum price including any change modification required at any time either in design/drawing, field for obtaining the approval.

3.0 DOCUMENTS REQUIRED FROM BIDDER

The deliverables to be submitted in various stages to GAIL for review / approval shall be as follows:

(⊕ : Means Data required from Vendor)

After Job awardS.N.

Description With bids For

Information For review

After Final data

1. Clean agent fire extinguishing System write up with deviation if any or modification to compliance to tender

⊕ ⊕ ⊕

2. System design calculation for Clean agent system for sizing, storage capacity, pipes and

⊕ ⊕

3. G.A. Drawings for Clean agent fire extinguishing system

⊕ ⊕

4. Complete detailed drawing for Clean agent system piping and storage arrangement and manifold

⊕ ⊕

5. Pre commissioning, commissioning and performance guarantee tests

⊕ ⊕





procedures

6. Item wise list of recommended spareparts for two years trouble free operation

⊕ ⊕ ⊕

7. Item wise list of commissioning spares

⊕ ⊕ ⊕

8. Installation, operation and spare parts manual

⊕ ⊕

9. As built drawings and Information/data

⊕

10. Filled up data sheet for Clean agent system

⊕ ⊕

GAIL(INDIA)LIMITED ENGINEERING CELL -

STANDARD SPECIFICATION FOR CLEAN AGENT SYSTEM (AS PER NEPA-

2001)DOCUMENT No. 0001-01-10-02-002


SPURELINES ON CHAINSA-JHAJJAR PIPELINE PROJECT

SPECIFICATION FOR CLEAN AGENT SYSTEM(AS PER NFPA-2001)

FOR PIPELINE LAYING TENDER(GENERAL CIVIL)



2001)DOCUMENT No. 0001-01-10-02-002

CONTENTS

1.0 SCOPE OF WORK


3.0 DESIGN REQUIREMENTS

3.1 SYSTEM DESIGN

3.2 SYSTEM FLOW CALCULATIONS

3.3 CLEAN AGENT QUANTITY

3.4 CLEAN AGENT STORAGE CYLINDERS

3.5 PIPING, FITTINGS AND DISCHARGE NOZZLES

3.6 DETECTION, ACTUATION AND ALARM SYSTEM 3.7 PAINTING

3.8 OPERATING DEVICES

3.9 LOCAL CONTROL PANEL FOR CLEAN AGENT SYSTEM

4.0 MATERIALS OF CONSTRUCTION

5.0 INSPECTION AND TESTING

6.0 VENDOR DATA REQUIREMENTS

6.1 ALONG WITH TECHNICAL BIDS

6.2 AFTER AWARD OF CONTRACT



2001)DOCUMENT No. 0001-01-10-02-002

7.0 MANDATORY SPARES

8.0 BID EVALUATION CRITERIA

ANNEXTURE -I : List of risk and clean agent quantity ANNEXTURE - II : Technical data sheet

1.0 SCOPE OF WORK

This specification covers the requirements of design, supply of materials, installation, testing and commissioning of total flooding centralised Clean Agent System (clean agents to be considered are : IG-541, IG-55, IG-01 and IG-100 as per NFPA-2001) for fire protection of Control Room building mentioned in this specification.

The work shall include electrically actuated automatic Clean Agent Fire Extinguishing System complete with clean agent cylinders, manifolds, pressure reducing devices, cylinder valves, directional valves, pipes, discharge nozzles, brackets supports, hangers and such other fittings as necessary for complete installation of the system including chipping of existing RCC/brick walls of control room buildings, fixing fasteners, etc. The system shall also comprise of both Automatic and Manual actuation, cancellation facility etc. with necessary control panel.

Complete Fire Detection and alarm system is in the scope of this requisition. The clean agent shall be discharged/actuated automatically after a adjustable time delay based on the detection signal received. The delay shall be maximum 180 seconds, however it shall be adjustable from 0 to 180 seconds.

It may be noted that clean agent system to be provided shall meet the requirements of NFPA-2001 (Latest). Hence any thing specified as “mandatory” in NFPA-2001, although not specifically mentioned in this specification, shall form part of this specification and scope of work for the job to be executed.



2001)DOCUMENT No. 0001-01-10-02-002


- NFPA 2001: Standard on Clean Agent Fire Extinguishing Systems, 2004 Edition.

- BS - 5445, 5446, 5839 : for detectors

- SMPV Rules, 1981, CCE , Nagpur : for Storage Containers.

- Clean Agent manufacturer's recommendations.

- Tariff advisory committee (TAC) rules

3.0 DESIGN REQUIREMENTS

Vendor shall design the system to meet the minimum requirements of total flooding fire extinguishing clean agent system as per NFPA-2001

and having design concentration as specified at 70˜F(21

˜C).

The system design shall be centralised and shall protect other risk as defined in the requirements and scope of work of the project.

3.1 SYSTEM DESIGN

The centralised system of a station shall be designed to protect any of the risk(volume wise) in a particular room of a building as defined in Annexure-I to this specification.

The quantity of Clean Agent gas provided shall be sufficient to protect the single largest risk in each building with 100% standby filled up cylinders. The system shall have its own storage, distribution piping, nozzles, alarm, and actuation system, etc.

Both primary and standby supply shall be permanently connected to the distribution piping through manifold and arranged for easy and auto changeover.



2001)DOCUMENT No. 0001-01-10-02-002

As the system is designed for the largest risk and there are several risks varying in size in particular building, the system shall permit use of required no. of cylinders for any individual risk involved so that the concentration of gas in that risk does not exceed the design concentration specified in the table below.

TABLE

PROPERTIES OF INERT GAS AGENTS USED AS FIRE EXTINGUISHING AGENTS

NAME FORMULA NOAEL %

LOAEL %

NORMAL CHARGING PRESSURE

MIN. DESIGN PRESSURE

AT 1300 F

EXTINGUISHING CONCENENTRATION

%AGE M3/M

3 OF VOL.

IG-541

IG-55

IG-01

IG-100

N2 (52%)

Ar (40%)

CO2(8%) N2-50% AR-50%

AR-99.9%

N2 (99.9%)

43

43

43

43

52

52

52

52

2175 psi

2222 psi

2371 psi

2404 psi

2575 psi

2475 psi

2650 psi

2799 psi

37.5

37.5(*)

37.5(*)

37.5(*)

0 .470

0.470(*)

0.470(*)

0.470(*)

NOAEL : No Observable Adverse Effect Level, the hightest concentration at which no adverse physiological or toxicological effect has been observed.

LOAEL : Lowest Observable Adverse Effect Level, the lowest concentration at which an adverse physiological or toxicological effect has been observed.



2001)DOCUMENT No. 0001-01-10-02-002

(*) Or higher %/quantity of volume as specified by clean agent manufacturer for clean agent system. IG-541, 55, 01 and 100 are called as inert gas as per NFPA-2001.

The agent discharge shall be substantially completed in a nominal 60 seconds for IG-541, 55, 01 and 100, or a shorter time .The measured discharge time is considered to be the time when the measuring device starts to record reduction of oxygen untill the design oxygen reduction level is achieved.

The min. Oxygen concentration shall be maintained after release of clean agent (IG) as 16%.

3.2 SYSTEM FLOW CALCULATIONS

System flow calculations shall be performed using A CALCULATION METHOD LISTED OR APPROVED BY THE AUTHORITY HAVING JURISDICTION (e.g. FM/UL/LPC/VDS) and TAC. The system design shall be within the manufacturers listed limitations. System design including computerised flow calculations, piping & storage layout of Clean Agent System shall be submitted along with the technical bids.

3.3 CLEAN AGENT QUANTITY

Minimum design concentration of Clean Agent gas shall be 37.5%(min) for IG-541,55, 01 and 100 at 70˜F by volume unless otherwise specified by the agent manufacturer for clean agent fire extinguishing system.

Clean Agent concentration requirement shall be computed considering the volume of the hazard as specified. The quantity of Clean Agent shall be worked out by the bidder, as per NFPA-2001 and in the Performa given in Annexure-I, however vendor shall quote minimum quantity of agent as given in the Annexure-I.

3.4 CLEAN AGENT STORAGE CYLINDERS

The Clean Agent storage cylinders shall be designed to hold clean agent



2001)DOCUMENT No. 0001-01-10-02-002

at ambient temperatures. Container shall be of approved type and freshly imported. Minimum container design level working pressure of storage container shall be as per clause 2.1.4 and table A-2-1.4.1 of Appendix-A to NFPA-2001. The containers shall not be charged to a fill density or superpressurisation (superpressurisation means the addition of a gas to fire suppression agent container necessary to achieve the pressure required for proper system operation) level different from manufacturer’s listing.

The vendor shall select the capacity of cylinder as follows : IG-01, 55, 541and 100 435 cu.ft

The vendor shall standardised the capacity of cylinder for better replacement & inter changeability.

The design pressure for cylinders shall be suitable for the maximum pressure developed at 130˜ F (55˜C) at the max. controlled temperature limit.

Each container shall have a permanent name plate specifying the agent, tare and gross weight in addition to the pressurisation level, and nominal agent volume.

All clean agent cylinders shall be seamless and bear the mark of manufacturer, serial number and shall be duly listed by a competent approval authority of country of origin (FM/UL/VDS/LPC) in addition to approval by CCE Nagpur (India). Cylinders without the approval will not be accepted. A reliable means of indication, other than weighing shall be provided to determine the pressure in refillable containers.

Each container shall have pressure relief valve to protect the cylinders against excess pressure conditions.

Clean Agent containers shall be arranged in the following manner:

i) In a battery of cylinders manifolded together and leading to common distribution pipe and discharge nozzles for the risk to be protected including below floor board and above false ceiling spaces.

ii) A reserve battery of cylinders with manifold, directional valve and automatic change over to any of the two banks after actuation shall be provided. The reserve of standby Clean Agent battery shall be 100% of the quantity required for the single largest risk as per scope of work.



2001)DOCUMENT No. 0001-01-10-02-002

Automatic means such as check valve shall be provided to prevent agent loss if the system is operated when any containers are removed for maintenance.

The manifolded containers referred to above shall be securely mounted on the floor and suitably supported in a rack with provision for convenient individual servicing and content weighing according to the manufacturers installation manual. Such servicing or weighing shall be possible without shutting down the system.

A space marked as cylinder shed on the drawing be made available to the contractor for placing Clean Agent cylinders. Vendors shall confirm the adequacy of space provided for storage of Gas cylinders.

3.5 PIPING, FITTINGS AND DISCHARGE NOZZLES

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

CLEAN AGENT PRESSURE U/S OF PRESSURE D/S OF FITTINGS U/S OF FITTINGS D/S OF

NAME PR / PIPE CLASS PR / PIPE CLASS PR PR ----------------------------------------------------------------------------------------

------------------------------------------------------------------------IG-541,55, 2650 PSIG/ 1000 PSIG/ AS PER TABLE AS PER TABLE 01 and 100 ASTM A-106,GR C ASTM A-106,GR C A-2.2.3.1 OF NFPA A-

2.2.3.1 OF NFPA SEAMLESS,WLD SEAMLESS,WLD

---------------------------------------------------------------------------------------------------------------------------------------------------------------

PR : STANDS FOR PRESSURE REDUCER ; WLD : STANDS FOR WELDED CONNECTION

PIPE THICKNESS CALCULATION SHALL BE AS PER ASME B31.1 POWER PIPING CODE AND FITTINGS SHALL CONFORM TO ANSI B1.20.

The pressure reduction device shall be easily identifiable.

Discharge nozzles shall conform to cl.2.2.5 of NFPA. Discharge nozzles



2001)DOCUMENT No. 0001-01-10-02-002

used in this system shall be listed for the use intended for discharge characteristics. The selection of nozzle orifice shall be such that the 95% of IGs is discharged within 60 seconds through the number of nozzles of the system. Each nozzle shall be permanently marked to identify by the part number, orifice code, or other suitable marking as specified by the authority having jurisdiction.

The vender to note that the clean agent piping to be laid in existing building, hence the clean agent piping and nozzles etc. shall have to be planned clearing other facilities coming in the areas where clean agent protection is being envisaged. The different items that are to be provided for efficient functioning of the automatic clean agent system have been indicated but not the quantity of any of them, which has to be worked out by the contractor. The clean agent piping shall have to clear:

i) The beams and ribs which criss cross the ceiling.ii) Path of AC ducts. iii) Cabling in false flooring.

The vendor shall have to lay the clean agent piping in existing building. All necessary civil works including breaking the Blast resistant RCC wall and brick walls and making them good shall be in the scope of work.

3.6 DETECTION, ACTUATION AND ALARM SYSTEM

Fire detection, actuation and alarm system for the system shall be as per NFPA-2001 latest revision.

There shall alarm in clean agent local control panel at the time of gas release.

3.7 PAINTING

Painting and colouring of pipelines, nozzles, clean agent storage containers, supports, etc. shall be done as per Specification O-611.



2001)DOCUMENT No. 0001-01-10-02-002

3.8 OPERATING DEVICES

a) Operating devices shall include clean agent releasing devices or valves, discharge controls, and shut down equipment necessary for successful performance of the system.

b) Electric Supply: The vendor shall provide 100 V + 6% @ 50 Hz +3%, 3 phase power supply at a convenient point. Convertor required to convert 24V shall be in vendor's scope.

c) Electric Supply: The vendor shall provide 100 V + 6% @ 50 Hz +3%, 3 phase power supply at a convenient point. Convertor required to convert 24V shall be in vendor's scope.

d) The clean agent cylinders shall be mounted on front and firmly supported in brackets in a manner that they will not be easily subjected to mechanical chemical or other damage, which would render the system in-operative.

e) In addition to Automatic actuation, there shall be a normal manual control for actuation, which shall be located so as to be conveniently and easily accessible at all times including the time of fire. This control shall cause the complete system to operate in its normal fashion.

f) Manual controls shall not require a pull of more than 40 lb nor a movement of more than 14 inches to secure operation. At least one manual control for activation shall be located not more than 4 feet above the floor.

g) i) signal shall be provided from the clean agent control panel to shut off the air handling unit and air conditioning dampers/louvers.

ii) Supervision of automatic systems shall be provided and shall include electrical supervisions of the actuating device and the wiring connecting the actuation device and the detection system.

h) Operating instructions shall be displayed on a name plate fitted permanently on the clean agent skid.

i) Clean agent extinguishing system shall incorporate a predischarge alarm with a time delay sufficient to allow



2001)DOCUMENT No. 0001-01-10-02-002

personnel evacuation prior to discharge.

3.9 LOCAL CONTROL PANEL FOR CLEAN AGENT SYSTEM

The system shall have a main control console and shall consist of:

I) Two alarms and one fault indicator lamp for each zone to be protected.

II) Combination of alarm silence and alarm off switch.

III) Combination of fault silence and trouble lamp switches.

IV) Alarm test switch

V) Alarm re-set switch.

a. The installation shall have arrangement to indicate by alarm as well as indication about actuation of the system, hazard to personnel of failure of any supervised system. The extent and type of alarms or indicators equipment shall be to the satisfaction of the Engineer-in-Charge.

b. The system shall have a positive warning device by sounding alarm to alert personnel of the impending discharging and also a positive indication to show that the system has actuated.

c. Alarm indicating failure of supervised devices of equipment shall give prompt and positive indication of any failure and shall be distinctive from alarm indicating operation of hazardous conditions.

d. Warning and instruction signs at entrance to and inside protection areas shall be provided.

The following additional provisions shall be made in the main control panel:

a. Automatic shut off of the Air conditioning dampers/louvers by solenoid damper closing unit or electrically operated damper motor. Only signal to be provided from clean agent system control panel. Rest of the job shall be done by others.

b. Automatic shut off of the air-handling units.

4.0 MA TERIALS OF CONSTRUCTION



2001)DOCUMENT No. 0001-01-10-02-002

4.1 The materials of construction used in the system shall be in accordance with NFPA-2001 or as specified by the equipment manufacturer for the intended use. (if the same is not specified in NFPA-2001).

5.0 INSPECTION AND TESTING

5.1 APPROVAL OF INSTALLATION

The completed system shall be tested to meet the approval of Owner. The entire clean agent system shall be TAC (Tariff Advisory Committee, India) approved & vendor to obtain the same. Only listed or approved equipment and devices shall be used in the systems. All critical equipments such as cylinders, cylinder valves, directional valves, pressure reducers, nozzles, actuatation controls, pressure gauges etc. shall have listings (FM/UL/Vds/LPC) To determine that the system has been properly installed and will function as specified, the following tests shall be performed:

a. A thorough visual inspection of the installed system and hazard area. The piping, operational equipment and discharge nozzles shall be inspected for proper size and location. The locations of alarms and manual emergency releases shall be confirmed. The configurations of the hazard shall be compared, to the original hazard specification. The hazard shall be inspected closely for un-closable openings and sources of agent loss, which may have been overlooked in the original specifications.

b. .A check of labelling of devices for proper designations and instructions. Nameplate data on the storage containers shall be compared to specifications.

c. A test for mechanical tightness of the piping and associated equipment to assure that leakage will not occur and that there will be no hazardous pipe movements during discharge.

d. Non-destructive operational tests on all devices necessary for proper functioning of the system.

Vendor shall provide suitable safety measures against increase in pressure inside the protected area due to release of clean agent.

6.0 VENDOR DATA REQUIREMENTS



2001)DOCUMENT No. 0001-01-10-02-002

6.1 Along with the Technical Bids

- List of clause wise deviations, if any, to the specifications. It will be vendor's responsibility to furnish the deviations. If the same are not furnished it will be assumed that the offered equipments meet the specifications of the enquiry document in toto.

- System design including computerised system flow calculations, piping & storage layout.

- Indian/International standards to which the offered equipments conform.

- Catalogues/Brochures giving technical particulars and details of operation/maintenance of the offered elements/system.

- Certificates of agencies who have accorded approval for the elements offered.

- Numbers & placement / Area coverage for type of nozzles used. - Quantity of each type of equipment offered along with the calculations. - Protected room/area layouts.- Quantity of clean agent offered for various areas as per specifications.- PFD, P&ID and GA drawing.

6.2 After Award of the Contract

- Calculations for pipe sizes, time of discharge, flow, nozzle rate of discharge etc.

- GA and dimensional drawings of the areas showing storage, piping and nozzles for various areas.

- Mounting/fixing details of all the elements. - Testing and inspection schedule and procedure. - Cylinders data sheets. - Other data sheets as per the list attached.

- If the vendor is collaborating with any foreign party for basic engineering, design etc., he should provide certificate of collaboration and first submission of design and detailed drawing shall be approved by the collaborator.

- List of drawings.

7.0 MANDATORY SPARES

The bid must include in the quoted price the following mandatory spares to be supplied with the clean agent system:



2001)DOCUMENT No. 0001-01-10-02-002

1. Clean Agent Cylinders for Centralised : 5% of the total cylinder (filled).

System

2. Automatic and Manual release system : One of each type/size used in the

system supplied.

3. Cylinder Valve with safety : One of each type/size used pressure relief

device in the systems supplied.

4. Clean Agent Nozzles : 10% of total nozzles used in each size/type.

5. Clean Agent Release Push Buttons : 10% of total used of each type etc.

Recommended Spares:

In addition to above mandatory spares, vendor must recommend list of spares required for 2 years trouble free operation with unit rates and quantity along with the offer.

8.0 BID EVALUATION CRITERIA

The bid shall be evaluated based on the following technical criteria,

- Vendor is registered with GAIL - Vender shall have done one of the following to qualify in last 3 years.

a) Inert gas, fire detection & alarm system

b) CO2 /Halon-1301 system, fire detection and alarm system

c) Fire alarm and detection system with back up consultant for inert gas

- The bidder shall very clearly mention in his offer that he has considered total flooding centralised system with directional valves and also have offered 100% standby Cylinders.

- No deviation from Specification is acceptable. - System supplied, design calculation is approved by FM/UL/VDS/LPC &

TAC or its accredited agency.



2001)DOCUMENT No. 0001-01-10-02-002

- Software is approved by FM/UL/VDS - All equipment shall be approved by FM/UL/VDS/LPC & TAC and

cylinder shall be seamless and CCE approved.- Vender not having direct experience shall produce along with offer the

collaboration Certificate.

Completion Certificate of jobs completed shall be produced along with offer.

ANNEXURE-I

LIST OF RISK AND CLEAN AGENT QUANTITY

SL NO

DESCRIPTION ROOM VOLUME (CUM.)

DES. VOL.

(+10%)

MAX VOL

GAS REQ.

(M3)

IG-01, 55,541 & 100 (0.47

M3/M3 OF

VOL)

FF MR FC TOTAL

1 RECEIVING TERMINAL, DOBHOL CONTROL ROOM BUILDING

RISK1 : CONTROL ROOM (8x8.5) RISK2 : UPS ROOM (8X6) RISK3 :

40.8 -

14.4

204 144 72

68 48 24

312.8 192

110.4

344.08 211.2 121.44

344.08

161.72



2001)DOCUMENT No. 0001-01-10-02-002

TELECOM ROOM (4X6)

Size of risk mentioned is approximate. Actual Volume of Clean agent quantity shall be calculated from Final Drg. by bidder / contractor

ABBREVIATIONS:

FF : FALSE FLOOR FC : FALSE CEILING MR : MAIN ROOM

ANNEXURE-II

TECHNICAL DATA SHEETS

DETAILS TO BE FURNISHED BY THE BIDDER ALONG WITH THE OFFER (Clean Agent Data sheets shall be filled in as per NFPA-2001separately for each stations)

C Means Vendor to furnish data/details

1. Type of system : Total flooding centralised system (Mention name of agent &



2001)DOCUMENT No. 0001-01-10-02-002

manufacturer) Formula

Normal Charging Pressure : ____C____ psig.

2. Design code/standard to which design/ manufacture/testing conforms. : NFPA-2001-(Latest)

3.0 System designed to protect the largest or total risk in the building as specified. : Largest risk

3.1 Risk name/volume : C

3.2 Design Concentration : C

3.2.1 Amount of gas required. (Attach separate sheet, if required). (List out gas supplied, number of cylinders etc. for working and standby requirements, risk wise.) : C

3.3 Clean agent Cylinder Details (Seamless)

a) Manufacturer : C

b) Design Code : NFPA-2001

c) Capacity : (Preferably:- IG-01,55,541 &100 : 435cuft filled with 439cuft of gas

d) Gas Holding Capacity (Kg) : C

e) Total Number supplied : C

f) Approving Agency FM/UL/LPC/ VDS & TAC (This must be accep-table to TAC). : FM/UL/LPC/VSD & TAC

g) Approved by CCE : YES

h) Working pressure (kg/cm²) : C

i) Design Pressure (kg/cm²) : As per NFPA-2001



2001)DOCUMENT No. 0001-01-10-02-002

j) Dimension of Cylinder Dia x length x thickness : C

3.4 Pipes, valves and fittings.

a) Manufacturers

i. Pipes : EIL approved vendor

ii. Fittings : EIL approved vendor

iii. Valves : C

b) Material for Construction

i. Pipes : As per spec

ii. Fittings : As per spec

iii. Valves : As per spec

c) Design Code

i. Pipes : As per NFPA

ii. Fittings : As per NFPA

iii. Valves : As per NFPA

d) Type of Joints : As per NFPA

e) Hydraulic test Pressure of Manifold/supply lines (kg/cm²) : As per NFPA

f) Directional Valve

i. Make and Type : C

ii. Material of Construction : C

iii. Test Pressure (kg/cm² ) : C

iv. Approved by FM/UL/VDS



2001)DOCUMENT No. 0001-01-10-02-002

/LPC & TAC (Yes/No) : C

g) Discharge Nozzles

i. Manufacturer and Type : C

h) Pressure Gauge

i. Make : C

ii. Pressure Range : C

iii. Approved by FM/UL/VDS /LPC & TAC (Yes/No) : C

i) Pressure Reducer

i. Make : C

ii. Approved by FM/UL/VDS /LPC & TAC (Yes/No) : C

j) Cylinder valve

i. Make : C


k) Cylinder valve actuator

i. Make : C


3.5 Painting and colouring of pipeline, : C (As per O-611)

3.6 Operating Devices

3.6.1 Signal from the Clean Agent Control Panel for shuttering off the air handling unit and Damper closing. : C



2001)DOCUMENT No. 0001-01-10-02-002

3.6.2 Detectors

i. Manufacturer : C

ii. Type : C

iii. Number : C

iv. Detectors guarded against false alarm (Yes/No) : C

v. Detectors approved by UL/FM/LPC /VDS & TAC (Yes/No). : C

3.6.3 Push Button Station

i. Type : C

ii. Manufacturer : C

iii. Model, numbers offered : C

3.6.4 Control Cables

i. Manufacturer : C

ii. Code/Standard : C

iii. Type : C

iv. Size : C

v. Rating : C

3.6.5 Main Control Panel

i. Manufacturer : C

ii. Mounting Detail : C

iii. Number of entries : C



2001)DOCUMENT No. 0001-01-10-02-002

iv. Sheet Thickness : C

v. Cable Entry : C

vi. Total heat load predicted for air conditioning. : C

vii. No. of AC/DC feeders and their rating. : C

3.7.1 Additional Requirements for Control Panel

a) Whether housing all the necessary printed card circuits, board cards, relays indicating lamps, push buttons, switches, etc. for the efficient operation of the system, (Yes/No). : C

b) Input power supply requirement for operation of panel. (AC/DC Volts) : C

c) Panel Signal Voltage (AC/DC Volts) : C

d) Type/APM Capacity of the : C

e) Interconnecting cabling between battery and panel. : C

f) Power supply unit incorporated in the panel. (Yes/No). : C

g) Audiovisual alarm on panel provided for battery low conditions(Yes/No). : C

h) Change over from AC Main supply to standby power supply fully automatic in either direction (Yes/No). : C

i) Regulated supply for detectors provided in the panel (Yes/No). : C



2001)DOCUMENT No. 0001-01-10-02-002

j) Dual Red Lamps windows provided for fire conditions in each zone. (Yes/No). : C

k) Dual yellow lamps windows provided for fault conditions in each zone (Yes/No). : C

l) Following push buttons provided

i) Alarm Accept : C

ii) Reset : C

iii) Test (Yes/No) : C

m) Audio visual indication for AC supply failure provided (Yes/No). : C

n) Pilot lamp for system ‘ON’ supply failure provided (Yes/No). : C

o) Dial tone hooter for fire/fault alarm provided & range of the same. : C

p) Painting (External/Internal) : C

4.0 Material of Construction selected in accordance with NFPA-2001 (Yes/No) : C

5.0 Inspection and Testing

a) Visual inspection of installed : C system & hazard area.

b) Check of labelling of devices. : C

c) Check for mechanical tightness of piping and associated equipments : C

d) Non-destructive operational tests for all devices included. : C

e) Test with clean agent gas : As per pump test



2001)DOCUMENT No. 0001-01-10-02-002

(one no. Cylinder)


SPECIFIC REQUIREMENTS FOR GEOTECHNICAL INVESTIGATIONS FOR PIPELINE LAYING AND ASSOCIATED

WORKS TENDER 0001-01-10-02-003 Page 1 of 9




WORKS TENDER(STRUCTURAL & ARCHITECH. DEPT.)

SPURELINES OF CHAINSA-JHAJJAR PIPELINE





SPECIFIC REQUIREMENTS FOR GEOTECHNICAL INVESTIGATIONS FOR PIPELINE LAYING AND ASSOCIATED WORKS

1.0 GENERAL

Geotechnical investigations shall be conducted at Despatch Terminal at Sultanpur, receiving Terminal at Neemrana and, SV stations, SV Cum CP stations, IP stations as per Process Flow Diagram . Bidder has to generate required Geotechnical data by investigations. The report shall be submitted to Owner for review and approval before adoption in design. Bidder shall acquaint himself with the site condition before quoting and no claim what so ever on cost and time shall be entertained by the owner on this account.

2.0 SCOPE Geotechnical investigations for Pipe laying and associated works tender is as following table:

Sl. No.

Location Chainage No. Borehole/ Depth Remarks

1 Dispatch Terminal (Sultanpur)

2 Nos.- (1no.) 10m & (1No.) 15m deep boreholes

1no.(15m) -Center of PORTA CABIN 1no(10m).- Center of metering area

2 SV1 1No.-10m deep borehole

Near the center of the plot





5 CGS(DHARUHERA) 1No. - 10m deep borehole


6 CGS(BHIWADI) 1No. - 10m deep borehole


7 CGS(KHUSKHERA) 1No. - 10m deep borehole


8 CGS(NEEMRANA) 1No. - 10m deep borehole


9 CGS(MANESAR) 1No. - 10m deep borehole






10 PRS AT HAYATPUR FOR GURGAON.

1No. - 10m deep borehole


11 RECEIVING TERMINAL AT NEEMRANA

2Nos. - (1no.) 10m & (1No.) 15m deep boreholes

1no (15m). –Near Center of control room 1no.(10m) - Center of scraper Launcher area

The work shall comprises but not limited to the following:

2.1.1 Equipment

Contractor shall mobilize necessary drilling rigs with adequate capacity for boring in all kinds of soil of specified depth of borehole.

2.1.2 Boring:

Boreholes of 10m to 15m deep as specified in the above tables the Table shall be carried out. Conducting standard penetration tests and collecting disturbed and undisturbed soil samples from boreholes.

Collection of soil and ground water samples for chemical testing.

Laboratory testing of soil samples collected. Minimum number of laboratory tests to be conducted per borehole are given in the following table.

Number of tests to be conducted SL.No Type of test

15m deep

Borehole

10m deep

Borehole

1 Grain size analysis 4 3

2 Atterberg limits (If clayey strata is found) 4 3





3 Free swell and swelling pressure(If soil is expansive in nature)

2 2

4 Consolidation tests (If clayey strata is found) 2 1

5 Unconfined compressive strength (If clayey strata is found)

2 2

6 Triaxial tests UU (If clayey strata is found) 1 1

7 Box shear Test in sandy soil sample 1 1

8 Dry density and moisture content relationship

1 1

9 Laboratory CBR test on soil samples to be used below road /pavement.

2 2

10 Chemical tests on soil and ground water samples

2 2

3.0 REQUIREMENTS

3.1 The contractor shall confirm their schedule of field / laboratory investigations well in advance for the purpose of witness of tests by GAIL if so desired. The contractor shall mobilize a qualified Geotechnical engineer for supervision of field works. Also an experienced Geotechnical Engineer with minimum postgraduate qualification should be engaged for preparation of the report and he should visit site to familiarize with the site conditions and to assess various field and laboratory tests to arrive at design parameters. All test equipments and tools shall conform to relevant IS code of practice.

3.2 BORING

Boring shall be carried out in accordance with the provision of IS: 1892. Minimum diameter of boring shall be 150mm. Auger boring shall be resorted to above the water table, whereas below the water table the boreholes shall be advanced by shell and auger/ rotary drilling with mud circulation through all kinds of soil other than rock. While boring above water table, no water shall be introduced in the boreholes. Casing shall be used to support the sides of boreholes in very soft to soft/loose soils.

Use of chisel, percussion and drilling with Nx size may be permitted exclusively in strata having SPT-N greater than 100 blows per 30cm penetration and as per direction of Engineer-in-charge.





Termination criteria of boreholes is as follows

i) Maximum depth as specified or

ii) After encountering soft/weathered rock

iii) After observing three consecutive SPT-N values greater than 100 at 1.0m interval which ever occurs earlier.

3.3 STANDARD PENETRATION TESTS (SPT)

These shall be conducted in boreholes at interval of 1.0m or at change of strata upto 5.0 mt. and at interval of 1.5 mt or change of strata beyond 5.0mt starting first test at 0.5m depths. Last SPT shall be conducted at the termination depth of borehole. The disturbed representative samples shall be visually classified, labeled for identification and properly preserved for laboratory testing. SPT shall be terminated at any depth after three consecutive SPT-N values greater than 100 (number of blows exceeds 100 for a penetration of 30cm or less). All test equipments and tools shall conform to relevant IS code of practice.

3.4 UNDISTURBED SAMPLES

Undisturbed samples of 100mm dia. shall be taken from all boreholes and from representative strata at intervals of 2.0m or change of strata whichever occurs earlier starting first UDS at 1.0 depth. For stiff clays, area ratio of the sampling tubes shall not exceed 20%. In soft deposits piston sampler shall be used to collect UDS.

Care shall be taken to minimize sample disturbance during collection of samples. Samples shall be collected by pushing the sampler. Driving by hammer above ground level (like SPT) is not acceptable. However, for stiff / hard soil a sliding hammer can be used for driving the sampler at sampler head. If at any depth SPT and UDS coincide, then UDS shall be taken at that depth. In case UDS slips then SPT shall be taken immediately below the depth after proper cleaning of the borehole.

3.5 DISTURBED SAMPLES

Disturbed soil / wash samples shall be collected at every 0.5m intervals and at every change of strata from boreholes. Identification labels indicating depth, borehole no. and visual soil classification shall be affixed on the containers.

4.0 LABORATORY TESTS:





4.1 After collecting disturbed and undisturbed samples from different boreholes at different depths, a laboratory test schedule shall be prepared and submitted to GAIL / Client for review. Adequate number of the following tests shall be conducted to clearly determine the mechanical strength and compressibility characteristics of each strata of soil encountered. All tests on rock and soil samples shall conform to relevant IS codes of practice. The laboratory tests shall essentially comprise of but not limited to the followings:

4.2 Grain Size Distribution

Wherever applicable both the sieve & hydrometer analysis shall be conducted to indicate complete range of grain sizes of soil samples tested.

4.3 Atterberg Limits

Wherever applicable, these tests shall be carried out by the skilled personnel. The test result should include liquid limit, plastic limit and shrinkage limit of the soil samples tested. These tests should be conducted as per IS-2720, Part V & VI.

4.4 Free Swell and Swelling Pressure Tests

If the soil is found to be expansive in nature then these tests shall be carried out by the skilled personnel.

4.5 Consolidation Tests

The following loading stages shall be employed:

0.10, 0.25, 0.50, 1.0, 2.0, 4.0, 8.0 kg/cm2.

From e Vs log p curves, pre consolidation pressure shall be determined to establish whether the soil is normally consolidated or over-consolidated. The point (e, p) showing initial condition of the soil under test must be specifically marked on the consolidation curves. Settlement predictions based on the field virgin compression curve shall only be acceptable. The procedure adopted in respect of obtaining compression indices from the field curve & that for computing settlements for the type of clay under consideration shall be clearly illustrated in the report.

It is to be noted that deviations from the standard procedure of performing consolidation tests given in IS-2720 Part XV are permissible in order to enable computation of settlements based on the above procedure i.e. cycle(s) of loading, unloading& reloading shall be employed wherever required.





The following curves shall be included in the report:

a) e Vs log P b) e Vs p c) Compression Vs log (t) or compression Vs t

The choice of relationship depends upon the shape of the plot, which enables clear determination of CV, the coefficient of consolidation. The time period required for 50% & 90% primary consolidation should be given in the report. Computation of secondary settlements, if significant, shall also be made and included in the report.

4.6 Unconfined Compressive Strength

These tests shall be done as per IS-2720 (Part- X) on selected soil sample.

4.7 Triaxial Tests

These tests shall be done on specimens saturated by the application of backpressure. Only if the water table is at sufficient depth so that chances of its rising to the base of the footing are meager or nil, the triaxial tests shall be performed on specimens at natural moisture content. The magnitude of the backpressure applied shall be indicated in the report.

All the stress strain diagrams as well as Mohr circle envelops shall be included in the report. Density and water content of the sample tested and modulus of elasticity along with shear strength parameters shall be reported.

In case the soils are predominantly sandy in nature and sampling is not possible for triaxial shear tests, box shear tests shall be carried out.

4.8 Modulus of Elasticity

E-value shall be determined from the triaxial tests. Relative corrections applied to the computed 'E' shall be clearly illustrated in the report.

4.9 Dry density and moisture content relationship

This test shall be conducted on soil sample collected within 1.0m from ground surface below the top soil. The test shall be carried out, as per IS 2720 Part-VIII.

4.10 Chemical tests on soil and Ground water samples.





This test shall be conducted on soil and water samples for pH, Chloride (Cl) and sulphite and Sulphate content.(SO3 & SO4)

5.0 REPORT:

5.1 Interim reports shall be furnished at various stages of investigation for our comments.

5.2 Detailed report shall be prepared and submitted to us as soon as the field and laboratory works are completed in a draft form for our review and comments. All the informations as mentioned below shall be furnished in the draft copy of final report. After reviewing, contractor shall be informed about our comments / remarks, if any, the same shall be incorporated. The report shall also include but not limited to following :

1. A plot plan showing all the test locations with respect to reference chainage.

2. General geological information of the site.

3. Character and genesis of soil.

4. Procedure of investigation and method of various testing adopted.

5. Detailed bore logs indicating co-ordinates, reduced level, ground water table etc., subsoil section along various profiles indicating boreholes nos. depth wise, in-situ tests like SPT.

6. All field and laboratory test results shall be plotted against depth and also in tabular form.

7. Summary of results obtained from various tests and their interpretation to evaluate various soil parameters.

8. Ultimate and safe bearing capacity from shear as well as from settlement criteria (i.e. for 25mm & 40mm) for the shallow footings of size ranging from 1m to 4m and for rafts of size greater 6.0m placed at different depths from 1 to 3 meters. The capacities shall be worked out based on the various field and laboratory tests viz. SPT, shear parameters etc.

9. Comments on chemical aggressiveness of soil and ground water on reinforced concrete, steel and other building materials and firm recommendations on remedial / preventive measures.





10. Recommendations regarding design and construction of roads and other paved structures and also suitability of soil for back filling foundations.

11. Recommendation related to site preparation including classification, placement and compaction of fill materials required to bring the general site level of final grade level, if so required. Recommendations regarding excavation, stable slopes for excavation, dewatering and method of dewatering, if warranted.

All recommendations shall be supported by back up calculations.

No extra payment shall be admissible for preparation of report.

DOCUMENT No. REV-0

GAIL (INDIA) LTD NEW DELHI

JOB SPECIFIC REQUIREMENTS FOR CIVIL-STRL WORKS FOR PIPELINE LAYING AND ASSOCIATED WORKS.

0001-01-10-02-004Page 1 of 4

GAIL(INDIA) LIMITED

JOB SPECIFIC REQUIREMENTS FOR CIVIL-STRL WORKS FOR

PIPELINE LAYING AND ASSOCIATED WORKS TENDER

DOCUMENT No. REV-0



0001-01-10-02-004Page 2 of 4

SPECIFIC REQUIREMENTS: CIVIL-STRUCTURAL WORKS

1. Structural concrete shall be of DESIGN MIX.

2. Concrete grade for RCC works shall be M 30, with minimum cement content

of 330kg/m3

and a maximum free-water-cement ratio of 0.5.

3. 75 mm thick lean concrete of proportion 1: 5: 10 shall be provided under all RCC foundations except under base slab of liquid retaining structures where 100 thick concrete of mix 1:3:6 shall be used. The lean concrete shall extend 50mm beyond the foundation for normal foundations and 75mm under liquid retaining structures.

4. Concrete grade for PCC works shall be M 15, with minimum cement content

of 265kg/m3

and a maximum free-water-cement ratio of 0.6.

5. Plain cement concrete mud mat of M15 (by weight) of minimum 150mm thickness shall be provided under all masonry wall foundations.

6. Type of cement and clear cover to reinforcing steel for all foundations and all structural elements in contact with soil shall be as per Geotechnical data.

7. Anti-termite treatment shall be provided for all buildings as per specifications.

8. Reinforcing steel shall be TMT deformed steel bars of grade Fe415 conforming to IS1786.

9. Structural steel shall be of yield stress of 250 MPa conforming to a minimum of Grade A of IS 2062. Tubular steel shall conform to Yst 240 of IS1161.

10. Anchor bolts shall be of mild steel confirming to IS: IS2062 grade A.

11. 40mm thick concrete of Grade M20 (using 10mm down aggregates) shall be provided as Damp Proof Course (DPC) at plinth level under all masonry walls, overlain with bitumen layers as per specifications.

12. Floor gratings and handrails shall be galvanized. Galvanized Electro forged MS Gratings shall be of mild steel and minimum 25mm deep. The maximum size of voids in the grating shall be limited to 30mmx55mm. Galvanizing shall be 900 g/m of surface area.

13. Shop primer and finish paint shall be applied on all fabricated structural steel (except handrails and gratings) with paint system as per specification No. 6-

DOCUMENT No. REV-0



0001-01-10-02-004Page 3 of 4

44-0004 - Table 8.0 (for a design temperature (-) 140

to 60C). Surface preparation of structural steel for application of paint shall be as per relevant clause of 6-44-0004.

14. Grouting shall be done with non-shrink grout as per specifications

15. Fabrication & erection drawings shall be prepared by the contractor as per clause. no. 3 of Specification .

16. Expansive soils, if encountered, the foundation shall be placed below the expansive soil or cushion of minimum 500 mm well compacted morrum/coarse sand laid below foundation. In case rock is encountered minimum depth of foundation shall be provided as per IS 1904.Expansive soils shall not be used for backfilling purposes.

17. Bricks for masonry work shall be of class 5.0

18. Review of design and approved for construction (AFC) drawings

Complete structural design and AFC drawings for the following structures shall be got reviewed by owner/owner’s representative in detail before taking up any construction activity at the work site.

1) Porta Cabin at Dispatch/Receiving Terminals and at SVs2) Porta Cabins at SV-1, SV-2, SV-3 and SV43) Guard Rooms at all SVs and Dispatch and Receiving Terminals4) Guard Rooms at SV-1, SV-2, SV-3 & SV-4

5) Pipeline facilities 6) Sump Tank 7) Pump Foundation 8) Support for Scraper launcher/receiver 9) Support for basket filters. 10) Compound Wall/ for all PRS , SVs, Despatch / Receipt Terminals


JOB SPECIFIC REQUIREMENTS FOR CIVIL-STRL WORKS FOR PIPELINE LAYING AND

ASSOCIATED WORKS. 0001-01-10-02-004 Page 4 of 4



JOB SPECIFICATIONFOR PACKAGED EQUIPMENT INPUTS

0001-01-10-02-005 Page 1 of 15



SPURELIENS ON CHAINSA-JHAJJAR PIPELINE PROJECT

Tender for Pipeline Laying & Terminal Works

JOB SPECIFICATION

(PACKAGED EQUIPMENT INPUTS FOR TENDER FOR PIPELINE LAYING & TERMINAL WORKS)



0001-01-10-02-005 Page 2 of 15


1.0 TECHNICAL REQUIREMENTS

a) The equipment shall be designed, manufactured, tested and supplied in accordance with the enclosed data sheets, this job specification, standard specification for Air conditioning plant, Electrical specifications/data sheets, Piping specifications, enclosed drawings and all other attachments of the material requisition.

b) The areas to be air-conditioned are shown in the enclosed architectural drawings. Accordingly, bidder shall provide all items on lump sum basis and SHALL NOT INDICATE QUANTITIES OF VARIABLE ITEMS IN THE BID.

c) Relevant constructional details for the areas to be air-conditioned shall be as per enclosed architectural drawings.

Bidder shall estimate plant capacity considering all internal electrical and instrumentation heat dissipation. However, minimum capacity of the plant shall be as indicated in this specification, which shall be complied by the bidder and bidder shall guarantee the inside conditions throughout the year.

Bidder shall be solely responsible to demonstrate the specified inside conditions. Bidder shall furnish heat load calculations for summer, monsoon & winter, psychrometric mixture conditions, and the processes which air undergoes in the conditioning equipment.

d) Bidder shall include all items required to complete the intent of this specification not withstanding the fact that such items may have been omitted from the specification or drawings.

e) Bidder shall furnish all data sheets and drawings for Purchaser's review before commencement of fabrication/ construction.

f) Bidder shall note that entire data presented by them at bid stage will be retained for information only. Purchaser shall review the data during detailed engineering after award of contract, within the framework of this specification. All comments of Purchaser shall be taken care without any cost and time implication.

g) Chipping of RCC slab for duct hangers is not allowed. Bidder shall provide anchor fasteners. Complete supporting structure for duct/ cable /pipe/ tubing etc. shall be provided by bidder.

h) Air handling section of Packaged Unit shall provide cooling and dehumidification in summer/monsoon by handling mixture of fresh and return air. Reheating shall be provided in monsoon to achieve specified inside conditions by means of finned strip heaters actuated by humidistat, backed up by safety thermostat.



0001-01-10-02-005 Page 3 of 15


Winter heating shall be achieved by finned strip heaters actuated by heating thermostat backed-up by safety thermostat.

i) Noise level in AC Plant Room shall not exceed 85 dBA at 1 meter away from source.

j) Standard Specification for air conditioning plant no. shall be referred for applicable items by bidder.

k) Bidder shall ensure that fixing arrangement of diffusers is such that there is no load on false ceiling. Size of diffusers shall match with light fittings. Diffusers shall be firmly fixed with the ductwork.

l) Insulation material to be used for duct shall have factory laminated aluminium foil.

m) All foundations including requisite multi layer virgin neoprene pads shall be provided by the Bidder between foundation blocks & equipments e.g. Package Unit.

n) All the equipment, electrical and controls shall be suitable for electrical area classification in which they are installed.

o) All couplings, gears and exposed rotating parts shall be provided with appropriate guards.

p) Electronically operated spring return type Fire Dampers shall be provided in supply air and return air paths.

q) Package unit & Fire dampers shall be interlocked by Contractor with gas / smoke detection and fire fighting system wherever such system exists.

r) The complete supply air ducts shall be insulated. Similarly return air ducts wherever provided shall be boxed (in exposed areas) and insulated.

s) Safety factor shall be considered as 12.5% in respect of Room Sensible Heat and 10% in respect of Room Latent Heat in heat load calculations. Packaged Units’ actual output capacity shall be worked out based on site conditions.

2.0 DESIGN DATA

2.1 Outside design conditions shall be as indicated.

DBT (0C) RH (%)

Summer 38 60



0001-01-10-02-005 Page 4 of 15


Monsoon 29.4 88 Winter 18.3 65%

2.2 Inside design conditions to be maintained shall be as under:

DBT 23 ± 10C and RH 50 ± 5 %

2.3 Architectural drawing (Areas/ Rooms to be air-conditioned are marked) Control Building, Drawing No. 0318-00-16-48-1104

2.4 Design information Hours of operation : 24 hours/ day, each day of the year

3.0 UTILITIES

Electric power shall be provided at single point as specified in Electrical Specification.

4.0 MAKES OF BOUGHT-OUT EQUIPMENT / MATERIAL

ITEM MAKE OF EQUIPMENT

1.Packaged Unit Blue Star/ Voltas/ Batliboi/ Carrier/ KPC/ York 4.Pulleys & Belts Fenner

/ Dunlop 5.Filters Tenacity / Kirloskar / Anfilco / Dyna 7.Fire dampers TSC Instruments

11.Thermal Insulation Lloyds / Metthur Beardsell / U.P.Twiga 12.Pr./Temp. Gauges

H.Guru / Gen.Instruments 13.Solenoid Valves Asco / Rotex / Harion 14.HP/LP/Oil

Pressure Indfoss/Switzer/Honeywell All other Electrical / instrumentation items shall be

of GAIL approved makes as per the approved vendor list. For items not covered in the

above list, bidder shall propose the sub-vendors for the same, with their proven track

record in similar service, which shall be subject to GAIL approval.

5.0 PREPARATION OF SHIPMENT AND PACKING

5.1 Vendor shall prepare equipment with packing appropriate for shipping. Packing shall be adequate to provide protection against mechanical damage and atmospheric corrosion in transit and for outdoor storage at job site.

5.2 Open ends of tubes shall be capped for protection.

5.3 One complete set of installation instructions shall be shipped with each unit.



0001-01-10-02-005 Page 5 of 15


6.0 IDENTIFICATION

6.1 Each major part of the equipment shall have a permanently attached stainless steel name plate.

7.0 LAYOUT

7.1 The condenser unit shall be so located that there is enough space at the back (if required) & sides for free flow of air.

MANUFACTURER SPECIFICATION

8.0 DATA SHEET OF PACAKGE UNIT

OPERATING CONDITIONS

Area Classification Safe

Refrigerant R-22

Type Air cooled

Capacity TR

Quantity

Working

Stand By

Ambient temperature for selection of air cooled condensers

400C

MANUFACTURER SPECIFICATION

COMPRESSOR

Make



0001-01-10-02-005 Page 6 of 15


Model

Quantity of compressors per package units

No

Saturated suction temperature Deg c

Saturated suction pressure Kg/Cm2

Saturated discharge temperature Deg c

Saturated discharge pressure Kg/Cm2

Nominal capacity TR

Capacity at design conditions TR

Capacity control arrangement

Type Seal/Open/Semi hermetic

Method of lubrication Oil pump/splash

Shaft power BKW

Shaft speed RPM

Motor KW RPM

Guaranteed power at motor terminals

KW

Grade of lubrication oil

Detail of unloaded starting arrangement

AIR COOLED CONDENSER

Make

Model

Quantity of condensers per package unit



0001-01-10-02-005 Page 7 of 15


Type

Total heat rejection TR

Face area of each coil Mm x mm

Face velocity across coil m/sec

Tube O.D. mm

Tube thickness mm

Bends thickness mm

Fin spacing FPI

Quantity of fans per condenser Nos

Air flow rate per fan M3/hr

Type of fan for air circulation

Motor (KW / RPM) per fan KW / RPM

Diameter of fan impeller mm

Make

Model

Total air flow rate - m3 / hr.

Size of filter element- mm x mm x mm

Air flow rate per element - m3 / hr.

Quantity of filter elements - Nos.

Face velocity- m /sec

Filtration efficiency-% down to



0001-01-10-02-005 Page 8 of 15


micron

Pressure drop in clean condition -mm WC

Maximumallowable pressure drop - mm WC

Fixing - Flange / Channel

Type of filter - HDPE mesh –reusable

COOLING COIL

Make

Model

Air entering condition 0C DB / 0C WB

Air leaving condition 0C DB / 0C WB

ADP 0C

Capacity TR

Total air flow rate CFM

Face size mm x mm

Number of rows Nos.

Type DX

Bypass factor

Pressure drop, air side mm WC

Tube O.D. mm

Tube wall thickness mm



0001-01-10-02-005 Page 9 of 15


Bends thickness mm

Fin spacing FPI

Bonding of fins Hydraulically / with mandrel

Velocity of air across coil m/sec.

BLOWER

Make

Model

Type Centrifugal

Blade profile Forward / Backward / Radial

Air Flow CFM

No of impellers Nos.

Impeller diametermm

Impeller speed RPM

Static pressure 50 mm WC

Power consumption at shaft kW

Guaranteed power at motor terminals

kW

Drive arrangement V-belt drive

Air outlet velocity m /sec.

MotorkW / RPM



0001-01-10-02-005 Page 10 of 15


Bearing lubrication Oil / grease

Noise level db

No. of belts Nos.

ACCESSORIES

Purchaser’sRequirement

Bidder’sConfirmation

Guard for moving parts Required

Belt tensioner Required

Insulated drain pan with drain connection

Required

First charge of refrigerant, oil, lubricants

Required

Grease nipple for bearings Required

Painting Required

Drain piping Required

V-belt drive package with V-belts Required

Anti vibration mounting Required

Lifting lugs Required

Base frame Required

On-Off damper at the outlet of each package unit

Required

HP / LP cutout Required

Low oil pressure cutout Required

Audio/visual annunciator Required



0001-01-10-02-005 Page 11 of 15


Refrigerant controls

AIR COOLED CONDENSER

Make

Model

Quantity of condensers per package unit

Nos.

Type

Total heat rejection TR

Face area of each coil mm x mm

Face velocity across coil m /sec.

Tube O.D. mm

Tube thickness mm

Bends thickness mm

Fin spacing FPI

Fin thickness mm

Quantity of fans per condenser Nos.

Air flow rate per fan m3 / hr.

Type of fan for air circulation

Motor (KW / RPM) per fan KW / RPM

Diameter of fan impeller mm

FILTER AT PACKAGE UNIT INLET & FINE FILTERS(95% at 5 microns) Make INLET FILTERS FINE FILTERS

Model

Total air flow rate - m3 / hr.

Size of filter element- mm x mm x mm Air flow rate per element - m3 / hr.

Quantity of filter elements - Nos.



0001-01-10-02-005 Page 12 of 15


Face velocity- m /sec .

Filtration efficiency-% down to micron Pressure drop in clean condition -mm WC-Maximum allowable pressure drop -mm WC Fixing - Flange / Channel

Type of filter - HDPE mesh – reusable

COOLING COIL

Make

Model

Air entering condition 0C DB / 0C WB

Air leaving condition 0C DB / 0C WB

ADP 0C

Capacity TR

Total air flow rate CFM

Face size mm x mm

Number of rows Nos.

Type DX

Bypass factor

Pressure drop, air side mm WC

Tube O.D. mm

Tube wall thickness mm

Bends thickness mm

Fin spacing FPI

Bonding of fins Hydraulically / with mandrel

Velocity of air across coil m/sec.

BLOWERMake



0001-01-10-02-005 Page 13 of 15


Motor kW / RPM

Bearing lubrication Oil / grease

Noise level

No. of belts Nos.

ACCESSORIES

Purchaser’s Requirement

Bidder’s Confirmation

Guard for moving parts Required

Belt tensioner Required

Insulated drain pan with drain connection

Required

First charge of refrigerant, oil, lubricants

Required

Grease nipple for bearings Required

Painting Required

Drain piping Required

V-belt drive package with V-belts Required

Anti vibration mounting Required

Lifting lugs Required

Base frame Required

Model

Type Centrifugal

Blade profile Forward / Backward / Radial

Air Flow CFM

No of impellers Nos.

Impeller diameter mm

Impeller speed RPM

Static pressure 50 mm WC

Power consumption at shaft kW

Guaranteed power at motor terminals kW

Air outlet velocity m /sec.

Drive arrangement V-belt drive



0001-01-10-02-005 Page 14 of 15


On-Off damper at the outlet of each package unit

Required

HP / LP cutout Required

Low oil pressure cutout Required Audio/visual annunciator Required

Refrigerant controls Required

MATERIAL OF CONSTRUCTION

Air Cooled Condenser

Tubes Seamless copper tubes

Fins Aluminium

Frame/casing Carbon steel / Galvanised sheet

Cooling coil

Tubes Seamless copper tubes

Fins Aluminium

Frame/casing Carbon steel / Galvanised sheet

Filter

Filter media HDPE mesh - reusable

Blower



0001-01-10-02-005 Page 15 of 15


List of Attachments

1. Scope of Work/ Scope of Supply, Document No. . 2. Drawing Data Requirements, Document No.. 3. Standard Specification for Air-conditioning Plant 4. Architectural Drawing of Control Building,

Impeller Carbon steel / aluminium / stainless steel

Shaft EN-8

V-pulleys C.I. multi grooves

DIMENSIONS / WEIGHT

Overall size mm x mm x mm

Overall weight

Kgs.

INSPECTION AND TEST

As per Standard Specification attached.


STANDARD SPECIFICATION FORSURVEY WORKS S-10-02-001 Page 1 of 7


STANDARD SPECIFICATION FORSURVEY WORKS




C O N T E N T S

1.0 GENERAL

2.0 SCOPE

3.0 PERFORMANCE REQUIREMENTS

4.0 LOCATION SURVEY OF EXISTING CONTROL POINTS

5.0 TOPOGRAPHICAL SURVEYS

6.0 SPOT LEVELS & CONTROL PLANS

7.0 SURVEY OF EXISTING STRUCTURES

8.0 GRID-STATIONS , BOUNDARY PILLARS AND PERMANENT PILLARS (BUOYS)

9.0 MAPS & DRAWINGS

10.0 DOCUMENTS TO BE HANDED OVER BY THECONTRACTOR TO CLIENT.

11.0 PAYMENT




1.0 GENERAL

The intent of this specification is to cover the basic requirements for conducting the landsurveys to generate requisite information for the design and field engineering activities.

2.0 SCOPE

This specification covers the land surveys consisting of the following works.

a) Preparation of contour survey maps, with spot levels.

b) Establishment of base line and grid system for defining the co-ordinates of the various areas.

C) Preparation of surveys maps. One set of survey maps shall be prepared as below :

d) Overall layout of the area to a scale of 1 :2000 with spot levels @ 50 m C/C and a contour interval of 0.5 meters unless specified otherwise.

e) Electronic file for spot levels.

2.1 The grid system shall be established by constructing cement concrete pillars brickpillars. stone masonry pillars @ 400 m C/C along the base line and a 200 m C/C at right angles to the baseline.

2.2 The survey maps shall show all cross drainage works, U/G cables, pipes etc. irrigation structures, building, trees, electric, Telegraphic poles, transmission towers or any other prominent physical feature.

2.3 Establish reliably High flood level and its source and indicate the source of information.

2.4 For sea shore locations, indicate tidal data such as low tide, high tide and mean tide

2.5 Identify storm water disposal point as naturally existing as per site conditions.

2.6 The contractors shall identify Bench mark of the area and shall carry over level from Bench Mark to the site bench mark. This reference of BM shall be recorded on survey drawings.

3.0 PERFORMANCE REQUIREMENTS




3.1.1 The work shall be carried out as per the well established, sound survey practices and standards and by qualified and competent surveyors under the direct supervision of qualified engineers and surveyors.

3.2 The Contour survey shall be carried out with reference to the existing permanent bench marks.

3.3 All measurements shall be in metric units.

3.4 The corrections arising from the standard errors, variations in temperatures, pulls etc. shall be incorporated to the linear ground measurements.

3.5 The observations for the measurement of vertical distances on bench marks and turning points shall be read nearest to 5 mrn and for other nearest to 10mrn.

3.6 The error for linear measurement shall not exceed 1: 10,000 and for angular measurements, six seconds per station.

4.0 LOCATION SURVEY OF EXISTING CONTROL POINTS

4.1 A preliminary survey to identify exising control points shall be carried out and their correctness ensured.

4.2 All such control points shall be demarcated in the area plan.

4.3 The nearest available permanent bench mark shall be transferred to the area either on a permanent feature or on a concrete pillar specially erected for the purpose.

5.0 TOPOGRAPHICAL SURVEY

The topographical surveys shall be carried out in the following way.

5.1 Horizontal Control

The horizontal control shall be fixed by one or a combination of the following:

a) Triangulation.

b) Closed Traverse.

5.1.1 Triangulation




The triangulation work shall start from a baseline, having a minimum length of 100 meters in relation to a point whose co-ordinates have been established. The accuracies of linear and angular measurement shall meet the requirements defined in Para 3.0.

5.1.2 Before starting the triangulation work, grid pillars shall be constructed on the base line.

5.1.3 Closed TraverseThe closed traverse shall be set by the measurement of angles between two successive lines.

The angles shall be measured with theodolite only. The distance between two traversestations shall not be more than 100 meters.

The cumulative angular error of the closed traverse shall not be more than 30lN seconds where N is the number of traverse station. All the traverse shall have an accuracy of not less than 1:5000.

5.2 Vertical Control

5.2.1 Vertical control points shall be fixed by dumpy level on all the traiangulationltraverseStation, and shall be closed by coming back to the starting point. The accuracy of the main control shall be + 5 4 K mrn where K is the distance in Kilometers,

5.2.2 After setting horizontal and vertical control, inter-filling can be done either by the theodolite or by any other means:

6.0 SPOT LEVELS & CONTOUR PLANS

6.1 For taking the spot levels, the area shall be divided into main grids of 50M x 50 M and levels observed at every inter section. These grids shall be further sub-divided into smaller grids of 25 M x 25 M to locate prominent physical features of the terrain. The field levels shall be so obtained as to get a countour interval of 0.5 meters.

7.0 SURVEY OF EXISTING STRUCTURES

The survey of the existing structures shall include road with centre line co-ordinates, width of roads, berms, details of curves, location of storm water drains, culverts etc.

8.0 GRID STATIONS, BOUNDARY PILLARS AND PERMANENTPILLARS (BUOYS) :These shall be constructed of cement concrete brick stone masonry work of sizes as below:

- Grid stations - 300 x 300 x 1200 mm deep (500 mm below G.L. and 700




mm above G.L.).

- Boundary pillars along land acquisition limits at all corners and at 400 mmC/C in straight reaches shall be constructed. Size shall be 300 x 300 x 1000mm deep. ( 500 mm below GL and 500 mm above GL).Permanent Pillars(Buoys) shall be of size 1500 x 1500 x 2000 mm with co-ordinates on RI for future reference as per locations marked in the reference drawings.

Grid stations and Permanent Pillars shall be provided with steel plates 150 x 150 x 10 mm embedded in concrete with 12 mm dia x 150 mm long anchor bolts. These shall be provided with punch lines & painted with anticorrosive paint. All Grid station andpillars shall be numbered for easy identification.

9.0 MAPS & DRAWINGSThe survey maps shall be based on the survey work executed and shall show all relevant information regarding existing features, physical terrain, grid system; permanent bench mark etc. These maps shall be the sole property of the owner.

10.0 DOCUMENTS TO BE HANDED OVER BY THECONTRACTOR TO CLIENT

10.1. The contractor shall hand over all field books neatly maintained as specified elsewhere. Any clarification required on the field book shall be promptly furnished by the contractor to Client/Engineer-in-charge.

10.2 Five copies of check prints of the plotted maps shall be supplied by the contractor toClient/Engineer-in-Charge for their approval along with original which shall be prepared on the tracing cloth.

10.3 On approval of check prints by Engineer-in-Charge, ten copies of blue prints along with original tracings on polyster non-tear transparent tracing film in ink for the map shall be handed over to Engineer-in-Charge.

10.4 In addition to the requirements given above the contractor shall furnish the field in Electronic file using NORTON EDITOR software in the following formats

STORE bnl,bx, by, bz, b*

STORE bn2, bx, by, bz, b*

nl 1,2,3,4 , n(node no. of spot level




b blank space

x x-coordinate

Y y-coordinate

Z z-coordinate* * from key board

Property of Maps

Maps prepared by the contractor based on survey work carried out under this agreement shall be the sole property of Client. The contractor shall have no right to use reproduce or pass on to the third party without prior written permission of Client.

11.0 PAYMENT

Payment for survey work shall be made on Area basis as per schedule of items Payment for grid stations, boundary pillars, permanent pillars (Buoys) shall be made on unit basis as per schedule of items. No other payment shall be made. All connected works including supply of drgs. and Electronic files shall be considered as part of the total work.


STANDARD SPECIFICATIONFOR

UNDERGROUND PIPING(GENERAL CIVIL)

S-10-02-002 Page 1 of 5


STANDARD SPECIFICATION FOR EARTHWORK FOR UNDERGROUND

PIPING(GENERAL CIVIL)




S-10-02-002 Page 2 of 5


C O N T E N T S

1. SCOPE

2. MATERIALS

3. EARTHWORK IN EXCAVATION FOR TRENCHES FOR PIPELINES

4. BACK FILLING AROUND VALVE PITS AND TRENCHES

5. TRANSPORTATION OF SURPLUS EARTH




S-10-02-002 Page 3 of 5


1. SCOPE

This specification deals with Earthwork for underground piping in all locations covered under this tender.

2. MATERIAL All workmanship and material shall conform to the provisions of the following codes and Standards Specifications IS : 1200 (Part-1) and IS : 3764.

3. EARTHWORK IN EXCAVATION FOR TRENCHES FOR PIPELINES

3.1 Trenching work shall be carried out in all classes of soil including soft rock and excluding hard rock.

3.2 The trench shall be cut true to the line and level as per drawings.

3.2.1 If the trench is excavated below the required level indicated in the drawing, the extra depth shall be filled with concrete or approved equivalent materials as directed by the Engineer-in-Charge at no extra cost to the owner.

3.3 In case of pressure piping, the trench shall be excavated generally as to provide a cover of 1000 mrn or dia of pipe whichever is more. In case of gravity sewer pipes, the trench shall be excavated to conform to invert levels as per drawings. However in certain cases the pipes may run shallower levels. or at deeper levels depending upon drawing, site condition etc. No rebate for lesser excavations nor extra payment due to deeper excavations shall be admissible in those cases where pipeline laying rates are inclusive of earthwork items. The rates quoted shall be deemed to cover all work connected with trenching, whether trenches with single pipeline or pipelines in common trenches including road cutting.

3.4 The width of the trench shall be sufficient to give free working space on each side ofthe pipe. The free working space shall confirm to IS : 783. Generally it shall not be less than 150 mm on either side or 1/3 dia of the pipe whichever is greater.

3.5 When pipelines are running parallel whether the trenching shall be individual or common shall be decided by the Engineer- in-Charge and such decision shall be final and binding on the contractor. No extra shall be payable for common excavations.

3.6 All earthwork involved in excavations of all types of manholes, catch pits, valve chamber, inspection chambers, chambers for instrumentation tapping etc. which are coming on the alignment of U/G piping or defined by drawing as a point of




S-10-02-002 Page 4 of 5


the U/G piping work is deemed to have been covered in the rate for pipe laying.

3.7 All types of shoring and strutting wherever necessary shall be adopted to with hold theface of earth or cutting in slope as per site requirements, and as directed by the Engineer- in-Charge . Earthwork in excavation includes dewatering if required, for which no extra payment will be made.

3.8 Excavated materials shall not be deposited within 1.5M from the top edge of theexcavation, or within a distance equal to the depth of excavation whichever is higher.

3.9 Any obstacle encountered during excavation shall be reported immediately to the Engineer-in-Charge and shall be dealt with as-instructed.

3.11 The contractor shall maintain excavated pit in a dry and trim condition

3.12 Necessary barricading and protection of slopes against slips due to traffic shall be provided to the satisfaction of Engineer-in-Charge. Also necessary warning flags and lights shall be provided to caution traffic.

3.13 In case of road cutting, all material i.e. metal, soling stone etc., shall be taken out carefully and kept separately for reuse and road work shall be redone up to the original level prior to cutting the road with the excavated road materials after lying and testing of the pipeline within 10 days from the date of starting this work at the cost of the contractor. The contractor shall provide suitable warning signs and barricades to prevent accidentsHe shall also provide reasonable bye pass at his own cost when a road is cut for laying pipeline. Tankage dykes cut due to laying of the pipes, shall1 be redone conforming to the original specifications by the Contractor at his own cost.

3.14 Dewatering shall be done in advance of the installation of the pipe to allow adequate inspection of padding of the bottom if required and dewatering shall be continued throughout during installation and backfilling. In muddy or slushy ground, the bed shall




S-10-02-002 Page 5 of 5


be provided with a layer of sand or concrete as directed by the Engineer-in-Charge at no extra cost. The trench shall follow the gradient of pipeline as specified in the drawing contractor shall keep the trench in good condition until the pipe is laid and tested . The and no extra claim shall be entertained due to its caving or setting down either before or after the pipe is laid. In case pipe is lowered in caved trench and backfilled before being inspected by the Engineer-in-Charge, the Contractor shall re-excavate the trench for inspection and backfill it at his own cost.

4.0 BACKFILLING AROUND VALVE PITS AND TRENCHES

4.1 The soil used should be selected and approved by Engineer-in-Charge. Suitable material can be extracted from available excavated material. The soil should be free from rubbish, grass, organic matter, stones, building waste etc. It should be free from clods and hard lumps.

4.2 The filling should commence only after approval of Engineer-in-Charge is obtained and after the structures or pipes getting buried are tested and approved. Otherwise, if required contractor shall uncover buried portion and refill at his own cost.

Filling should be done in layers. Each layer should be not more than 20 cm thick when loose and should be well rammed. With necessary watering, to obtain at least 90% of maximum laboratory dry density


STANDARD SPECIFICATION FOR BARBED WIRE S-10-02-003 Page 1 of 5


STANDARD SPECIFICATION FOR

BARBED WIRE




CONTENTS

1.0 SCOPE

2.0 MATERIALS

3.0 EARTHWORK

4.0 PLAIN CEMENT CONCRETE

5.0 BARBED WIRE FENCING WITH R.C.C. POSTS

6.0 BARBED WIRE FENCING WITH M.S. ANGLE POSTS




1.0 SCOPE This specification establishes and defines the material and construction requirements for barbed Wire Fencing.

2.0 MATERIALS

2.1 Materials for Civil Works Refer Technical Specification Civil & Structural works - Materials - Spec. No.S-11-02-002.

2.2 Miscellaneous

All other materials not specified, but required to complete the work shall be of approved type, make as per relevant Indian Standard Specification (if applicable) and shall be approved by the Engineer-in-Charge before Procurement.

3.0 EARTHWORK

3.1 Refer Technical spec. Civil & Strl works - Earth work Specification No. S-11-02-003.

4.0 PLAIN CEMENT CONCRETERefer Technical spec. Civil & Structural works - Plan and Reinforced Cement concrete -Spec. No. S-11-02-004.

5.0 BARBED WIRE FENCING WITH R.C.C. POSTS

5.1 Cement Concrete in Precast Post Struts

5.1.1 Cement concrete shall be of M-15 grade with 20 mm and down size crushed stone aggregates conforming to IS : 383.

5.1.2 The work shall be carried out as per IS:456 in all respects.

5.1.3 Necessary moulds shall be provided for casting the concrete posts and the same sRall be smooth finished with 1:3 cement sand mortar as directed by the Engineer-in-Charge.

5.1.4 The concrete shall be cured for a minimum period of 14 days.

5.1.5 Payment for this item shall be made on cubic meter basis and the rate shall include labour, materials, mixing, placing, leaving pockets, fixing barbed wires, inserts in concrete posts while casting as shown in the drawing or as per the directions of Engineer-in-Charge. keeping the concrete posts in proper position while concreting, scaffolding, shuttering, all moulds, curing etc. complete

5.1.6 including handling & transportation from precasting yards to place of fixing, preparation of precasting yard etc. but excluding cost of reinforcement.

5.2 Barbed Wire for Fencing




5.2.1 Barbed wire shall conform to IS : 278. The coating on the wire shall be smooth and relatively free of lumps, globes or points. Wires with excessive roughness, blisters, salarnmoniac spots shall be rejected. Barbed wire shall be made from two strands of galvanised, twisted 2.5 rnm (12 gauge) steel wire with 4 points of barbs. Each barb shall have two turns, tightening around one or both line wires making altogether four complete turns. The barb shall be so finished that four points are set and locked at right angles to each other. The barbs shall be of gauge 12.

5.2.2 Bracing of the rows of barbed wire shall be as shown in drawing.

5.2.3 All miscellaneous material like staples, straining bolt etc. shall be galvanised. Minimum length of staples shall be 50 mrn.

5.2.4 The fencing shall be plumb, taut, true to line and complete in all respects.

5.2.5 The barbs shall have a length of not less than 13 mm and not more than 18 mm.

5.2.6 Payment for barbed wire shall be made on running metre basis of two ply, four points barbed wire fixed in position. The rate shall include supplying and fixing necessary G. 1. staple, clips, straining bolts painting, tensioning the barbed wire and all materials, labour etc. required to complete the job.

6.0 BARBED WIRE FENCING WITH M.S. ANGLE POSTS

6.1 M.S. Angle Posts & Struts

6.1.1 Structural steel work shall conform to latest edition of IS : 2062 or equivalent. Barbed wire fencing shall be as per 5.2 above.

6.1.2 Structural steel work shall be fabricated and erected as shown in the drawings. Fabrication and erection shall conform to IS : 800.

6.1.3 All materials used for fabrication shall be of new and unused stock and shall be free from twist, kinks, buckles, or any other defects. Maker's test certificate shall be made available to the Engineer-in-Charge when called for.

6.1.4 All materials, tools and plants required for fabrication shall be provided by the contractor and the rates quoted shall make the allowance for the same.

6.1.5 Changes in direction where the angle of deflection exceeds 20" shall be considered corner post.

6.1.6 Painting shall not commence till it has been inspected by Engineer-in- Charge.

6.1.7 All the paints used shall be synthetic enamel conforming to IS :293 and of approved manufacturer.




6.1.8 All loose scales, dirt, rust etc. shall be removed with steel wire brushes before applying a coat of red oxide primer conforming to IS : 2074.

6.1.9 The surface after applying primer shall be made absolutely dry before applying paint.

6.1.10 Two coats of approved synthetic enamel paint over a coat of red oxide primer shall be applied unless otherwise specified.

6.1.11 Each coat shall be allowed to dry for sufficient time as per manufacturer's directions.

6.1.12 The payment shall be made on weight of the installed structural steel work. The weight shall be calculated on the basis of IS hand book. The rate shall include supply of all necessary materials and labour for fabrication, cutting, drilling holes, aligning, fixing barbed wires, keeping the post in proper position while concreting, including painting etc. complete as per drawings and directions of Engineer-in-Charge.


STANDARD SPECIFICATION FORCHAIN LINK FENCING

(GENERAL CIVIL)S-10-02-004.

Page 1 of 5



(GENERAL CIVIL)




Page 2 of 5


1.0 SCOPE

This specification specifies the requirements of chain link fence for security purposes. The height of the fence shall be approximately 2.00 m to the top of the chain link fencing at the posts and approximately 2.5 m in vertical height at the top line of barbed wire attached to the cranked tops of the posts.

2.0 EARTHWORK FOR CIVIL WORKSRefer specification No S-11-02-003

3.0 CEMENT CONCRETE FOR FOUNDATION & SILL

Refer specification NO S-11-02-004 .

4.0 CEMENT CONCRETE IN PRECAST POSTSISTRUTS(Straining posts, intermediate posts and struts)

4.1 Post RCC shall be M25 , size 200 sq. Cover R/f 45 stirrups dia 8 ,

Continuous 500mm high & 230 m wide Brick masonry wall (in 1:4 CM with 16 thk. 1:3 CM with 16 thk. 1:3 CM) plaster with proper Fdn. And leveling PCC (M125) shall be provided . Top of the wall shall be finished with 50 thk. M20 coping Post Fdn. PCC M15 ht. of Overhang 500. Ht. of Chain link fencing 1650 (500 depth high adjusted with Brick wall beneath chain link fencing) and down size crushed stone aggregates conforming to IS : 383.

4.2 The work shall be carried out as per IS : 456 in all respects.

4.3 Necessary moulds shall be provided for casting the concrete posts and the same shallbe smooth finished with 1:3 cement sand mortar as directed by the Engineer-in-Charge.

4.4 The concrete shall be cured for a minimum period of 14 days.

4.5 Payment for this item shall be made on cubic metre basis and the rate shall includelabour, materials, mixing placing, leaving pockets, fixing chain link fencing, line wires, barbed wires inserts in concrete post while casting as shown in the drawing or as per the directions of Engineer-in-Charge, keeping the concrete post in the proper position while concreting, scaffolding, all moulds, curing etc. complete including handling & transportation from precasting yards to place of fixing, preparation of precasting yards etc. but excluding cost of reinforcement.

5.0 REINFORCEMENT

Refer specification NOS S-11-02-004. & 11-02-005.




Page 3 of 5


6.0 CHAIN LINK FENCING

6.1 Materials

6.1.1 Chain Link Fencing

The material requirement shall conform to IS:2721 latest edition. The chain link fencing shall be woven from 3.55 mm dia wire with mesh size of 50 mm. The mesh wire shall not vary from the specified dia by more than + 0.05mm.

6.1.2 Galvanised Wires

6.1.2.1 All steel wires shall be hot dipped galvanised wire and dia of the wire shall be 3.55MM. over the galvanised coating.

6.1.2.2 The line wire shall be 4 mm dia mild steel.

6.1.2.3 The stirrup wire for securing the line wires to the concrete intermediate posts &dl be 2.5 mm diameter mild steel.

6.1.2.4 The tying wire for securing the chain link fencing to the line wire shall be 1.6mmdiameter mild steel.

6.1.2.5 Hair pin staples for fastening down the bottom of galvanised chain link fencing to the concrete sill shall be of 3.55 mm wire. The ends shall be bent outwards to secure anchorage.

6.1.3 Cleats for eye bolts shall be of uniform size and shall consists of mild steel angle of75x50X6 mm.

6.1.4 Eye Bolt Strainers

6.1.4.1 The eye bolt strainer shall consist of bolts with welded eye sufficiently threaded and fitted with a nut and waster.

6.1.4.2 Two-way eye bolt strainer shall have suitable ring nuts, fitted after wires have been strained on one side.

6.1.5 Stretcher bar shall consist of mild steel flats 25 mm x 4.75 mm. They shall be secured to the cleats by steel bolts.

6.1.6 Droppers for barbed wire shall be of M.S not less than 25mm x 4.75 mm thick with38mm x 4.85 mm half round staples for fastening the barbed wire to them.




Page 4 of 5


6.1.7 Barbed Wire

6.1.7.1 Barbed wire shall conform to IS : 278. The coating on the wire shall be smooth and relatively free of lumps, globes or points, wire with excessive roughness, blisters, salarnmoniac spots shall be rejected. Barbed wire shall be made from two strands of galvanised, twisted 2.5 mm (12 gauge) steel wire with 4 points of barbs. Each barb shall have two turns, tightening around one or both line wires making altogether four complete turns. The barb shall be so finished that four points are set and looked at right angles to each other.

6.1.7.2 Bracing of the rows of barbed wire shall be as shown in drawing.

7.1.6.3 The barbs shall have a length of not less than 13 mm and not more than 18 rnrn.

6.2 Erection

6.2.1 Straining posts shall be provided at all ends and corners of fences, at changes in direction or acute variations in level and at intervals not exceeding 66 mm on straight lengths of fence. Intermediate posts shall be spaced at regular intervals not exceeding 3m.

6.2.2 Struts shall be fitted to all straining posts behind the chain link fabric in the direction of the line of fence.

6.2.3 Fixing chain link fencing

6.2.3.1 There shall be four evenly spaced rows of line wire. the top wire shall be doubled, making five line wires in all. The bottom wire shall be close to the ground.

6.2.3.2 Each line wire shall be strained tightly by means of eyebolt strainers or winders at each straining point.

6.2.3.3.1 Each line wire shall be secured to each intermediate post by a wire stirrup passed through a hole in the posts and secured to the line wire by three complete turns on each side of the post.

6.2.3.4 The chain link fencing shall be strained between each pair of straining posts and secured to each straining post by means of a Stretcher bar. One of the top linewires hall be threaded through the appropriate adjacent rows of mesh, care being taken that no meshes in the rows are bypassed by the line wire except wheredeviation is necessary at the straining posts. The second top line wire shall be strained in front of the fencing. The fencing shall be attached to the top and bottom line wire by wire ties spaced 150mm apart and to the other line wires by wire ties spaced 450 mm




Page 5 of 5


apart.

6.2.3.5 The bottom of the fencing shall be treated as follows:

Continuous concrete sill 125 mtr wide x 225 high for full length between post shallbe cast with the top 25 mm above G.L. and 25 mm below the chain link fencing. Hair pin staples shall be threaded through the bottom row of mesh at 0.75 m clc andset in the sill to a depth of 150 mm.

6.2.3.6 Payment

Payment for chain link fencing shall be made on running meter basis for bottom 2.0meter height of the total fence height including supply of chain link fencing in 1.9meter width roll, fixing in position true to line and as per drawing. The rate shall also include supplying and fixing necessary galvanised line wires, stirrup wires, tying wires, hair pin staples for fixing the fence in conc. sill, etc. tensioning the line wire and fencing, all materials and labour etc. required to complete the job as per drawings and direction of Engineer-in Charge.

6.2.4 Fixing barbed wires for Anticlimbing device

6.2.4.1 Three lines of barbed wire shall be provided as shown in drg. The wires shall beattached by eye bolts to the cranked tops of the straining posts. On concrete intermediate posts they shall be secured to cranked tops with stirrup wires. The barbed wire shall be fitted with one dropper at the centre of each bay, secured to the wires so that they cannot be bunched together.

6.2.4.2 Payment

Payment for barbed wire shall be made on running meter basis of two ply, four points barbed wire fixed in position. The rate shall included supply and fixing necessary droppers, straining bolts tensioning the barbed wire etc. and all materials and labour etc. required to complete the job.


STANDARD SPECIFICATION FORCLASSIFICATION OF SOIL FOREARTHWORK IN SITE GRADING S-10-02-005

Page 1 of 5


STANDARD SPECIFICATION FORCLASSIFICATION OF SOIL FOREARTHWORK IN SITE GRADING



Page 2 of 5


CONTENTS1 .0 SCOPE

2.0 ORDINARY SOIL

3.0 SOFT ROCK

4.0 HARD ROCK

5.0 FILLING SOIL

6 .0 METHOD OF FILLINGIFIELD DENSITY FOR SOIL COMPACTION



Page 3 of 5


1 .0 SCOPE

This Specification covers classification of soil for earth work in excavation and filling for site grading work. Method of field density for soil compaction using soft rock and hard rock is also explained.

2.0 ORDINARY SOIL

2.1 Soft Soil/loose Soil

Generally any soil which yields to the ordinary application of pick and showl, or to phawra, rake or other ordinary digging implements such as :

i) Sand, gravel, loam, clay, mud, black cotton soil.

ii) Vegetables or organic soil, turf, peats, soft shale or loose moorum.

iii) Mud concrete below ground level.

iv) Any mixture of soil mentioned above.

2.2 Hard/ Dense Soil

Generally any soil which requires the close application of picks or jumpers or scarifier and rippers to loosen the same, such as :

i) Stiff heavy clay, hard shale or compact moorum requiring grafting tool and / or pick and shovel.

ii) Shingle and river or nallah bed boulders.

iv) Soling or roads, paths, etc. and hard core.

v) Macadam surface of any description (water bound, grouted tarmac etc.).

vi) Lime concrete, stone masonry in lime or cement mortar below ground level.

vii) Soft conglomerate when the stone can be detached from the matrix with picks andshovels.

3.0 SOFT ROCK

This is fissured/disintegrated rocky strata, boulders (volume less than 0.4M3 and more than 0.028 SqM ) and also which cannot be quarried excavated by using above manual



Page 4 of 5


tools but can be quarried I excavated manually by using crow bars is classified as soft rock. Soft rock shall include all kinds of stiff and stratified rock as shales, thinly bedded philites, laterite hard conglomerate, lime stone, sand stone, unreinforced cement concrete below ground level. Soft rock may be queried or split with crow bar or picks and can also be excavated by rippers, dozers and other mechanical equipment but without the aid of blasting. If required, light blasting may be resorted to for loosening the materials, but this will not any way entitle the material to be classified as "Hard Rock".

4.0 HARD ROCK

4.1 Hard Rock (Not Requiring Blasting)

This shall include all types of hard and compact rock having closely spaced fissures or joints on account of which blasting is not considered necessary.

4.2 Hard Rock (Requiring General Blasting)

This shall include all types of hard and compact rock occurring in unfissured masses or similar foundations, boulders (volume more than 0.4m3) for excavation of which blasting is considered necessary such as quartzite, granite, basalt stones, reinforced cement concrete (reinforcement to be cut through but not separated from concrete) below ground level and the like.

4.3 Hard Rock (Requiring Controlled Blasting)

This type of excavation becomes necessary when excavation is done in formations mentioned in clause 4.2 in the vicinity of existing foundations I structures. Mode of blasting shall be decided by Engineer-in-charge keeping in view the sensitivity of structures.

4.4 Hard Rock (Blasting Prohibited)

Hard rock requiring blasting as described in clause 4.2 above but when blasting is prohibited for any reasons and excavations has to be carried out by chiseling, splitter or any other agreed method.

The use of excavation shall not be considered as a reason for classification under hard rock requiring blasting unless clearly found necessary in the opinion of Engineer-in-Charge.

5.0 FILLING SOIL

5.1 Ordinary soil used for filling shall meet requirements of clause 3 of Spec.No S-10-02-



Page 5 of 5


005 for site grading.

5.2 Use of soft rock for filling shall be determined based on compaction test of filling material. Well graded soft rock with sufficient fines should make a good filling material. This shall be tested in field for compaction and then density of compacted soils shall be determined. Test patches shall be made in field using this material and number of passes of rollers determined for each patch. A minimum of 3 test patches of 10M x 10M shall be made. Density of compaction shall be determined in each patch. A density of 1.90gmlcc or more shall be acceptable.

5.3 Use of hard rock with soft rock and soil for filling shall be determined based on compaction test of rock material to be used for filling. Test patches shall be made as in case of soft rocks and number of rolls shall be determined for each test patch. Density of material in all test patches shall be found which should not be less than 2.0gmIcc.

5.4 Engineer-in-charge decision with regard to suitability of such materials shall be final.

6 .0 METHOD OF FILLINGIFIELD DENSITY FOR SOIL COMPACTION

6.1 Filling With Soft Rock/hard Rock Soil

The earth for filling shall be rock soil mass available from cutting areas. Filling shall be done in loose thickness of 400mm. Voids shall be filled with smaller size material to ensure well graded and compacted fill, watering, ramming, and compacting with rollers or other suitable means as approved by Engineer-in-Charge shall be done to achieve atleast 90% maximum dry density. Stones used in fill material shall not exceed 150mm in size.

6.2 Field Testing For Density

Each layer shall be tested in field for density and accepted by the Engineer-in-Charge subject to achieving the required density before laying the next layer. In the event if it is not possible to conduct compaction test due to presence of stones, the compaction shall be determined at site by excavating a pit of size O.5m x 0.5m x0.3m (depth) in compacted area. The excavated soil shall be weighed. The pit shall be filled with water after laying a thin polythene sheet and weight of water so filled shall be determined. Alternatively sand can also be used for filling the pit for determine the density. Density of Filled Material shall be = Weight of Soil/Weight of water This shall not be less than 1.90gm/Cubic Centimetre for soft rock and 2.0 gm/Cubic Centimetre for hard rock fill area. One test/ 4 0 0 0 SqM compacted area shall be done for every layer of filling. No. of tests can be increased due to variation in quality of fill material and/or at the discretion of Engineer-in-Charge.


STANDARD SPECIFICATION FORSITE GRADING & ROCK CUTTING

FOR SITE GRADINGS-10-02-006 Page 1 of 13



FOR SITE GRADING





C O N T E N T S

1.0 SCOPE

2.0 GENERAL

3.0 MATERIAL FOR EARTHWORK

4.0 CUTTING TREES

5.0 CLEARING AND STRIPPING

6.0 EARTHWORK IN EXCAVATIONICUTTING

7.0 EARTHWORK IN FILLING

8.0 REMOVAL OF SURPLUS EARTH

9.0 EXCAVATION IN ROCK





1.0 SCOPE

This specification and the method of measurements described thereon are applicable for Earthwork involved in Site Grading & Rock Cutting.

1.1 Reference StandardsClassification of soil for earth work in site grading 6-65-0016.

2.0 GENERAL

2.1 CONTRACTOR shall maintain adequate drainage facilities at SITE at all times during the execution of work. Additional ditches, drains & such other temporary means to achieve this, over and above what is shown in the drawings, will be provided and maintained by CONTRACTOR at his own cost.

2.2.1 Adequate dewatering facilities like dewatering pumps, piping etc. will also be provided by the CONTRACTOR for this work and also for dewatering during excavation etc. at his own cost.

3.0 MATERIAL FOR EARTHWORK

3.1 Only Material considered suitable for the Engineer-in-charge shall be employed for the construction and that considered unsuitable shall be disposed off, as directed by Engineer-in- charge, at his own cost and no claim for compensation will be entertained.

3.2 The CONTRACTOR shall give the samples of earth he proposed to use for filling along with the following characteristics of the samples to Engineer-in-charge, prior to collection and use, for approval. The tests for these characteristics shall be done in a laboratory 1 test house as approved by Engineer-in-charge.

I. Mechanical analysis or grain size distribution as per IS:2720 part IV.ii. Liquid limit as per IS:2720 part v.iii. Plastic limit as per IS-2720 part v.iv. Moisture density relationship as per IS-2720 part VII.

3.3 The material ( soil) used for filling shall be free from boulders, lumps, tree roots, rubbish or any organic deleterious matter.

3.4 Material (Soil) having plasticity index less than 20 shall be used for filling purpose.

3.5 Soil having laboratory maximum dry density of less than 1.5 gms/cc shall not be used.

3.6 Care shall be taken to see that unsuitable waste material is disposed off in such a manner that there is no likelihood of its getting mixed with the material proposed to be used for filling.





3.7 The work shall be so planned and executed that the best available material (soil) are reserved for the top portion of Embankments.

4.0 CUTTING TREES

4.1 All trees having girth between 30 cms and 120 cms and which are not marked forpreservation, shall be cut down and their roots dug up to a depth of 1 meter from theexisting ground level.

4.2 All holes or hollows produced by digging up roots shall be carefully filled with approvedmaterial (soil) including all leads and lifts, rammed and compacted to obtain 90%

of maximum laboratory dry density of soil and levelled as directed.

4.3 All uprooted trees shall be stacked or disposed off as directed by Engineer-in-charge.

4.4 PaymentCutting of trees above 30 cms girth shall be paid per number. The rate quoted shall include cutting, uprooting removing the trees within plant boundary as directed, including filling holes or hollows produced by removal of roots etc. as per specifications.

5.0 CLEARING AND STRIPPING

5.1 The areas including depressions, where filling or cutting is to be carried out shall be cleared and stripped completely of bushes, roots, vegetation, plantation trees, shrubs, trees upto 30 cms girth, organic and other objectionable materials. All these shall be completely uprooted and virgin soil exposed and not merely scrapped at the surface. The roots of trees of girth upto 30cmsshall be removed to a minimum depth of 1M below existing ground level and holes, hollows filled up with selected approved available earth within all leads and lifts and compacted to obtain 90% of laboratory dry density of soil and leveled as directed by Engineer-in-charge. All soft patches must be worked out to remove soft soil and selected approved earth must be filled back and the areas areas coming under filling) compacted to obtain 90% of maximum laboratory dry density of soil, as per IS:2720 part VII. The depth of stripping shall be generally 50 to 150 mm as decided by Engineer-in-charge.

5.2 Material obtained from clearing shall be stacked or disposed off as directed by Engineer-in-charge within a lead of 2000M.

5.3 PaymentNo separate payment shall be made for clearing, stripping and disposal of materials obtained from clearing. This shall be considered as part of cutting work in areas of





cutting and filling work in areas of filling and the rates quoted under the respective items of

i. Earthwork in Excavation/Cutting

ii Earthwork in filling (Both with available earth & earth obtained from approved borrow areas), shall be inclusive of clearing and stripping with all operations described above in clause no.5 in respective areas of cutting and filling.

No separate payment shall be made for cleaning, stripping and disposal of materials obtained from clearing of borrow areas for earth as directed by Engineer-in-charge. This shall be considered a part of filling work in area of filling and the rate quoted under the respective items.

6.0 EARTHWORK IN EXCAVATION I CUTTING

6.1 After clearing, stripping of areas as specified above in clause No.5, spot levels at intervals, and pattern as decided by the Engineer-in-charge shall be taken jointly with the CONTRACTOR AND Engineer-in-charge, and Excavation 1 cutting shall commence only after the levels are signed by the contractor as a token of his acceptance.

6.2 Excavation I cutting for this work shall be carried out strictly as per the instruction of Engineer-in-charge.

6.3 If the contractor excavates 1 cuts beyond the required level, additional quantity of earthwork shall not be paid for. The excavation taken below the specified level shall be made good by filling with approved material to the required compaction at Contractor's cost.

6.4 The final bed and sides of excavation must be leveled, dressed and compacted. In case of areas under excavation for Site Grading, the final surface shall be leveled, dressed and consolidated by means of sheep footlpower driven rollers to obtain maximum compaction. However, no test control is required in such areas.

6.5 Shoring and strutting shall be adopted only with the permission of Engineer-in-charge in writing. Such shoring and strutting shall be follow the necessary specification and shall be paid for under the relevant item of Schedule of Rates.

6.6 Provisions for dewatering shall be governed by the relevant clauses.

6.7 Payment

Payment for Excavation shall be on the basis of volume of excavation calculated on the basis of joint level taken as per clause 6.1, and the final finished grade levels, the volume being calculated by the Trapezoidal rule. Intermediate payment will be on the





basis of volume calculated based on spot levels taken during the time of the billing, reference is also invited to clause 6.3.

7.0 EARTHWORK IN FILLING

7.1 After clearing, stripping and consolidation of areas as specified in clause 5, spot levels at intervals and pattern as decided by Engineer-in-charge shall be taken jointly with the CONTRACTOR and Engineer -in-Charge and filling shall commence only after the levels are signed by the CONTRACTOR as a token of his acceptance. Approved fill Material shall be spread in uniform layers not exceeding 30 cms in loose depth.

The contractor has to make his own approach and access roads from the borrow area to the demarcated filling areas. While the CONTRACTOR may make use of such short cuts as may be available to him for earth movement from borrow areas to the filling areas, the OWNER does not guarantee any passage way or right of way for the CONTRACTOR work other than available at site. No claim shall also be admissible to the CONTRACTOR on account of his having to take longer leads or routes for earth movement, than envisaged by him, either due to any road cuttings, non-availability of routes, or any other grounds whatsoever.In case total filling required in any area consists of earth both from borrow areas and available approved excavated material from within plant area, then joint levels, shall be taken before commencing filling with earth from borrow area.

However earth from borrow areas required for filling can be used only after the available earth from excavation within demarcated area has been utilised and clearance to this effect obtained from the Engineer-in-charge.

7.2 All clods, lumps etc, shall be broken before compaction.

7.3 Successive layers of filling shall not be placed until the layer below has been thoroughly compacted to satisfy the requirements laid down in this specification.

7.4 Prior to rolling, the moisture content of material shall be brought to within plus or minus 2 % of the Optimum Moisture Content as described in IS:2720 part VII. The moisture content shall preferably be on the wet side for potentially expansive soil.

7.5 After adjusting the Moisture Content as described in clause 7.4, the layers shall Be thoroughly compacted by either sheep foot roller or power driven roller or vibratory roller as approved by Engineer-in-charge till the specified maximum laboratory dry density is obtained..

7.6 Each layer shall be tested in field for density and accepted by Engineer-in-charge subject to achieving the required density before laying the next layer. A minimum of one test per 5001112 for each layer shall be conducted.





7.7 If the layer fails to meet the required density, it shall be reworked or the material shall be replaced and method of construction altered as directed by Engineer-in-charge to obtain the required density.

7.8 The filling shall be finished in conformity with the alignment, levels, cross-section and dimensions as shown in the drawing.

Earthen embankment shall be filled 300mm more on both sides, where height is more than 1 M, and this extra filling shall be dressed, after compaction, in conformity with alignment, level, cross-section and dimension as shown in the drawing to achieve proper compaction in the slope. No extra payment shall be made in this regard.

7.9 Extra material shall be removed and disposed off as directed by the Engineer-in-charge.

7.10 TolerancesGeneral site grading including cutting and filling in depressions shall be carried out to within up down tolerance o +5 cms of final lines grades and slopes.

7.11 PaymentPayment for filling shall be made on cubic meter of volume calculated on the basis of cross section plotted from the levels of ground, where filling is to be carried out and the levels reached after filling is duly consolidated, volume being calculated by Trapezoidal method. In case of simultaneous cut and fill operation, wherever specified, payment shall be made on the basis of one composite rate for cutting and filling, all other details about measurement etc. remaining same as above. No extra payment shall be made towards testing charges.


8.1 Surplus earth and soil excavation and general site grading shall be removed from theconstruction areas to the area demarcated by the Engineer-in-charge.

8.2 PaymentPayment shall be made only for lead beyond initial lead from construction area. Rate shall include loading, transportation, dumping, stacking the surplus earth and soil in the area demarcated by the Engineer-in-charge.

Payment shall be made on cubic meter basis of the difference of measurements of The volumes of the excavation and the measurement of the filling with the excavated earth. However, the contractor's entitlement to payment shall be restricted to the actual quantity of earth removed. Quantity generated due to void in back filled volume of earth shall also be removed by the contractor at no extra





cost and this disposal of earth shall not be measured and paid under any item.

9.0 EXCAVATION IN ROCK

9.1 Blasting operations shall be carried out with the prior permission and in the presence of the Engineer-in-charge or his authorised representative and during fixed time hours of the day.

Blasting operations shall be carried out as per Indian Explosive Rules 1983, amended up to date. The contractor shall obtain license from controller of explosives to carry out blasting operations as well as for obtaining and storing the explosives as per Indian Explosive Rules (latest). All safety precautions such as providing safety nylon netting etc. shall be carried out as per instructions of the Engineer-in-charge.

9.1.1 The contractor shall ensure that all workmen and the personnel at site except those who have actually to light the fuse are evacuated from the unsafe area to be determined by the Engineer warned by loud speaker in local language to safe distance, not less than 200 meters at least 15 minutes before firing time by sounding warning siren. The area shall be encircled by red flags. The contractor shall be responsible for any accident to workmen, public or property due to blasting operation.

9.1.2 Gun powder, gelatin and other safe explosives only shall be used wherever possible.Explosives with nitroglycerine shall be used only under exceptional circumstances with prior approval of the Engineer.

9.1.3 All fuses shall be cut to the length required before being inserted into the holes.

9.1.4 The no. of charges to be fired and the actual no. of shots heard shall be compared and the person responsible must satisfy himself by examination that all the charges have exploded before work people are permitted to approach the scene. The withdrawal of a charge which has not exploded shall under no circumstances be permitted, but the charges shall be flooded with water and the hole marked into a distinguishing manner. The next hole to be fired shall be at a distance of about 500 mm from the old hole and fired in the usual way.

9.1.5 The contractor or any of his competent authroised person shall be in charge of the blasting operations and shall be held responsible for strictly observing the safety rules, particularly applicable to blasting operations, in addition to other safety rules.

9.1.6 In blasting rocks with dynamite , the following general principles shall be observed.

In genera1, the following diameter of drills shall be used for different depth of bore-holes.





From 1-2 meters 25mm diameter

From 2-3 -25 meters 37-50mm diameter

From 3.25-4.75metres 50-65mm diameter

The boreholes should generally be not more than 1.5m deep and the distance apart should be from one and a half to twice their depth.Cracks and fissures in the rock to be blasted shall be carefully studied to ascertain the best position for the boreholes. The charge shall always be placed in a sound piece of rock, if possible not nearer than 300mm from the crack.

9.2 Rules for Blasting with Dynamite and other High Explosives

9.2.1 The Person-in-charge must show that he is thoroughly acquinted with the blasting operations and that he understands the rules herewith laid down. We will be held responsible for any accident that may occur. He must be a licenced blaster with a valid license from DGMS.

9.2.2 Boreholes must be of such a size and uniform that the cartridges can easily pass down them.

9.2.3 The position of all holes to be drilled must be marked out with white paint thus and the person-in-charge must take particular note of these positions.

9.2.4 The drilling operation being finished, the person-in-charge must make a second inspection and satisfy himself that the boreholes marked out by him have been drilled and cleaned properly.

9.2.5 The person-in-charge must prepare all charges necessary for boreholes.

9.2.6 Number of holes to be loaded and fired at one time shall be as per explosive rules. Boreholes must be thoroughly cleared before a cartridge is inserted. The loading is to be done by the person-in-charge himself and the position of the charge holes carefully noted by him. Wooden tamping rods only to be used in charging holes (not pointed out cylindrical thought, one cartridge at a time must be inserted) and gently pressed with the tamping rod.

9.2.7 Immediately before firing a blast, due warning must be given and the person-in-charge must see that all the labour have retired to safety.

9.2.8 The safety fuse of the charged holes are to be lighted in the presence of the person-in-charge who must see that the fuses of the holes charged have properly ignited .After





the blast, the person-in-charge must carefully inspect the work and satisfy himself that all the charges have exploded.

9.3 Misfires

9.3.1 Misfires are a source of great danger, if it is suspected that part of the blast failed to fire is delayed, allow sufficient time to elapse before entering the danger zone. When fuse and blasting caps are used, a safe time, atleast an hour should be allowed.

9.3.2 None of the drillers are to work near these holes until the three following operations have been done by the person-in-charge.

a. The Person-in-charge should very carefully extract the tamping with a wooden scrapper and withdraw the fuse with the primer and detonator attached, after which a fresh primer and detonator with fuse should be placed in this hole and fired; or

b. The hole may be cleared of 300mm of tamping and the direction then ascertained by placing a stick in the hole. Another hole may then he drilled 150mm away and parallel to it: this hole to be then charged and fired when the other charge should explode.

c. Drilling in holes not completely exploded by blasting shall not be permitted.

9.4 Precautions Against Misfire

9.4.1 The safety fuse should be cut in an oblique direction with a knife.

9.4.2 All saw dust must be cleared from the inside of the detonator; this can be done by blowing down the detonation and tapping the open end. No instrument shall be inserted into the detonator for this purpose.

9.4.3 After inserting the fuse in the detonator, it shall be fixed by means of nippers.

9.4.4 If there is water present, or if the boreholes be damp, the junction of the fuse and detonator must be made water tight by means of grease, white lead or tar.

9.4.5 The detonator should be inserted into the cartridge, so that about one third of the copper tube is left exposed outside the explosives. The safety fuse outside the detonator, should be necessarily tied in position in the cartridge. Water proof fuse only to be used in the damp boreholes, or when water is present in the bore-hole.

9.4.6 If a misfire has been found to be due to defective fuse, detonator or dynamite, the whole quantity or box from which the detective article was used shall be rejected.





9.4.7 Storage of materials for blasting shall be as per statutory regulations / stipulations of the concerned authorities.

It shall be the Contractor's responsibility to arrange for proper storage of Explosives obtain required permissions from concerned authorities. No separate payment shall be payable for the above.

9.4.8 Cleaning of Excavation

Excavation shall be cleaned, trimmed to exact shape and all disturbed material and other debris shall be removed. When the excavation have been taken out to the lines specified as shown on the drawings and the surface cleaned as specified, the contractor shall notify the Engineer that the excavation is ready for inspection and no further work shall be done with concrete or backfill until it has been inspected and approved by the Engineer. Cost of this work is deemed to have been included in the until rates for excavation.

9.4.9 Use of Excavation on Material

Where any material obtained from the excavation is in the opinion of the Engineer suitable for use in a particular section of the work as fill or backfill such material shall be selected if necessary, loaded, hauled, placed, spread and used to construct the fill of backfill the lines and grades specified for the work. As far as possible the most suitable of the materials excavated for the work shall be used to construct the fill and backfill embankments, roads and storage areas where required. The useful rock available shall be stacked at the locations as decided by the Engineer and the rate is inclusive of the same also. Materials containing brush roots or other perishable materials will not be considered suitable.

The suitability of the materials and their disposition in the work shall be subject to The approval of the Engineer.

9.4.10 Disposal of Surplus

All surplus materials shall be carried away from the site and disposed at dumping sites selected by the Engineer, upto a lead as indicated in the relevant items of the schedule of rates. The Engineer may ask the contractor to dump the excavated materials in regular heaps, bunds, blankets, riprap with regular slopes as directed by the Engineer and leveled so as to provide natural drainage. As a rule, all softer material shall be laid along the centre of heaps, the harder and more weather resisting materials forming the casing on the sides and the top. Excavated rocks which can be used in soling, as road metals or for making concrete aggregates shall be stacked separately as directed by the Engineer. All such works as mentioned above is deemed to have been taken into account while quoting for the excavation and no extras shall be claimed by the





contractor for the above works.

All rock excavated from the pits shall be the property of the Owner.

9.4.11 Stock Piles

When the removal of material from excavations progresses at a faster rate or at different times then placement in backfill is being accomplished, such excavated materials shall be stock piled at approved locations adjacent to the work until their use is authorised.

9.4.12 Spoil Areas

Material excavated for the works which is rejected as unsuitable or not required by the Engineer shall be disposed of in spoil areas as specified by the Engineer.

The spoil areas shall be left in a neat and sightly condition and sloped to drain properly as may be directed by the Engineer.

9.5 Control Blasting

9.5.1 General

These specifications lay down the requirements for control blasting for rock excavations wherever required.

Wherever required by the Engineer, the rock blasting shall be controlled so that vibration generated during the blasting do not cause damage to the buildings and installation around built up areas. Similarly the rock pieces should not fly off the pits and thus damage the buildings and installation around. Apart from the general precautions mentioned in the preceding paragraphs following protective measures are suggested as guidelines. Tenderers are requested to carefully check the site conditions and submit the details of the scheme they propose to adopt for controlling the blast.

9.5.2 Protective Measures

a). Short delay blasting with light charges shall be used.

b). The blast hole shall be covered with 0.6 to 1.0 sqm. mild steel plate of minimum 6mm thickness.

c. Reinforcement rod mesh not less than 20mm dia at 150mm centers in both directions shall be over the steel plates.





d. Steel plate and reinforcements shall be inspected after every blasting operation and all twists shall be removed before reuse to the satisfaction of the Engineer.

e. The thickness of the covering plate and the kind of dead weight is to be duly approved by the Engineer.

When blasting is necessary adjacent to partially or completely built structures the contractor shall take all precautions necessary to prevent flying rock from causing damage to the structures. In no case shall blasting be allowed closer than 15m to any structure after concrete placing has started.

The contractor shall be responsible for all damage caused by blasting whether to permanent or temporary structure and shall replace or repair the structures at his own cost.

9.6 PaymentIf soil of any classifications other than that specified in the Schedule of Rates is met during Excavation, the decision of the Engineer-in-charge as to the classification of soil, levels of the strata of different classifications and their locations shall be binding. In above case, the total quantity of Excavation shall be computed from the measurement of the pit trench excavated. The hard rock and soft rock shall be measured separately from the relevant stacks and each shall be reduced by fifty percent for voids, and paid under the relevant items. The balance, that is the total quantity of excavation minus the reduced ( for voids) quantity of excavation for rocks shall be paid as soil as per the discretion of the Engineer-in-Charge. However, the maximum payment shall be limited to the volume of the excavated pit trench as approved by Engineer-in-charge.



CONCRETE PAVEMENTS-10-02-007 Page 1 of

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CONCRETE PAVEMENT




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Abbreviations:IS INDIAN STANDARD

WBM WATER BOUND MACADAM

RCC REINFORCED CEMENT CONCRETE

PCC PLAIN CEMENT CONCRETEmm MILL1 METER

Kg/cm2/cm KILOGRAM/SQUARE CENTIMETEWCENTIMETER

M.S. MILD STEEL

"C DEGREE CELCIUS

BS BRITISH STANDARD

C1. CLAUSE




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CONTENTS

0.0 SCOPE

0.0 REFERENCE CODES AND SPECIFICATIONS

0.0 MATERIALS

0.0 GRADES AND PROPORTIONING

0.0 EQUIPMENTS

0.0 PREPARATION OF SUB GRADE

0.0 BASE COURSE

0.0 FORMS

0.0 LAYING OF REINFORCEMENT, MIXING, PLACING, COMPACTION &FINISHING AND CURING

10.0 JOINTS

11.0 OPENING TO TRAFFIC

12.0 METHOD AND BASIS FOR PAYMENT




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1.0 SCOPEThis specification establishes the requirements of material, laying and finishing of concrete pavements.

2.0 REFERENCE CODES AND SPECIFICATIONSIS: 456- Plain and Reinforced Concrete-Code of Practice.

IS: 1834- Specification for Hot Applied Sealing Compounds for Joints in Concrete.

IS: 1838, Part-l- Specification for Preformed Fillers for Expansion Joints in Pavements and Structures (Non Extruding and Resilient Type): Part 1 Bitumen Impregnated Fiber.

IS: 2720, Part-8- Method of Test for Soils-Part 8: Determination of Water Content-Dry Density Relation Using Heavy Compaction.

IS: 9214- Method of Determination of Modulus of Sub-grade Reaction (k value) of Soils in the Field.

Standards for RCC pavement Details.

Standards for Standard Specification for Roads and Flexible Pavement (Upto WBM Layer)

Standards for Technical Specification - Civil & Structural Works -Materials.

Standards for Technical Specification - Civil & Structural Works -Plain andReinforced Cement Concrete.

In case of conflict between the Clauses mentioned in this Specification and those in above Codes And Specifications, this Specification shall govern.

3.0 MATERIALS

3.1 Material for Cement Concrete viz. Cement, Sand, Coarse and Fine aggregate and water,Reinforcements Bars, Embedment, Inserts and Admixture etc.

3.2 Material for WBM shall be as described in GAIL Specification no. 6-65-001 8.

0) GRADES, TYPE OF CONCRETE MIX, PROPORTIONING AND BATCHING




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4.1 The grades of concrete shall be as follows:Type-I Pavement - M30Type-I1 Pavement - M25Type-I11 Pavement - M25

4.2 Specification for Concrete mix, Mix Proportioning and Batching shall be as described in Standard Specification S-11-02-004 and IS: 456.

5.0 EQUIPMENTSAll equipments like sub grade templates, hand tempers, vibrating screens, internal vibrators, longitudinal floats, bridges, push brooms, straight edges, edging tools etc. shall be on the worksite in first class working condition and shall have been inspected by the Engineer-in-Charge before paving operations are permitted to start. Throughout the construction period, the contractor shall maintain adequate equipment in first class working conditions to ensure the proper execution of the work.

5.0 PREPARATION OF SUB GRADE

5.0 The area where concrete is to be placed must be cleared of all loose material and virgin soil must be exposed. Such exposed surface must be consolidated properly to obtain 95% of Maximum Laboratory Dry Density of the soil. All soft patches must be worked out to remove the soft soil and selected approved earth must be filled back and compacted.

5.0 For areas, where pavement is to be laid on cutting / natural grade level, Sub grade shall be thoroughly compacted to 95% of laboratory dry density as per IS: 2720 Part VIII. For filled up areas, top 450 mm of the soil shall be compacted to 95% of laboratory dry density below pavement in layers of 150 mm.

5.0 The difference between the sub grade levels of Type-I, Type-I1 and Type-I11 Concrete pavements (due to difference in thickness of Type-I, Type-I1 and Type-I11 pavements) shall be achieved by stripping the grade level and not by filling. Hence, site-grading level below pavement shall be kept up to sub grade level of Type-I1 or Type-I11 as the case may be, to avoid filling of smaller thickness at later stage.

5.0 The sub grade or sub base for laying of the concrete pavement shall comply with the following requirements:

5.0.0 No soft spots shall be present in the sub grade5.0.0 The uniformly compacted sub grade or base course shall extend at least 300mm on

either side of the area to be concreted.

6.4.3 The sub grade shall be properly drained.




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6.4.4 The minimum modules of sub grade in wet condition, reaction obtained with a Plate Bearing Test as per IS: 92 14, shall be 6.0 Kg/cm2/cm.

6.4.5 Sub grade shall be prepared to the lines and grades to match with the slope of pavement as shown on the drawings.

7.0 PREPARATION OF SUB BASE

7.1 WBM under Type-1 Pavement (Ref. GAIL Standard Drawing No. )WBM Base Coarse shall consist of 2 layers of WBM Gr.-11, each of 75mm compacted thickness, as per IRC-19 and described in GAIL Specification no.

7.2 PCC 1 :5: 10 under Type-I1 and Type-I11 Pavement (Ref. GAIL Standard Drawing No.

6.2 PCC 1 :5:10 in sub base layer shall be as described in GAIL Specification no.

6.2 Sub Base layer shall be prepared to the lines and grades to match with the slope of pavement as shown on the drawings.

7.5 No concrete shall be placed around manholes or other structures until they have been brought to required grade and alignment. All sides of manholes / pits etc. shall have same elevation.

7.6 The sub base layer shall be in moist condition at the time of concrete placement.

8.0 FORMS

8.1 All side Forms shall be of mild steel unless use of wooden sections is specially permitted. The steel forms shall be of MS channel sections and their depth shall be equal to thickness of the pavement. The sections shall have a length of at least 3.0m except on curves, where shorter sections may be used. These forms should be provided with ample bracing and supports to prevent the springing of the forms under the concrete pressure or thrust of machinery operating nearby.

8.2 The forms should be in a sufficient number and they should not be removed until concrete has hardened sufficiently.

8.3 In case wooden forms are permitted, these shall have minimum base width of 100 mm for 15Omm or lesser thick slabs and 15Omm for 200mm thick slabs.

9.0 LAYING OF REINFORCEMENT, MIXING, PLACING, COMPACTION &FINISHING AND CURING




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9.1 Laying Of ReinforcementAll reinforcement work shall confirm to IS: 456 and as described in GAIL Specification

no

9.2 MixingMixing shall be as described in GAIL Specification no. 6-68-0004.

9.3 Placing

8.2.0 The place where concrete is to be poured should be clean and free from all loose dirt, wooden pieces, dust, standing water etc.

8.2.0 Walking on reinforcement layers is not permissible. Walkways of wooden planks or similar material can be placed with removable supports and should be independent of the reinforcement. The reinforcement position should not be disturbed nor should it sag during carriage and placement of concrete.

8.2.0 Placing and vibration should not take totally more than 20 minutes from time of mixing. Method of placing should be got approved by Engineer-in-Charge. Segregation during carriage and placement should be avoided. If during carriage concrete segregates, it should be remixed before placement.

8.2.0 Concrete should not be dropped from a height of over 1.5m.

8.2.0 To ensure bond and water tightness between old concrete surface and fresh concrete to be placed, the surface should be cleaned and roughened by "initial green cut" by wire brushing or chipping. The initial green may be done by wire brush after 6 hours of placing concrete in order to facilitate the work. Chipping can be done only after 48 hours. A layer of cement slurry with 1:l mix (1 cement: 1 sand) should be poured to obtain a uniform coating on old concrete. Immediately thereafter, the fresh concrete should be poured.

8.2.0 Concrete shall be mixed in quantities required for immediate use and shall be deposited on the sub-grade in a single operation to the required depth and width of the pavement. Spreading shall be as uniform as possible to avoid re-handling of concrete. Where however, a certain amount of redistribution is necessary, it shall be done with shovels and not with rakes. Concrete shall be vibrated with internal vibrators. Concrete shall be placed continuously until completion of the part of the work between construction joints or as directed by Engineer-in-Charge continuously until completion of the part of the work between construction joints or as directed by Engineer-in-Charge.

8.2.0 Placing in inclement weather




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All precautions shall be taken for concreting in extreme weather in accordance with the relevant clauses of IS: 456. Due protection shall be provided to prevent cement being blown away while proportioning and mixing during windy weather. No concreting shall be carried out in continuous heavy rains. Necessary arrangements to cover the freshly poured concrete shall be provided, to protect it from the direct rays of the sun and from drying winds.

8.2.0 All concreting placement should be co-coordinated with placement of conduits, inserts, embedded parts etc. executed either by same agency or separately.

8.2.0 Concrete shall be laid in panels as shown in the standard drawing or as directed to; Engineerin-Charge.

8.2 Compaction & Finishing

8.2.0 CompactionThe surface of the pavement shall be compacted either by means of power driven finish machine or a vibrating hand screed. For areas where width of the pavement is very small, hand consolidation and finishing shall be done as follows:

9.4.1.1 Concrete as soon as placed, shall be struck off uniformly and screened to the crown and cross-section shown on the plans and to such level above the base that when compacted and finished, the pavement shall conform to the grade and cross-section indicated by the plans. The entire surface shall then be tamped until a close-knit dense

surface is obtained.

9.4.1.2 The Tamper shall rest on the side forms and shall be drawn ahead with a swing motion in combination with a series of lifts and drops alternating with lateral shifts. The aim of this operation is compaction and screeding to the approximate level required. Subsequent tamping should advance 75 mm at a time in the direction in which the work is proceeding and in final stages, the tamping should be closer, about 12 mm at a time, until a level and dense surface is obtained.

9.4.1.3 If so directed by Engineer-in-charge, hand operated vibrating tamper consisting of normal type of hand tamper attached to a pneumatic or electric vibrating unit shall be

used for compaction.

9.4.1.4 Segregated particles of coarse aggregate, which collect in front of the tamper, shall be thrown outside the forms or thoroughly mixed by hand with a mass of concrete

already on the base.

9.4.1.5 Compaction by tamping shall be carried on till the mortar in the mix just works up to the surface. The surface shall be examined after compaction correction. If needed

correction shall be made by adding or removing concrete, followed by further compaction and finishing.




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9.4.2 FloatingAs soon as practicable, after concrete has been struck off and compacted, it shall be further smoothened and compacted by means of a longitudinal float, 1200 mm long and 75 mm wide, operated from a foot bridge.

9.4.3 Straight EdgingAfter floating is completed and excess water removed but while concrete is still plastic, the slab surface shall be tested for trueness with a straight edge and rectified, if necessary.

9.4.4 BroomingAfter belting and as soon as surplus water has risen to the surface, the pavement shall be given a broom finish to produce corrugations of uniform appearance of not more than 1/16 inch in depth.

9.4.5 EdgingBefore the concrete has its initial set, the edges shall be carefully finished with an edger of the radius required and pavement edge shall be left smooth and true to line.

t

9.5 CuringCuring of concrete shall be as described in EIL Specification no. 6-68-0004.

10.0 JOINTS

10.1 Wherever called for on the drawings, expansion joints, construction joints and sealing joints shall be provided as per details indicated in the drawing and as directed by Engineer-in-Charge.

10.2 Sealing of Joints

10.2.1 After the curing, the temporary seal or other intruded materials of all expansion andcontraction joints shall be removed completely and the slots filled with approved joint

sealing compound as conforming to IS: 1834, Type B. The filler material for Expansion and Sealing joints shall be preformed fillers of Bitumen Impregnated Fiber, conforming to IS: 1838, Part-I.




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10.2.2 The edges of the joints shall be thoroughly cleaned and primed with a thin bituminous paint, which shall be allowed to dry before the sealing compound is applied.

10.2.3 The primer shall be applied with a brush. The composition of primer shall be as follows:

Name of Material Percent by weight1. 200-Penetration Bitumen 66

Blended2. Light creosote oil 14

Hot/ Cold

3. Solvent Naphtha 20

The bitumen shall be melted and fluxed with oil. When cold, solvent Naphtha shall be added. BITUMINOUS emulsion shall not be used as primers. Care shall be taken to ensure that the sealing compound is not heated above 200•‹C and the temperature does not exceed 180•‹C for long periods.

9.1.3 Sealing compound shall be poured into the joint opening in such a manner that the material will not be spilled on the exposed surface of the concrete. When required to prevent pick up under traffic, the exposed surface of the sealing compound shall be dusted with hydrated lime.

1 1.0 OPENING TO TRAFFIC1 1.1 Traffic shall not be allowed for a period of 28 days after laying of concrete in

pavement.

1 1.2 Before opening the pavement to traffic, all joints shall be filled and trimmed or topped out as required.

1 1.3 Sampling, testing and acceptance of concrete work shall be according to IS: 456-2000

12.0 METHOD AND BASIS FOR PAYMENT

12.1 Plain and Reinforced Concrete

12.1.1 Payment for plane and reinforced concrete in pavements shall be made on cubic metre basis of the volume of the actual finished work done and shall be inclusive of cost of providing Forms, Pockets, Chamfers, Fillets, Grooves, Cement wash, Curing by normal moist curing or using curing compound etc. as directed by Engineer-in-Charge. The rates shall be deemed to include complete cost of getting the respective




12


mix designs approved, making and testing concrete cubes and carrying out other tests including tests of various ingredients, as per specifications and as directed by Engineer-in-Charge.

12.1.2 No separate payment shall be made for any admixture used by the contractor for accelerating or retarding the strength of concrete or for achieving specified workability / water tightness The rate quoted shall be deemed to be inclusive of all costs related to any such additive /admixture.

12.1.3 The rate shall however be exclusive of reinforcement, metal inserts, pipe sleeves and any filler material in expansion / sealing joints.

12.1.4 Where the strength of concrete mix (nominal or design mix) as indicated by tests, lies in between the strengths of two grades given in Table-1 of GAIL Specification No. it is accepted by owner/Engineer-in-charge, such concrete shall be classified as a gradebelonging to the lower of the two grades between which it lies. In case the cube strength shows higher results than those specified for the particular grade of the concrete, it shall not be placed in the higher grade nor shall the Contractor be entitled for any extra payment on such account. The concrete giving lower strength than specified may be accepted at reduced rates after satisfying the safety of the structure by checking it with tests as specified or rejected entirely at the discretion of the Engineer-in Charge. The rejected concrete shall be dismantled at no extra cost to the owner and no payment or extension of time shall be granted for the concrete

so rejected and the formwork and reinforcement used for the same. Cost of anymaterial supplied by the Owner free of cost shall be recovered from the contractor at double the prevailing market rate. In case the concrete of lower strength can be improved by carrying out some strengthening measures entirely at the discretion of the Engineer-in-Charge, then Contractor shall carry out the said measures including all related tests at his own cost. If the Contractor is able to make up the strength to the required grade by such improvement measures to the entire satisfaction of Engineer-in-Charge, payment shall be made for the grade achieved. However, if the strength of concrete is not made up to the strength of required grade, payment shall be made only for the lower strength if such concrete is accepted by the Engineer-in-Charge.

12.1.5 Deductions for openings, pockets etc. shall be as specified in relevant Indian Standard Codes.

12.2 Reinforcement

12.2.1 Payment for plain round mild steel reinforcement bars and high strength deformed steel bars shall be on the basis of weight of bare steel, irrespective of any coating applied, in metric tons.The weight of the bar shall be derived from the sizes and

corresponding unit weights given in hand book of Bureau of Indian Standards. Standard hook length, chairs, spacer bars and authorised laps only shall be included in the weight calculated. Binding wire shall not be weighed nor otherwise measured.




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Measurement for weight shall not include cutting allowance etc.

12.2.1 Rate quoted for reinforcement shall include cost of supplying, decoiling, straightening, cleaning, cutting, bending, placing, binding, welding if required, and providing necessary cover blocks of concrete.

12.3 JointsPayment for expansion joints, construction joints and sealing joints shall be made on running meter basis. The rate shall include cleaning of joints, filler material and sealing with approved compound, all material, labour etc. complete, as per

drawing.


STANDARD SPECIFICATION FORFLEXIBLE PAVEMENTS WITHBITUMEN PREMIX CARPET

S-10-02-008 Page 1 of 8





S-10-02-008 Page 2 of 8


CONTENTS1 . SCOPE

2. BITUMEN PREMIX CARPET

3. QUANTITIES OF MATERIALS(PREM1X CARPET)

4. LAYING

5. PAYMENT

6. REMOVEL OF SURPLUS EARTH

7. JOB SPECIFICATION FOR BRICK PITCHING



S-10-02-008 Page 3 of 8


1.0 SCOPE

This specification establishes the material and construction requirements for the flexible pavement with Bitumen-Premix Carpet.

2.0 BITUMEN PREMIX CARPET

2.1 Material

2.1.1 Coarse aggregate

The aggregate shall consist of crushed stone of Clean,hard,tough,durable rock of uniform quality and shall be clean, free from excess of dust, flat or elongated pieces ,soft or disintegrated stone, clay or other deleterious matter. The size of aggregate shall be as mentioned in the schedule of quantities.

2.1.2 Sand

The sand shall consist of clean hard, durable, uncoated, coarse dry particles and shall be free from injurious amounts of dust, soft or flaky particles, organic matter or other deleterious substances.

2.1.3 Binder

The binder shall be bitumen of penetration 80/100 conforming to IS:73. The bitumen shall be collected on road side drums. Any drum leaking or damaged shall not be accepted.

3.0 QUANTITIES OF MATERIAL( PREMIX CARPET)

3.1 For Premix Carpet 20mm thick



S-10-02-008 Page 4 of 8


Material For Premix Carpet For seal coatPer 100 m2 per 100m2

1) Coarse Aggregate 2.75m3 --12mm and down size.

2) Bitumen 801 100 150 Kg 68.3 Kg

3) Coarse sand as -- 0.6 M3sealing aggregate

3.2 For Premix Carpet 25mm thick

1) Coarse Aggregate 3.5m3 --12mm and down size.

2) Bitumen 801 100 185 Kg 68.3 Kg

3) Coarse sand as - 0.6 M3sealing aggregate

3.3 For Permix Carpet 50mm thick

1) Coarse aggregate 25mm 5.5M3 --and down size 5.5m3(For 35mm thick Carpet 1 Layar).

2) Coarse Aggregate 12mm 2.0 m3 --and down size (For 15mmthick Carpet layer).

3) Bitumen 801 100 269 Kg 68.3m3a). For 35mm thick Carpet( 1 layer)

b) For 15mm thick Carpet 110 Kg( I1 layer)

4) Coarse sand as sealing -- 68.3 kg.aggregate

.3.4 For Permix Carpet 75mm thick



S-10-02-008 Page 5 of 8


i) Coarse Aggregate 25mmand down size ( For 50mmthick 1 layer)

ii) Coarse Aggregate 25n1mand down thick I1 layer

iii) Bitumen 801 100a) For 50 thick I layer 375 kg 68.3 kg.

b) For 25 thick I1 layer 185 kg. --

iv) Coarse sand as sealing -- 0.6m'aggregate

4.0 LAYING

4.1 Preparation of Road Surface

The existing surface shall be thoroughly cleaned of dust, loose materials caked mud and other foreign matter with the help of wire brush, chisel, picks etc. before laying the tack course. The cleaning shall be carried out in such a manner as to expose the stone metal to a depth of 1 to 2mm without dislodging the interlocking of the metal. All dust and other material thus removed shall be carried away and dumped at suitable places as directed by the Engineer-in-charge.

4.2 If pot holes or ruts are found on the existing road surface, these irregularities must be filled in with premix chippings and well rammed about a week before the carpet is laid.

4.3 Tack Coat

4.3.1 The bitumen shall be heated in asphalt boilers to 1770 - 1880 C and shall be spread uniformly at the rate of 1 kg/m2 - by means of sprayers. The applied binder shall be evenly burshed. 4.3.2 The tack coat shall be applied just ahead, keeping pace with laying of premix carpet.

4.4 Preparation of Premix

4.4.1 Mechanical mixers shall be generally used for preparation of premix Improvised hand mixing drums may be used if permitted by the Engineer-in-charge. 4.4.2 Stone chippings of specified size shall be thoroughly mixed dry in the mixer at the rate indicated above. Binder heated at temperature suitable for the grade of bitumen is added to the mixer drum at the specified rate per loom3 of surface and thoroughly mixed till the stone chips are completely coated with the binder.



S-10-02-008 Page 6 of 8


4.4.3 The premix shall be emptied on to wheel barrows or stretchers and carried to work site.

4.5 Spreading of PremixImmediately after applying the tack coat, the premix shall be spread with rakes to therequired thickness land distributed evenly by means of a drag spreader. The cambershall he checked by means of camber board and the uneveness shall be rectified.

4.6 Rolling

When the premix has been laid for a length of 15-20 meters. rolling shall be commencedwith tandem rollers ( 8 to 10 tonnes). Rolling should commence from edges and proceedtowards centre longitudinally. The wheels of roller shall be continuously moistened to prevent the permix adhering to the wheels and being picked up.

After the preliminary rolling and honey combing, high spot or depressions shall be rectified by adding or removing the premix as per requirements and the surface shall be rolled again to compaction. Camber shall be checked at every stage and any defects found shall be rectified. Excessive rolling shall be avoided.

4.7 Seal Coat ( For low rainfall areas - under 150 cm/yr )

4.7.1 A premix seal coat, mix preferably in a mechanical mixer after heating the sand should he

applied immediately after laying the carpet and rolled. Materials required for this seal coat are as per clause 3.

4.7.2 Seal Coat ( For high rainfall areas- over 150cmlyr)The material requirement for seal coat in high rainfall areas is as under :-

Binder 80/ 100 = 98 kg / 100m2 of road surface

Coarse aggregates6.3mm passing IS l0mmSquare mesh retained onIS sive 2.36mm = 0.9m31 100m2 of road surface.

A liquid seal coat, preferably with chippings as above ( through coarse sand canalso be used) should be applied after laying the carpet. The binder, heated to permitted temperature, should be applied to the cleaned surface, blinded with chippings and rolled.



S-10-02-008 Page 7 of 8


Traffic may be allowed on the road preferably 24 hours after providing the seal coat.

5.0 Payment

Payment shall be made on sq.m. basis of finished surface including all labour & materials as per above specifications.


6.1 11 be removed from construction area to the area Surplus earth and soil from excavation shall demarcated by the Engineer-in-charge.

6.2 payment shall be made only for lead beyond initial 50M from construction areas Rate shall include loading, transportation, dumping, stacking the surplus earth and soil in the area demarcated. Payment shall be made on cubic meter basis of the difference of measurements of the volumes of the excavated pits and the measurements of the backfilling.

7.0 JOB SPECIFICATION FOR BRICK PITCHING

7.1 ExcavationTrench shall be excavated /dressed true to line, section and grade as per drawings prior to starting the pitching work.

7.2 Material

7.2.1 Bricks shall be locally available best bricks.7.2.2 Cement, sand and water used shall be as per IS:269,2 1 16.

7.3 The concrete mix used for bedding shall be as per drawings and schedule of rates.7.4 The work of pitching shall be done after the bottom concrete has been laid and sides

properly trimmed to the required grade and thoroughly compacted.

7.5 Brick pitching shall be done in 1 :4 cement mortar using best quality locally available bricks.

7.6 Bricks shall be laid in herring bone pattern with their length at 450 to the length of the ditch as shown in drawings.

7.7 Mortar joints shall never exceed 6mm in thickness and all bricks shall be laid with vertical joints quite full of mortar.

7.8 Bricks shall be soaked for a period of at least 12 hours immediately before use and nobroken and damaged bricks shall be used in any part of the work except such as will he



S-10-02-008 Page 8 of 8


required to close any line of bricks.

7.9 The face of pitching shall be made even and smooth.

7.10 The brick work shall be raked and flush pointed with cement mortar 1 : 3 as specified.

7.10 Payment

Payment for brick pitching shall be made on the basis of area paved. It shall include alloperations described above except the excavation item.


STANDARD SPECIFICATION FOR RCC PIPE CULVERTS & ERC CROSSING ETC.

S-10-02-009 Page 1 of 5


GAIL(INDIA) LIMITED

STANDARD SPECIFICATION FOR RCC PIPE CULVERS

& ERC CROSSING ETC.



S-10-02-009 Page 2 of 5


CONTENTS

1. SCOPE

2. MATERIALS

3. TRANSPORTATION AND STACKING

4. LOWERING AND LAYING OF PIPES



S-10-02-009 Page 3 of 5


1. SCOPE

The scope of this specification covers R.C.C pipes culverts and ERC crossings etc.

2. MATERIALS

2.1 the pipe materials , the following codes shall apply:

Specification for precast Concrete Pipes(With and without reinceforcement ) IS : 458

Code of practice laying of concrete Pipes IS 783

2.2 All pipes must be new and perfectly sound free from cracks cylindrically straight and of standard nominal diameter and length with even texture. Each pipe shall have collar.

2.3 The contractor shall submit a Manufacture’s test certificate wherever demanded by Engineer-In- charge or his authorized Representative.

2.4 Spun yarn for pipe joints shall be best quality. It shall be from dust etc.

3.0 TRANSPORTATION AND STACKING

3.1 The transportation of materials to the worksite and stacking shall be done in manner to cause minimum inconvenience to the traffic and other construction work.

3.2 The pipe shall be protected during handling against impact, shock and free fall to avoid cracks and damage.

3.3 The contractor shall be fully responsible for the safety and security for materials transported and stacked in the field.

3.4 Earthwork

Refer STD Specification No S-10-02-005

4. LOWERING AND LAYING OF PIPES

4.1 GENERAL

Laying and jointing of pipes shall confirm to IS : 783 Pipe shall jointly by collar Joints.



S-10-02-009 Page 4 of 5


The trench shall be checked for proper level, grade and alignment before lowering the pipes.

4.2 Lowering

The pipe shall be lower cautiously to prevent disturbance of the bed and sides of the trench. The heavy pipes shall be lowered by means of proper tripodes. Chain pulley blocks or as directed by Engineer-In-Charge. Maximum care should be taken to prevent sand etc.

4.3 Laying

4.3.1 Laying of pipes shall proceed up grade of slopes.

4.3.2 The error of grade shall not be rectified by packing up earth under neath the pipe. If required . Concrete shall be used for packing.

4.3.3 The ends of the pipes shall be kept closed to keep dirt, mud and foreign materials out . Adequate provision shall be made to prevent floating of pipes in the event of flooding of trenches.

4.3.4 The body of the pipe for its entire length shall rest on an even bed in the trench and places shall be excavated to receive the collar for the purpose of joining.

4.4 Jointing of Pipes

4.4.1 A few skeins of spun yarn, soaked in neat cement wash shall be inserted in the groove at the end of the pipes and the two adjoining pipes butted against each other . The collar shall than be slipped over the joint covering equally both the pipes. Spun yarn soaked in neat cement wash shall be passed round the pipes and inserted in the joint means of caulking tools from both end of the collar. More skein of yarn shall be added and well rammed home. The object of the yarn is to center the two end of the pipes within the collar and to prevent the cement mortar of the joint penetrating in to the pipes.

4.4.2 Cement Mortar 1:2 ( 1 Cement : 2 Sand ) shall be slightly moistened and must on no amount be soft or sloppy and shall be carefully inserted by hand into the joint. The mortar shall than be punched and caulked into the joint and more cement mortar added until the space of the joint has been filled completely with tightly caulked mortar. The joint shall be finished off neatly outside the collar on both side at an angle of 45 degree.

4.4.3 Any surplus mortar projecting inside the joint is to be removed and the guard against



S-10-02-009 Page 5 of 5


any damage sack or gunny bags be drawn past each joint after completion.

4.5 Curing

The cement mortar joints shall be cured at least for seven days.

4.6 Testing

All joints in culverts pipe lines shall be tested to a head of 1.5 meters of water above the top of the highest pipe.

4.7 Payment

Payment shall be made on running Meter basis which includes supplying, lowering, alying, jointing, curing , all complete.


STANDARD SPECIFICATION FOR UNDERGROUND AND BOVE GROUND G.I. PIPELINE SYSTEM (WATER SERVICES S-10-02-010 Page 1 of 4


STANDARD SPECIFICATION FOR UNDERGROUND AND BOVE GROUND G.I.

PIPELINE SYSTEM (WATER SERVICES)




CONTENTS

1. SCOPE

2. MATERIAL

3. EARTHWORK IN EXCAVATION AND BACK FILLING

4. FABRICATION AND ERECTION OF G.I. PIPING SYSTEM

5. TESTING

6. PAYMENTS

1. SCOPE




This specification covers the fabrication, and erection of G. I. pipeline system both underground and above ground including excavation, backfilling for the pipeline and testing of completed system. Rates shall include all incidental work such as transportation of all materials from owners stores, custody , and fabrication and laying of G.I. piping system.

2. MATERIALS

a) All G.I. piping shall conform to IS: 1239 part I . b) All gun metal valves shall conform to IS : 778 Class 11. c) All G.I. fittings shall conform to IS : 1239 Part I1 .

The schedule of pipes & fittings shall be as per schedule of items under respective works.

3. EARTHWORK IN EXCAVATION AND BACKFILLING ETC.

All earthwork for G.I. lines shall be governed by the provisions of GAIL specification s-10-02-002 "Earthwork for underground piping " to the extent applicable. All earthwork in excavation, backfilling and transportation are included in the quoted rates.

4. JOINTING AND ERECTION OF G.I. PIPING SYSTEM

4.1 Screw socket Joints.

The screwed end of all GI pipes shall be thoroughly cleaned and painted with a mixture of red and white lead or teflon before jointing. The joint shall be made by winding afew threads of hamp round the ends of tubes and then screwing them into sockets to the full depth of threads. Exposed threads shall be coated with approved anticorrosive paint. No pipe shall be bentloffset to save fittings. The offset in GI pipes shall be made only after the permission of the Engineer-in-charge . If threaded end of pipe is damaged, the contractor shall cut the end with hacksaw and shall prepare new threads conforming to IS :554 to required length .

All fittings shall be malleable galvanised iron approved by the Engineer-in-charge. Fitting in GI line shall include all couplings, elbows, tees,bends,unions,nipples,reducers,flanges with nuts and rubber insertion and all other fittings to make a complete job.

4.2 Flanged Joints

Flanged joints shall be made by painting the faces of the flanges with red lead and bolting up evenly on all sides with compressed asbestos gasket as per piping material specification.




4.3 Valves

Flanged or screwed valves shall be installed in locations shown on the drawings as per specification for screwed or flanged joints.

5. TESTING All completed G.I. lines shall be hydrostatically tested to a test pressure of 5 Kg/cm2.

6. PAYMENT

Payment shall be made on running meter basis of finished pipeline with fitting after testing etc, complete. No separate payment shall be made for earthwork in trenching and backfill, road cutting etc. Payment for valves and flanges etc. shall be made as per schedule of items on unit rate basis The unions shall be provided at every 50 meter unless otherwise stated in schedule of items/contraction drawing.


STANDARD SPECIFICATION FORCOATING AND WRAPPING OF

UNDERGROUND PIPES S-10-02-011Page 1 of 14



UNDERGROUND PIPES





CONTENTS

1. SCOPE

2. REGULATIONS

3. LIMIT OF UTILIZATION

4. MATERIAL AND PROCEDURE OF WORK

5. REPAIR OF PIPE





1. SCOPE

The scope of this specification is to describe the method of protecting the underground pipelines by the process of coating and wrapping. The job shall be generally performed in the following operations:

i) Cleaning the external pipe surface by blasting

ii) Priming with synthetic primer

iii) First coat of coal tar enamel

iv) First layer of inner wrapping with glass fibre

v) Final Coat (2nd. coat) of coal tar enamel

vi) Outer wrap of coal tar impregnated glass fibre

vii) Kraft paper

viii) White wash

In addition, this specification also covers and defines the material specification. method of cleaning, priming, procedure of coating & wrapping, testing, repairing, handling and storing etc., required for the satisfactory completion of the job.

2. REGULATIONS

2.1 All materials used shall conform to the quality and testing requirement indicated in ANSI\AWWA C-203-91 - Coal-Tar Protective Coatings and Linings for steel water pipelines - Enamel and Tape-hot applied or BS 4164-1987 Coal-Tar - based hot applied coating materials for protecting iron and steel, including a suitable primer. or ASTM Standards and or as directed by Engineer-in-charge.

2.2 ISO-850 1 - 1988 Pictorial surface preparation standard for painting steel surfaces.

2.3 SSPC-SP steel structure painting council surface preparation specifications.

SSPC-SP- 1 Solvent cleaningSSPC-SP-3 Power tool cleaningSSPC-SP-10 Near white metal blast cleaning





2.4 All appurtenances and equipment to be used for cleaning, priming, coating and wrapping and testing shall be approved by the Engineer-in-charge.

2.5 If any procedure/specification is seen not covered by this specification then ANSI/AWWA C-203, BS 4164 clause shall apply.

3. LIMIT OF UTILISATION

The underground pipe line protected by coating and wrapping as described in this specification should be able to carry a liquid at a temperature up to 600C.

4. MATERIAL AND PROCEDURE OF WORK

4.1 Preparation and Cleaning of Piping

4.1.1 The exterior surafaces of pipes shall be thoroughly cleaned of all rust, mill scale, oil, grease, dirt, weld scales, weld burrs or other foreign matter etc. mechanically as per SSPC-SP3. All oil, grease or other contaminants shall be removed by solvent cleaning in accordance with SSPC-SPI prior to shot or grit blast cleaning. All exterior surfaces of pipes shall be blasted to SSPC-SP10 or IS0 grade 2%). The surface profile after blasting shall be 15-25 microns. The procedure for cleaning shall be approved by Engineer-in-charge. The primer application after cleaning should be within 4 hours of completion of blasting.

4.1.2 The abrasive blast material shall be free of impurities and inclusion of water and oil. All abrasives shall be removed by brush off, blast or vacuum type cleaner prior to applying coatings.

4.1.3 The compressed air for blasting shall be free of impurities and inclusion of water and oil. Separators and traps shall be provided at the compressor and blasting station. Separators and traps shall be checked daily for effective moisture and oil removal during coating operations.

4.1.4 Blast cleaning operation shall not be conducted on surfaces that are less than 15oCor when the relative humidity is greater than 85% unless preheating of the pipe is performed. Blast cleaning under these conditions may be performed, provided the pipe can be warmed to a temperature (not to exceed 400 C) sufficient to perform the blasting operations.

4.1.5 Prior to primer application, the pipe shall be cleaned to remove any wetness or other contaminations.

4.1.6 The pipe can be rejected if any laminations or other irregularities at the steel surface become visible after blast cleaning unless in the opinion of Engineer-in-charge, it can be





accepted by grinding and re-blasting.

4.1.7 The cleaning, priming, coating and wrapping should be carried out by suitable machine either in contractor's workshop or in well organised site (yard). The entire pipe length shall be cleaned, primed and coated and wrapped but the ends of the pipes shall be left without coating and wrapping for a distance of 200mm on each end of pipes for joints, which shall be coated and wrapped manually at site with two wraps of coal tar tape coating 2mm thick each as per ANSI IAWWA -C-203-91SEC-8.0 after welding and testing the pipes. At the end of coated section of the pipe, coating and wrapping should be tapered for length of 50mm for producing better bond with tape to be done for field weld joints. The weld end bevels shall be protected at all times during surface preparation. handling, coating and wrapping of large diameter pipes shall be done individually before jointing of pipes whereas coating and wrapping of smaller diameter pipes shall be done after jointing of two or three or more pipe lengths together depends on facilities available.

4.1.8 Alternatively, if permitted by the Engineer-in-charge. the pipelines shall be adequately scrubbed manually with stiff wire brushes and scrapped where necessary. The primer coating should immediately follow the cleaning of pipes. The primer coating may also be done manually if permitted by the Engineer-in-charge.

4.2. Priming

4.2.1. Material

The primer shall be a type B (fast drying, synthetic) certified to meet ANSIIAWWA C-203-91 or British Standard BS-4164, Section 3. The primer shall consist of chlorinated rubber, synthetic plasticiser and solvents suitably blended to produce a liquid coating which can be readily applied cold by brushing or spraying and which will produce effective bond between the metal and subsequent coating of coal tar enamel. The main characteristics of the primer shall be as follow:

-Drying time to touch at normal humidity @ 30•‹C (70%) Approx 5- 15 minutes.-Flash point, BS 2000: part 170 230 C (minimum)-Flow time (4mm flow cup) at 230 C,BS 3900: part A6 35-60 Sec.-Volatile matter (105-1100C), max.BS 4164 Appendix A 75% loss by mass-Coverage @ 25 microns/coat 8-12 m2/lit.

4.2.2. Priming Operation (Cold Application)

- The primer shall be applied on the pipes in uniform thin film (Single coat)@ 25 microns DFT/Coat leaving no drips or runs. The entire surface of the pipe should





be primed without any patch left out by spray I hand brushing. Any holidays or unprimed places shall be reprimed immediately. Any flooded areas or primer applied on improperly cleaned pipe shall be cut down to surfaces of pipe and reprimed at Contractor's cost. The primer shall be cold applied to a clean dry surface, immediately after cleaning operation.

- The surface shall be dry at the time of applying primer coat. Primer shall not be applied during rain or fog or on wet surface.

- Primer which becomes foul with foreign substances or thickened through evaporation of solvent shall not be used.

- Freshly primed pipe shall be placed on clean square cut skids and shall not be allowed to come in contact with the ground or with any other foreign matter. It shall remain on skids until lifted or cradled for the coating & wrapping operation.

- During the periods of cold weather, when the temperature of the steel is below 7Oc (45oF) or at any time where moisture collects on the steel, the steel shall be warmed to a temperature of approximately 30o C which shall be maintained long enough to dry the pipe surface prior to priming.

- All primed pipes which have excessive coat of dust or primer accumulated over them before the primer is dry or where primer has become dead shall be reprimed. The application of coal tar coating shall be taken up after the primer coat has dried up completely and normally within 24 hours after priming with maximum limit of 5 days. Otherwise a fresh coat of primer shall be applied at contractor's cost. The Engineer-in-charge shall approve the primer coat before the next coat is applied.

- The primer shall be kept in tightly sealed containers when not in use to prevent evaporation.

- The primer shall be applied as received from the manufacturer and should not be thinned under any circumstances.

4.3 Coating And Wrapping

4.3.1. Coal Tar Enamel

Enamel shall be composed of a specially processed hard coal tar pitch combined with an inert mineral filler. Coal tar shall be produced from coal that has a minimum heating value of 13,000 Btu/lb (7.233x106 Cal/kg) on a moisture and mineral free basis (ASTM D 388), and that has been carbonised in a slot type coke even at a temperature of not less than 900o.C No Asphalt of either petroleum or natural base shall be acceptable as part of





the ingredients. The enamel (Type -I) shall have the following physical characteristics conforming to ANSIIAWWA C 203-911BS-4164-1987.

Min. Max.- Softening point (Ring and ball)

ASTMD – 36 1040C 1160C

- Filler (Ash) ASTM D-2415 by wt. 25% 35%

- Fineness of filler, through 200 meshASTM D-546 by wt. 90% -

- Specific gravity at 25 "C ASTM D 71 1.4 1.6

- Penetration, ANSI/AWWA C 203-91,Sec.7.2, 0.1 mm@77 " F(2S " C)- 100 gm . weight for 5 sec. 5 10@ 1 15 "F(46 "C) 50 g. weight for 5 secs. 12 30

- High Temperature Sag Test@ 160•‹F(71 "C) ANSI/AWWA C-203-91sec.7.4 - 1/16” (1.6mm)

- Low Temperature cracking test @-10•‹F,(-23.3 "C) ANSI/AWWA C 203-91,sec.7.5 - None

- Impact test @77"F (2S•‹C)650 gm ball,8ft drop ANSI/AWWA C-203, Sec. 7.7Direct impact disbonded area - 16in2 (10.323 mm2)Indirect impact disbonded area

- Peel test, ANSI/AWWA C-203-91, Sec.7.6 - 6 in2 (3871 mm2)

- Spark test 15 KV low amperage - None

- Water absorption, 35 weeks - 0.3%

- Application temperatures(max) - 2250 C2450 C

- Cathodic disbondment test BS 4164 5mm (max)

4.3.2. Glass Fibre Mat for Inner Wrapping





The fibre glass mat for inner wrapping shall be thin, flexible, uniform mat composed of chemically resistant borosilicate glass fibre tissue or hydrolitic class 3-m conforming to DIN-12-111 mono - filaments distributed in a random open porous structure, bonded together with a thermosetting phenolic type resin which shall be compatible with the coal tar enamel. The inner wrap glass fibre tissue shall be longitudinally reinforced by continuous filament glass yarn embedded in mat & shall have nominal thickness of 0.5 mm (0.02") and shall conform to ANSIIAWWA C 203-91, Sec. 10.3.1 .excepting the paramters defined above.

- No disbonding of individual glass fibre shall occur during or following the embedding process.

- The glass fibre mat shall not cause bubbling under the condition of application.

- The glass fibre mat shall be sufficiently porous so that it can be embedded in the hot coal tar enamel as it is applied to the exterior of the pipe.

- The glass fibre mat shall be free from thin spots, pimples, lamination, uncured binder flows, wrinkles, torn edges, dust oil and grease etc.

- The glass fibre mat (reinforced glass wrap) shall also conform to ANSI/AWWA C 203-9 1 section 10.3.1 and the following characteristics

- Weight (minimum) 41 gms/m2

- Nominal thickness 0.5 mm + 0.1 mm

- Tensile Average, Breaking Strength

- Longitudinal direction 2280 N/M of width (min)

- Transverse direction 700 N/M of width

- Porosity The Glass Fibre mat shall have a prosperity of not more than 1.90mm of water gauge measured at pressure difference across the sample at an air velocity of 61 M/Minutes,

- Temp. Resistance The glass fibre tissue shall be unaffected under load in hot enamel at 5300F (2880C) for one minute

- Moisture absorptionby wt. at relative humidityof 95 " at 120•‹F (50•‹C) for 24 hrs.





4.3.3. Outer Wrap Coal Tar Impregnated Glass Fibre

The outer wrap shall be non-woven, thick, reinforced glass fibre mat uniformly impregnated with coal tar enamel and shall conform to ANSI\AWWA C-203-91, Section 2.4.2 with following characteristics:

- Glass Tissue Base 0.77kg per 100 ft2(9.3 m2)

- Weight (Finished Material) 5.4kg to 6.8 kg per 100 ft2(9.3 m2)

- Thickness 0.76 mm (30 mills)

- Tensile strength(Average Breaking Strength)

- Longitudinal Direction 6130 N/m of width (min)

- Transverse Direction 4730 N/m of width (min)

- Pliability(1" dia Mandrel 25"C, 2 sec) No cracking

- Weight loss on heating at 2 % (max)820 C for 2 hours.

- Moisture absorption 5% (max)percentage of weight ata relative humidity of95% & 1200F (500C)for 24 hours.

The finished reinforced glass fibre mat outer wrap shall have a smooth, uniform surface free of visible defects. When unrolled at a temperature from 0•‹C to 50•‹C, the outer wrap shall not crack or stick to such an extent as to cause breaking or tearing. The outer wrap shall he purchased in tightly wound tied rolls with a 3" diameter core in widths and lengths as specified at the time of purchase. The rolls shall he packed to exclude dust and dirt during shipping and handling and shall have card board separators and end shields adequate to prevent roll damaged when stacked. The sides of the rolls shall be clean, smooth and squared cut and shall have no telescoping.

4.3.4 Polyethylene craft paper shall be as per sec. 2.4.3 and 2.5 of ANSI\AWWA-203.

4.3.5 The white wash used as a final coat shall be manufactured in accordance with white wash formulas as specified in ANSI\AWWA C-203-9 1, Section 2.7.





4.3.6 Preparation Of Coating Materials

The coal tar enamel shall be furnished in expandable sheet metal or drums that shall be cropped or cut out on a suitable platform to prevent the enamel from coming in contact with weeds, cinders, grass and other form of contamination. The cropped or cut pieces of enamel may not weigh more than 10 kgs. The pieces of enamel shall be covered when they are in danger of contamination because of atmospheric conditions. The broken enamel shall be placed in a clean melting kettle and slowly heated at a uniform rate of 2250C to 2450C (application temperature) or manufacturer's recommended temperature. Any coating material heated to more than the above mentioned temp. shall be rejected. Spilled material which has become contaminated shall not he returned to the melting kettle.

The coating being prepared for use by coating machine shall be agitated in melting kettles having continuous mechanical agitators. The melted enamel in these kettles shall be stirred at an interval of not more than 15 minutes during heating with metal agitators. Wooden paddles or sticks shall not be used for stirring. Accurate thermometers shall be used on heating kettles in such a way as to be read clearly. The thermometer bulb shall be within 100 mm from the bottom of the kettle, and shall have temperature range from 1000C - 3000C. Thermocouple can also be used for monitoring the temperature.

Any coating material that has been heated in the kettles to a temperature in excess or what is specified herein or by manufacturer's recommendation shall be condemned and shall not be used.

4.4 Application Of Hot Coal Tar Enamel And Inner Glass Fibre

4.4.1. First coat of hot coal tar enamel shall be applied over the adequately cured primed surface to a minimum thickness of 2.0 mm. The Engineer-in-charge shall cut samples and test the thickness of coating and further work of outer coating shall be taken up only after the inner coating has been approved by the Engineer-in-charge.

Simultaneously with first coat of coal tar the glass fibre mat shall be mechanically applied in machine. It is preferable to pass the fibre glass mat through a bath of hot coal tar enamel before being applied over the pipe. Sufficient tension shall be applied to the rolls of fibrous mat to embed it in the coal tar enamel before it cools to furnish a proper bond with the next layer of coal tar enamel. The glass fibre mat shall be of suitable uniform width for smooth spiral application. The over lap of the mat shall not be less than 112 inch (12mm). A second coat of hot coal tar enamel shall then be applied of such a thickness that finished thickness of two layers of enamel, inner and outer wraps shall be a minimum of 4.0 mm.

4.5 Application Of Second (Outer) Layer Of Coal Tar Enamel Coating & Glass Fibre





Wrapping

Immediately after application of the 2nd layer of coal tar enamel, outer wrap of coal tar impregnated glass fibre mat shall be applied in a tight uniform spiral and shall be spirally wound round the pipe with a minimum of 15 mm of overlap on each spiral. The thickness of final coat of enamel shall he so adjusted that the total finished thickness of double coating & wrapping in dividing outer wrap is maintained minimum 4.0mm. The coating and wrapping must be free of pin holes, bubbles or holidays. The Engineer-in-Charge shall cut samples from the coating from time to time to determine the thickness and bond of coating.

4.6 Primer, Coating and Wrapping Application for Field Joints of Pipes after Laying at Site.

4.6.1. Primer shall be applied with brushes after cleaning the pipe throughly (joints portion etc) as per specification.

4.6.2. Two wraps of coal tar tape 2mm thick each shall be applied as per ANSIIAWWA C-203-91 Sec.8.0.

4.7 Inspection

The word 'Inspector' means a person designated by the Engineer-in-Charge for inspection and approval of the work under this specification. The entire procedure of applying the protective coating material as herein specified will be rigidly inspected from the time the bare pipe is received until the coated pipe is laid in the trench and back-filled and/or installation of coated pipe is complete. Such inspection shall not relieve the contractor of his responsibility to furnish material and perform work in accordance with these specifications and shall not relieve him of the guarantees under this contract. All coating and wrapping work to be acceptable must be applied in the presence of the inspector. and all such work done in his absence will be subject to rejection unless the continuance of the work during his absence in specifically allowed by the inspector. If at any time it is found that the procedure of applying the protective coating and wrapping material in not in accordance with these specifications, all such coating work may be rejected. The coating and wrapping work will be inspected in stages namely after cleaning of the pipes, application of primer coat, application of coal tar enamels, fibre glass inner wrap and outerwrap, coal tar impregnated glass fibre.

Prior to approval of the contractor's material, samples of materials submitted by the contractor will be tested by the contractor for various tests as per the relevant standards and if any sample is found not conform to these specifications, material represented by such samples will be rejected. If samples of contractor's approved materials are found not to conform to the specifications all such materials will also be rejected.





Samples submitted to the Engineer-in-charge will be tested in an approved responsible commercial laboratory, designated by the Engineer-in-charge.

The expenses of testing of all samples of materials offered by the contractor and the expenses of all subsequent tests due to failure of samples of material originally offered to comply with these specifications will be borne the contractor.

In addition to above, the contractor shall submit manufacturer's certificates. in original for each batch of materials used on the job.

The contractor shall furnish the inspector reasonable facilities and space without charge for the inspection testing and obtaining of such information as he desires regarding the characteristics of materials used and the manner in which the work is progressing.

Inspection shall be carried out for coating thickness adhesion and holidays along with visual inspection.

The Field Peel Test Procedure, as per ANSI\AWWA C-203-91 section 7.8 or BS 4164 Appendix -L shall be applied to each pipe initially till the Engineer-in-charge relaxes it later to a random of one in ten pipes.

The pipe shall be thoroughly inspected for any holidays, pinholes, torn, abraided or mutilated spots.

The contractor shall furnish and operate at his own cost, a high voltage electronic holiday detector of type acceptable to Engineer-in-charge. The detector will have to be calibrated by the contractor at his own cost before use and the calibration shall be witnessed and approved by the Engineer-in-charge.

4.8 Testing and Repairs

4.8.1. Repair of Pinpoint Or Bubble Type Damage

Dirt, foroeign matter, kraft paper and outerwrap shall be removed using a sharp kinfe, taking care not to damage the surrounding enamel. Correctly heated enamel shall be poured over the prepared area to the specified thickness and covered with a patch of outer wrap.

4.8.2 Repair of Exposed Metal Type Or Extensive Damage

Remove dirt, foreign matter and all surrounding disbonded enamel with a shart knife. Make a square repair area of 4sq.inch(min) by cutting with a kinfe or higher size if required. Remove the primer by emery paper. Feather out the edges of coating wrapping over 112 inch width with a file. Clean the entire area with compressed air. Apply one coat





of synthetic primer.

Use hot-applied coal tar tape (4rnm thick) as per AWWA C-203(91) section 8 for repair. Take a square cut of the tape with 1 inch higher dimension than the size of the damaged area. Feather out around 1 inch width on all four sides with a file. Hot apply the tape patch as per manufacturer instructions. Allow to cure.

4.8.3 Both the repaired area in 4.8.1. and 4.8.2 shall be electrically inspected using a holiday detector after curing.

4.9 Handling & Supporting Coated Pipes

4.9.1. Contractor shall develop the method of stock piling and loading out coated pipes and shall receive approval from Engineer-in-charge prior to handling of coated pipes.

4.9.2 The coated pipes shall be carefully handled so as not to damage them in any way. No wire ropes or chains shall be used to lift the coated pipe. Canvas or rubber belts of minimum 300mm width and sufficient strength shall be used. The use of tongs, Bare pinch bars, , chain slings, protruding rivets, pipe hooks without proper padding or any other handling equipment that may injure the coating shall not be permitted.

4.9.3. If the pipes are coated in a shop, one pipe should not be placed above another during transit in the wagon or truck. The pipe shall be carried on suitable paddle skids mounted on the wagon or a truck to ensure that the coating will not be damaged in any way.

4.9.4. Pipes shall be stored in the field under covered protection during rains. Pipe shall he kept on clean square cut padded wooden skids protected with fibre glass mat felt or straw until ready to be lowered in the trench.

4.9.5. The contractor handling and transporting the pipe shall conform to standards as set out in ANSI\AWWA C 203-91 section 9.1 "Handling and Transporting Enameled Pipe".

4.10 Adjacent pipe-lines, Structures etc.

If any damage is caused to the coating and wrapping of adjacent pipes or any other existing structure during excavation of subsequent work or during coating and wrapping of field joints the contractor shall carry out necessary repairs at his own cost in an a manner as directed by the Engineer-in-charge.

5.0 REPAlR OF PIPE

Any damage to the pipe, Such as dents, gauges, flattening or damage caused by contractor to bevels shall be cut out, the pipe beveled and if necessary, re-welded with prior approval of Engineer-in-Charge. All such re-welding shall conform to the applicable





provisions of codes. The cost of work, plus the cost of pipe lost due to repair will be to the account of contractor.



Misc. CIVIL & STRUCTURS-10-02-012 Page 1 of 7


STANDARD SPECIFICATION FOR MISC. CIVIL & STRUCTURAL

WORKS FOR U/G PIPING & OTHER (CIVIL WORKS)





CONTENTS

1. SCOPE

2. EARTHWORK AND BACK FILLING

3. PLAIN AND REINFORCED CEMENT CONCRETE

4. BRICK WORK

5. CEMENT PLASTERING

6. M.S. RUNGSIC. I. STEPS

7. CHEQUERED PLATES AND STRUCTURAL STEEL WORKS

8. C. I. MANHOLE FRAME AND COVER

9. VENT PIPES

10. FUNNELS, CLEAN OUTS, PLUGS

11. BRICK BAT FILL





1. SCOPE

This specification covers the material and construction details for various civil works as given below:

a. All Earthwork except for Site Grading and UIG Piping.

b. Plain and reinforced cement concrete work in catch pits clean outs manholes, pipe

supports, water monitors, hydrant pedestals, Thrust block etc.

c. Brick work for various structures such as Manholes, Catch basins, Valve Chambers,

instrument tapping chambers, Flushing chambers, etc

d. Plastering for the above structures as applicable.

e. Manhole frames, manhole covers, ladder rungs etc. for the above structures as applicable.

f. Miscellaneous structure steel work such as ladders, platforms, chequered plate covers, gratings etc.

The work shall include supply of various materials as per relevant standards, required for the execution of work except for those items designated as Owner's scope of supply in the special conditions of contract or elsewhere in the contract documents. Contractor shall transport from Owner's stores those materials which are a part of owner's supply.

All materials not fully specified herein and which may be used in the WORK shall be of quality approved by the Engineer-in-charge and he shall have the right to determine whether all or any of the materials offered or delivered for use in the WORK are suitable for the purpose. CONTRACTOR shall give the samples of material to the Engineer-in-charge and shall get it approved before procurement and use.

2.0 EARTHWORK & BACKFILLING

2.1 Refer the specification covered elsewhere in the tender document.

3. PLAIN AND REINFORCED CEMENT CONCRETE

3.1 Refer the specification No S-11-02-004 covered elsewhere in the tender document. Plain





and Reinforced Cement Concrete work shall confirm to Indian Standard for Plain and Reinforced Cement Concrete- Code of Practice ( Fourth Revision) IS 456:2000.

4.0 BRICK WORK

4.1 Refer the specification covered elsewhere in the tender document

5.0 CEMENT PLASTERING

5.1 Materials

The specifications for cement, sand and water shall be as given in specification of the materials.

5.2 Cement mortar shall be of grade and thickness specified in drawing or as directed by theEngineer-in-Charge, if not specified. The surface on which plastering is to be done shall be thoroughly cleaned from dust, dirt, oil, etc. It should be washed properly and watered for 4 hours before plastering. The joints of brick work shall be raked out to a depth of at least 12mm when plastering has to be done. On cement concrete surface, the surface shall be scarified by lines with trowel when it is still green or hacked if concrete is hard a as directed by Engineer-in-Charge.

5.3 Plaster shall not in any case, be thinner than specified. It shall have uniform specified thickness. Any extra thickness of plaster done by contractor will not be paid for. When smooth finishing is required the cement plaster shall be floated over with neat cement within 15 minutes of the application of the final coat. During the process of plastering all corners shall be rounded to a radius of 25mm unless otherwise specified.

5.4 The plaster shall be protected from sun and rain by such means as the Engineer-in-Charge may approved. The plaster shall be cured for 7 days.

5.5 Construction joint shall be kept in plastering work at places approved by Engineer-in- Charge.

5.6 Payment

5.6.1 Payment for plastering shall be made on basis of the area of surface plastered, measured before plastering. All Measurements shall be separately made for each face of walls.

5.6.2 The rate of plastering shall include cost of scaffolding, swings, cleaning the surface, raking out joints, hacking concrete surfaces, etc. needed for carrying the work and shall cover the extra labour for plastering the jambs, sills, and soffits or opening except for plastering bands, cornices and skirting upto 30 cm width.





6.0 M.S. RUNGSIC. I. STEPS

The rungs for valve pits and manholes shall be of M.S. conforming to Indian Standard and to the shape and size as shown Drgs. C.I. steps for manholes if used shall be as per IS : 5455. M.S. Rungs or CI steps shall be coated with 2 coats approved bituminous paint.

Payment for steps/ rungs shall be made per number and the rate shall include supply and fixing, finishing the wall etc. complete.

7.0 CHEQUERED PLATES & STRUCTURAL STEEL WORKS

Chequered plates shall be 6mrn (7mm moreover chequers and shall conform to IS : 3502). Steel for chequered plate shall conform to IS32062 and shall be clearly rolled and free from harmfull surface defects such as crack surface flaws etc. The plate shall be cut to shape and fixed to the bearing members as shown in relevent drgs and as directed by Engineer-in- Charge. The edges shall be made smooth, no burrs or gagged ends shall be left. The plates may be spliced with prior consent of the Engineer-in-Charge. But in that case care should be taken so that there is continuity in the pattern of the plates between the portions. Lifting arrangements shall be provided including lifting rods.

Grating shall be fabricated out of M.S flats, angles and rounds etc., as per drawings and as approved by Engineer-in-Charge. Steel for grating plates shall conform to IS : 2062 of general Weldable quality and shall be clearly rolled and shall be free from harmful1 surface defects.

Payment shall be made on the basis of weight of M.S Gratings/ chequered plate and supporting frame actually laid. The rate shall include supply of all necessary, steel materials cutting to size, fabricating, smoothening edge if necessary, transporting and fixing at all positions and providing lifting arrangements. Full deductions shall be made for all opening above 30mm square and the rate shall include making of opening of all sizes and supplying and painting 2 coats of anticorrosive paint over a coat of red oxide zinc chromate primer. The expose surface of grating and frame shall be painted with two thick coats of coal tar. The rate shall include providing and laying M.S grating and frame, breaking and making good existing concrete/brick masonry surface if necessary finishing, painting etc. complete with all labour and materials. Payment shall be on number basis.

8. C.I. MANHOLE FRAME AND COVER

C I manhole frame and covers shall conform to IS : 1726 with size and grade as shown in Drgs .

9.0 VENT PIPES





These shall be M .S. Black Steel Tube conforming to IS : 1239 Medium grade or as specified in drgs. The pipe bends shall be embedded in M-20 grade plain cement concrete suitable for sever exposure condition confirming to IS 456:2000. All pipes shall be 25mm clear of wall or column with M.S. holder bat clamp as per instructions of the Engineer-in-Charge. All holes in walls and column shall be made good by M-30 grade plain cement concrete suitable for sever exposure condition confirming to IS 456:2000.

All pipes and clamps shall be painted with two coats of paints of approved make. Payment shall be made on running meter basis and the rate shall include supply of all materials, cutting, edge preparation, jointing by welding, fixing in concrete block, cutting of walls or concrete and making good the same, painting with 2 coats of anticorrosive paint necessary scaffolding etc. complete. The rate shall also include excavation and backfilling if any.

10. FUNNELS, CLEAN OUTS., PLUGS

These shall be fabricated from M.S Plates, pipes chequered Plates, rounds, angles etc., to be supplied the by contractor. The fabric action shall be in accordance with the approved drgs.

Payment for these items shall be made on weight basis and rate shall include fabrication, erection, welding jointing and painting etc. all complete.

11.0 BRICK BAT FILL

11.1 The brick bat used as filling in valves pit shall be from common burnt clay building bricks. A sample of brick bats used shall be got approved from Engineer-in-charge.

11.2 The compaction of the layer of brick bats shall be proper so that brickbats are not disturbed and do not sink in the soil.

11.3 The payment for brick-bat fill shall be made on MP basis as shown in drawing and the rate shall include supply, laying, compacting etc. complete with all materials & labour.







UNDERGROUND SEWER SYSTEM-PRE CAST RCC PIPES

S-10-02-013Page 1 of 6



UNDERGROUND SEWER SYSTEM -PRE CAST R.C.C. PIPES




S-10-02-013Page 2 of 6


CONTENTS

1. SCOPE

2. MATERIAL

3. EARTHWORK IN EXCAVATION, BACK FILLING, TRANSPORTATION

4. LOWERING AND LAYING

5. JOINTING

6. TESTING

7. RESTORATION OF DAMAGED SURFACES AND CLEARING THE SITE.




S-10-02-013Page 3 of 6


1.0 SCOPE

This specification covers the supply, laying, cutting, jointing and testing of Precast RCC pipes and related works.

2.0 MATERIALS

2.1 The pipes shall be centrifugal cast concrete pipes with reinforcement conforming to IS : 458. The class of pipes shall be as specified on drawings.

2.2 The surfaces and edges of the pipes shall be well defined and their ends shall be perpendicular to longitudinal axis.

3.0 EARTHWORK IN EXCAVATION, BACKFILLING AND TRANSPORTATION

3.1 All earthwork involved in laying of RCC pipes and related works is deemed to have been included in the quoted rates for the laying of RCC pipes.

3.2 All earthwork shall be carried out as per specification No.6-65-0006 "Earthwork for underground piping system".

3.3 The bed of trench if in soft 'or' made up earth shall be well watered and rammed before laying the pipes and the depressions, if any shall be properly filled with earth and consolidated in 20 cm layers.

3.4 If the trench bottom is extremly hard 'or' rockey or loose stoney soil, the trench shall be excavated at least 150 mm below the trench grade. Rocks, stone 'or' other hard substances from the bottom of the trench shall be removed and the trench brought back to the required grade, by filling with selected fine earth 'or' sand (in fine murrum if fine sand 'or' soil is not available ) and compacted so as to provide a smooth bedding for the pipe.

Where excavation requires blasting operations, it shall be ensured that no pipes are stacked in vicinity and complete pipe lines in the vicinity have already been covered before starting of blasting operation.

3.5 The trench shall be kept free from water. Shoring and strutting / timbering shall be done wherever required. Excavation below water table shall be done after dewatering the trenches.

3.6 After excavation of the trench is completed, hollows shall be cut at the required position to receive the socket of the pipes and these hollows shall be of sufficient depth to ensure that the barrels of the pipes shall rest throughout their entire length on the solid ground and that sufficient spaces left for jointing the underside of the pipe joint. These hollows shall be refilled with sand after jointing the pipe.

4.0 LOWERING & LAYING

4.1 The pipes shall be lowered when the trench is ready and the bottom has been properly graded as per drawings.




S-10-02-013Page 4 of 6


4.2 Before lowering, the pipes shall be inspected carefully. Broken or cracked pipe shall be rejected. The inside of the pipe shall be cleaned off from sand, earth or any other matter.

4.3 The pipe shall be lowered carefully so as not to disturb the bed and sides of the trench. Heavy pipes shall be lowered with chain pulley blocks or crane.

4.4 Pipes shall be set according to line and grade. Prior to making joints all surface shall bethoroughly cleaned and prepared as required for the type of joint to be made. Pipe shall be carefully centered so that the completed sewer will have a smooth uniform invert.

4.5 In socket & spigot pipes the socket end shall face the upstream direction.

4.6 In case of RCC pipes with collar joints, the collar shall be slipped on before the next pipe is laid.

4.7 Railway authorities or other appropriate authorities shall be consulted wherever the pipeline crosses a railway line, canal, etc.

4.8 Connection to existing sewer shall be done through a manhole generally.

4.9 The ends of the pipe line shall be kept sealed to prevent entry of any foreign materials. The seals will be broken before/after the testing is done.

4.10 Wherever the joining material is cement, six or more lengths of pipe shall be laid in advance of each joint before it is finished.

4.11 In cases where the natural foundation is inadequate the pipes shall be laid either in concrete craddle supported an proper foundations 'or' any other suitably designed structure. If a concrete cradle bedding is used the depth of concrete below the bottom of pipe shall be atleast 1/4th of the internal dia of the pipe subject to the min. of l0cm and a maximum of 30 cm, the concrete shall extend upto the sides of the pipe atleast to a distance of 114 of the outside diameter of pipes 300mm and above in dia. The pipes shall be laid in this concrete bedding before the concrete has set. Pipeslaid in trenches in earth shall be bedded evenly and firmly and as far as up the haunches of the pipes so

as to safety transmit the load expected from the backfill through the pipe to the bed.

This shall be done either by excavating the bottom of the trench to fit the curve of the pipe or by compacting the earth under and around the curve of the pipe from an even bed. Necessary provision shall be made for joints wherever required.

5.0 JOINTING

5.1 Joint in the pipe line shall be of the socket and spigot type and conforming to relevant Indian standards.

5.2 As per IS 458-1988 joints in pressure pipes shall be flexible rubber ring joints only. Contractor shall provides Pipes of socket and spigot type meeting the above requirements.




S-10-02-013Page 5 of 6


5.3 Concrete pipes where permitted by site -in-charge with collar shall be water tight.

5.3.1 The groove in between the pipe ends is to be filled with jute impregnated with bitumen rolled in the form of gasket ring centrally around the pipe to ensure uniform annular space between the collar and the pipe.

5.3.2 Cement mortar of proportion 1:2 shall be used for caulking the annular space. Care shall be taken to see that the bottom of the collar joint is also caulked properly.

5.3.3 The joint shall be finished at an angle of 45 Deg and shall be kept wet for 10 days for curing.

6.0 TESTING

6.1 The pipeline shall be tested for water tightness of joints. The test shall be carried out from manhole. Pipe ends shall be closed and filled with water so that water level is up to the top of the manholes.

6.2 The line shall be kept full for 24 hours. Observations shall be taken after one hour interval and if leakage is within 2.5 liters/km/hrs/cm of dia of pipeline, it shall be deemed to have passed the test..

6.3 Engineer-in-Charge may at his own discretion ask the subcontractor to test the laid pipe line in sections, in which case the subcontractor will do the same as per the procedure to be decided by the Engineer-in-Charge without any extra cost to Owner. The procedure adopted in such cases, however, will be to test the pipeline according to the criteria mentioned in 6.2 above.

6.4 In case joints are found to leak, they shall be repaired or redone and test shall be repeated until the joints are approved by Engineer-in-Charge.

6.5 After completion of the test all temporary seals will be removed, the test water shall be drained out/pumped out and the line cleaned properly.

6.6 Before commissioning the cleanliness of the pipeline will be checked by :-

6.6.1 Torch & Mirror Test

In this method of testing, a torch will be held at one end of the pipeline inside a manhole and its image through the pipeline will be reflected and seen on a mirror held at the opposite end of the pipeline, inside the next manhole. Any obstruction/debris/major misalignment will not give a clear image in which case the pipeline will again be cleaned/rectified and the test redone.

6.6.2 Ring Test

In this method of testing, two steel wooden rings of suitable thickness and design shall be fixed facing each other at a distance of 2 feet or more. The block of rings shall be inserted from one end of the pipeline, inside manhole and pulled by a rope fixed to the block from the other end of the pipeline inside the next manhole. The rings shall be of dia. 2" less than the inside dia of pipe under testing. The rope used for pulling the ring block may be inserted in the pipeline by the subcontractor either during construction or afterwards by




S-10-02-013Page 6 of 6


suitable means. Any obstruction/debris/major misalignment will prevent the ring to pass through the pipeline in which case the pipeline will again be cleaned/rectified and the test redone.

The ring test shall be performed for the complete network of the sewer system before thesame is put in commission.

7.0 RESTORATION OF DAMAGED SURFACES AND CLEARING THE SITE

7.1 All pavements, structures, pipelines, cables, etc. removed, damaged or disturbed during the pipe laying work shall be restored to original conditions.

7.2 Surplus excavated soil or rubbish material shall be removed to a place as directed by Engineer-in-Charge.

8. PAYMENT

8.1 Measurement of pipeline work for the purpose of payment shall be taken in running meters of the laid pipe measured along centre line, inclusive of joints . No extra payment shall be made for providing, laying etc., of fittings like bends, tees, etc. (except valves) that may he necessary in work. The rate quoted shall be inclusive of excavation, lowering. laying, jointing, testing, cleaning of pipe lines, backfilling and any other operation involved in the



PLUMBING AND BUILDING DRAINAGE S-10-02-014Page 1 of 10



PLUMBING & BUILDING DRAINAGE





CONTENTS

1.0 SCOPE

2.0 STOP COCKS

3.0 H .C.I. NAHNI TRAP (FLOOR TRAP)

4.0 STONEWARE GULLY TRAP CHAMBER

5.0 BRICK MASONRY (MANHOLESIINSPECTION CHAMBER & VALVE CHAMBERS)

6.0 C.I. SOILIWASTE PIPES

7.0 C.1. SOILIVENT PIPES

8.0 G.I. PIPES AND FITTINGS

9.0 GUNMETAL VALVE

10.0 HALF ROUND CHANNEL

11.0 PRECAST RCC PIPES

12.0 M.S. RUNGS/CI STEPS

13.0 SOAK PITS

14.0 SEPTIC TANKS





1.0 SCOPE

1.1 The specification is intended to establish and define the materials and constructional requirements for plumbing &building drainage works.

1.2 All materials. fixtures and workmanship shall be in accordance with the relevant Indian Standards Specifications, Codes of practices and good Engineering practices.

2.0 STOP COCKS

2.1 Stop cocks of screw-down type shall conforms to IS:781. All taps shall be of heavy grade. The taps shall be chromium plated brass or ordinary easy cleaning type as specified.

2.2 The payment shall be made on units basis. The rate quoted shall include supplying and fixing bib or stop cocks with white zinc and yarn etc. complete.

3.0 H.C.I. NAHNI TRAP (FLOOR TRAP)

3.1 Nahni trap shall be of heavy cast iron as per IS:3989 with l00mm inlet and 80/100mm outlet with CP pressed steel grating. It shall be of self-cleaning design. Grating shall be of either hinged or screwed down type. It shall be fixed in cement mortar 1:2 and as directed by Engineer-in-Charge.

3.2 The payment shall be made per number basis. The rate shall include supplying and tixing Nahni trap, including cement mortar, cutting walls and floors and making good the same, providing and fixing chromium plated pressed steel grating all complete.

4.0 STONEWARE GULLY TRAP CHAMBER

4.1 The square mouth guilly trap shall be of l00mm dia, conforming to IS:651 of specified and/or approved quality stoneware, complete with cast iron grating. and shall be got approved by the Engineer-in-Charge. The size of CI frame and cover shall be of 3000mm x 300mm. It shall be properly fixed as directed by the Engineer- in-Charge. The size of the chamber shall be 300 x 300 x 675mm (internal) it shall be constructed of brick masonry walls 125mm thick in 1.4 cement mortar and M-15 concrete foundations. Inside &outside faces of the masonry walls shall be plastered with 1:3 cement mortar. The top of the chamber shall be provided with CI cover and frame.

4.2 The payment shall be made on per number basis. The rate shall include supplyingand fixing of stoneware gully trap, CI grating, construction of masonry chamber. providing and fixing CI frame and cover, earthwork in excavation, foundation concrete and backfilling removal of surplus earth upto a lead of 30m. etc and labour and material complete.

5.0 BRICK MASONRY (MANHOLESIINSPECTION CHAMBER & VALVE CHAMBER)

5.1 The size of the manholes and valve chambers shall be as specified in the drawings or





items. It shall be constructed of brick masonry walls 230mm thick in CM 1 :4 (1cement. 4 sand) resting on M-20 concrete foundations. The inside and outside faceof the masonry wall shall be plastered with 13mm thick plaster of cement motar 1:3(1 cement : 3 sand) The top of chamber shall be provided with reinforced concrete M-20 grade slab as per drawing and direction of the Engineer-in- Charge. M.S. rungs made out of 16mm dia M.S. bars shall be fixed inside the manhole as shown in the drawing after applying two coats of anticorrosive paint.

Valve chambers shall be provided and fixed with a light duty CI cover and frame. The top of chamber shall be provided with reinforced cement concrete M-30 grade as per drawings and direction of Engineer-in-Charge.

The C. I. manhole covers and frames shall conform to IS: 1726. The type size and grade shall be as per drawing. schedule of items and the directions of the Engineer-in-Charge. The frame shall be fixed in position during concreting of top slab, inside faces of frame and cover shall be given two coats of approved anti-corrosive paint.

The specification for brick masonry, plastering, concreting, excavation, and back-fill ing ,etc . as given under relevant clauses shall be applicable for this work also.

5.2 Payment shall be made as per number basis including excavation, backfilling,

removal of earth, construction of the chamber/manhole, making connections of pipes through the walls, cost of M.S. rungs, cover slab, cost of CI cover and frame, etc. as per the directions of the Engineer-in-Charge.

The rate shall include breaking concrete or brick masonry work and making good the same with 1 :4 cement mortar if necessary, finishing. painting, etc. as per directions of Engineer- in-charge.

6.0 C.I. SOILIWASTE PIPES

6.1 Cast iron pipe, socket and spigot shall be of standard quality conforming to IS : 1729 including encasing the pipe in 50mm thick PCC M10.(heavy duty).

The spigot of the pipe shall be placed fully resting inside the socket and hemp caulked home to leave space for lead depth as specified. Lead conforming to IS : 782 in molten state shall then be poured into the joint filling the same in one pouring. The lead shall be caulked by proper tools to make it even all round. Depths of lead in the joints from the top of the socket shall be 37mm for 150mm dia pipes, 25mm for l00mm and 5Omm dia pipes. All pipes shall be fixed 25mm clear of the wall with MS holder bat clamps or as approved by the Engineer-in-Charge. All holes in walls and floors shall be made good by cement concrete M- 15 grade and should be leak proof. All soil and waste pipes shall he tested for leakage by hydraulic test.

All pipes shall be painted with two coats of paint of approved make and shade over a coat of prime. Earthwork in excavation backfilling and removal of surplus earth shall be considered as a part of the work. No separate payment will be made for





the same.

6.2 The payment shall be made per running metre of pipe laid with fitting as required on site. The rate quoted shall include supplying and fixing of pipes and necessary specials including cowl with hemp and lead, jointing & testing, bat clamps, fixtures painting, cutting of walls, flloors and making good the same and necessary scaffolding, earthwork in excavation, back fllling & removal of surplus earth etc. complete.

7.0 CI/SOIL/VENT PIPES

7.1 C1 pipes shall be standard quality conforming to IS : 1729. The supply shall include all necessary accessories e.g . bends, tees etc. complete. Jute yarn gasket of suitable diameter shall be used as required to support the spigot of the pipe at the proper grade and make truly concentric joints. Single piece of sufficient length shall be used to pass around the pipe and lap at the top and shall be throughly saturated in bitumen. This gasket shall be laid in the socket for lower third of the circumference of the joint and covered with cement mortar. The spigot of the pipe throughly cleaned with wet brush, inserted and carefully driven home after which a small amount of cement mortar ( 1 :2) shall be inserted in the annular space around the entire circumference of pipe and solidly rammed into the joint with caulking tool. The joint shall then be completely filled with mortar and bevelled off at angle of 45" with outside of the pipe: Cement used to joint shall conform to IS : 269

All holes in walls and floors shall be made good by cement concrete M-15 grade. All CI pipes shall be painted with two coats of anticorrosive bituminous paint externally. The payments shall be on running metre basis of pipes laid. The rate shall include supplying and fixing pipes jute gaskets dipped into bitumen and cement mortar and necessary specials including jointing with clamps, painting, cutting of walls, floor and making good the same, necessary scaffolding etc. complete.

8.0 GI PIPES AND FITTINGS 8.1 All G.I. pipes and fittings shall conform to IS : 1239 and shall be of medium grade for water supply system.

All screwed tubes and sockets shall have pipe threads in accordance with the requirements specified in IS : 554. Unless specified otherwise, pipes shall be supplied screwed with taper threads and sockets parallel thread.

All fittings shall be malleable galvanlsed iron approved by the Engineer-in-Charge. Fittings in G.I. line shall include all couplings, elbows tees, bends, unions, nipples, reducers, flanges with nuts bolts and rubber insertions, bushes and all other fittings





to make a complete job.

Screwed G.I. pipes shall be jointed with screwed socket joints using screwed tittings. Care shall be taken to remove any burr from the end of the pipes after threading. While lead with a few strands of fine hemp shall be applied while tighting. Compounds containing red lead shall not be used.

All pipes above ground shall be fixed with G.I. holders bat clamps clear off the wall at 1.2 M centres. If the pipes are fixed in encased or embedded in wall, they shall be secured in position by iron hoops at 1.2 M centres. All visible pipes and clamps ithin and outside building shall be painted with two coats of white paint or aluminium paint as directed by the Engineer-in-Charge. No extra payment shall be made for clamps, hooks, cutting holes in walls, chasing and making good the same.

All underground pipes shall have a minimum earth cover of 600mm or as directed by the Engineer-in-Charge. No extra payment shall be made for excavation in trenches, refilling the same and removal of surplus earth. Before any pipes are painted or covered up they shall be tested to a hydro-static pressure of 6 kg/sq.cm.

8.2 Payment shall be on running meter basis of actual pipeline laid. In addition to the

Sectional testing of water supply piping, the contractor shall test entire installation

on completion of the job to satisfaction of the Engineer-in-Charge. No extra payment shall be made for testing. The contractor shall make his own arrangement for supply of water for testing at his own cost. The rate for this item shall include supply and laying of G.I. pipes with necessary fittings, cutting of pipes to required lengths, threading; making holes in walls and floors and making good the same, jointing, painting, excavation and refilling including the testing and directed by the Engineer-in-Charge.

9.0 GUN METAL VALVE

9.1 All full way and globe valves shall be of heavy gunmetal and tested at 300 psi and shall he approved by the Engineer-in-Charge. Valves shall conform to IS : 778. Size of valve chamber shall be as per item description, construction of valve chamber shall be carried out as detailed in clause 13.0 above. Valve chamber shall be provided & fixed with heavy duty C.I. surface box conforming to IS : 3950. The surface box shall be hinged pin open type & shall be fixed in the chamber slab. It shall have a hole for opening.

9.2 The payment shall be made per number basis including valve chamber & surface box. The rate shall include construction of valve chamber supplying and fixing valves & surface box in position as per drawings and directions of Engineer-in-Charge.

10.0 HALF ROUND CHANNEL

10.1 Half round channel shall be plain or with stop end and shall have internal dia of I00 mm approved by the Engineer-in-Charge. The jointing work shall be done with





white cement slurry. The drains shall be provided with proper slopes as indicated in drawings or as specified by the Engineer-in-Charge. Channel shall be covered with matching tiles leaving provision for cleaning the same.

10.2 The payment shall be made per meter basis and shall include all labour, material etc. complete including laying, jointing etc.

11.0 PRECAST R. C. C. PIPE

11.1 Materials

For pipe materials, the following specifications shall apply :

Spec. for Pre cast concrete pipes IS : 458

(With and without reinforcement)

Code of practice for laying of concrete pipes IS : 783

For cement sand, mortar, water etc. the specifications laid down for concrete works shall apply

All pipes must be new and perfectly sound, free from cracks, cylindrical, straight,and of standard nominal diameter and length with even texture. Each pipe shall have one collar with it. The contractor shall submit manufacturer's test certificate whenever demanded by Engineer- in-Charge or his authorised representative. Spun yarn for pipe joints shall be of best quality. It shall be free from dust etc.

1 1.2 Transportation and Stacking

The transportation of materials to the work site and stacking shall be done in a manner to cause minimum inconvenience to the traffic and other construction works. The pipe shall be protected during handling against impact; shocks add free fall to avoid cracks and damage.

The contractor shall be fully responsible for the safety and security of materials transported and stacked in the field.

1 1.3 Lowering and Laying of Pipes

General

The laying and jointing of pipes shall conform to IS : 783. The trench shall be checked for proper level, gradient and alignment before lowering the pipes.

Lowering





The pipes shall be lowered cautiously to prevent disturbance of the bed add sides of the trench. The heavy pipes shall be lowered by means of proper shear legs, chain pulley blocks or as directed by Engineer-in-Charge. Great care should be taken to prevent sand etc. from entering the pipes.

Laying

Laying of pipes shall proceed up grade of slopes. The error of grade shall not be rectified by packing up earth underneath the pipes. If required, concrete shall be used for packing. The ends of the pipes shall be kept closed to keep dirt, mud and foreign materials, out. Adequate provision shall be made to prevent floating of pipe in the event of flooding of trenches.

The body of the pipe for its entire length shall rest on an even bad in the trench and places shall be excavated to receive the collar for the purpose of jointing.

1 1.4 Jointing of Pipes

Joint in the pipe line shall be of the socket and spigot type and conforming to relevant Indian Standards.

As per IS 458-1988joint in pressure pipes shall be flexible rubber ring joint only. Contractor shall provide pipes of socket and spigot type meeting the above requirement. Concrete pipe where permitted by site incharge with collar shall be water tight.

A few skeins of spun yarn soaked in neat cement wash shall be inserted in the groove at the end of the pipe and the two adjoining pipes butted against each other. Collar shall the he slipped over the joint covering equally both the pipes. Spunyarm soacked in neat cement wash shall be passed round the pipes and inserted in the joint by means of caulking tools from both ends of the collar. More skeins of yarn shall be added and well rammed home. The object of the yarn is to centre the two ends of the pipes within the collar.

Cement mortar 1:2 (1 cement 2 sand) shall be slightly moistened and must on no account be soft or sloppy and shall be carefully inserted by hard into the joint. The mortar shall then be punched and caulked into the joint and more cement mortar added until the space of the joint has been filled completely with tightly caulked mortar. The joint shall be finished off neatly outside the collar on both side at an angle of 45".

Any surplus mortar projecting inside the joint is to be removed and to guard against any such projections. Sack or gunny bags shall be drawn past each joint after completion.

11.5 Curing

The cement mortar joints shall be cured at least for seven days.

11.6 Testing





All joints in the pipes shall be tested to a head of 1.5 meters of water above the top of the highest pipe.

Payment for supplying, lowering, laying, jointing and testing shall be made on running meter basis. The length of pipes laid include collars and the rate shall include all supplies and works mentioned in proceeding paras, including excavation backfilling, concrete, removal surplus earth etc . complete.

12.0 M.S. RUNGS1C.I. STEPS

12.1 The rungs for pits manholes and septic tanks shall be of M.S. conforming to Indian Standard and to the shape and size as shown in drawings. C1 steps for manholes if needed shall he as per IS-5455.

M.S. rungs shall be coated with 2 coats of approved bituminous paint.

Payment for rungs steps shall be made as per number and the rate shall include supply, fixing, finishing the walls. painting etc. complete

13.0 SOAK PITS

All earthwork in excavation, brick work etc. shall conform to relevant I. S . standard. The brickbats should preferably be slightly over burnt or throughly well burnt, deep red in colour with some proportion of deep blue of black veins.Spongy or vitrified material as a result of excessive over burning is useless and shall be rejected. Brick bats bigger than specified size shall be reduced to required size (40 to 50mm) before filling in soak pit and no extra payment shall be made for this. It shall be stacked at site as directed by Engineer- in-Charge. Soak pit & septic tank shall be connected with required piping.

Payment of soak pit shall be made per number basis. Rate quoted shall include brick

masonry work, providing & filling brick bats, earthwork in excavation backfilling making

inlet connection with pipe and connecting same to septic tank etc. complete as shown in drawing.

14.0 SEPTIC TANK

14.1 Ready made septic tank shall be as per drawing , consisting of sewage chamber inspection door, vent pipe, inlet / outlet connections, manhole cover, MS rungs etc. shall be used. Supply, installation, testing and commissioning of septic tank shall conform to IS : 2470 Part-I. Access opening shall be provided for desludging & inspection.

The ventilating pipe shall be provided with pipe of atleast 50mm dia extended 2 meters above the nearest working platforms.





14.2 Payment of septic tank shall be made per number basis & Rate shall include all accessories like, inlet, outlet, vent pipe, manhole cover & C.I. steps, earthwork in excavation &



CO2 TYPE ESTINGUISHERS-10-02-015 Page 1 of 3


STANDARD SPECIFICATIONS FOR CO2 TYPE FIRE EXTINGUISHERS





CONTENTS

1.0 SCOPE

2.0 MATERIAL, SHAPE, CONSTRUCTION, METHOD OF OPERATION, PERFORMANCE, CONTENTS AND TESTS

3.0 APPROVALS

4.0 MARKING

5.0 ACCESSORIES

6.0 INSPECTION





1.0 SCOPE

This standard lays down requirements regarding material, shape, construction, method of operation performance and tests of portable fire extinguisher of carbon dioxide type The extinguisher shall be supplied along with C02gas duly charged.

2.0 MATERIAL, SHAPE, CONSTRUCTION, METHOD OF OPERATION, PERFORMANCE, CONTENTS AND TESTS

2.1 The material, shape, construction, method of operation, performance and test shall comply with IS. 2878.

2.2 Nominal sizes,

2.2.1 The extinguisher shall be of following nominal sizes in Kg : 2,3 and 5.0 for portable type and 7,9 and 22.5 for trolley mounted.

2.3 Contents

2.3.1 Carbon dioxide gas used shall conform to I.S. 307 and extinguisher shall be filled as per CI. 4.0 of I.S. 2878.

3.0 APPROVALS

3.1 A clearance/approval certificate for filling the extinguisher from "Chief' Controller Explosive" Govt. of India, Nagpur shall be submitted for each cylinder.

4.0 MARKING

4.1 Each extinguisher shall be clearly and permanently marked as per I.S. 2878 along with I.S. certification mark and purchaser's name.

5.0 ACCESSORIES

5.1 Each extinguisher shall be supplied with M .S. bracket, wood screws and spanner as may be necessary. The details of the bracket shall be submitted with the offer.

6.0 INSPECTION

GAIL or its authorised representative shall have access at all reasonable time to the manufacturer's works where extinguishers ordered are being manufactured and or tested.


STANDARD SPECIFICATION FORPORTABLE DRY POWER TYPEEXTINGUISHER S-10-02-016 Page 1 of 4



PORTABLE DRY POWER TYPE EXTINGUISHER




CONTENTS

1 .0 SCOPE

2 .0 MATERIAL, SHAPE, TYPES. CONSTRUCTION,ANTICORROSIVE TREATMENT. PAINTING AND TEST

3 .O PRINCIPLE

4.0 CAPACITY

5 .O ACCESSORIES

6.0 MARKING

7.0 INSPECTION




1.0 SCOPE

1.1 This specification lays down die requirements regarding material, shape, type. construction, anticorrosive treatment and test for ordinary dry powder type fire extinguisher. The extinguisher shall be supplied along with the dry powder duly charged.

2.0 MATERIAL, SHAPE, TYPES, CONSTRUCTION, ANTICORROSIVETREATMENT, PAINTING AND TEST.

2.1 The material, shape, construction, anticorrosive treatment, painting and test shall be as per I.S. 2171.

2.2 The extinguisher shall be gas cartridge or pressure type.

3.0 PRINCIPLE

The method of expulsion of type powder shall be as per I.S.2171 with either of the method of operation specified therein. The vendor shall indicate clearly the method adopted for operation.

4.0 CAPACITY

4.1 Nominal capacity of the extinguisher and the dry powder contents of the assembled hody or dry powder container shall be as follows when charged with dry powder conforming to I.S. 4308.

Nom. capacity of Dry powder contents whenExtinguisher (kg) charged Min. (kg)

1 1

2 2

5 510 10

4.2 Only dry powder conforming to I.S. 4308 shall be used for charging the extinguisher.




5.0 ACCESSORIES

Each extinguisher shall be supplied with a suitable wall bracket or holder onto which it may be mounted and from which it may be removed for use in an emergency and screws and spanner as may be necessary.

6.0 MARKING

Each extinguisher shall he clearly and permanently marked with the information specified in I.S. 2171 along with I.S. certification mark and purchaser's name.

7.0 INSPECTION

7.1 GAIL or its authorized representative shall have access at all reasonable times to the manufacturer’s works where the extinguishers are being manufactured and or being tested Samples from lots under a quality control system shall be done as per Appendix B of I.S.





STANDARD SPECIFICATION FORSTAND POST TYPE FIRE HYDRANT

(WITH OR WITHOUT PUMPERCONNECTION)

S-10-02-017Page 1 of 4







S-10-02-017Page 2 of 4


CONTENTS

1. SCOPE

2. CODES AND STANDARDS

3. MATERIAL

4. DESCRIPTION

5. WORKMANSHIP AND FINISH

6. TESTING

7. PAINTING

8. MARKING

9. INSPECTION




S-10-02-017Page 3 of 4


1.0 SCOPE

This standard lays down the requirements of codes and standards, type. shape, dimensions, material and test for vertical stand post type fire hydrant (with or without pumper connection) to be installed on fire water main. The Hydrant shall be supplied normally without pumper connection unless specifically mentioned in the Material Requisitions.


IS : 3 1 8 Leaded tin bronze ingots and castingsIS:902 Suction hose couplings for fire fighting purposesIS : 903 Fire hose delivery couplings. branch pipeIS: 1239 Mild steel tubes, tabulars and otherIS: 1367 Wrought iron fittingsIS : 2062 Steel for general structural purposesIS :27 12 Compressed asbestos fiber jointingsIS:2932 Enamels, synthetic, exterior

(a) undercoating(b) finishing

3.0 MATERIAL

3.1 Hydrant vertical post and hydrant arms shall be fabricated from pipe conforming to I.S. 1239 heavy grade and shall be with welded construction.

3.2 Flanges shall be of M.S. plate to 1.S. 2062 FIF slip on type.3.3 Hydrant valves 75 mm size shall comply to I.S. 5290 type A.3.4 63 mm. coupling shall comply to I.S. 903, while bllind cap (for pumper connection) with

its lugs shall be of gun metal complying to IS: 3 18 Gr.11. Chain shall be of mild steel.3.5 Bolts and nuts for flanges shall comply to IS: 1367 class 10.9 and 12 respectively while

gasket 2mm thick full face shall be made of CAF 40 to IS:2712.

4.0 DESCRIPTION

4.1 The hydrant shall be stand post type. The vertical post shall be of 100 mm diameter with two horizontal hydrant arms each 80mm diameter on which independent hydrant valve shall be fixed. Hydrant valve shall comply to I.S. 5290 type A.

4.2 63mm coupling shall comply to IS:903, and that the lug shall be twist release type.4.3 For hydrant assembly with pumper connection, the vertical post shall have 100 min

outlet as pumper connection and provided with a blind cap as shown in the enclosed sketch. The 100 mm outlet shall have round male threads conforming to IS:902 and blind cap. Shall be provided with four fixing lugs and 500 mm long M.S. chain.

4.4 All flanges for hydrant valve and base shall have drilling dimensions conforming to




S-10-02-017Page 4 of 4


ANS1.B. 16.5 lbs rating flat face, slip on type.

5.0 WORKMANSHIP AND FINISH

5.1 All parts shall be good workmanship and finish. All parts and sharp edges shall be removed. The waterways shall have smooth finish.

5.2 Wherever B.1.S has been specified the latest edition of the same shall be followed.

6.0 TESTING

Hydrant assembly with hydrant valves closed shall be satisfactorily tested and proved water tight under a hydraulic pressure of 18.0 kg/cm2. The pump connection shall he kept closed during testing in case the same is provided on hydrant assembly.

7.0 PAINTING

7.1 The stand post and its arms shall be painted with three coats of anti-corrosive fire red paint conforming to I.S. 2932 from outside while internal surface shall be painted with three coats of chlorinated rubber based rasin paint or zinc chromate paint.

8.0 MARKING

8.1 Each hydrant shall be clearly and permanently marked with thea) Manufacturers name or trade markb) I.S. 5290 on hydrant valvec) Year o f Manufactured) Purchaser name.

9.0 INSPECTION

GAIL's authorized representative shall have access at all reasonable times to the manufacturer's work where hydrant are being ordered and or tested.


STANDARD SPECIFICATION FORSTAND POST TYPEWATER MONITOR

S-10-02-018 Page 1 of 4


STANDARD SPECIFICATION FOR STAND POST TYPEWATER MONITOR



S-10-02-018 Page 2 of 4


CONTENT

1.0 SCOPE

2.0 MATERIAL

3.0 CONSTRUCTION


5.0 ANTICORROSIVE TREATMENT AND PAINTING

6.0 TEST

7.0 ACCESSORIES

8.0 MARKING



S-10-02-018 Page 3 of 4


1.0 SCOPE

This specification lays dawn the requirement of material, design, method of construction and test for stand post type water monitor.

2.0 MATERIAL

2.1 Body, elbows, bends (45", 90•‹, 180") shall be either M.S. seamless or carbon steel conforming to I.S. 4310.

2.2 Swivel joints shall be made of copper alloy as specified in CL. 3.3.1 of l.S 8442 and locks of horizontal and vertical rotation shall be made of brass to I.S. 291. Ball bearings shall be of stainless steel S.S. 304.

2.3 Base flange shall conform to I.S. 2004 class 2 and 3. Bolts and nuts shall conform to 1.S 1367 class 10.9 and class 12 respectively while gasket CAF 40 to I.S. 27 12.

2.4 Water barrel and pipe for drain connection shall be of M. S. seamless pipe to I. S.1239 med- grade (pt -I).

2.5 Nozzle shall be of copper or aluminium alloy. Copper alloy shall be as per I.S. 8442 clause 3.8 while aluminium alloy used for casting shall conform to 1.S. 617 designation 4450 (A-8- WP) or 4225 (A-16-WP).

2.6 Handle shall be of M.S. bar to I.S. 1732.

2.7 Drain valve shall conform to I.S. 778.

3.0 CONSTRUCTION

3.1 In general water monitor shall conform to type I of I.S. 8442 with a discharge capacity of 2.58 m3/mnt at a pressure of 7 kgf/cm2. The minimum water jet throws shall be 60 m horizontally at 45" trajectory and 28 M vertically up in still air at 7 kgf/cm2 pressure.

3.2 Monitor shall have traversing mechanism to give 360" rotation in either direction in the orizontal plane and 125 " in the vertical plane (+80" ,-45 ") with separate swivels through a quick acting handle bar. For unattended operation of the monitor at the desired angles, suitable locks or swivel joints shall be provided. One handle for traversing both the horizontal and vertical rotation of the monitor shall be



S-10-02-018 Page 4 of 4


provided on the monitor body.

3.3 The monitor shall be mounted on a 100 mm (4") NB. M.S. FIF slip on type flange whose drilling dimensions shall conform to ANSI. B-16.5 lbs rating. Bolts and nuts for base flange shall have dimensions conform to ANSI B 16.5. Gasket shall be full face 3 mm thick drilled to suit the hole on the flange.

3.4 Near the base flange a drain connection shall be provided with a drain valve 15 mm

(112") NB to drain the water out of the vertical post of monitor. The drain pipe

shall be long enough to discharge water away from the base flange.

3.5 At the end of water barrel the nozzle shall be fixed. The outlet of barrel shall have external threads conforming to 1.S. 2643 (Pt-1) with class A tolerance. The nozzle shall conform to fig. 5 of I.S. 8442 with orifice dia of 38 mm and its performance requirements given in clause 8.0, the internal threads on the inlet connection of the nozzle shall suit the external threads on the barrel pipe. The threaded end of the nozzle shall be hexagonal to facilitate screwing of the nozzle on the outlet connection of the barrel with nozzle spanner.

3.6 External threads near the nozzle outlet shall be provided to enable a fog nozzle or a blank cap to be connected when desired. Threads shall suit both the requirements. Blank cap shall be supplied by the Vendor alongwith monitor.


4.1 The complete assembly shall be of good workmanship and finish free from burrs and sharp edges, particularly water way and nozzle shall have smooth finish.

5.0 ANTICORROSIVE TREATMENT AND PAINTING

5.1 All steel components subject to direct water contact shall be hot dip galvanised to a thickness of not less than 0.012 mm. the thickness of coating shall be measured as per 1.S. 3203.

External surfaces and non-ferrous components may be coated with lead tin alloy by electrical deposition process.

5.2 Monitor shall be painted with fire red colour conforming to I.S. 5 shade No. 536 and the paint shall conform to I.S. 2932.

6.0 TEST

6.1 For performance the monitor shall be tested at operating pressure of 7 kgtlcm2 to give a discharge of 2.58 M3/minute with a minimum horizontal and vertical throws of 60m and 28m respectively in calm air.

6.2 The entire assembly shall be hydraulically tested to a pressure of 23 kgf/cm2 for 5 minutes without any leakage.


STANDARD SPECIFICATION FOR FIXED CO2 FIRE EXTINGUISHINGSYSTEM S-10-02-019 Page 1 of

10


STANDARD SPECIFICATION FORFIXED CO2 FIRE EXTINGUISHING

SYSTEM



10


C O N T E N T S

1.0 SCOPE

2.0 REFERENCE CODE

3.0 GENERAL DESCRIPTION OF SYSTEM

4.0 THERMO SWITCHES

5.0 CHARACTERISTICS OF FIXED INSTALLATION

6.0 CHARGING

7.0 DISCHARGE HEADS

8.0 MANIFOLD WITH CONNECTION TO DISCHARGE HEADS

9.0 DISCHARGE NOZZLES

10.0 CO, SYSTEM CONTROL PANEL

11.0 MATERIAL SPECIFICATION

12.0 STATUTORY APPROVAL

13.0 TESTING AND MARKING

14.0 PAINTING

15.0 SPARES

TECHNICAL DATA SHEET - PAGE 6-9 OF 9



10


1.0 SCOPE

This specification covers the general description, material of construction and test for the fixed type carbon dioxide fire extinguishing system designed to be actuated by electronic control/thermo electric process.

2.0 REFERENCE CODE

(i) NFPA- 12 - Carbon Dioxide Extinguishing system.(ii) SMPV (unfired) Rules 1981 by CCOE).

3.0 GENERAL DESCRIPTION OF SYSTEM

3.1 The CO, system shall be designed and supplied strictly as per the requirements of NFPA-12 and the criteria given herein below:

3.2 The system shall be a high pressure (850 psi) and shall be such that it is -

a) Extremely quick in actionb) Non poisonousc) Safe andd) Clean

3.3 Fire shall be extinguished by the total flooding of the space with CO, gas to render the atmosphere inert and non supporting to combustion.

3.4 CO, gas cylinder's capacity provided shall be sufficient to discharge CO, gas, equivalent to 50 per cent of the cubical content of the space involved, depending on the floor area of the premises. Consideration of extra requirement due to opening in the room shall also be given.

3.5 All the mandatory requirements of NFPA-12 shall be fully complied.

3.6 The vendor shall fill the required data in the Technical data sheet on page no. 6 of 9 and submit along with the offer.

4.0 THERMO SWITCHES

4.1 Thermo switches for releasing the C02 gas by temperature shall be of vapour proof, single pole, open circuit and designed to close at 220 volts A.C. 11 10 volts DCII independent battery when the surrounding air reaches 77oC / or any other desired temperature. Each thermo switch shall be mounted on half inch conduit box. These shall be provided around the place to the protected against fire hazard. The range of thermoswitch is from 0 – 100 C.



10


5.0 CHARACTERISTICS OF FIXED INSTALLATION

5.1 Carbon dioxide shall be stored in the high pressure steel cylinders, and when released it shall travel in the same form through the pipe work to the discharge nozzles. The release of pressure allows the liquid to turn partly to snow emerging at a temperature of -110 F (-79 C). A battery of CO, cylinders fitted with the above device shall be connected to the main manifold of the pipe work.

5.2 The storage cylinders shall be located in a dedicated room for the building for which protection is envisaged.

5.3 The time to reach the specific concentration of CO, shall be clearly mentioned. The system shall be interlocked with the air conditioning /ventilation system wherever applicable. In case of CO, injection into the rooms, the relevant air handling units shall be automatically shut off.

5.4 The distribution piping shall have to clear the RCC beams and ribs which criss cross the ceiling, path of air ducts and electrical conduits. All supports, hangers and clips etc. required for supporting the distribution piping, cylinders, manifold etc. shall also be supplied along with the system. The number of supports, hangers and clips etc. shall be as per the drawings approved by the owner.

6.0 CHARGING

Each CO, cylinder shall be equipped with a valve permitting refilling of cylinder. The cylinder shall be sealed with a puncturable diaphragm and shall be provided with a safety pressure relief for abnormal pressure formation.

7.0 DISCHARGE HEADS

Each cylinder in the CO, battery shall be equipped with a discharge head for automatic piercing of the sealing diaphragm. One or two cylinders in the multiple cylinder discharge group shall have discharge heads operated directly from the control panel and the others shall be operable by the gas pressure discharged from the first one or two.

8.0 MANIFOLDS WITH CONNECTIONS TO DISCHARGE HEADS

The pressure manifold shall be designed in such a way that it shall collect the gas from all the cylinders and discharge collected quantities of the gas in the main manifold which shall be connected with the discharge of outlets in the room.



10


9.0 DISCHARGE NOZZLES

9.1 Suitable number of distribution nozzles shall be properly located within the rooms to be protected for assuring a uniform distribution of the carbon dioxide.

9.2 The nozzles for discharging CO, gas into the hazardous areas, shall be of such shape as to spread the gas without freezing. The shall be made of heat resisting material and threaded to fit standard pipes, or pipe fittings.

9.3 A suitable arrangement shall be made in room for effective removal of CO, being released.

10 CO2, SYSTEM CONTROL PANEL

10.1 The control panels shall be located in individual buildings and shall be wall mounted type. The control panels shall be provided for manual actuation and shall be designed to accommodate relays, auxiliary switches, pilot and signal lamps. The control panel shall also be provided with the facility of audio alarm and on receipt of fire alarm signal from tire alarm panel, audio alarm shall be initiated from CO, control panel with necessary signal to shut off air conditioning/ventilations system. Manual push button for discharge of CO, in each protected area (after audio alarm and 30 seconds time delay) shall be provided near exit of the room.

10.2 Sign boards, caution boards, illumination board, alarm, given as per requirements of NFPA 12 shall be provided in and around building protected with CO, system.

11.0 MATERIAL SPECIFICATION

11.1 Material for cylinder body, valve, nozzle shall conform to Clause 5 of IS:287. CO, gas quality shall conform to IS:307.

11.2 All piping, spray nozzle shall be as per NFPA-12.

12.0 STATUTORY APPROVAL

Approval from 'Chief Controller of Explosives' for CO, system for handling, storage, disposal shall be taken by the contractor.

13.0 TESTING AND MARKING

13.1 Every CO, cylinder shall be made and tested, approved, equipped and marked in accordance with IS :2878.

13.2 CO2 piping shall be hydrotested as per NFPA-12.



10


13.3 Each cylinder shall be clearly and permanently marked with the following information:a) Manufacturer's name and trade mark.b) Year of manufacture.c) Cylinder marking as per IS:2872.

14.0 PAINTINGPainting and colouring of pipelines, nozzles, C02 cylinders, supports, etc. shall be done as per standard practice including supply of all paints and consumables and other items required for carrying out painting and colouring.

15.0 SPARES

15.1 The bid must include in the quoted price, the mandatory spares to be supplied with the CO2 system.

15.2 In addition to the above spares, vendor shall recommend the list of spares required for two years trouble free operation with unit rates and quantity along with the offer.

TECHNICAL DATA SHEETSDETAILS TO BE FURNISHED BY THE BIDDER



10


ALONG WITH THE OFFER

C MEANS VENDOR TO FURNISH DATA 1 DETAILS1.0 Type of system- Fixed C02 Fire Extinguishing System

2.0 Design code/standard to which- NFPA-12 & SMPV Rules 198 1 (CCOE)Design/manufacture for cylinders/testing conforms

3.0 System designed to protect risks- Specify Areain the building as specified.

3.1 Design Concentration- C

3.1.1 Amount of gas required- C(Attach separate sheet, if required)

(List out gas supplied, number ofcylinders etc for working andstandby requirements, risk wise)

3.2 C02 storage cylinder details

A Manufacturer- CB Design code- CC Capacity in litres- CD Gas holding capacity (kg)- CE Total number supplied- CF Aprpoving agency FM/UL/- CLPC/VDS/TAC(This must be acceptableto TAC)G Approval by CCE- CH Working pressure (kglcm2)- C

NormalI Design pressure (kglcm2)- CJ Dimension of cylinder- C

Dia x length x thickness

3.3 Pipes, Valves and Fittingsa. Manufacturersi) Pipes- Cii) Fittings- Ciii) Valves- C



10


b. Material of Constructioni) Pipes- Cii) Fittings- Ciii) Valves- C

c. Design Codei) Pipes- Cii) Fittings- Ciii) Valves- C

d. Type of joints

e. Hydraulic test pressure- Cof manifold/supply lines(KgIcm2)

f. Discharge nozzlesi) Manufacturer and type- Cii) Material of construction- Ciii. Number supplied- Civ. Approved by FM/UL/VDS/ CFOC and TAC(Yes1No)

3.4 Painting and colouring of pipeline,nozzles, cylinder supports included(2 coats of red oxide and syntheticenamel)- C

3.5 Operating devices

3.5.1 Push Button Stationi) Type- Cii)Manufacturer- Ciii) Model, numbers offered- Civ Overall dimensions- C

3.5.2 Control Cablesi) Manufacturer- Cii) Code/standard- Ciii) Type- Civ) Size- Cv) Rating- C



10


3.6 Main Control Panel

i) Manufacturer- Cii) Mounting detail - Ciii) Number of entries- Civ)Sheet thickness- Cv) Cable entry- Cvi) No. of ACIDC feeders- C and their rating

3.7.1 Additional Requirements for Control Panel

a) Whether housing all thenecessary relays indicating lampspush buttons, switches, etc. for theefficient operation of the system,- C(YesINo)

b) Input power supply requirement- Cfor operation of panel.

AC/DC- CVolts

c) Panel Signal VoltageVoltsAC/DC- C

d) Type/APM capacity of the battery- C

e) Inter correcting cabling betweenbattery & panel- C

f) Power supply unit incorporatedin the panel, Yes/No- C

g) Audiovisual alarm on panelprovided for battery lowconditions Yes/No- C

h) Change over from AC mainSupply to standby powerSupply fully automatic in eitherdirection Yes/No- C



10


i) Following push buttons provided

a. Alarm acceptb. Resetc. Test Yes/No- C

j) Audio visual indication for ACsupply failure provided.- C

Yes/No

k) Pilot lamp for system 'ON' provided- CYes/No

l) Dual tone hooter for fire/faultalarm provided & range of the same- C

Yes/No

m. Painting (External/Internal)- C

4.0 Material of instructions selected in- Yes/Noaccordance with NFPA- 12.

5.0 Inspection and testing

a. Visual inspection of installed- Csystem & hazard area

b. Check of labellng of devices- C

c. Check for mechanical tightness- Cof piping and associated equipment

d. Non-destructive operational tests- Cfor all devices included



HOSE CABINET. S-10-02-020Page 1 of 4


STANDARD SPECIFICATIONFOR HOSE CABINET





C O N T E N T S

1. SCOPE

2. DESCRIPTION

3. MATERIAL

4. PAINTING AND MARKING





1.0 SCOPE

1.1 This specification covers the general requirements regarding the material, design, and construction of hose cabinet and fire fighting equipments, contained in the cabinet.

1.2 The Hose cabinet shall be supplied along with the fire fighting equipmentscontained in it.

2.0 DESCRIPTION2.1 Hose cabinet shall be of two types to accommodate delivery hose and jet nozzle with

branch pipe or universal branch pipe.

2.1.1 Type I shall be suitable to accommodate one delivery hose of size 63 mm, 15 metre long with end couplings, one jet nozzle with branch pipe or one universal branch pipe.

2.1.2 Type I shall be capable of being mounted on wall. Necessary hangers and bracket for hose, nozzle and branch pipe or universal branch pipe shall be provided, with the cabinet.

2.1.3 Type II shall be suitable to accommodate two delivery hoses 63 mm, 15 metre long with end couplings, two jet nozzle with branch pipe or two universal branch pipes.

2.1.4 Type II shall be of self supporting type suitable for outside installation. Necessary hangers and brackets for hose, nozzle and branch pipe or universal branch pipe shall be provided with the cabinet.

2.2 Type I cabinet shall be provided with single panel glass door while Type II with double panel glass door.

2.2.1 Both the types shall be provided with handle type lock, a small recess to keep cabinet key under glass cover, a small hammer secured to the cabinet with a chain to break key glass cover.

3.0 MATERIAL

3.1 Cabinet shall be made of 18 gauge M. S. sheet suitably welded with single/double MS door frame glass covered. Glass shall be securely fitted to the door frame in a standard manner.

3.2 Door shall be provided with standard handle type lock-Godrej, Mortise or equivalent.

3.3 Hammer shall be of M.S. with G.I. chain.

3.4 Suitable size angle iron shall be provided to support type II cabinet.





3.5 Delivery hose shall be either of following typea) Flax canvas hose to I.S. 4927 or

b) Reinforced rubber lined hose to I.S. 636

or

c) Controlled percolating hose to I. S. 8423.

3.6 End couplings, jet nozzle and branch pipe shall conform to I.S. 903.

3.7 Universal branch pipe shall conform to I.S. 2871.

4.O PAINTING AND MARKING

4.1 The hose cabinet shall be painted with 3 coats of anticorrosive fire red paint from outside and white paint from inside.

4.2 Each cabinet shall be clearly and permanently marked with following.a) The words Hose Cabinet-Type I or IIb) Instructions for use.

4.3 Each equipment in the cabinet shall be marked with I.S. certification mark and purchaser's name.


LIST OF ATTCHMENTS CIVIL

0001-01-10-11-001 Page 1 of 2


STANDARDS & STANDARD SPECIFICATIONS

GENERAL CIVIL

SPECIFICATION

01 S-10-02-001 7 0 Standard specification for survey works

02 S-10-02-002 6 0Standard specification for earthwork for underground piping

03 S-10-02-003 5 0 Standard specification for barbed wire fencing

04 S-10-02-004 7 0 Standard specification for chain link fencing.

05 S-10-02-005 50 Standard specification for

Classification of soil for earthwork in site grading.

06 S-10-02-006 110 Standard specification for Site

grading & rock cutting for site grading

07 S-10-02-007 10 0 Standard specification for concrete pavements


flexible pavements withBitumen premix carpet

09 S-10-02-009 50 Standard specification for RCC

pipe culverts andERC crossings etc.

10 S-10-02-010 40 Standard specification for U/G

and A/G GI pipeline system (water services)


Coating and wrapping of U/G pipes

12 S-10-02-012 6

0 Standard specification for misc. Civil & structuralWorks for U/G piping & other civil works

13 S-10-02-013 60 Standard specification for U/G

sewer system-pre cast RCC pipes


REV. TITLE


LIST OF ATTCHMENTS CIVIL

0001-01-10-11-001 Page 2 of 2


14S-10-02-014

100 Standard specification for

plumbing and & building drainage

15 S-10-02-015 3 0 Standard specification for CO2 type extinguisher

16S-10-02-016

40 Standard specification for

portable dry powder type extinguishers

17 S-10-02-017 40 Standard specification for stand

post type fire hydrant (with or without pumper connection)

18 S-10-02-018 5 0 Standard specification for stand post type water monitor

19 S-10-02-019 9 0 Standard specification for fixed CO2 fire extinguishing system

20 S-10-02-0120 4 0 Standard specification for hose cabinet

STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI

ABBRIVIATIONS AND LEGENDS

S-10-01-001 Page 1 of 5


ABBREVIATIONS & LEGEND



S-10-01-001 Page 2 of 5




S-10-01-001 Page 3 of 5




S-10-01-001 Page 4 of 5




S-10-01-001 Page 5 of 5



CABLE CROSSINGS UNDER ROADS PVC PIPES S-10-01-002 Page 1 of 1



STANDARD DRGS FORROAD CURVES AND CROSSINGS S-10-01-003 Page 1 of 1



STANDARD SECTION OF STORM WATER DITCHES

S-10-01-004 Page 1 of 1



PIPE CULVERTS FOR STORM WATER DRAINAGE

S-10-01-005 Page 1 of 3




S-10-01-005 Page 2 of 3




S-10-01-005 Page 3 of 3



BOX CULVERTS TYPE-I,II,III & IVS-10-01-006 Page 1 of 2



DETAILS OF RUNGS FOR MANHOLES, VALVES, PITS , TANKS ETC. S-10-01-007 Page 1 of 1



STANDARD DRGS FORMISC DETAILS FOR MANHOLES S-10-01-008 Page 1 of 1



STANDARD DRGS FORMISC DETAILS FOR MANHOLES S-10-01-008 Page 1 of 1



CONC. BEDDING AND ENCASEMENT FOR PIPES S-10-01-009 Page 1 of 1



GULLY TRAP CHAMBERS-10-01-010 Page 1 of 1



INSPECTION CHAMBER S-10-01-011 Page 1 of 1



SEPTIC TANK TYPE I, II & III S-10-01-012 Page 1 of 1



DETAILS OF SOAKPIT

S-10-01-013 Page 1 of 1



VALVE PIT TYPE-I FOR DIA < 1.5 “

10-01-014Page 1 of 1



VALVE PIT TPYE III FOR DIA 8” TO 16”S-10-01-015 Page 1 of 1



CHEQUERED PLATE DETAILS (FOR MASONER VALVE TYPE-I,II,III &IV)

S-10-01-016 Page 1 of 1



MANHOLE TYPE-I FOR DEPTH (FOR < 1 M, DIA 300MM) S-10-01-017 Page 1 of 1



DETAILS OF NEUTRALISATION PITS-10-01-018 Page 1 of 1



STANDARD DETAILS FOR CHAIN LINK FENCING WITH CONCRETE POST S-10-01-019 Page 1 of 1



RCC PAVEMENT DETAILS S-10-01-020 Page 1of 1



CONCRETE SLIDING SLEEPER CAST IN SITU TYPE-II S-10-01-021

Page 1 of 1



CONCRETE SLIDING SLEEPER CAST-SITU-TYPE-III S-10-01-022 Page 1 of 1



INSTALLATION DETAILS OF FIRE WATER HYDRANT, WATER MONITOR & FOAM / WATER MONITOR S-10-01-023 Page 1 of 1



STANDARD FOR INSTALLATION DETAILS OF WATER MONITOR

S-10-01-024 Page 1of 1



UPFLOW ANAEROBIC FILTER

S-11-01-025 Page 1 of 1



STANDARD FOR STEEL GATE FOR ENTRANCE S-10-01-026 Page 1 of 1



REPEATER ROOM AT SV STATION (WITHOUT DG ROOM)

S-10-01-027 Page 1 of 7




S-10-01-027 Page 2 of 7




S-10-01-027 Page 3 of 7




S-10-01-027 Page 4 of 7




S-10-01-027 Page 5 of 7




S-10-01-027 Page 6 of 7




S-10-01-027 Page 7 of 7



TECHNICAL SPCIFICATIONCIVIL & STRUCTURAL WORKS

GENERAL SCOPE S-11-02-001Page 1 of 4



GENERAL SCOPE





CONTENTS

1.0 SCOPE

2.0 GENERAL





1.0 SCOPE

These specifications establish and define the material and constructional requirements for CIVIL and STRUCTURAL WORKS.

2.0 GENERAL

2.1 Methods of measurements are indicated in these specifications; where not so specified, latest revision of IS: 1200 shall be applicable.

2.2 Providing and operating all necessary measuring and testing devices including all materialsand consumables are included in the scope of work. No separate measurement or payment for testing the quality of work and materials shall be made, but rates quoted for various items shall be deemed to include the cost of such tests which are required to ensure achievement of specified quality.

2.3 All materials shall be of standard quality, manufactured by renowned concerns conforming to Indian Standards or equivalent, and shall have IS mark as far as possible unless otherwise approved by the Engineer-in-Charge. The Contractor shall get all materials approved by the Engineer-in-Charge prior to procurement and use. The Contractor shall furnish manufacturer's certificates for the materials supplied by him when asked for. Further to that he shall get the materials tested from an approved test house if asked for by the Engineer-in- Charge. The cost for all the tests and test certificates for the material procured by the Contractor shall be borne by the Contractor. No separate payment shall be made for the testing. The Engineer-in-Charge shall have the right to determine whether all or any of the materials are suitable. Any materials procured or brought to site and not conforming to specifications and satisfaction of the Engineer-in-Charge shall be rejected and the Contractor shall have to remove the same immediately from site at his own expense and without any claim for compensation due to such rejection.

2.4 Wherever referred to in the tender document, only the latest revision of Specifications, Codes of Practice and other publications of Bureau of Indian Standards shall be applicable.

2.5 Wherever the Contractor executes civil and structural works involving buildings, equipment foundations, supporting structures, pipe racks, etc., the following works are deemed to have been included in the quoted rates for various works.

- Marking of centre lines of foundations etc.

- Establishing layout and levels of foundations and superstructure etc., including establishment of reference lines, bench marks on various floors, platforms etc.

- General upkeep of the plant site.





- Preparation of "As-Built" scheme of structural drawings indicating constructed details including levels, centre lines, layouts, member sizes etc. complete.

2.6 The provisions of schedule of rates, specifications and drawings shall be read in conjunction with each other and in case of conflict amongst them, clarification shall be obtained from the Engineer-in-Charge whose decision shall be final and binding. However, the following procedure may generally be followed.

- Description of items in schedule of rates shall be followed when provisions therein are different from those in specifications.

- Where the description of item does not call for some specific requirement but the same is given in specifications, the specifications shall be followed in addition to the requirement given in description of item.

- Where drawings call for requirements different from or additional to those given in item description and specifications, the decision of the Engineer-in-Charge shall be obtained as to what shall be followed.

DOCUMENT No. REV-0 (INDIA) LTD NEW DELHI

TECHNICAL SPECIFICATIONCIVIL AND STRUCTURAL WORKS

MATERIALS S-11-02-002 Page 1 of 19

Copyright – All rights reserved


MATERIALS





CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 WATER

4.0 AGGREGATE

5.0 SAND

6.0 CEMENT

7.0 STEEL

8.0 BRICK

9.0 STONE

10.0 ADMIXTURES

11.0 WATER BARS

12.0 BITUMEN/BITUMINOUS MATERIALS

13.0 PVC PIPES

14.0 WOODITIMBER

15.0 EPOXY COMPOUND

16.0 PAINT

17.0 ANTITERMITE COMPOUNDS

18.0 POLYSULPHIDE SEALANTS





1.0 SCOPE

1.1 This specification establishes and defines the requirements of various materials to be used in Civil and Structural works.

1.2 Whenever any reference to BIS Codes is made, the same shall be taken as the latest revision (with all amendments issued thereto) as on the date of submission of the bid.

1.3 Apart from the BIS Codes mentioned in particular in the various clauses of this specification, all other relevant codes related to specific job under consideration regarding quality, tests, testing and/or inspection procedures shall be applicable. Reference to some of the Codes in the various clauses of this specification does not limit or restrict the scope of applicability of other referred or relevant codes.

1.4 In case of any variation/contradiction between the provision of BIS Codes and this specification, the provision given in this specification shall be followed.

1.5 All materials shall be of standard quality and shall be procured from renowned Sources / manufacturers approved by the Engineer-in-Charge. It shall be the responsibility of the Contractor, to get all materials1 manufacturers approved by the Engineer-in-Charge prior to procurement and placement of order.

1.6 Whenever called for by the Engineer-in-Charge all tests of the materials as specified by the relevant BIS Codes shall be carried out by the Contractor in an approved laboratory and test reports duly authenticated by the laboratory, shall be submitted to the Engineer-in-Charge for his approval. If so desired by the Engineer-in-Charge, tests shall be conducted in the presence of the Engineer-in-Charge or his authorized nominee.

1.7 Quality and acceptability of materials not covered under this specification shall be governed by the relevant BIS Codes. In case BIS code is not available for the particular material, other codes e.g. BS or DIN or API/ASTM shall be considered. The decision of Engineer-in-Charge, in this regard, shall be final and binding on the Contractor.

1.8 Whenever asked for, the Contractor shall submit representative samples of materials to the Engineer-in-Charge for his inspection and approval. Approval of any sample does not necessarily exempt the Contractor from submitting necessary test reports for the approved material, as per the specification/relevant BIS Codes.

1.9 The Contractor shall submit manufacturer's test reports on quality and suitability of any material procured from them and their recommendation on storage, application, workmanship etc. for the intended use. Submission of manufacturer's test reports does not restrict the Engineer-in-Charge from asking fresh test results from an approved





laboratory of the actual material supplied from an approved manufacturer/source at any stage of execution of work.

1.10 All costs relating to or arising out of carrying out the tests and submission of test reports and or samples to the Engineer-in-Charge for his approval during the entire tenure of the work shall be borne by the contractor and included in the quoted rates.

1.11 Materials for approval shall be separately stored and marked, as directed by the Engineer-in-Charge and shall not be used in the works till these are approved.

1.12 All rejected materials shall be immediately removed from the site by the Contractor at his own cost.

2.0 REFERENCES

As mentioned in the respective clauses.

3.0 WATER

3.1 Water used in construction for all civil & structural works shall be clean and free from injurious amount of oil, acids, alkalis, organic matters or other harmful substances which may be deleterious to concrete, masonry or steel. The pH value of water sample shall be not less than 6. Potable water shall be considered satisfactory. Underground water can also be used with the prior approval of Engineer-in-Charge, if it meets all the requirements of IS:456.

3.2 Tests on water samples shall be carried out in accordance with IS:3025 and they shall fulfill all the guidelines and requirements given in IS:456.

3.3 The Engineer-in-Charge may require the Contractor to prove, that the concrete prepared with water, proposed to be used, shall have average 28 days compressive strength not lower than 90% of the strength of concrete prepared with distilled water.

3.4 The Engineer-in-Charge may require the Contractor to get the water tested from an approved laboratory before starting the construction work and in case the water contains any oil/organic matter or an excess of acid, alkalis or any injurious amount of salts etc., beyond the permissible maximum limits given in IS:456, the Engineerin-Charge may refuse to permit its use. In case the water is supplied by the owner, contractor shall get himself satisfied regarding its quality before using the same in his works at his own expense. In case there is any change in source of water, water samples shall be tested again to meet the specified requirements.

3.5 Water shall be stored in tin barrels, steel tanks or water-tight reservoirs made with bricks / stone or reinforced concrete. Brick/stone masonry reservoirs shall have RCC





base slab and shall be plastered inside, with 1 part of cement and 4 parts of sand and finished with neat cement punning. These reservoirs shall be of sufficient capacity to meet the water requirement, at any stage of construction.

3.6 Water for curing shall be of the same quality as used for concreting and masonry works. Sea water shall not be used for preparation of cement mortar, concrete as well as for curing of plain/reinforced concrete and masonry works. Sea water shall not be used for hydro testing and checking the leakage of liquid retaining structures also.

4.0 AGGREGATE

4.1 General

4.1.1 Coarse and fine aggregates for Civil and Structural Works shall conform in all respects to IS:383 (Specification for coarse and fine aggregates from natural sources for concrete). Aggregates shall be obtained from an approved source known to produce the same satisfactorily. Aggregates shall consist of naturally occurring (crushed or uncrushed) stones, gravel and sand or a combination thereof. These shall be chemically inert, hard, strong, dense durable, clean and free from veins, adherent coatings, injurious amount of alkalis, vegetable matter and other deleterious substances such as iron pyrites, coal, lignite, mica, shale, sea shells etc.

4.1.2 Source and type of aggregates shall be got approved by the Engineer-in-Charge prior to procurement. Change in source and type of aggregates, at later stage, shall not be generally permitted; but under specific circumstances, Engineer-in-Charge can allow a change in source and type of aggregate. Contractor shall produce necessary test certificates from approved laboratories regarding the quality and suitability of the proposed aggregates and submit fresh mix design for approval of the Engineer-in-Charge. Any such change, if permitted by the Engineer-in-Charge, shall be without any time and cost implication to the owner.

4.1.3 Aggregates which may chemically react with alkalis of cement or might cause corrosion of the reinforcement, shall not be used. If so desired by the Engineer-in-Charge, the Contractor shall carry out alkali reactivity tests and submit the results to him for approval.

4.1.4 The maximum quantities of deleterious materials in the aggregates as determined in accordance with IS:2386 - Part I1 (Methods of Test for aggregates for concrete), shall not exceed the limits defined in IS:383. No special test is required to prove the absence of such deleterious matters if the aggregates are from a known source with satisfactory prior data on the properties of concrete made with them. In case of newly developed quarry sites, the contractor shall submit necessary test results as per IS:383 and IS:2386 to the Engineer-in-Charge prior to his acceptance and approval. The method of Sampling shall be in accordance with the requirements given in IS:2430.





4.1.5 Coarse and fine aggregates shall be batched separately. All-in-aggregate shall be used only where specifically permitted by the Engineer-in-Charge.

Separate sieve analysis and grading curves shall be prepared by the Contractor for Any/all batches of coarse and fine aggregates, and submitted to the Engineer-in-Charge, whenever asked for, to ensure conformity with those submitted along with the mix design.

4.1.6 Whenever required by Engineer-in-Charge, the aggregates (coarse/fine) shall be washed and/or sieved by the contractor before use in the works to obtain clean and graded aggregate at no extra cost to the owner.

4.1.7 Aggregates not in conformity with the specifications shall be rejected and the Contractor shall immediately remove them from the site of work.

4.2 Coarse Aggregates

4.2.1 Coarse aggregates are the aggregates, which are retained on 4.75mm BIS Sieve. It shall have a specific gravity not less than 2.6 (saturated surface dry basis).

4.2.2 These may be obtained from crushed or uncrushed gravel or stone as per clause 3.1 and may be supplied as single sized or graded. The grading of the aggregates shall be as per IS1383 or as required by the mix design, to obtain densest possible concrete. For this purpose, the contractor shall submit to the Engineer-in-Charge at least three sets of mix design and test results, each with different gradings of coarse aggregates, proposed to be used. The Engineer-in-Charge may allow "All-in-aggregates" to be used provided they satisfy the requirements of IS:383.

4.3 Fine Aggregates

4.3.1 Fine aggregates are the aggregates which pass through 4.75mm BIS sieve but not more than ten percent (1 0%) pass through 150 micron BlS sieve. These shall comply with the requirements of grading zones I ,I1 and 111 of IS:383. Fine aggregates conforming to grade zone IV shall not be used for reinforced concrete works.

4.3.2 Fine aggregates shall consist of material resulting from natural disintegration of rock and which has been deposited by streams or glacial agencies, or crushed stone sand or gravel sand. Sand from sea shores, creeks or river banks affected by tides, shall not be used for filling or concrete works.

4.4 Sampling and Testing

The Contractor shall carry out all tests including mix designs of concrete, at his own





expense, at the start of work as well as during any stage of construction as required by the Engineer-in-Charge. Test shall be carried out in accordance with IS:516- Methods of test for strength of concrete and IS:2386-Methods of test for aggregates for concrete. Testing shall be carried out from laboratories approved by the Engineer-in-Charge. The method of sampling shall be in accordance with the requirements given in IS:2430.

4.5 Storage of Aggregates

4.5.1 Storage of all types of aggregates at site of work shall be at contractor's expense and risk and shall be stored as specified in IS:4082. Aggregates shall in no case be stored near to the excavated earth or directly over ground surface.

4.5.2 The Contractor shall maintain sufficient quantities of aggregates, near to the place of work, required for the continuity of the work. Each type and grade of aggregate shall be stored separately on hard, firm surface having adequate slope for drainage of water.

4.5.3 Aggregates delivered at site in wet condition or becoming wet due to rain or any other means, shall not be used for atleast 24 hours. The Contractor shall obtain prior approval of the Engineer-in-charge for the use of such aggregates and shall adjust the water content in accordance with IS:2386 to achieve the desired mix. In the absence of test results, and to allow variation in mass of aggregates and water content on account of moisture content, the Contractor can make suitable adjustment in the masses as per IS:456, for preparation of nominal mix concrete only.

5.0 SAND

5.1 Sand for Masonry Mortars

5.1.1 The sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a combination of any of these. The sand shall be hard, durable, clean and free from adherent coatings and organic matter and shall not contain the amount of clay, silt and fine dust more than specified in IS:2 1 16.

5.1.2 The sand shall not contain any harmful impurities such as iron pyrites, alkalis, salts, coal or other organic impurities, mica, shale or similar laminated materials, soft fragments, sea shells in such form or in such quantities as to affect adversely the hardening, strength or durability of the mortar.

5.1.3 Unless found satisfactory as a result of further tests as may be specified by the Engineer-in-Charge, or unless evidence of such performance is offered which is satisfactory to him, the maximum quantities of clay, fine silt, fine dust and organic impurities in the sand, when tested in accordance with IS:2386, shall not be more than 5% by mass in natural sand, or crushed gravel sand or crushed stone sand. For organic impurities, when determined in accordance with IS:2386, colour of the liquid shall be





lighter than that indicated by the standard solution specified in IS:2386.

5.1.4 Grading of Sand

The particle size grading of sand for use in mortars shall be within the limits as specified below:

GRADING OF SAND FOR USE IN MASONRY MORTARS------------------------------------------------------------------------------IS SIEVE DESIGNATION PERCENTAGE REF. TOIS:460 (PART I) PASSING BY MASS METHOD OF

4.75 mm 100 IS:2386(Part-I)2.36 mm 90 to 1001.18 mm 70 to 100600 micron 40 to 100300 micron 5 to 70150 micron 0 to 15

In case of a sand whose grading falls outside the specified limits due to excess or deficiency of coarse or fine particles, this shall be processed to comply with the standard by screening through a suitably sized sieve and/or blending with required quantities of suitable sizes of natural sand particles or crushed stone screenings which are by themselves unsuitable. Based on test results and in the light of practical experience with the use of local materials, deviation in grading of sand may be considered by the Engineer-in-Charge. The various sizes of particles of which the sand is composed shall be uniformly distributed throughout the mass.

5.1.5 Sampling and Testing

The method of sampling shall be in accordance with IS:2430. The amount of material required for each test shall be as specified in relevant parts of 1S:2386. Any test which the engineer-in-charge may require in connection with this, shall be carried out in accordance with the relevant parts of IS:2386.

If further confirmation as to the satisfactory nature of the material is required, compressive test on cement mortar cubes (1:6) may be made in accordance with IS:2250 using the supplied material in place of standard sand and the strength value so obtained shall be compared with that of another mortar made with a sand of acceptable and comparable quality.

5.2 Sand for Filling

Sand for filling shall meet the requirements of IS:383 and shall be natural sand, hard,





strong, free from any organic and deleterious materials. Any sand proposed for filling, shall be used only after it is approved by the Engineer-in-Charge. Sand obtained from sea shores, creeks or river banks affected by tides, shall not be used for filling. Fine aggregates suitable for concreting works shall be suitable for filling also. No sand below grading zone-111 as per IS:383 shall be allowed for filling.

6.0 CEMENT

Cement to be used for civil and structural works shall be one of the following. Specific requirement for the type of cement to be used shall be as shown in the drawings or as specified in the contract or as directed by the Engineer-in-Charge.

Specification for 33 grade ordinary portland cement IS:269

Specification for portland slag cement IS:455

Specification for Portland pozzolana cement (fly ash based) IS: 1489 Pt. 1

Specification for Portland pozzolana cement(calcined clay based) IS: 1489 Pt.2

Specification for Masonry Cement IS:3466

Specification for high alumina cement for structural use IS:6452

Specification for rapid hardening portland cement IS:8041

Specification for 43 grade ordinary portland cement IS:8112

Specification for 53 grade ordinary portland cement IS: 12269

Specification for Sulphate Resisting Portland cement IS: 12330

6.1 Storage at Site

6.1.1 The storage of cement (lifted from the Owner's godown or procured by the Contractor himself) at the site of work shall be at contractor's expense and risk and shall meet the requirements of IS:4082. The cement shall be stored above ground in a suitable weather tight building or godown and in such a manner as to permit easy access for proper inspection and also to prevent deterioration due to moisture. In the event of any damage occurring to the quality of cement due to faulty storage or on account of negligence on the part of the contractor, such damages shall be borne by the contractor himself.





6.1.2 All approved cement shall be arranged in batches with type, brand and date of receipt flagged on them. A maximum of eight bags shall be stacked one over the other. Cement bags shall be used in the same order as received from the manufactured owner. The contractor shall maintain a register, on day to day basis, giving the details of the receipt/consumption, source of supply and type of cement etc. The register shall always be accessible to the Engineer-in-Charge for verification.

6.2 Tests after Delivery

Each consignment of cement supplied by Owner or contractor, shall, after delivery at site and at the discretion of the Engineer-in-Charge, be subjected to any or all of the tests and analyses, required by the relevant Indian Standard Codes. In case the cement is supplied by the owner, the contractor shall get himself satisfied regarding its quality before using the same in his works at his own expense. The contractor shall carry out and bear the cost of all tests and analyses required to ensure quality of cement before using in actual works, irrespective of the fact whether the cement is supplied by the Owner or procured by him.

6.3 Rejection

The Engineer-in-Charge may reject at his discretion any cement, notwithstanding the manufacturer's certificate or failing to meet the requirements of relevant BIS Codes for testing of cement. He may similarly reject any cement which has deteriorated owing to inadequate protection from moisture or due to intrusion of foreign matter or any other cause. Any cement which is considered defective, shall not be used and shall be promptly removed from the site by the contractor.

7.0 STEEL

7.1 General

All steel bars, sections, plates, and other miscellaneous steel materials, etc shall be free from loose mill scales, rust as well as oil, mud, paint or other coatings. The materials, construction specifications such as dimensions, shape, weight, tolerances, testing etc, for all materials covered under this section, shall conform to respective BIS Codes.

7.2 Reinforcement Bars

Reinforcement bars, to be used for civil and structural works shall be one of the following or in combination thereof.

Specification for mild steel and medium tensile steel barsand hard drawn steel wire for concrete reinforcement (grade I). IS:432





Specification for hard drawn steel wire fabric for concretereinforcement. IS:1566

Specification for plain hand drawn steel wire for prestressed concrete. IS: 1785

Specification for High strength deformed steel bars and wires forconcrete reinforcement. IS: 1786

Steel for general structural purposes (Grade A). IS:2062

Specification for indented wire for prestressed concrete. IS:6003

7.3 Structural Steel

Structural steel to be used for general structural purposes shall be one of the following or in combination thereof.

Structural steel sections shall conform to following BIS Codes.

Steel tubes for structural purposes. IS:1161

Mild Steel Tubes,tubulars and other wrought steel fittings. IS: 1239

Steel for general structural purposes (Grade A). IS:2062

Hollow steel sections for structural use. IS:4923

7.4 Miscellaneous Steel Materials

Miscellaneous steel materials shall be conforming to the following B IS Codes.

Expanded Metal Steel Sheets for General purposes. IS:412

Specification for mild steel and medium tensile steel bars and harddrawn steel wire for concrete reinforcement (grade I) (For mild steelbars of anchor bolts, rungs, metal inserts, grating etc.) IS:432

Hexagonal headbolts, screws & nuts of product grade C. IS:1363

Cold formed light gauge structural steel sections. IS:811

Technical supply conditions for threaded steel fasteners. IS: 1367

Plain washers IS:2016





Steel wire ropes for general engineering purposes IS:2266

Thimbles for wire ropes. IS: 2315

Bulldog grips. IS:2361

Mild Steel Tubes, tubulars and other wrought steel fillings.(For Hand rail tubular sections). IS: 1239

Drop forged sockets for wire ropes for general engineering purposes. IS:2485

Steel chequered plates. IS:3502

Hexagonal bolts and nuts (M42 to M1 50). IS:3138

7.4.1 Anchor Bolts

Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves and plates etc. shall be as per relevant BIS Codes mentioned above.

7.5 Storage

The storage of all materials at site of work shall be at the contractor's expense and risk and shall be done as per the requirements given in IS:4082. The contractor shall maintain the proper records of receipt/consumption. The records shall always be accessible to the Engineer-in-Charge for verification.

The reinforcement bars, structural steel sections and other miscellaneous steel materials etc, shall be stored in such a way as to avoid and prevent deterioration, corrosion, bending, twisting and wrapping. In case of any damage occurring to the material on account of faulty storage or negligence by the contractor, same shall be borne by the contractor himself.


Materials supplied by the Owner or Contractor, shall, after delivery at site and at the discretion of Engineer-in-Charge, be subjected to any or all of the tests, required by the relevant BIS Codes. The Contractor shall carry out and bear the cost of such tests irrespective of the fact whether the material is procured by the Owner or the contractor. In case steel is supplied by the Owner, the Contractor shall get himself satisfied regarding its quality before using the same in his works at his own expense.

7.7 Rejection





The Engineer-in-charge may reject at his discretion any materia1,not withstanding the manufacturer's certificate or failing to meet the requirements of relevant BIS Codes for testing of materials. He may similarly reject any material, which has deteriorated or corroded etc., due to improper storage, handling or transport. Defective materials shall not be used and removed from the site by the contractor at his own expense.

8.0 BRICK

8.1 General

Bricks for masonry works shall conform to IS: 1077 - Specification for common burnt clay building bricks and shall be of class 5.0 (with minimum compressive strength of S.ON/mm' ). Specific requirement for any other class of bricks shall be as shown in drawings or as described in the contract for a particular site or type of work. Physical requirements, quality, dimensions, tolerances etc. of common burnt clay building bricks shall conform to the requirements of IS:1077.

Bricks shall be hand - moulded or machine moulded and shall be made from suitable soils. The bricks shall have smooth rectangular faces with sharp comers and shall be well burnt, sound, hard, tough and uniform in colour. These shall be free from cracks, chips, flaws, stone or humps of any kind.


The Contractor shall take samples of each type of brick as directed by the Engineer-in-Charge as per the requirements of IS:5454 and tests shall be carried out as per IS:3495. The cost for carrying out any or all the tests, shall be borne by the Contractor. The bricks, when tested, as per 1S:3495 shall have a minimum average compressive strength, as given in the Code, for a particular class of brick. Water absorption shall not be more than 20% by its dry weight, when soaked in cold water for 24 hours.

Brick samples so approved, shall be deposited with the Engineer-in-Charge. All subsequent deliveries shall be upto the standards of the approved samples.

8.3 Stacking of Bricks

Bricks shall be stored at site as per the requirements given in IS:4082 and shall not be dumped at site. They shall be unloaded from trucks to a place on a leveled surface near to the work site. They shall be stacked in regular tiers even as they are unloaded, to minimise breakages and defacement of bricks. The supply of bricks shall be so arranged that as far as possible, at least two days' requirements of bricks are available at site at any time. Bricks, of different class, shall be stacked separately.





8.4 Local Bricks / Class 3.5 Bricks.

Where shown on drawings, locally available bricks of non modular size (230mm x 1 15mm x 75mm) in place of bricks of modular size (190mm x 90mm x 90mm) can be used in case the bricks satisfy the other requirements of IS:1077. Minimum compressive strength of these bricks shall not be less than 3.5N/mm?

9.0 STONE

9.1 General

All Stones used for masonry works shall conform to the requirements of following BIS Codes.

Method of identification of natural building stones. IS: 1123

Recommendations for dimensions and workmanship of naturalbuilding stones for masonry work. IS: 1127

Recommendations for dressing of natural building stones. IS: 1 129

9.2 Quality of Stones

Stones shall be of approved quality, hard, dense, strong, sound, durable, clean and uniform in colour. They shall also be free from veins, adherent coatings, injurious amount of alkalies, vegetable matters and other deleterious substances such as iron pyrites, coal, lignite, mica, sea shells etc. Unless otherwise approved, stones from one single quarry shall be used for any one work. The strength of stones should be adequate to carry the imposed load and shall meet all the requirements of IS:1905, taking into account the appropriate crushing strength of stone and type of the mortar used. The percentage of water absorption, when tested in accordance with IS: 1124, shall not exceed 5 percent.

Stones normally used, shall be small enough to be lifted and placed by hand. The length of the stone shall not exceed 3 times the height. Width of stone on base shall not be less than 150mm and in no case exceed 314th thickness of the wall. Height of the stone shall not be more than 300mm.

9.3 Unloading/Stacking

The stones shall be unloaded from the trucks to a site near to the place of work as defined in IS:4082 and shall be stacked on a firm ground having adequate stope for drainage. The supply of stones shall be so arranged that as far as possible, at least two days' requirements of stone are available at site at any time.





10.0 ADMIXTURES

10.1 General Requirements for Admixtures

10.1.1 All concrete admixtures shall in general comply with the following BIS Codes unless otherwise stipulated in this specification.

Specification for integral cement water proofing compounds. IS:2645

Specification for other admixtures for concrete. IS:9103

10.1.2 Generally, admixtures shall have IS1 certification marks. However, even in case of BIS certified admixtures, Engineer-in-Charge may require the Contractor to carry out and submit any or all the tests (as specified in relevant BIS Codes), from approved laboratories, over and above the manufacturer's test certificate, before giving his final approval.

In case, admixtures certified by BIS are not available, the contractor shall submit to the Engineer-in-Charge the type and/or proprietary brand of the admixture from only reputed manufacturers along with necessary test certificates from recognised and approved laboratories or any other document directed by Engineer-in-Charge for the latter's final approval. In such cases, names of at least two manufacturers shall be submitted to the Engineer-in-Charge for his selection. In case, both the names are rejected, the contractor shall submit a fresh list of two manufacturers for approval by the Engineer-in-Charge.

The Engineer-in-Charge may direct the contractor to submit test results as required by IS:2645 or IS:9 103 for any admixture proposed to be used in the concrete in any approved laboratory at his discretion at any stage of the work. The cost of any/all tests required to satisfy compliance with this specification shall be borne by the Contractor.

In case of non-availability of any BIS code for testing and acceptability criteria, relevant American, British or German Code shall be applicable.

10.1.3 Prior approval of the Engineer-in-Charge shall be obtained while using waterreducing admixtures in the concrete (PCCIRCC) or mortar. Other type of admixtures such as accelerating admixtures, retarding admixtures or air entraining admixtures, shall not be used unless specified on the design drawings or prior approval taken from the design approving authority. Once approved, utmost care shall be exercised at site by the Contractor to maintain the consistency in the quality of admixture and the concrete/ mortar so produced.

10.1.4 The suitability and effectiveness of any admixture shall be verified by trial with the





designed concrete mixes using cement, aggregates together with any other materials to be actually used in the works as per the direction of Engineer-in-Charge. If two or more admixtures are to be used simultaneously in the same concrete mix, the Contractor must submit necessary test results from an approved laboratory to show their interaction and compatibility. Any/all tests specified in BIS Codes shall be carried out only with the type of material and mix design, to be actually used in the work site.

10.1.5 No admixture shall impair the durability of the concrete nor combine with the ingredients to form harmful compounds nor increase the risk of corrosion of reinforcement. Use of admixtures shall not reduce the dry density of concrete. Once the proportion of admixture has been established, strict check shall be maintained not to alter the proportions of ingredients and water-cement ratio of the Design Mix during execution.

10.1.6 The chloride contents in admixtures shall not exceed 2% by mass of the admixture or 0.03% by mass of the cement.

10.1.7 Admixtures which do not meet the requirements stipulated in this specification shall be rejected and shall not be used.

10.2 Water Proofing Compounds

10.2.1 Water proofing compounds shall be mixed with only ordinary portland cement of grade 33, conforming to IS:269.

10.2.2 The permeability of the specimen with the admixture shall be less than half of the permeability with similar specimen without the use of these compounds. These compounds shall be used in such proportion as recommended by manufacturer but inno case it shall exceed 3% by weight of cement.

10.2.3 The initial setting time of the cement with the use of these compounds shall not be less than 30 minutes and final setting time shall not be more than 10 hours. Test shall be carried out in accordance with IS:4031.

10.2.4 Compressive strength of specimen at 3 days shall not be less than 160kglsq.cm nor 80% of the 3 days compressive strength of mortar cubes prepared with same cement and sand only, whichever is higher. Similarly compressive strength at 7 days shall not be less than 220 kg/sq.cm nor less than 80% of the 7 days compressive strength prepared with the same cement and sand only, whichever is higher. The test to determine the compressive strength shall conform to 1S:403 1.

11.0 WATER BARS (WATER STOPS)

11.1 PVC water bars shall be used in reinforced concrete construction of liquid retaining





structures or any other structure to safeguard them from hydrostatic pressure and water leakage and any relative movement between two parts of the structure due to thermal loading shrinkage or differential movement of foundations. Wherever desired or shown in the drawings, they shall be used at expansion/contraction/construction joints. These shall be pre-formed and shall provide a permanent water tight seal along the entire joint in the poured concrete structures. These shall also be flexible enough to withstand deflection/displacements at joints arising due to variation of temperatures or settlement of foundations. The minimum thickness of water bar shall be as shown on drawings or described in the schedule of rates and unless otherwise mentioned, these shall be able to withstand a water head of at least 12 meters.

11.2 Performance requirements of P V C water bars shall meet the requirements of IS:12200. These shall be of approved make and of ribbed/serrated/plane type with a bulb at the centre. The thickness and width of water bars shall be as per schedule of rates/ drawings but in no case the thickness shall be less than 5mm and width less than 150mm. The joining of the water bars shall be carried out by vulcanising strictly as per the manufacturer's specifications. Lapped joints shall not be allowed under any circumstances.

12.0 BITUMEN/BITUMINOUS MATERIALS

Bitumen to be used for various types of work shall meet all the requirements of relevant BIS Codes as given below:

Specification of Paving Bitumen. IS: 73

Specification for bitumen mastic for flooring. IS: 1195

Specification for Bitumen felts for water proofing anddamp proofing. IS: 1322

Specification for Bituminous compounds for water proofingand caulking purposes. IS: 1834

Specification for preformed fillers for expansion jointin concrete pavements and structures. IS: 1838

Specification for bitumen mastic for use in water proofing of roofs. lS:3037

Specification for bitumen primer for use in water proofing anddamp proofing. IS:3384

Specification for Bitumen Mastic for Tanking and Damp proofing. IS:5871





Specification for Glass fibre base coal tar pitch & bitumen felts. IS:7193

Code of practise for damp proofing using bitumen mastic. IS:7198

Specification for bitumen Mastic, Anti Static andelectrically conducting grade. IS: 8374

The type and grade shall be as shown on the drawings or as indicated in schedule of quantities or as directed by Engineer-in-Charge. Tests and acceptable criteria shall be as per relevant BIS Codes.

13.0 PVC PIPES

PVC Pipes shall conform to the requirements of IS:4985.

14.0 WOOD/TIMBER

14.1 Wood recommended for platforms of cold vessels or below cold vessels/ exchangers shall be hard and shall be of group A, grade I, and shall have safe permissible stress of 7Nlmm' in compression, perpendicular to grains on outside location as per IS3883. General characteristics like durability, treatability etc. shall conform to IS: 883 and IS:3629.

14.2 Timber required to be used for formwork shall be fairly dry before use. It should maintain its shape during the use and even when it comes into contact with moisture from the concrete. Storage of Wood/Timber shall be as per the requirements of IS:4082.

For proper identification and selection of suitable timber for formwork, following codes shall be referred.

Classification of commercial timbers and their zonal distribution IS:399

Specification for ballies for general purposes. IS:3337

Specification for Ply wood for concrete shuttering work. IS:4990

15.0 EPOXY COMPOUNDS

Refer relevant GAIL Specification.





16.0 PAINT

16.1 Refer GAIL Specification No. 6-44-0004.

17.0 ANTITERMITE COMPOUNDS

17.1 Chloropyrifos emulsifiable concentrates (1%) conforming to IS:8944 shall be used for treatment of soil for protection of buildings against attack by subterranean termites.

18.0 POLYSULPHIDE SEALANTS

Polysulphide sealents shall confirm to IS 12118 and be of approved make. Test condition and requirements shall be as given in the above refered BIS code.


TECHNICAL SPECIFICATIONCIVIL & STRUCTURAL WORKS

EARTHWORK S-11-02-003Page 1 of 13



EARTHWORK





CONTENTS

1. SCOPE

2. CLASSIFICATION OF SOIL

3. BACKFILLING MATERIAL

4. SETTING OUT

5. EARTHING IN EXCAVATION

6. SHORING AND STRUTTING

7. BACKFILLING AROUND FOUNDATIONS AND PLINTH

8. TRANSPORTATION OF SURPLUS EARTH





1.0 SCOPE

This specification deals with earth work in excavation and filling.

2.0 CLASSIFICATION OF SOIL

2.1 Soft/Loose/Hard/Dense Soil and Mud

Generally any soil which yields to the application of pick and shovel or to phawra, rake or other ordinary digging implement such as vegetable or organic soil, turf, gravel, sand, silt. loam, clay. peat, cobble stone. mud etc.

2.2 Soft/Disintegrated/Weathered Rock (Not Requiring Blasting)

Rock or boulder which may be quarried or split with crowbar. This wilt also include laterite and hard conglomerate.

2.3 Hard Rock (Requiring Blasting)

Any rock or boulder for the excavation of which blasting is required.

2.4 Hard Rock (Requiring Controlled Blasting)

Due to any reason if general blasting is prohibited, for rock excavation, controlled blasting shall be used, with approval of the Engineer-in-Charge.

2.5 Hard Rock (Blasting Prohibited)

Hard rock requiring blasting as described under cl. No. 2.3 above, but where blasting is prohibited for any reason(s), breaking up of rock shall be done by chiselling. wedging or by using Hydraulic Splitter and chemical substances mixed in an appropriate proportion.

3.0 BACKFILLING MATERIAL

3.1 Backfilling material shall be as approved by the Engineer-in-Charge.

3.2 Backfilling of excavation in trenches, foundations and elsewhere shall consist of one of the following materials as shown on drawing, or directed by the Engineer-in-Charge.

i) Soil

ii) Selected earth from heaps or brought from borrow areas.





In case (i) or (ii) are not available, the Engineer-in-Charge may approve use of any of the following :

iii) Stone/gravel

iv) Sand

v) CNS material.

3.3 The material shall be free from rubbish, roots, hard lumps and any other foreign organic material.

4.0 SETTING OUT

4.1 The Contractor shall be responsible for the true and proper setting out of the work in relation to original points, lines and levels of reference and for the correctness of the levels, dimensions and alignment of all parts of the work. If at any time during progress of the work any error appears or arises in the position of level, dimension, or alignment of part of the work, the Contractor at his own expense shall rectify such errors to the satisfaction of the Engineer-in-Charge. The checking of any line or level by the Engineer-in-Charge shall not in any way relieve the Contractor of his responsibilities.

4.2 The Contractor shall lay out and construct one or more permanent bench marks in some central place before the start of the work, from which all important levels for the excavations will be set.

These permanent bench marks shall consist of masonry pillars with top neatly plastered and levelled as per the directions of the Engineer-in-Charge. Bench marks shall be well connected with triangular grid system or any other bench mark approved by the Engineer-in-Charge.

5.0 EARTHWORK IN EXCAVATION

5.1 Excavation shall be carried out in any material met on the site to the lines, levels and contours shown on the detailed drawings and the Contractor shall remove all excavated materials to spoil heaps on site or transport for use in filling on the site or stack them for reuse as directed.

5.2 Excavated material shall not be deposited within 1.5m from the top edge of the excavation.

5.3 The sides of the excavation may be cut sloping, or shored and strutted to hold the face of earth as per site requirements and as directed by the Engineer-in- Charge.





5.4 Foundation pits/trenches shall not be excavated to the full depth unless construction is imminent. The last fifteen (15) cm depth of the excavation shall not be done until concreting work is imminent. The full depth may at the discretion of the Engineer-in-Charge be excavated and the bed covered with a fifty (50) mm (minimum) thick (or as indicated on drawing) layer of lean concrete 1 :5: 10 mix (1 cement:5 coarse sand: 10 crushed stone aggregate) or as specified in schedule of rates/shown on drawing, after watering if required, and consolidating the bed.

5.5 If the bottom of any excavation has been left exposed by the Contractor and in the opinion of the Engineer-in-Charge. that has become badly affected by the atmosphere or by water, then the Contractor shall remove such portions of the deteriorated material as the Engineer-in-Charge may direct and shall make good with lean concrete 1:5: 10 mix (1 Cement : 5 Coarse Sand : 10 Crushed Stone Aggregate). All expenses for such additional concrete and excavation shall be borne by the Contractor.

5.6 Where excavation is made in excess of the depth required, the Contractor shall, at his own expense, fill upto required level with lean concrete 1:5: 10 mix (1 Cement : 5 Coarse Sand : 10 Crushed Stone aggregates ) or as decided by Engineer-in-Charge.

5.7 The Contractor shall provide suitable drainage arrangement to prevent surface water from any source entering the foundation pits at his own cost.

5.8 The Contractor shall make all arrangements for dewatering during excavation and subsequent works, the accumulated water from any source (including subsoil water) in the excavated pits/trenches and keeping the excavated pits/trenches dry for subsequent works.

5.9 The Contractor shall make necessary arrangements for lighting, fencing and other suitable measures for protection against risk of accidents due to open excavation.

5.10 Where the excavation is to be carried out below the foundation level of an adjacent structure, the precaution to be taken such as under pinning, shoring and strutting etc. shall be determined by the Engineer- in-Charge. No excavation shall be done unless such precautionary measures are carried out as per directions of the Engineer-in-Charge. The payment for such precautionary measures shall, however, be made separately.

5.11 Loose or soft bed ground encountered in excavation at the required depth shall on the Engineers-in-Charge's instructions be excavated to a firm bed and difference made up to the required level with lean concrete l:5: 10 mix (1 Cement : 5 Coarse Sand : 10 Crushed Stone Aggregates).

5.12 In those cases where during excavation, side slips occur for reasons not attributable to the Contractor (e.g. side slips which take place on their own but not due to surcharge





of earth kept near the edge of excavation and cracking of excavation top strata due to clay drying out leading to collapse of excavation sides), the Engineer-in-Charge shall admit payment at his discretion.

5.13 Any obstacle encountered during excavation shall be reported immediately to the Engineer-in-Charge and shall be dealt with as instructed by him. Removal of buried pipes or cables shall not be done without prior permission of the Engineer-in-Charge and the Contractor shall provide all measures to protect the same. Cost of such protective measures are deemed to be included in the rates for various items of excavation.

5.14 The Contractor shall not undertake any concreting in foundation until the excavation pit/trench is approved by the Engineer-in-Charge.

5.15 The specification for earth work shall also apply to excavation in rock in general.

5.16 In case of hardrock requiring blasting, the provisions mentioned below shall be strictly followed.

5.16.1 General

Where hard rock is met with and blasting operations are considered necessary, the Contractor shall intimate about the same to the Engineer-in-Charge, and obtain his approval in writing for resorting to blasting operation.

The Contractor shall obtain licence from the district authorities for undertaking blasting work as well as for obtaining and storing the explosive as per Explosive Rules 1983, corrected upto date. He shall purchase the explosives, fuses, detonators etc. only from a licensed dealer. He shall be responsible for the safe custody and proper accounting of the explosive materials. The Engineer-in-Charge or his authorised representative shall have the access to check the Contractor's store of explosive and his accounts.

In case where explosives are required to be transported and stored at site, relevant clauses of the Explosive Rules, 1983 as amended subsequently, shall apply.

The Contractor shall be responsible for any accident to workmen: public or property, due to blasting operations.

5.16.2 Precautions

Blasting operations shall be carried out under the careful supervision of a responsible authorized and licensed blaster of the Contractor (referred subsequently as "blaster" only) during specified hours, as approved in writing by the Engineer-in-Charge. The blaster shall be fully conversant with the rules of blasting.





Proper precautions for safety of persons shall be taken. Red flags shall be prominently displayed around the area to be blasted and all the people on the work except those who actually light the fuses, shall withdraw to a safe distance of not less than 200 metres from the blast. Precautions as per Explosive Rules 1983 with amendment shall be followed.

5.16.3 Fuses

All fuses shall be cut to the lengths required before being inserted into the holes. Joints in fuses shall be avoided. Where these are unavoidable: a semicircular niche shall be cut in one piece of fuse about 2 cm. deep from the end and the end of other piece inserted into this niche, and the two pieces then wrapped together with a string. All joints exposed to dampness shall be wrapped with rubber tape. Fuse and detonators shall be kept separated from the explosives.

5.16.4 Blasting with Gun Powder

Blasting shall normally be done with gun powder. Dynamite, gelatine or any other high explosive shall only be used in special cases with the written permission of the Engineer-in-Charge.

In case of blasting with gun powder, the position of all bore holes to be drilled shall be marked out in circles with white paint. The bore holes shall be jumped or drilled in the rock face. The depth of bore hole shall be about the same as that of the line of least resistance and its size shall be such that the cartridges can easily pass down to the bottom. The bore holes must be dried before being charged and these shall be inspected by the Contractor's agent.

Gun powder may be used in the form of pellet blasting cartridges or as powder or granules. Cartridges are provided with tapered central hole. One end of fuse is passed through the narrow end of the hole and a sufficient length of the fuse is doubled back so that when the fuse is pulled, it is held tight in the tapered hole of the cartridge. Other cartridges are then inserted in the fuse to make up the required charge. The cartridge along with the fuse is lowered down in the bore hole, placed in position and gently filled and pressed home with dry hay or turf. The rest of the bore shall then be filled with dry clay, which shall be tamped with copper or brass rod until it becomes compact. Care shall be taken to avoid any possibility of an air space around the fuse. The safety fuses shall be taken to the required distance so as to allow the blasting to take place after the person lighting the fuse has withdrawn to a safe distance.

Where gun powder is used in the form of powder or granules it shall be introduced in the bore hole by means of funnel or copper tube. The bore holes shall be loaded with





two thirds of the quantity of charge required. and safety fuse then directly introduced over the charge. Remaining one third charge shall then be introduced, and gently filled and pressed home with dry hay or turf. The rest of the bore hole shall be filled with dry clay in the same way as for cartridges, and the safety fuse taken to the required distance.

The charges shall be fired by igniting the fuse. The number of charges to be fired and the actual number of shots heard, shall be compared, and the Contractor's blaster shall satisfy himself by examination that all the charges have exploded: before workmen are permitted to approach the site. The charge which has not exploded, shall not be permitted to be withdrawn. The tamping and charge shall be flooded with water and the holes marked with a red cross (X) over it. Another hole shall be jumped at a distance of about 45 cm from the old hole and fired in the usual way. This operation shall be continued. till the original and any subsequent unfired charges are exploded.

5.16.5 Blasting with Dynamite or any other High Explosive

In case of blasting with dynamite or any other high explosive the position of all bore holes to be drilled shall be marked out in circle with white paint. These shall be inspected by the Contractor's blaster. Bore holes shall be of a size that the cartridge can easily pass down. After the drilling operation, the blaster shall reinspect the holes to see that the holes marked out by him have been drilled. He shall then prepare all charges necessary for the bore holes. The bore holes shall be thoroughly cleaned before a cartridge is inserted. Wooden tamping rods (not pointed but cylindrical throughout) shall be used, in charging holes. Metal rods shall never be used for tamping. One cartridge shall be first placed in the bore hole. gently pressed and not rammed down. Other cartridges shall then be added as may be required to make up the necessary charge for the bore hole. The top most cartridge shall be connected to the detonator which shall in turn be connected to the safety fuse of required length.

The maximum of eight bore holes shall be loaded and fired on each occasion. The charges shall be fired successively and not simultaneously.

Immediately before firing a blast, due warning shall be given and the blaster shall see that all persons have retired to a place of safety. The safety fuses of the charged holes shall be ignited in the presence of the blaster, who shall see that all the fuses are properly ignited.

Careful count shall be kept by him and others of each blast as it explodes. After the blast the blaster shall inspect the work and ascertain that all the charged holes have been exploded. In case of misfired holes, he shall inspect the same after half an hour and mark red crosses (X) over the holes. During this interval of half an hour, no body shall approach the misfired holes. None of the drillers shall work near such holes, until one of the two following operations has been done by the blaster.





a) Either the Contractor's blaster shall very carefully (when the tamping is of damp clay) extract the tamping with a wooden scraper and withdraw the fuse, primer and detonator, after which a fresh detonator, primer and fuse shall be placed in the misfired holes and fired.

OR

b) The hole shall be cleaned for 30 cm of tamping and its direction ascertained by placing a stick in the hole. Another hole shall then be drilled 15 cm away and parallel to it. This hole shall be charged and fired. The misfired hole should also explode along with the new one.

Before leaving the work, the blaster of one shift shall inform another blaster relieving him for the next shift. of any cases of misfire, and shall point out their positions denoted by red crosses and also state the action; if any, to be taken in the matter.

The Engineer-in-Charge shall also be informed by the blaster of all cases of misfire, their causes and steps taken in that connection.

5.16.6 Controlled Blasting

Whenever required by the Engineer-in-Charge, rock blasting shall be carefully controlled so that vibrations generated during the blasting do not cause damage to the buildings and installation around. Similarly, the rock pieces should not fly off and endanger the buildings and installations around. Apart from the general precautions mentioned in the preceding paragraphs, following protective measures and limits for use of explosive are suggested as guidelines. Tenderers are requested to carefully check the site conditions and submit details of the scheme they propose to adopt for controlling the blast.

Following protective measures shall be adopted while carrying out blasting operations

The hole shall be covered with mild steel plate of minimum 12mm thickness.

Reinforcement rod mesh not less than 20mm dia. at 150mm centre in both directions shall be placed over the steel plates.

Steel plate and reinforcement shall be inspected after every blasting operation and all twists shall be removed before reuse to the satisfaction of the Engineer-in- Charge.

Sand filled bags of 6 to 8 layers shall be placed over the mesh suitably covering the whole region under blasting operation.





The thickness of covering plate and the kind of dead weight is to be duly approved by the Engineer-in-Charge .

5.16.7 Hard rock requiring blasting as described under cl.no. 2.3 above, but where blasting is prohibited for any reason(s) breaking up of rock can be done by using Hydraulic Splitter and chemical substances of approved manufacturer (Lifton or equivalent) mixed in an appropriate proportion. The method involves drilling holes into rock and then inserting/injecting hydraulic splitter/chemical solvents into the holes. The breaking-up of rock takes place in a controlled fashion without much noise and spark.

5.17 Payment

5.17.1 Payment for earth work in excavation shall be made on cubic meter (m3) basis on the measurement of volume of pit/trench of excavation with working space as per relevant Indian Standards (IS: 1200) and slopes/steppings as permitted by the Engineer-in-Charge. The rate shall include cost of all the operations of blasting with explosives & accessories, making of all arrangements for dewatering the accumulated water from any source in the excavated pit or trench, removal and disposal of surplus excavated soil within a lead of 100m from construction areas. The rate shall also include setting out and line out work required for the excavation.

5.17.2 The following works shall not be measured separately and allowance for the same shall be deemed to have been made in the description of main item:

a) Setting out works, profiles, etc.;

b) Site clearance, such as cleaning grass and vegetation;

c) Unauthorized battering or benching of excavation;

d) Forming (or leaving 'dead men' or 'tell-tales' in borrow pits and their removal after measurements;

e) Forming (or leaving) steps in sides of deep excavation and their removal after measurements;

f) Excavation for insertion of planking and strutting;

g) Unless otherwise specified, removing slips or falls in excavations;

h) Baling out or pumping of water in excavation from rains;

i) Baling out or pumping of water in excavation from sub-soil water, and





j) Slinging or supporting pipes, electric cables, etc, met during excavation.

5.17.3 Special pumping other than what is included in 5.17.2 (h and i) and well point dewatering where resorted to. shall each be measured separately, unless otherwise stated, in kilolitres of water against separate specific provision(s) made for the purpose.

5.17.4 The Contractor shall intimate to the Engineer-in-Charge as soon as different classification of soils are met with. The measurements of various soil classifications then shall be worked out by either of the following alternatives in the order of their decreasing importance.

a) Joint levels shall be taken as to the levels of different soil classifications and volume worked out on the basis of levels only.

b) Where levels of different strata cannot be clearly marked and defined, the Contractor shall stack different soils of various classifications separately for measurement purpose and then dispose it off.

c) If the quantum of work involved in (b) above is extensively large & time consuming, then the total area may be divided into various zones and reasonably representative samples as in (b) above may be taken and quantities of soils of various classifications finalized for the entire zone based on the representative.

If soil of any classification other than that specified in the Schedule of Rates is met with during excavation, the decision of the Engineer-in-Charge as to the classification of soil, levels of the strata of different classifications and their location shall be binding.

In above case, the total quantity of excavation shall be computed from the measurement of the pit/trench excavated. The hard rock and soft rock shall be measured separately from the relevant stacks and each shall be reduced by fifty percent for voids, and paid under the relevant items. The balance. that is the total quantity of excavation minus the reduced (for voids) quantity of excavation for rocks shall be paid as softlhard soil as per the direction of the Engineer-in-Charge (However, the maximum payment shall be limited to the volume of the excavated pit/trench asapproved by Engineer-in-Charge) .

6.0 SHORING AND STRUTTING:

6.1 The shoring and strutting of the sides to withhold the face of excavation pits/trenches shall be done when approved or directed by the Engineer-in-Charge.

6.2 The shoring shall be of close or open timbering type depending upon the site requirements and as directed by the Engineer-in-Charge whose decision shall be final





and binding as to the type of shoring to be used.

6.3 The arrangement of the shoring and strutting shall be sound and safe and shall be got approved from the Engineer-in-Charge before installation. The approval shall not absolve the Contractor of his responsibilities of safety and any other requirements of the contract.

6.4 The shoring and strutting shall be kept in position till all the relevant work in the excavated area is completed and approved. It shall be dismantled and removed only after the permission to do so is obtained from the Engineer-in-Charge.

6.5 Payment

Payment for shoring and strutting by close and open timbering shall be made on square meter (m2) basis as separate items. In both the cases, the measurement shall be done on the basis of the surface area of the sides of the excavation actually shored and strutted.

The rate shall include all labour, materials, erection of the poling boards, wales: struts, ballies etc., fixing and keeping the same in position as required, dismantling and removing the same after the work is over as directed.

7.0 BACK FILLING AROUND FOUNDATIONS AND IN PLINTH

7.1 Back filling around completed foundations, structures, trenches and in plinth shall be done to the lines and levels shown on the drawings including any trimming of the surfaces, as may be necessary. This shall be done with selected and approved earth from excavation or otherwise with materials described under clause 3.2 as directed by the Engineer-in-Charge. Where sufficient suitable material is not available from the excavation, the Engineer-in-Charge may direct to import suitable earth from other sources. The filling shall be done in layers of thickness not exceeding 15 cm with watering, rolling and ramming by manual methods1 mechanical compactors to grade and level as shown on drawings to obtain 90% laboratory maximum dry density.

7.2 The Contractor shall not commence filling in and around any work until it has been permitted by the Engineer-in- Charge.

7.3 Backfilling around liquid retaining structures and pipes shall be done only after approval of the Engineer-in- Charge is obtained.

7.4 Payment

Payment for backfilling with earth shall be based on volume in cubic meters (m3) of consolidated fill. This volume shall be derived from the difference between the volume of excavation and the structure or trenches as the case may be. The rate shall include





cost of extracting suitable approved earth from available excavated soil from spoil heaps within a lead of 100m. placing. watering, rolling, ramming compacting in layers, trimming and dressing finished surface and disposal of surplus material upto a lead of 100m.

However, backfilling done with materials other than earth shall be paid separately under relevant items.

8.0 TRANSPORTATION OF SURPLUS EARTH

8.1 Surplus earth and soil from excavation shall be removed from construction area to the area demarcated by the Engineer-in-Charge.

8.2 Payment

8.2.1 Payment shall be made only for the lead beyond initial lOOm from construction area. Rate shall include re- excavation, loading: transportation, dumping, stacking or spreading (as per directions of the Engineer-in-Charge) the surplus earth and the soil in the area demarcated by the Engineer-in-Charge. Payment shall be made on cubic metre (m3) basis on the difference of measurements of the volume of the excavated pits and the measurement of the back filling. Quantity generated due to voids in back filled volume of earth shall also be removed by the Contractor at no extra cost and this disposal of earth shall not be measured and paid under any item.

8.2.2 In exceptional circumstances the Engineer-in-Charge may direct the Contractor to remove surplus earth, concrete debris or any other waste material from site to the areas of disposal on the basis of truck measurement. In such cases volume of material shall be calculated on the basis of truck volume reduced by 30% for voids in case of soft/hard soils and 50% for soft/hard rock. All other provisions of disposal such as spreading, leveling, grading shall apply in this case also.


STATNDARD SPECIFICATIONPLAIN & RCC WORK S-11-02-004 Page 1 of 42



PLAIN AND REINFORCED CEMENTCONCRETE




CONTENTS

1. SCOPE

2. MATERIALS

3. GRADES OF CONCRETE

4. TYPE OF CONCRETE MIX

5. CONCRETE MIX PROPORTIONING

6. BATCHING

7. CONCRETE MIXING

8. TRANSPORTATION, PLACING AND COMPACTION

9. CONSTRUCTION JOINTS

10. SEPARATION JOINTS

11. EXPANSION JOINTS/ISOLATION JOINT

12. WATER STOPS

13. PROTECTION OF FRESHLY LAID CONCRETE

14. CURING

15. FIELD TESTS

16. INSPECTION AND TESTING OF STRUCTURES

17. FINISHING OF CONCRETE

18. CEMENT WASH

19. FORM WORK

20. EXPOSEDIARCHITECTURAL CONCRETE WORK

21. REINFORCEMENT




22. PRECAST CONCRETE

23. CONTINUOUS CONCRETING

24. PAYMENT




1. SCOPEThis specification establishes the requirements of materials, mix proportioning, placing, curing, etc. of all types of cast-in-situ and precast concrete used in foundations, underground and overground structures, floors, pavements etc. Any special requirements as shown or noted on the drawings shall supersede over the provisions of this specifications.

1.1 Reference Codes and Specifications

Apart from this specification, construction of plain and reinforced concrete works shall be in accordance with the Indian Standard Code of Practice for "Plain and Reinforced Concrete" IS:456 and other relevant codes mentioned therein.

1.2 For Liquid Retaining Structures GAIL Specification No. 6-68-0005, shall hold good.

1.3 For Structural Steel works GAIL Specification No. 6-68-0006 & 0008, shall hold good.

1.4 In case of conflict between the clauses mentioned in this specification and those in the Bureau of Indian Standards (BIS), this specification shall govern.

2. MATERIALS

2.1 Materials for concrete viz cement, sand, coarse aggregate, water, etc. shall be as described in GAIL Specification No.S-11-02-002

2.2 Materials for all reinforcements, embedment, inserts, water bars etc. shall conform to GAIL Specification No.s-11-02-005

2.3 Materials suggested to be used as additive to concrete shall conform to GAIL specification

3.0 GRADES OF CONCRETE

Unless otherwise noted on the drawings, or called for in the schedule of rates, the grades of concrete shall generally be as per Table-1.

TABLE-IGRADES OF CONCRETE

Grade designation Specified Characteristic Comprehensive Strength of 150 mm cube at 28 days

(N/mm2)M 15M20M25

152025




M30M35M40M45M50M55

303540455055

Note for Table - 1 : The characteristic strength is defined as the strength of material belowwhich not more than five (5) percent of the test results are expected to fall.

3.1 Plain and reinforced cement concrete work shall confirm to Indian Standard for plain and concrete- Code of practice fourth revision IS 456:2000.

4.0 TYPE OF CONCRETE MIX

4.1 Unless otherwise noted on drawings, all lean/plain and reinforced concrete shall be of M20 grade suitable for sever exposure condition and Reinforcement Cement Concrete shall be of grade M30 suitable for sever exposure condition confirming to IS 456:2000.

4.2 Nominal Mix ConcreteThis concrete shall be made (without preliminary tests) by adopting nominal concrete mix with proportions of materials as specified in Table-1A.

TABLE - 1APROPORTIONS FOR NQ

Nominal mix of concrete (by mass)

Quantity of water per 50 kg of cement(Max)Litres

1:5:101:3:6M 15 (1:2:4)M 20 (1:1 ½: 3)

60343234

Note:1. The proportions of the fine to coarse aggregates should be adjusted from upper limit to lower limit progressively as the grading of the fine aggregates becomes finer and the maximum size of coarse aggregates becomes




1arger.Graded coarse aggregates shall be used.

2. The cement content of the mix shall be proportionately increased if the

quantity of water in a mix has to be increased to overcome the difficulties of placement and compaction, so that the water-cement ratio, as specified, is not exceeded.

4.3 Design Mix ConcreteThe mix shall be designed to produce the grade of concrete having the required workability and characteristic strength not less than appropriate values given in Table-1. The target mean strength of concrete mix shall be equal to the characteristic strength plus 1.65 times the standard deviation. As long as the quality of materials does not change, a mix design done earliel; may be consideredadequate for later work. However, in case the quality of materials change or there is a break in the continuity of construction and the same work is allocated to a new contractor, the Engineer-in-Charge shall ask for a new design mix.

Irrespective of the grade of concrete required to be produced as per characteristicstrength criteria, the minimum cement content and maximum free water cement ratio in the design concrete shall be strictly maintained as stipulated in Table 2A for the corresponding grade of concrete.

5.0 CONCRETE MIX PROPORTIONINGProportioning, as used in this specification, shall mean the process of determining the proportions of the various ingredients to be used to produce concrete of the required workability when freshlgreen and strength, durability and surface finish, when hardened.The following information shall be collected prior to design of the concrete mix :

a) Grade designation.

b) Type of cement.

c) Maximum nominal size of aggregate.

d) Minimum cement content.

e) Maximum free water cement ratio

f) Workability requirements.




The Engineer-in-Charge shall verify the strength of the concrete mix, before giving his sanction of its use. However, this does not absolve the Contractor of his responsibility as regards achieving the prescribed strength of the mix. If during the execution of the work, cube tests show lower strengths than required, the Engineer-in-Charge shall order fresh trial mixes to be made by the Contractor.

No claim to alter the rates of concrete work shall be entertained due to such changes in mix variations. Any variation in cement consumption shall be taken into consideration for material reconciliation. Preliminary mix designs shall be established well ahead of start of work.

5.1 Maximum Density

Suitable proportions of sand and the different sizes of coarse aggregates for each grade of concrete shall be selected to give as nearly as practicable the maximum density. This shall be determined by mathematical means, laboratory tests, field trials and suitable changes in aggregate gradation. The contractor shall submit to the Engineer-in-Charge at least three sets of mix design and corresponding test results after varying the mix proportions and 1 or grading of aggregate so as to establish themaximum density of any particular grade of concrete.

5.2 Free Water Cement Ratio

Once a mix, including its free water cement ratio, has been determined and approved for use by the Engineer-in- Charge, that free water cement ratio shall be maintained. The Contractor shall determine the water content of the aggregates frequently as the work progresses, and the amount of mixing water shall be adjusted so as to maintain the approved free water cement ratio.

5.3 Consistency

The concrete shall have a consistency such that it shall be workable in the required position and when properly vibrated it flows around reinforcing steel, all embedded fixtures, etc.

5.4 Workability

5.4.1 The concrete mix proportion shall be such that the concrete is of adequate workability for the placing condition and can be properly compacted with the means available. Use of additives of approved make shall be taken recourse to where required for attaining proper workability as specified under cl. 5.4.2.




5.4.2 The suggested ranges of values of workability of concrete measured in accordance with IS: 1199 are indicated in Table-:! below. However, the actual values to be followed shall be established depending on aggregate sizing, mix proportions, placing conditions, etc and shall be got approved by the Engineer-in-Charge .

TABLE - 2VALUES FOR WORKABILITY

Placing conditions Degree of workability Slump (rnrn)

.5.5 Durability

For achieving sufficiently durable concrete, strong, dense aggregates, low water-cement ratio and adequate cement content shall always be used. Workability of concrete shall be such that concrete can be completely compacted with the means available. Leak-proof formwork shall be used so as to ensure no loss of cement-slurry during pouring and compaction. Cover to reinforcement shaI1 be uniform and as shown on drawings. Concrete mix design shall always take into account the type of cement, minimum cement content irrespective of the type of cement and maximum free water cement ratio and minimum grade of concrete conforming to the exposure conditions as given in Table-2A.

TABLE - 2A

MINIMUM CEMENT CONTENT, MAXIMUM FREE WATER CEMENT RATIO AND MINIMUM GRADE OF CONCRETE FOR DIFFERENT EXPOSURE CONDITIONS

Plain Concrete Reinforced Concrete

ExposureMinimum Cement Content Ratio (Kg/M3)

Maximum Free Water content ratio

Minimum Grade of concrete

Minimum cement content ratio(Kg/m3)

Maximum Free Water content ratio

Minimum Grade of concrete

Mild 240 0.60 M 15 330 0.55 M 20Moderate 265 0.60 M 15 330 0.50 M 25




Sever 275 0.50 M 20 350 0.45 M 30Very Sever

280 0.45 M 20 375 0.45 M 35

Extreme 310 0.40 M 20 400 0.40 M 40

Generally, the following types of cement shall be used for Plain and Reinforced concrete works:

a) 33 Grade Ordinary Portland Cement conforming to IS: 269.

b) 43 Grade Ordinary Portland Cement conforming to IS: 8112.

c) Portland Slag Cement conforming to IS:455.

d) Portland Pozzolana Cement conforming to IS: 1489.

e) Sulphate Resisting Portland Cement conforming to IS: 12330

Sulphate Resisting Portland Cement shall be used only for specific requirements depending on environmental and process exposure conditions to which the structures may be subjected to like high sulphate concentrations, processes involving sulphur handling etc.

The minimum cement content as mentioned in Table-2A shall be adjusted for aggregates other than 20mm nominal maximum size. The minimum cement content in the concrete mix shall be increased by 40kg/m3 and decreased by 30 kg/m3 for lOmm and 40mm nominal maximum size aggregates respectively.

5.6 Limits to Deleterious Constituents

Careful selection of the mix and the constituent materials shall be made to limit the presence of deleterious constituents in concrete. The total acid soluble chloride content calculated from the mix proportion and the measured chloride content of each of the constituents shall not exceed 0.6 kg/m3 at the time of placing of concrete. The total water soluble sulphate content of the concrete mix shall not exceed 4 percent by mass of the cement in the mix.

6.0 BATCHING

6.1In proportioning concrete, the quantity of both cement and aggregate shall be determined by mass.Where the mass of cement is determined on the basis of mass of cement per bag, a reasonable number of bags shall be weighed periodically to check the net mass.Where the cement is weighed at site and not in bags, it shall be weighed




separately from the aggregates.Water shall be either measured by volume in calibrated tanks or weighed.Any solid admixtures that are to be added, shall be measured by mass; liquid and paste admixtures shall be measured by volume or mass. Batching plant, shall conform to IS:4925. All measuring equipment shall be maintained in a clean serviceable condition, and their accuracy shall be within +2% and t3%for measurement of cement and aggregates/water/admixtures, respectively.

6.2 Except where it can be shown to the satisfaction of the Engineer-in-Charge that supply of properly graded aggregate of uniform quality can be maintained over the period of work, the grading of aggregate shall be controlled by obtaining the coarse aggregate in different sizes and blending them in the right proportions when required, different sizes being stacked in separate stock piles. The grading of coarse and fine aggregates shall be checked frequently, the frequency for a given job being determined by the Engineer-in-Charge to ensure that the approved grading is maintained.

6.3 Under very special circumstances change from weigh batching to appropriate volume batching may be permitted by Engineer-in-Charge. However, in such cases all conversions from mass of ingredients to volume shall be based on actual and appropriate bulk densities physically measured at site and approved by the Engineer-in-Charge.

6.4 The amount of added water shall be adjusted to compensate for any observed variations in the moisture contents in both fine and coarse aggregates. For the determination of moisture content in the aggregates, IS:2386 (Part-3) may be referred to. To allow for the variation in mass of aggregates due to variation in their moisture content, suitable adjustments in the mass of aggregate shall also be made. In the absence of exact data, only in the case of nominal mixes, the amount of surface water may be estimated from the values given in Table-3.

TABLE – 3SURFACE WATER CARRIED BY AGGREGATE

APPROX QUANTITY OF SURFACE WATERAGGREGATESURFACE BY MASS LITER/M3

Very wet sand

Moderate wet sand

Moist sand

Moist gravel or crushed rock

7.5

5.0

2.5

1.25 – 2.5

120

80

40

20- 40




6.5 No substitutions in materials used on the work or alterations in the established proportions, except as permitted in 6.4 shall be made without additional tests to show that the quality and strength of concrete are satisfactory. In case the Contractor proposes any change in the already approved mix design, fresh mix design with supportive laboratory tests shall be submitted to the Engineer-in-Charge and his approval has to be obtained prior to using the revised mix proportion in the works. However, such proposals for revision shall only be entertained in case of successivefailure of test cubes to achieve the required strength.

7.0 CONCRETE MIXING

7.1 Approximate quantity of surface water The mixing of concrete shall be strictly carried out in an approved type of mechanical concrete mixer. The mixer shall be fitted with water measuring devices. The mixing shall be continued until there is a uniform distribution of the material and the mass is uniform in colour and onsistency.If there is segregation after unloading from the mixer, the concrete shall be remixed.Percent bv mass Use of Ready Mixed Concrete supplied by Ready Mixed Concrete Plants or from onloff-site batching plants (IS:4926) shall be prefered for structural concrete. Litre / m3 All records and charts for the batching and mixing operations shall be prepared and maintained by the contractor as per the instructions of Engineer-in-Charge.

7.2 Mixer

7.2.1 Mechanical Mixers shall comply with IS:1791 and 121 19 and shall be maintained in satisfactory operating condition. These shall be used only for producing lean/ plain concrete and/ or nominal mix concrete wherever permitted.

7.2.2 Mixing Time

Mixing time shall be as indicated in the following table. Excessive mixing requiring additions of water shall not be permitted. Time shall start when all solid materials are poured in the revolving mixer drum, provided that all of the mixing water shall be introduced before one-fourth of the mixing time has elapsed. The Engineer-in-Charge may, however, direct a change in the mixing time, if he considers such a change necessary.

MINIMUM MIXING TIME FOR MIXERS

Capacity of mixer Minimum mixing time




2 m3 or less

Above 2 m3

2 minutes

3 minutes or as recommended by the mixer manufacturer.

7.3 Hand Mixing

Hand mixing of concrete shall not be permitted. However, for non-critical applications namely foundations for crossovers, isolated operating platforms etc. using concrete of maximum grade M20 and located at far away isolated places, this may be permitted by the Engineer-in-charge as a special case.Ten percent (10%) extra cement shall be added to the design proportion. Mixing shall be carried out on a water tight platform and care shall be taken to ensure that mixing is continued untilthe mass is uniform in colour and consistency. No extra payment shall be made to the Contractor for mixing by hand or for using extra cement due to hand mixing.

7.4 Additives

Additive in concrete shall be used only with the prior approval of the Engineer-in-Charge and shall comply with cl. 5.5 of IS:456. Any additive used for obtaining proper workability or leak-proofness of concrete or repaidrendering works of concrete due to non-conformance to the specifications, shall not be measured and paid for. All costs relating to such usage shall be borne by the Contractor.

8.0 TRANSPORTATION, PLACING AND COMPACTION

8.1 General

The entire concrete placing programme including transportation arrangements, deployment of equipment, layout, proposed procedures and methods, shall be submitted to the Engineer-in-Charge 24 hours prior to concreting for approval. No concreting shall be placed until his approval has been received. Approval of the Engineer-in-Charge for pouring concrete shall be taken as 'conveyed', when the concrete pour card is signed by him.

8.1.1 Chuting

The use of long troughs, chutes and pipes for conveying concrete from the mixer to the forms shall be permitted only on written authorization from the Engineer-in-Charge. In case an inferior quality of concrete is produced by the use of such conveyors, the Engineer-in-Charge may order discontinuance of their use and the substitution of a satisfactory method of placing the concrete. Open troughs and chutes shall be equipped




with baffles and be in short lengths to avoid segregation.

Chutes shall be designed so that the concrete is, to some extent, remixed at the lbwer end by passing down through a funnel shaped pipe or drop chute. Alternatively, they shall discharge into a storagehopper from which the concrete shall be transported to the point of placing by wheel barrows or other means. Where drop chutes are used, a sufficient number of these must be provided, so that the concrete discharged from the chute is not required to flow laterally more than 1.0 metre. Where a drop chute is swung from the vertical, the bottom two sections must be maintained in a vertical position to avoid segregation. The addition of water at any point in the system of tran~portation~to facilitate the movement of concrete shall not be permitted. All chutes, troughs and pipes, shall bekept clean and free from coatings of hardened concrete by thoroughly flushing them with water after each run; water used for flushing shall be discharged clear of the structure. Concrete shall not be normally permitted to fall freely from a height of more than 1.5 metre nor to strike the forms at an angle. However, a deviation from this normal practice may be allowed provided proper precaution is taken, while placing concrete into the forms to avoid segregation, to the satisfaction of theEngineer-in-Charge.

8.1.2 Vibrators

8.1.2.1Concrete shall be compacted with mechanical vibrating equipment supplemented, ifnecessary to obtain consolidation, by hand spreading, rodding and tamping. The vibrators shall be of immersion type with operational frequency ranging between 8,000 to 12,000 vibrations per minute. All vibrators shall comply with IS:2505. Screed board concrete vibrators or concreting vibrating tables or form vibrators conforming to IS:2506,2514 and 4656, respectively, shall be used where specifically required and directed by Engineer-in-Charge. .

8.1.2.2 Immersion type vibrators shall be inserted in a vertical position at intervals of about600mn-1, depending upon the mix, the equipment used, and experience on work. Thevibrators shall be withdrawn slowly. The spacing shall provide some overlapping of the area vibrated at each insertion. In no case shall vibrators be used to transport concrete inside the forms. Over vibration or under vibration shall not be permitted as both are harmful. Hand tamping in some cases may be allowed subject to the approval of the Engineer-in-Charge.

8.1.2.3 In placing concrete in layers which are advancing horizontally as the workprogresses, great care shall be exercised to ensure adequate vibration, bonding and

moulding of the concrete between the succeeding batches.

8.1.2.4 The vibrator shall penetrate the layer being placed and also penetrate the layer below while the under layer is still plastic to ensure good bond and homogeneity between the two layers and prevent the formation of cold joints




.8.1.2.5 Care shall be taken to prevent contact of vibrators against all embedded

reinforcing steelor inserts.Vibrators shall not be allowed to come in contact with forms.

8.1.2.6 The use of form vibrators shall not be permitted for compaction of in-situ concrete without specific authorization of the Engineer-in-Charge.

8.1.2.7 The use of surface vibrators of screed board type shall not be permitted for consolidation of concrete under ordinary conditions. However,for thin slabs (of thickness less than 200mm) surface vibration by such vibrators may be permitted, upon approval of the Engineer-in-Charge.

8.1.2.8 Whenever vibration has to be applied externally, the design of formwork and the disposition of vibrators shall be carefully planned to ensure efficient compaction and to avoid surface blemishes.

8.2 Transportation

8.2.1 All concrete shall be conveyed from the mixer to the place of final deposit such as formwork as rapidly as possible using suitable buckets, dumpers, pumps, transit mixers containers or conveyors which shall be mortar leak tight.Care shall be taken to prevent the segregation or loss of the ingredients and maintaining the required workability .For structural concrete produced from Ready Mixed Concrete Plants as per cl. 7.1, concrete shall be transported from the plants to the sites only by transit mixers.

8.2.2 During hot or cold weather, concrete shall be transported in deep containers.Other suitable methods to reduce the loss of water by evaporation in hot weatherand heat loss in cold weather may also be adopted.Al1 equipment used for transporting and placing of concrete shall be maintained in clean condition.Al1 buckets, hoppers, chutes, dumpers and other equipment shall be thoroughly cleaned after each use.

8.3 Placing and Compaction

8.3.1 Before placing concrete, all soil surfaces upon which or against which concrete is to be placed shall be well compacted and free from standing water, mud or debris. Soft or yielding soil shall be removed and replaced, with lean concrete or with selected soils/sand and compacted to the density as directed by Engineer-in-Charge. The surface of absorptive soil (against which concrete is to be placed) shall be moistened thoroughly so that moisture is not drawn from the freshly placed concrete. Similarly, for concrete to be placed on formworks, all chippings, shavings and sawdust etc. shall be removed from the interior of the forms before the concrete is placed.

8.3.2 Concrete shall not be placed until the formwork, the placement of reinforcing steel, embedded parts, pockets etc. have been inspected and approved by the Engineer- in-




Charge. Any accumulated water on the surface of the bedding layer shall be removed by suitable means before start of placement.No concrete shall be placed on a water covered surface.

8.3.3 Concrete shall be discharged by vertical drop only and the drop height shall not normally exceed 1.5 metre throughout all stages of delivery until the concrete comes to rest in forms. For continuous concreting operation windows of suitable size shall be kept in the formwork or chutes shall be used to avoid segregation of concrete.

8.3.4 Concrete shall be deposited as near as practicable in its final position to avoid rehandling. Concrete shall be placed in successive horizontal 1ayers.The bucket loads, or other units of deposit, shall be placed progressively along the face of the layer with such over-lap as will facilitate spreading the layer of uniform depth and texture with a minimum of hand shovelling. Any tendency to segregation shall be corrected by shovelling coarse aggregates into mortar rather than mortar on the coarse aggregates. Such a tendency for segregation shall be corrected by redesign of mix, change in process or other means, as directed by the Engineer-in-Charge.

8.3.5 All struts, stays and braces (serving temporarily to hold the forms in correct shape and alignment pending the placing of concrete at their locations) shall be removed when the concrete placing has reached an elevation rendering their service unnecessary.These shall not be buried in the concrete.Concrete shall be thoroughly compacted with vibrators and fully worked around the reinforcement, embedded fixtures and into corners of formwork before setting commences and shall not be subsequently disturbed.Methods of placing shall be such as to preclude segregation and avoid displacement of reinforcement or formwork. The formation of stone-pockets or mortar bondage in corners and against face forms shall not be permittedShould these occur, they shall be dug out, reformed and refiIled to sufficient depth and shape for thorough bonding as directed by the Engineer-in-Charge.Care shall be taken to avoid displacement of reinforcement and embedded inserts or movement of formwork.

8.3.6 Unless otherwise approved, concrete shall be placed in single operation to the full thickness of foundation rafts,slabs, beams and similar members. Concrete shall be placed continuously until completion of the part of the work between approved construction joints or as directed by the Engineer-in-Charge.

8.3.7 The method of placing and compaction employed in any particular section of the work shall be to the entire satisfaction of the Engineer-in-Charge.

8.3.8 During hot weather (atmospheric temperature above 40 degree Celsius) or cold weather (atmospheric temperature less than 5 degree Celcius, the concreting shall be done as per the procedure set out in IS:7861.

8.3.9 Concrete that has set standing and becomes stiffened shall not be used in the work.




8.4 Items Embedded in Concrete

8.4.1 Concreting shall not be started unless the electrical conduits, pipes, fixtures etc., wherever required ,are laid by the concerned agency. The Contractor shall afford all the facilities and maintain co-ordination of work with other agencies engaged in electrical and such other works as directed by the Engineer-in-Charge.

8.4.2 Before concreting the Contractor shall provide, fabricate and lay in proper position all metal inserts, anchor bolts, pipes etc. (which are required to be embedded in concrete members) as per relevant drawings and directions of Engineer-in-Charge.

8.4.3 All embedment, inserts etc. shall be fully held and secured in their respective positions by the concerned agencies to the entire satisfaction of Engineer-in-Charge so as to avoid any dislocation or displacement during the concreting operations. The Contractor shall take all possible care during concreting to maintain these embedmenthnserts in their exact locations.

9.0 CONSTRUCTION JOINTS

9.1 Construction joints shall be provided in position as shown or described on the drawings or as directed by the Engineer-in-Charge. Such joints shall be kept to the minimum. These shall be straight and at right angles to the direction of main reinforcement and shall be placed at accessible locations to permit cleaning out of laitance, cement slurry and unsound concrete.

9.2.1 In a colurnn,the joint shall be formed about lOO mrn to 150mrn below the lowest soffit of the beams framing into it. Concrete in a beam and slab shall be placed throughout without a joint but if the provision of a joint is unavoidable, the joint shall be vertical and located within 113 to 114 of the span,unless otherwise shown on the drawings.

9.3 When stopping the concrete on a vertical plane in slabs and beams, an approved stopboard shall be placed with necessary slots for reinforcement bars. The construction joints shall be keyed by providing a triangular or trapezoidal fillet nailed on the stop board. Inclined joints shall not be permitted. Any concrete flowing through the joints of stop board shall be removed soon after the initial set. When concrete is stopped on a horizontal the surface shall be roughened and cleaned after the initial set and a triangular or trapezoidal groove shall be provided for keying with the new concrete later.

9.4 When the work has to be resumed on a surface which has hardened,such surface shallbe cleared of any foreign materials and roughened to expose the tips of the coarse




aggregate. This may be done by manual chipping of concrete, with a high pressure water jet or by any other appropriate means as per Engineer-in-Charge's directions. It shall then be swept clean and thoroughly washed and wetted before any new concrete is poured. Any set mortar or concrete sticking to the exposed reinforcing rods in and around such joints shall be thoroughly removed. The reinforcements shall be wire brushed and washed just before pouring any cement slurry or mortar. For vertical joints neat cement slurry shall be applied on the surface before it is dry. For horizontal joints the surface shall be covered with a layer of mortar about 10 to 15mm thick composed of cement and sand in the same ratio as the cement and sand in concrete mix. This layer of cement slurry or mortar shall be freshly mixed and applied immediately before placing new concrete.

9.5 Where the concrete has not fully hardened,all laitance shall be removed by scrubbing the wet surface with wire or bristle brushes, care being taken to avoid dislodgement of particles of aggregate. The surface shall be thoroughly wetted and all free water removed. The s urface shall then be coated with neat cement slurry. On this surface layer of concrete not exceeding 150mm in thickness shall first be placed and shall be well rammed against old work, particular attention being paid to corners and close spots; work thereafter shall proceed in normal way.

10.0 SEPARATION JOINT10.1 Separation joint shall be obtained by using an approved alkathene sheet stuck on the

surface against which concrete shall be placed. Adequate care shall be taken to cause no damage to the sheet.

11.0 EXPANSION JOINTS/ISOLATION JOINT

11.1 Expansion/ Isolation joints in structures shall be formed in the positions and to the shapes shown in the relevant drawings. Joints shall be filled with joint filling material as stipulated in the drawing/schedule of rates. Isolation joints shall be provided around all equipment foundations, columns, pedestals, trenches etc. on grade.

12.0 WATER STOPSPVC water stops as per GAIL Specification No. 6-68-0002 for materials shall be accurately cut, fitted and integrally joined as per manufacturer's specifications to provide a continuous, watertight diaphragm at all points.

The water stops shall be located and embedded at expansion/contraction/ construction joints as indicated in the drawings or directed by the Engineer-in-Charge.

Adequate provision shall be made for the support and protection of water stops during the progress of the work.Damaged water stops shall be replaced and/or repaired as directed.




13.0 PROTECTION OF FRESHLY LAID CONCRETE

13.1.1 Newly placed concrete shall be protected, by approved means, from rain, sun and wind. Concrete placed below the ground level shall be protected from falling earth during and after placing. Surface shall be kept free from contact with such ground or with water draining from such ground during placing of concrete for a period of at least 3 days, unless otherwise directed by the Engineer-in-Charge. The ground water around newly poured concrete shall be kept to an approved level by pumping or other approved means of drainage and adequate steps shall be taken to prevent floatation and flooding. Steps shall be taken to protect immature concrete from damage by debris, loading, vibration, abrasion, mixing with deleterious materials, that may, in the opinion of the Engineer-in-Charge, impair the strength and/or durability of the concrete.

14.0 CURINGConcrete shall be cured by keeping it continuously moist wet for the specified period of ime to ensure complete hydration of cement and its hardening. Curing shall be started after 8 hours of placement of concrete in normal weather, and in hot weather after 4 hours. The water used for curing shall be of the same quality as that used for making of concrete.

Curing shall be assured by use of an ample water supply under pressure in pipes, with all necessary appliances such as hose, sprinklers etc. A layer of sacking, canvas,hessian, or other approved materia1,which will hold moisture for long periods and prevent loss of moisture from the concrete,shall be used as covering. Type of covering which would stain, disfigure or damage the concrete, during and after the curing period,shall not be used. Only approved covering shall be used for curing. Exposed surfaces of concrete shall be maintained continuously in a damp or wet condition for at least the first 7 days after placing of concrete.

The Contractor shall have all equipment and materials required for curing on hand and ready to use before concrete is placed.

For curing the concrete in pavements, floors, flat roofs or other level surfaces, the ponding method of curing shall be used. For the first 24 hours after concreting the concrete shall be cured by use of wet sacking, canvas, hessian etc. The minimum water depth of 25mm for ponding shall be maintained.The method of containing the ponded water shall be approved by the Engineer-in-Charge. The ponded areas shall be kept continuously filled with water, and leaks, if any, shall be promptly repaired. Areas cured by ponding method shall be cleared of all debris and foreign materials after curing period is over.

Alternatively, membrane curing may be used in lieu of moist curing with the permission of the = Engineer-in-Charge. Such compounds shall be applied to all exposed surfaces of the concrete by spraying or brushing as soon as possible after the concrete has set.




Minimum film thickness of such curing compounds shall be as per the recommendation of the manufacturer so as to obtain an efficiency of 90% as specified by BS-8110. This film of curing compound shall be fully removed from the concrete surface after the curing period specified earlier. Engineer-in-Charge may notallow curing by curing compounds for those surfaces where use of curing compound may be detrimental to application of future finishes over the concrete. Impermeable membranes such as polyethylene sheeting closely covering the concrete surface may also be used.

14.2 For concretes containing Portland pozzoolana cement or Portland slag cement, the curing period as given in 14.1 shall be doubled. Curing by ponding shall, however, commence after the first 24 hours of concreting.

15.0 FIELD TESTS

15.1 Grading TestGrading test on fine and coarse aggregates shall be carried out as per IS:2386 at intervals specified by the Engineer-in-Charge.

The mandatory tests and their frequencies shall be done on sand and stone aggregates as given in Table-4

TABLE - 4 MANDATORY TESTS ON SAND & STONE AGGREGATES

Sr No. MATERIAL

TEST FIELD / LABTEST

MINIMUMQUANTITYOFMATERIAL/ WORKFORCARRYINGOUT THE TEST

FREQUENCY OF TESTING

1. Sand (a) Bulking of Sand

Field

Field

20 m3

20 m3

Every 20 m3 or part thereof ormore frequently as decided bythe Engineer-in-Charge




Stoneaggregate

(b) Silt Content

(c) ParticleSize distribution

a) Precentage of soft or

deleterious materials

b) Particlesizedistribution

Ten precentFine value

Field or Lab asdecided by theEngineer-in-Charge

General visuali n s p e c t i o n ,laboratory testwhere required bythe Engineer-in-Charge or asspecified

Field or lab. asrequired byEngineer-in-Charge

Laboratory

40 m3

As requiredby Engineerin-Charge

45 m3

45 m3

- DO-

1)Every 40 m3 of fine aggregate1sand required in RCC works only2)Every 80 m3 of fineAggregate/sand required for otheritems

For all quantities

For every 45 m3 or part thereofas decided by Engineer- in-Charge

Initial test and subsequent testas & when required byEngineer-in-Charge




15.2 Vee-Bee TestISlump Test of Concrete

15.2.1 For structural quality concrete (excluding pavements, flooring etc.) at least one Slump Test shall be made for every compressive strength test carried out. More frequent tests shall be made if there is a distinct change in working conditions or if required by the Engineer-in-Charge.

15.2.2 For structural quality concrete for pavements & floorings, measurement of workability shall be by determination of compacting factor. Value of compacting factor of 0.75 to 0.8 shall generally be acceptable.

15.3 Strength Test of Concrete15.3.1 Samples from fresh concrete shall be taken as per IS: 1 199 and cubes shall be made,

cured and tested at 28 days in accordance with IS:516.

15.3.2 In order to get a relatively quicker idea of the quality of concrete, optional tests on beams for modulus of rupture at 722 2 hours or at 7 days, or compressive strength tests at 7 days may be carried out in addition to 28 days compressive strength tests. For this purpose, the values shall be arrived at based on actual testing. In all cases, the 28 days compressive strength specified in Table-1 shall alone be the criterion for acceptance or rejection of the concrete.

15.3.3 Procedure

A random sampling procedure shall be adopted to ensure that each concrete batch shall have a reasonable chance of being tested, that is the sampling should be spread over the entire period of concreting and cover all mixing units.

15.3.4 Frequency of Sampling

The minimum frequency of sampling of concrete for each grade shall be in accordance with Table-5

TABLE - 5FREOUENCY OF CONCRETE SAMPLING

Quantity of concrete in the work in m3

Number of Samples

1-5

6-15

16-30

1

2

3




31-50

51 & above

4

4 plus one additional sample for each additional 50m3 or partthereof.

At least one sample shall be taken from each shift. Where concrete is produced at continuous production units such as ready mixed concrete plants, frequency of sampling may be agreed upon mutually by Engineer-in-Charge.

15.3.5 Test Specimen

Three test specimens shall be made from each sample for testing at 28 days. Additional cubes may be required for various purposes such as to determine the strength of concrete at 7 days or at the time of striking the formwork or to check the testing error. Additional samples may also be required for testing samples cured by accelerated methods as described in IS:9013. The specimen shall be tested as described in IS:516.

15.3.6 Test Results of SampleThe test results of the sample shall be the average of the strength of three specimens. The individual variation should not be more than + 15 percent of the average. If the individual variation is more than f 15 percent, the test results of the sample shall be considered invalid.

15.3.7 Standard Deviationi) Standard deviation based on test results of samples :

a) The total number of test samples required to constitute an acceptable record for calculation of standard deviation shall be not less than 30. Attempts shall be made to obtain the 30 samples, as early as possible, when a mix is used for the first time.

b) For design of mix in the first instance, the value of standard deviation given in Table-6 may be assumed.

c) As soon as sufficient results of samples are available, actual calculated standard deviation shall be used and the mix design revised/ updated.

TABLE - 6ASSUMED STANDARD DEVIATION

Grade of Concrete Assumed Standard Deviation (N/mrn2)




M 15

M 20

M 25

M 30

M 35

M 40

M 45

M50

3.5

4.0

4.0

5.0

5.0

5.0

5.0

5.0

15.3.8 Acceptance Criteria

15.3.8.1 Compressive Strength

The concrete shall be deemed to comply with the strength requirement when both theconditions as given in Table-7 for that particular grade of concrete are simultaneously met.

TABLE - 7CHARACTERISTIC COMPRESSIVE STRENGTH COMPL

Specified Grade Mean of group of 4 Non-OverlappingConsecutive Test Results (N/mm2)

Individual Test Results (N/mm2)

M 15 Greater than or equal to ( fck+f0.825 x ) established standard deviation(rounded off to nearest 0.5 )Or fck + 3whichever is greater

Greater than or equal to ( fck – 3)

M 20 and above Greater than or equal to Greater than or equal to




( fck +0.825 x) established standard deviation above (rounded off to nearest 0.5 )Or fck + 4 whichever is greater

(fck –4)

15.3.8.2 Flexural Strength

The concrete shall be deemed to comply with flexural strength requirements when both the following conditions are simultaneously met :

a) The mean strength determined from any group of four consecutive test results exceeds the specified characteristic strength by at least 0.3 N / d .

b) The strength determined from any test result is not less than the specified characteristic strength less 0.3 N/mm2.

15.3.8.3 Quantity of Concrete Represented by Strength Test Results

The quantity of concrete represented by a group of four consecutive test results shall include the batches from which the first and last samples were taken together with all intervening batches.

For the individual test result requirements given in Table 7 or in item (b) of 15.3.8.2, only the particular batch from which the sample was taken shall be at risk.

Where the mean rate of sampling is not specified, the maximum quantity of concrete that four consecutive test results represent shall be limited to 60m3 .

15.3.8.4 If the concrete is deemed not to comply persuant to 15.3.8.3, the structural adequacy of the parts affected shall be investigated and any consequential action as needed shall be taken (Refer cl. 16.0 & 17.0).

15.3.8.5 Concrete of each grade shall be assessed separately.

15.3.8.6 Concrete is liable to be rejected if it is porous or honey-combed, its placing has Been interrupted without providing a proper construction joint, the reinforcement has been displaced beyond the tolerances specified, or construction tolerances have not been met. However, the hardened concrete may be accepted after carrying out suitable remedial measures and tests to the fullest satisfaction of the Engineer-in-Charge.

16.0 INSPECTION AND TESTING OF STRUCTURES




16.1 InspectionTo ensure that the construction complies with the design, an inspection procedure shall be set up by the contractor and duly approved by Engineer-in Charge covering materials used, receipt of materials, there test results, records, workmanship and construction etc.

16.2 Immediately after stripping the formwork, all concrete shall be carefully inspected and any defective work or small defects either removed or made good before concrete has thoroughly hardened.

16.3 TestingIn case of doubt regarding the grade or soundness of concrete used, either due to poor workmanship or based on results of cube strength, compressive strength tests of concrete on the basis of c1.16.4, 16.5, 16.6, 16.7 and/ or load test (see cl. 16.6) shall be carried out.

16.4 Core Test16.4.1 The points from which cores are to be taken and the number of cores required shall be

at the discretion of Engineer-in-charge and shall be representative of whole of concrete concerned. In no case, however, shall fewer than three cores be tested.

16.4.2 Cores shall be prepared and tested as described in IS:516.

16.4.3 Concrete in the member represented by a core test shall be considered acceptable if the average equivalent cube strength of the cores is equal to at least 85 percent of the cube strength of the grade of concrete specified for the corresponding age and no individual core has a strength less than 75 percent.

16.4.4 In case the core test results do not satisfy the requirements of cl. 16.4.3 or where such tests have not been done, load test may be resorted to.

16.5 Load Tests for Flexural Member

16.5.1 Load test shall be carried out as soon as possible after expiry of 28 days from the time of placing of concrete.

16.5.2 The structure shall be subjected to a load equal to full dead load of the structure plus 1.25 times the imposed load for a period of 24 hours and then the imposed load shall be removed. The dead load shall include self weight of the structural member plus weight of finishes and wall or partitions, if any, as considered in the design.

16.5.3 The deflection due to imposed load only shall be recorded. If within 24 hours of removal of the imposed load the structure does not recover at least 75 percent of the deflection under superimposed load, the test may be repeated after a lapse of 72 hours.




If the recovery is less than 80 percent, the structure shall be deemed to be unacceptable.

16.5.4 If the maximum deflection in mm, shown during 24 hours under load is less than 40 L21D, where L is the effective span in m, and D, the overall depth of the section in rnm, it is not necessary for the recovery to be measured and the recovery provisions of 16.5.3 shall not apply. 16.5.5 The Engineer-in-Charge shall be the final authority for interpreting the results of all tests and shall decide upon the acceptance or otherwise. The decision of the Engineer-in-Charge shall be final and binding on the contractor. In case the results of the tests are unsatisfactory, the Engineer-in-Chargemay instruct the contractor to demolish and reconstruct the structure or part thereof without any extra cost to the Owner.

16.6 Members other than Flexural MembersMembers other than flexural members like columns etc. shall be referred to the designer to investigate the structural adequacy. The decision of the designer shall be final and binding on the contractor.

16.7 Non - destructive TestsNon-destructive tests using Ultrasonic Pulse Velocity and Rebound Hammer methods shall be resorted to for checking the soundness of concrete placed and shall be as per the directions of Engineer-in-Charge. The testing shall be based on IS: 133 1 1, Part-1 . However, the Rebound Hammer test shall only be used in combination with other tests (Destructive or Non-Destructive) for checking the concrete quality.

17.0 FINISHING OF CONCRETE

17.1 On striking the formwork, all surface defects such as bulges, ridges and honey-combing etc. observed shall be brought to the notice of the Engineer-in-Charge. The Engineer-in-Charge may,at his discretion allow rectification by necessary chipping and packing or grouting with concrete or cement mortar. However, if honey-combing or sagging are of such extent as being undesirable, the Engineer-in-Charge may reject the work totally and his decision shall be binding. No extra payment shall be made for rectifying these defects, demolishing and reconstructing the structure. However,quantity of cement actually used for this purpose may be considered for reconciliation of materials. All burrs and uneven faces shall be rubbed smooth with the help of carborundum stone.

The surface of non-shuttered faces shall be smoothened with a wooden float to give a finish similar to that of the rubbed down shuttered faces. Concealed concrete faces shall be Ieft as from the formwork except that honey-combed surface shall be made good as specified above. The top faces of slabs not intended to be covered shall be levelled and floated to a smooth finish to the rises or falls shown on the drawings or as directed. The floating shall not be executed to the extent of bringing excess fine materials to the




surface. The top faces of slabs intended to be covered with screed, granolithic or similar finishes, shall be left with a rough finish.

17.2 Repair and Replacement of Unsatisfactory Concrete

17.2.1 Repair shall be made as soon as possible after the forms are removed and before the concrete becomes too hard with prior permission from the Engineer-in-Charge, in writing. Stone pockets, segregation patches and damaged areas shall be chipped out and the edges undercut slightly to form a key. All loose material shall be washed out before patching. No excess water shall be left in the cavity, but the concrete shall be damp. A good bond between the patch and parent concrete shall be obtained by sprinkling dry cement on the wet surface or by throwing mortar with force on to thewetted concrete, or by brush in a coat of thick cement grout of about 1 : 1 ( 1 cement: 1 sand) just before applying the patching material. Before this has dried, the remainder of the patch shall be filled with mortar or concrete, depending on the extent of the repair.

17.2.2 Cement concrete/mortar used in repair of exposed surfaces shall be made with cement from the same source as that used in concrete and blended with sufficient amount of white Portland cement to produce the same colour as in the adjoining concrete. The proportions of ingredients shall be same as those used in parent concrete. The mortar shall be as dry as possible and well compacted into the cavity. All filling shall be tightly bonded to the concrete and shall be sound, free from shrinkage cracks after the filling has been cured and dried.

17.2.3 For larger repairs to hardened concrete, necessary formwork bearing tightly at the edges of the cavity shall be provided. Concrete shall be chipped out to a depth of at least l00 mm and preferably 150mm. Mortar shall be scrubbed into all surfaces with a wire brush before placing the concrete. Damaged reinforcement shall be adequately spliced with new steel so as to maintain the original strength. Additional reinforcement, if required in the patch, shall be provided as per the instructions of Engineer-in-Charge.

17.2.4 In case in the opinion of the Engineer-in-Charge defects in the concrete is excessive or beyond repair, the contractor shall either redo the structure or take other remedial measures as instructed by the Engineer-in-Charge. The decision of the Engineer-in-Charge shall be final and binding to all in this respect.

17.2.5 Approved epoxy formulation for bonding fresh concrete used for repairs with already hardened concrete shall be used by the Contractor if asked by the Engineer-in-Charge. Epoxy shall be applied in strict accordance with relevant GAIL Specification and the instructions of the manufacturer.

17.2.6 All repair works due to non-conformance or non-adherence to specification, if allowed by the Engineer-in-Charge, shall be carried out free of cost to the owner.




17.3 Curing of Patched WorkImmediately after patching is completed, the patched area shall be covered with an approved non-staining water saturated material which shall be kept wet and protected against sun and wind for a period of 12 hours. Thereafter, the patched area shall be kept continuously wet by a fine spray or sprinkling for not less than 10 days.

18.0 CEMENT WASHIf not otherwise provided with protective coating due to architectural and/ or geo-technical requirements, all concrete elements (whether cast-in-situ or precast) exposed to atmosphere shall be provided with three coats of cement based waterproof paint as per IS5410. Prior to application of the paint, the surface shall be prepared to remove all foreign particles, loose materials, extra deposited concrete lumps, etc. using appropriate mechanicall manual means.

19.0 FORM WORK

19.1 General

19.1.1 Forms for concrete shall be of plywood conforming to IS:6461 or steel or as directed by the Engineer-in-Charge and shall give smooth and even surface after removal thereof.

19.1.2 If it is desired by the Engineer-in-Charge, the Contractor shall prepare, before commencement of actual work, design and drawings for formwork and get them approved by the Engineer-in-Charge. For details regarding design, detailing etc., reference may be made to IS: 14687.

19.1.3 Form work and its supports shall maintain their correct position and be to correct shape and profile so that the final concrete structure is within the limits of dimensional tolerances specified below, unless required otherwise, for functional/ aesthetic reasons. The decision of the Engineer-in-Charge shall be final and binding in this regard.(a) Deviation from specified dimensions - 6mm to + 12mm of cross section of columns

and beams.

(b) Deviation from dimensions of footings (see Note below)

(i) Dimensions in plan -12mm to +50mm

(ii) Eccentricity 0.02 times the width of the footing in the direction of deviation but not more than 50 mm.

(iii) Thickness - +0.05 times the specified thickness.

Note: These tolerances apply to Cast-in-situ concrete dimensions only, not to positioning of vertical reinforcing steel or dowels.




(c) Deviation in length (major dimension of single unit)up to 3 m +_ 6 mm

3 m to 4.5 m +_ 9 mm

4.5 m to 6.0 m +_ 12 mm

additional deviation for every subsequent 6m. - +6mm

(d) Deviation in straightness or bow (deviation from specified line) for a single or continuous member) e.g. beam, column or slab edge.

up to 3 m 6 mm

3 m to 6 m 9 mm

6 m to 12 m - 12 mm

additional for every subsequent 6m. -6mm

(e) Deviation in squareness shall be measured taking the longer of two adjacent sides as the base line.

The shorter side shall not vary in its distance from a perpendicular so that the difference between the greatest and shortest dimensions exceeds 6mm. For this purpose, any error due to lack of straightness shall be ignored. Squareness shall be checked with respect to the straight lines that are most nearly parallel with the features being checked. When the nominal angle is other than 90 degree ,the included angle between check lines shall be varied accordingly.

(f) Deviation in twist shall be within a limit such that any corner shall not be more than the limit given below from the plane containing other three comers:

upto 600mm wide and upto 6m in length -6mm

over 600mm wide and for any length -12mm

Maximum deviation in flatness from a 1.5m straight edge placed in any position on anominally plain surface shall not exceed 6mm.

(h) The tolerance limits for concrete columns/pedestals shall be same as given in relevant Specification .




19.2 Form Requirement:

19.2.1 The formwork shall be true, rigid and adequately braced both horizontally as well as diagonally. The forms shall have smooth and even surface and be sufficiently strong to carry, without deformation, the dead weight of the green concrete, working load, wind load and also the side pressure exerted by the green concrete. As far as practical, clamps shall be used to hold the forms together. Where use of nails is unavoidable minimum number of nails shall be used. Projected part of nail shall notbe bent or twisted for easy withdrawal.

19.2.2 Where through tie rods are required to be put to hold the formwork and maintain accurate dimension, they shall always be inserted through a precast concrete block (of same mix proportion as is to be used for concreting) with a through hole of bigger diameter. The Precast block shall tightly fit against in inner faces of formwork. The holes left after the withdrawal of tie rods shall be fully grouted with cement-sand mortar of same proportion as that used for concrete. However, use of such precast block shall in no case impair the desired appearance or durability of the structure. No such tie rods shall be used in any liquid retaining or basement structure.

19.2.3 Tie wires shall be permitted only upon approval of the Engineer-in-Charge and shall be cut off flush with the face of the concrete or counter sunk, filled and finished in the manner specified in clause 17.

9.2.4 Form joints shall not permit any leakage. The formwork shall be strong enough to withstand the effect of vibrations practically without any deflection, bulging, distortion or loosening of its components.

9.2.5 Forms for beams and slabs (span more than 6.0m) shall have camber of 1 in 500 so as to offset the deflection and assume correct shape and line after deposition of concrete. For cantilevers, the camber at free end shall be 11100th of the projected length. Where architectural considerations and adjunctive work are critical, smaller form cambers shall be adopted as decided by the Engineer-in-Charge.

19.2.6 All vertical wall forms may be designed and constructed for the following minimum pressure. The pressures listed in Table-8 are intended as guide only and the Contractor shall ensure that the formwork is adequately strong and sturdy.

TABLE – 8 MINIMUM DESIGN PRESSURE FOR WALL FORMWORK

Rate of pour in meter/hour

Pressurc in kN/m2




at 10 Degree (In Celsius) at 24 Degree (in Celsius0.6 36 290.9 40 321.2 44 351.5 46 37

All horizontal forms shall be designed and constructed to withstand the dead load of the green concrete, reinforcement, equipment, material, embedment and a minimum live load of 2.0 kN/m2.

19.3 Inspection of FormsTemporary openings shall be provided at the base of column and wall forms and other places necessary to facilitate cleaning and inspection. Before concrete is placed, all forms shall be carefully inspected to ensure that they are properly placed, sufficiently rigid and tight, thoroughly cleaned, properly treated and free from foreign material. The complete form work shall be inspected and approved by the Engineer-in-Charge before the reinforcement bars are placed in position. When forms appear to be unsatisfactory in any way, either before or during the placing of concrete, thework shall be stopped until the defects have been corrected as per the instructions of the Engineer-in-Charge.

19.4 Cleaning and Treatment of FormworkThe surfaces of forms that would come in contact with concrete shall be well treated with approved non- staining form release agents such as soft soap, oil, emulsions etc. Release agents shall be - applied so as to provide a thin uniform coating to the forms without coating the reinforcement.

19.5 Chamfers and Fillets

All corners and angles shall be formed with 45 degree mouldings to form chamfers or fillets on the finished concrete. The standard dimensions of chamfers and fillets, unless otherwise detailed or specified shall be 25x25mm. For heavier work chamfers or fillets shall be 5Ox50mm. Care shall be exercised to ensure accurate mouldings. The diagonal face of the moulding shall be planed or surfaced to the same texture as the forms to which it is attached.

19.6 Reuse of formsBefore reuse, all forms shall be thoroughly scrapped, cleaned, examined and when necessary, repaired and retreated, before resetting. Formwork shall not be reused, if declared unfit or un-serviceable by the Engineer-in-Charge.

19.7 Removal of Forms/Stripping Time

In the determination of time for removal of forms, consideration shall be given to the




location and character of the structures, the weather and other conditions including the setting and curing of the concrete and material used in the mix.

Forms and their supports shall not be removed without the approval of the Engineer-in-Charge. Forms shall not be released until the concrete has achieved a strength of at least twice the stress to which the concrete may be subjected at the time of removal. The formwork shall be removed without shock and methods of form removal likely to cause over stressing* or damage to the concrete, shall not be adopted. Supports shall be removed in such a manner as to permit the concrete to uniformly and gradually take the stresses due to its own weight.

In normal circumstances when average air temperature exceeds 15 degree Celsius during the period under consideration after pouring of concrete and where ordinary Portland cement is used, forms may generally be removed after expiry of following periods.

(a) Walls, columns and vertical faces of all 16 to 24 hours as may be structural members decided by the Engineer-in-

Charge.

(b) Slabs (props left under) 3 days.

( c) Beam Soffits (props left under) 7 days

(d) Removal of props under slabs: .

Spanning upto 4.5m. 7 days

Spanning over 4.5m. 14 days.

(e) Removal of props under beams and arches:

Spanning upto 6m 14 days

Spanning over 6m 21 days

(f) Cantilever Construction Formwork shall remain till structures for counter acting or bearing down have been erected and have attained sufficient strength (minimum 14 days).

Notes:1. For other cements, the stripping time recommended for ordinary Portland cement shall




be suitably modified as per the instructions of the Engineer- in-Charge.

2. The number of props left under, their sizes, supporting arrangement, anddisposition shall be such as to be able to safely carry the full dead load of the slab, beam or arch as the case may be together with any live load likely to occur during curing or further construction.

3. Where the shape of the element is such that the formwork has re-entrant angles, the form work shall be removed as soon as possible after the concrete has set, to avoid shrinkage cracking occurring due to the restraint imposed.

4. For rapid hardening cement, 317 of the above mentioned periods shall be consideredsubject to a minimum of 16 hours.

19.8 Staging scaffolding

19.8.1 Staging scaffolding shall be properly planned and designed by the Contractor. Use of only steel tubes is permitted for staging scaffolding. The Contractor shall get it reviewed by Engineer-in-Charge before commencement of work. While designing and during erection of scaffolding staging, the following measures shall be considered:

(a) Sufficient sills or under pinnings in addition to base plates shall be provided particularly where scaffolding are erected on soft grounds.

(b) Adjustable bases to compensate for uneven ground shall be used.

(c) Proper anchoring of the scaffolding staging at reasonable intervals shall be provided in each direction with the main structure wherever available.

(d) Horizontal braces shall be provided to prevent the scaffolding staging from rocking.

(e) Diagonal braces shall be provided continuously from bottom to top between two adjacent rows of uprights.

(f) The scaffolding staging shall be checked at every stage for plumb line.

(g) Wherever the scaffolding staging is found to be out of plumb line it shall be dismantled and re-erected afresh and effort shall not be made to bring it in line with a physicalforce.

(h) All nuts and bolts shall be properly tightened and care shall be taken that allclamps/couplings are firmly tightened to avoid slippage

(i) Erection work of a scaffolding staging under no circumstances shall be left totally to




semi-skilled or skilled workmen and shall be carried out under the supervision of atechnically qualified civil engineer of the Contractor.

19.8.2 For smaller works or works in remote areas, wooden ballies may be permitted forscaffolding staging by the Engineer-in-Charge at his sole discretion. The contractor must ensure the safety and suitability of such works as described under clause 19.8.1 above.

20.0 EXPOSED/ARCHITECTURAL CONCRETE WORK

20.1 Form Work

Other things remaining same as per clause 19.0, formwork shall be of high quality. Care shall be taken to arrange the forms so that the joints between forms correspond with the pattern indicated in the drawings. The forms shall be butting with each other in straight lines, the corners of the boards being truly at right angles. The joints between the forms shall cross in the two directions at right angles. The size of forms shall be so selected as to exactly match with the pattern of forms impression on the concrete face indicated in the drawings. Maximum care shall be taken to make the form work watertight. Burnt oil shall not be used for treatment of forms. The Contractor shall be permitted reuse of forms brought new on the work for exposed concrete work as specified below. Such reuses shall be permitted only if forms are properly cared for, stored, repaired and treated after each use.

a) Plywood Forms 6 Reuses (max.)

b) Steel Forms 10 Reuses (max.)

The Engineer-in-Charge may, at his absolute discretion, order removal of any forms considered unfit for use in the work irrespective of the number of uses specified above.

20.2 FinishingRepairing to exposed concrete work shall be avoided. Rendering and plastering shall not be done. Minor repairing if unavoidable shall be done as specified in clause 17.0 with the written permission of the Engineer-in-Charge .

21.0 REINFORCEMENT

21.1 The Contractor shall develop the bar bending schedule for all RCC structures1 structural parts at no extra cost to the Owner and shall get it reviewed by the Engineer-in-charge. Reinforcement shall be cut and bent to shape as per dimensions shown in the bar bending schedule1 drawings. If protective fusion bonded epoxy coating is required to be applied on reinforcement bars, the same shall be done as per BS:7295. All repairs to applied protective coating required due to mishandlingand/ or bending of reinforcement bars shall also be done as per relevant clauses of




BS:7295.

2 1.2 Straightening, Cutting and BendingProcedure for cutting and bending shall be as given in IS:2502. In case bars are supplied in coils, they shall be smoothly straightened without any kinks.

Cold twisted deformed bars shall be bent cold. Bars larger than 25mm in size (except cold twisted deformed bars) may be bent hot at cherry red heat to a temperature not exceeding 850' Celsius as per the instructions of the Engineer-in-Charge. The bars shall be allowed to cool gradually without quenching. Bars shall be bent in a slow and regular movement to avoid fractures.

Bars which develop cracks or splits after bending shall be rejected. A second bending of reinforcement bars shall be avoided but when reinforcement bars are bent aside at construction joints and afterwards bent back into their original position, care should be taken to ensure that at no time is radius of the bend Iess than 4 times bar diameter for plain mild steel or 6 times bar diameter for high strength deformed bars. Care shall also be taken when bending back bars to ensure that concrete around the bars is not damaged. All bars shall be properly tagged for easy identification.

21 .3 Placing and Fixing

All reinforcement shall be cleaned to ensure freedom from loose mill scale, loose rust, oil, form releasing agents, grease or any other harmful material before placing them in position. Reinforcement shall not be surrounded by concrete unless it is free from all such materials. Rough handling, and dropping of reinforcement from a height shall be avoided

All reinforcement shall be fixed in the correct position and shall be properly supported to ensure that displacement will not occur when the concrete is placed and compacted. The uncoated reinforcement bars shall be tied at every intersections by two strands of 16 SWG black soft annealed binding wire. The Epoxy coated reinforcement bars shall be tied with 2 strands of PVC coated GI 18 SWG wire at every intersection. Crossing bars shall not be tack welded for assembly of reinforcement. The reinforcement bars shall be kept in position by using the following methods:

a) In case of beam and slab construction, precast cover blocks (having the same cement sand contents as the concrete which shall be placed) of size 40 x 40 mm and thickness equal to the specified covers shall be placed firmly in between the bars and forms so as to secure and maintain the specified covers over the reinforcement.When reinforcement bars are placed in two or more layers in beams, the vertical distance between the horizontal bars shall be maintained by introducing spacer bars at 1 to 1.2m centre to centre.




b) In case of thick rafts & pile caps having two or multilayers of reinforcement, the vertical distance between the horizontal bars shall be maintained by introducing suitable chairs, spacers, etc.

c) In case of columns and walls, the vertical bars shall be kept in position by means of timber templates with slots accurately cut in them. The templates shall be removed after the concreting has been done below it.

d) Exposed portions of reinforcement bars shall not be subjected to impact or rough handling and workmen will not be permitted to climb on extending bars until the concrete has attained sufficient strength so that no movement of the bars in the concrete is possible.

21.4 Special requirements for Handling, Stacking, Placing of Epoxy coated Reinforcing bars.

Epoxy coated reinforcing bars shall be carefully handled and it shall be ensured that these do not rub on any hard surface or against another epoxy coated/uncoated reinforcing bar whether during conveying/transportation, stacking or placing.

During transportation and while stacking the epoxy coated reinforcing bars shall be placed on wooden planks not spaced farther than 600mm. When placed in stacks the epoxy coated reinforcing bars shall be neatly tied in bundles using PVC binding material.

The cut ends of bars shall be touched up with special touch up material of specifications as provided by the coating agency. After cutting of the bar the application of touch up material shall be completed within four hours.

While bending the bars the pins of work bench(s) shall be provided with a PVC or plastic sleeve. Each bending operation on epoxy coated reinforcing bar shall be completed in time not less than 90 seconds.Epoxy coated reinforcing steel bar shall not be directly exposed to sun rays or rain, and shall be protected with opaque polyethylene sheets or similar means as approved by the Engineer in Charge.

While doing concreting the workmen or machinery shall not rest or move on the epoxy coated reinforcing bars. Wooden planks shall suitably be placed to create proper gang-way.

21.5 Splicing/ Overlapping

Only bars of full length shall be used as shown in the drawings. But where this cannot be done, overlapping of bars shall be done as directed by the Engineer-in- Charge. Where practicable, the overlapping bars shall not touch each other, but these shall be kept apart by 25mm or 1.25 times the maximum size of the coarse aggregate




whichever is greater. But where this is not possible, the overlapping bars shall be tied with two strands of 16 SWG black soft annealed binding wire for uncoated bars and with PVC coated GI 18 SWG wire for Epoxy coated bars. The overlaps shallbe staggered for different bars and located at points along the span where neither shear nor bending moment is maximum.

21.6 Welded JointsWelding of reinforcing bars shall not be permitted without the written permission of the Engineer-in-Charge. If Fusion Bonded Epoxy coated bars are used, welding of reinforcing bars shall generally not be permitted. However, if permitted, the joint shall be coated with epoxy as per BS:7295. Where welding of uncoated reinforcing bars is permitted, it shall be in accordance with the recommendations of IS:2751 and IS:9417. Welded joints shall be located at suitable staggered positions. Tests shall be made as directed by the Engineer-in-Charge to prove that the joints are of the full strength of the bars. Maximum one welded joint shall be allowed per bar.

21.7 Mechanical ConnectionsThe mechanical splices in reinforcement by means of couplers, clamps etc. shall be used (as per manufacturer's specifications) with the written approval of the Engineer-in-Charge. However, tests shall be made as directed by Engineer-in-Charge to prove that such connections are of the full strength of the bars on trial joints. Mechanical connections for Fusion Bonded Epoxy coated bars shall not be used.

21.8 Tolerances on Placing of Reinforcement

Unless otherwise directed by the Engineer-in-Charge, reinforcement shall be placed within the following tolerances:a) For effective depth 200mm or less - + 10mmb) For effective depth more than 200mm - + 15mm

21.9 Substitution

When indicated diameter of reinforcement bar is not available, the Contractor shall use other diameter of reinforcement bars on written approval of the Engineer-in-Charge.

21.10Tolerance to CoverThe actual concrete cover shall not deviate from the required nominal cover by - 0 to + 10 mm measured over the steel reinforcement including links.

22.0 PRECAST CONCRETE

22.1 Specifications contained in clauses above regarding concrete, formwork and reinforcement shall apply in addition to the clauses given as under. The Contractor shall get the precasting bed approved by the Engineer-in-Charge.




22.2 Necessary lifting hooks of suitable (but not less than 12mm dia) diameter M.S. rounds shall be provided for handling, as indicated in drawings or as directed by the Engineer-in-Charge.

22.3 Unless otherwise specified, the exposed surfaces of precast members shall be integrally finished smooth. For precast slabs or planks,the top surface shall be finished with 1:3 (1 cement : 3 sand) cement mortar. Surface used as walkways shall be given a non-skid finish.

22.4 The precast concrete units shall be marked clearly on top surface with the letter "T" for identification of surfaces at the time of erection and shall be stored properly until required for erection. The precast units shall be handled and erected by methods approved by the Engineer-in-Charge to protect them from damage.

22.5 Precast concrete elements shall not be removed from the casting bed until the concrete has developed its characteristic compressive strength based on cube test results.

22.6 The units shall be suitably handled, transported, stored and placed taking all necessary safety precautions to avoid development of undue stresses caused by vibrations, impact or lateral forces. During shipment and while in storage, the units shall be placed on suitable blocks to provide clearance from bed/ground.

22.7 The Contractor shall take all necessary precautions for safe handling during the course of erection. The Contractor shall replace at his own expense all such units which are damaged during the course of erection. Cement used for a damaged/rejected precast elements shall not be taken into account for material reconciliation.

22.8 The inspection for precast concrete units during casting shall be same as applicable to normal concrete works. However, additional inspection checks shall be made during and after erection of units to ensure its suitability for the required service as a structural memeber. These checks shall include inspection to detect chipping, cracks, warpages in the precast units etc due to improper handling and storage, improper jointing (if required) of the precast unit with the structure and improper finishing .

22.9 Fabricated precast concrete units containing defects originating due to use of improper materials or workmanship, excessive repair and not conforming to design drawings shall be rejected. Such rejected units shall not be taken into account for material reconciliation or payment.

23.0 CONTINUOUS CONCRETING

23.1 Where called out on the drawings, continuous concreting shall be done in a single




operation as per the requirements of IS:456 and IS:2974. It shall be ensured that clause 8.3 of these specifications is not violated in case of continuous concreting. Sufficient "Windows" shall be left in the formwork for pouring & compaction of concrete and inspection. These windows shall be fixed tight once the level of concrete reaches their levels.

24.0 PAYMENT24.1 Plain and Reinforced Concrete24.1.1 Payment for plain and reinforced cement concrete (cast- in-situ) shall be made on

cubic metre basis of the volume of the actual finished work done or as per approved construction drawings, whichever is less and shall be inclusive of providing pockets, openings, recesses of all sizes, chamfers, fillets, grooves, separation/ expansion/ isolation/ construction/ movement joints, cement wash, curing by normal moist curing or using curing compound etc. as directed by Engineer-in-Charge etc.The rates shall be deemed to include complete cost of getting the respective mix designs approved, making and testing concrete cubes and carrying out other tests including tests of various ingredients, as per specifications and as directed by Engineer-in-Charge. Payment shall, however, be separately made for tests on concrete cubes done by accelerated methods of curing as defined in IS:9013.

24.1.2 No separate payment shall be made for any additive1 admixture used by the contractor for accelerating or retarding the strength of concrete or for achieving specified workability/water tightness. The rate quoted shall be deemed to be inclusive of all costs related to any such additive/admixture.

24.1.3 The rate shall however be exclusive of reinforcement, metal inserts, pipe sleeves, formwork, water stops and any filler material in expansion/isolation joints.

24.1.4 Where the strength of concrete mix (nominal or design) as indicated by tests, lies in between the strengths of any two grades given in Table-1 and it is accepted by the Owner/Engineer-in-Charge, such concrete shall be classified as a grade belonging to the lower of the two grades between which it lies. In case the cube strength shows higher results than those specified for the particular grade of the concrete, it shall not be placed in the higher grade nor shall the Contractor be entitled for any extra payment on such account. The concrete giving lower strength than specified may be accepted at reduced rates after satisfying the safety of the structure by checking it with tests as specified or rejected entirely at the discretion of the Engineer-in- Charge. The rejected concrete shall be dismantled at no extra cost to the owner and no payment or extension of time shall be granted for the concrete so rejected and the formwork and reinforcement used for the same. Cost of any material supplied by the Owner free of cost shall be recovered from the Contractor at double the prevailing market rate. In case the concrete of lower strength can be improved by carrying out some strengthening measures entirely at the discretion of the Engineer-in-Charge, then the said measures including all related tests shall be carried out by Contractor at his own




cost. If the Contractor is able to make up the strength to the required grade by such improvement measures to the entire satisfaction of Engineer-in-Charge, payment shall be made for the grade achieved. However, if the strength of concrete is not made up to the strength of required grade, payment shall be made only for the lower strength if such concrete is accepted by the Engineer-in-Charge.

24.1.5 Deductions for openings, pockets etc. shall be as specified in relevant Indian Standard Codes.

24.1.6 Payment under continuous concreting item in the schedule of rates shall be made only where the total quantity of concrete between two consecutive construction joints specific all^ called-out on the drawings exceeds 250 cubic meters. For any foundation/ structure involving concrete quantity upto 250 cubic meters between two consecutive construction joints shown on drawings, the concrete shall not be measured or paid for under this category (i.e. continuous concreting), although the same is required to be constructed in single pour. The rate quoted against this item shall be inclusive of all extra costs incurred by the Contractor for arranging continuous pouring of concrete and others as specified complete.

24.2 Form Work

Unless otherwise specified, payment for form work shall be on square meter basis of the actual area _ in contact with the concrete cast. The rates shall be inclusive of keeping the formwork for the full period as specified in the above clauses and removing the same after the period is over. No extra payment shall be made for providing scaffolding/staging/access/stairways/ladders etc.

The rates shall be inclusive of any provision to be made or kept in the formwork for providing dowels, inserts etc.

Superior quality formwork for exposed/architectural concrete work shall be measured and paid separately under the relevant item in the schedule of rates.

24.3 Reinforcement

24.3.1 Payment for plain round mild steel reinforcement bars and high strength deformed steel bars shall be on the basis of weight of bare steel irrespective of any coating applied in metric tons. The weight of the bar shall be derived from the sizes and corresponding unit weights given in handbook of Bureau of Indian Standards. Standard hook lengths, chairs, spacer bars and authorised laps only shall be included in the weight calculated. Binding wire shall not be weighed nor otherwise measured. Measurements for weight shall not include cutting allowance etc.

24.3.2 Rate quoted for uncoated reinforcement shall include cost of supplying, decoiling, straightening, cleaning, cutting, bending, placing, binding, welding, if




required, and providing necessary cover blocks of concrete.

24.3.3 Rate quoted for Fusion Bonded Epoxy Coated bars shall also include, apart from those mentioned in C1. 24.3.2, cost of coating of the bars, all necessary tools and tackles and any repairs required due to damage to coating as per BS:7295.

24.3.4 Payment for mechanical threaded couplers shall be made on number basis (each). The rate shall include supply of complete assembly, fixing, testing etc. all complete.

24.4 Water StopsIWater Bars & Expansion/Isolation Joints

24.4.1 Payment for PVC water bars shall be made on running metre (RM) basis of the water stops provided in position. Rate shall include supplying cutting, fixing, jointing by vulcanising or any other approved method, wastage, etc. complete.

24.4.2 Payment for filler materials in Expansion/Isolation joints shall be made on running metre basis of the joint provided. For boards provided at expansion/isolation joints, the measurement shall be made on square metre basis. Rate shall be inclusive of supply, cutting, fixing, jointing, wastage etc.complete.

24.5 Pre-cast Concrete

24.5.1 Payment for precast concrete members shall be made on cubic metre basis of the volume of the finished member. The rate quoted shall include cost of formwork, preparation of casting yard, finishing as specified, curing, handling, fixing in position, breaking masonry and/or concrete surfaces and making good the same etc. Reinforcement shall be paid separately under relevant items. Lifting hooks shall be paid on the same basis as reinforcement. Metal inserts shall be paid as per relevant clauses of Specification No. 6-68-0008 (Miscellaneous Steel Works).

24.5.2 The quoted rate shall be inclusive of providing pockets, openings, recesses of all sizes, chamfers, fillets grooves, holes, cement wash, curing (hot, cold or by using curing compounds). The rate shall be deemed to include complete cost of taking and testing concrete cubes and carrying out other tests including tests of various ingredients as per specification and as directed by the Engineer-in-Charge.

24.5.3 The rate shall however be exclusive of reinforcement, metal inserts, pipe sleeves. Where the strength of concrete mix (nominal or design) as indicated by tests, lies in between the strengths of any two grades given in clause 3.0 and it is accepted by the Owner/Engineer-in-Charge, such concrete shall be classified as a grade belonging to the lower of the two grades between which it lies. In case the cube strength shows higher results than those specified for the particular grade of the concrete, it shall not be placed in the higher grade nor shall the Contractor be entitled for any extra payment on such account. The concrete giving lower strength than specified may be accepted at




reduced rates after satisfying the safety of the structure by checking it with tests as specified or rejected entirely at the discretion of the Engineer-in- Charge. The rejected concrete shall be dismantled at no extra cost to the owner and no payment or extension of time shall be granted for the concrete so rejected and the formwork and reinforcement used for the same. In case the concrete of lower strength can be improved by carrying out some strengthening measures entirely at the discretion of the Engineer-in-Charge, then the said measures shall be carried out by Contractor at his own cost. If the Contractor is able to make up the strength to the required grade by such improvement measures to the entire satisfaction of Engineer-in-Charge, payment shall be made for the grade achieved. However, if the strength of concrete is not made up to the strength of required grade, payment shall be made only for the lower strength if accepted by the Engineer-in-Charge.

24.6 Cement Wash

24.6.1 No payment shall be made for cement wash separately and is deemed to be covered in cl. 24.1.1 & 24.5.2.

24.7 Continuous Concreting

Payment shall be made as per clause 24.1 of this specification. The rate shall be deemed to be inclusive of all extra cost related to labour, shuttering, staging and making all other arrangements for such continuous casting e.g. provisions for adequate movement and storage spaces, special gangways, scaffolding, additional construction equipments, adequate lighting and supervision while the work continues round the clock etc. The rate shall also be inclusive of all costs related to concreting in any thickness, shape and position and at any height or depth so as to avoid any cold joint between specified construction joints.


STANDARD SPECIFICATIONCIVIL & STRL WORKS FOR REINFORCED

CEMENT CONCRETEFOR LIQUID RETAINING

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REINFORCED CEMENT CONCRETEFOR LIQUID RETAINING

STRUCTURES




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CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 MATERIALS

4.0 GENERAL REQUIREMENTS

5.0 CONCRETE

6.0 RENDERING

7.0 SLIDING LAYER

8.0 FORM WORK

9.0 CURING

10.0 FINISHES

11.0 HYDRAULIC TESTING

12.0 PAYMENT




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SCOPE1.1 Concrete structures meant for liquid retaining shall cover under/overground

Reservoirs/tanks, sumps, channels, launders, swimming pools, etc. which are required to retain any liquid internally. However for basements, tunnels, ducts etc . which are in direct contact with the sub-soil water from outside, shall also be applicable, in case referred in drawings.

2.0 REFERENCES

2.1 BIS Codes

IS:3370, 6494, 121 18, 1838

2.2 GAIL specifications

S-11-02-002 : MaterialsS-11-02-004 : Plain and Reinforced Cement Concrete

3.0 MATERIALS

3.1 Materials for concrete viz. cement, sand, aggregate, water etc., admixtures and water stops shall be as described in relevant specification.


4.1 The concrete structure by itself shall be leak proof to the extent as acceptable (refer to cl. 1 1.0). Damp patches, if any at the initial stage, shall not be acceptable if the samedo not disappear after three months of putting the structure in service. The basic requirement is to make the concrete sound, dense and impervious. The Contractor shall take all necessary precautions in selecting the materials, mix design and method of construction so as to achieve this objective. If any additional liquid-proof material is specified and/or shown on drawings, the same shall be considered as a second-line of defence and shall not entail the contractor to any relaxation from the conditions for the structure being leak-proof by itself.

4.2 This specification defines the materials, constructional and performance requirements for liquid retaining concrete structures. Any special requirements as shown or noted in the drawings shall govern over the provisions of this specification.

4.3 The work shall be done in accordance with this specification together with IS:3370 & IS:6494. In case of conflict between the clauses mentioned in this specification and those in the Indian Standards, this specification shall govern.




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4.4 After construction, the structure shall be tested for watertightness11eakproofness as detailed hereunder.

5.0 CONCRETE

5.1 GAIL specification no. 6-68-0004 shall be applicable together with the following clauses :

5.1.1 Special care shall be taken to get the most suitable grading of aggregates so as to produce the densest possible concrete. The maximum size of coarse aggregate shall be limited to 20 rnm, unless shown on the drawing. Water-cement ratio shall be strictly controlled (by making due allowance for the surface water carried by the aggregates), consistent with the requirement of workability to produce an impervious concrete.

5.1.2 Concrete shall have a minimum cement content of 350 kg/m3. Maximum water cement ratio permissible shall be 0.45. In order to achieve required workability and slump, cement and water content may be suitably adjusted, keeping the water cement ratio constant.

5.1.3 The joints of shuttering board shall be made tight to produce a face free from pores.

5.1.4 The concrete shall be so placed and vibrated that a well compacted dense concrete free from honeycombing is produced.

5.1.5 Admixtures

Admixtures in concrete shall be used only with the prior approval of the Engineer-in-Charge. Any admixture used for obtaining proper workability or leak-proofness of concrete or repair/rendering works of concrete due to non-conformance to the GAIL specifications, shall not be measured and paid for. All costs relating to such usage shall be borne by the Contractor.

5.2 Construction, Contraction & Expansion Joints

5.2.1 All vertical and horizontal joints in liquid retaining structures shall be located and executed as shown in the drawings. For construction joints not shown in the drawing, specific approval of the Engineer-in-Charge shall be obtained. Every endeavour shall be made to avoid vertical construction joints. The number of construction joints shall be kept to the minimum. Where horizontal or vertical joints are required to be left after the day's work, the same shall be done as per directions of the Engineer-in-Charge. The face of the old concrete shall be well hacked to expose the aggregate, care being taken to avoid damaging the aggregate.




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While the remainder of the concrete should be kept continuously wet, curing of the joint surface may be suspended a few hours before concreting is to be resumed so as to permit no more than superficial drying of the joint surface. Just before concreting is resumed, the roughened joint surface shall be thoroughly cleaned and freed from loose pieces of gravel, stone chips, wooden chips, nails, laitance or any other foreign material, preferably, without re-wetting, and then treated with a thin layer of cement grout, worked well into the surface, or treated with cement-sand mortar in which water-cement and sand-cement ratios do not exceed those in the new concrete.

5.2.2 Horizontal joints in vertical walls of the structure shall preferably form a closed loop.

5.2.3 Water stops installation shall be done by embedding one half of the water stop along the proposed joints on each side of the joint by suitable jigs/supporting arrangement between the adjacent sections of the concrete as per the manufacturer's specifications and directions of the Engineer-in-Charge. Water stops shall be positioned accurately and supported against any displacement during concreting. All precautions shall be taken to avoid folding or twisting of water stops during pouring and compacting concrete. To achieve the continuity of the water stop all along the joint, at crossings and at change of alignments, the water stops shall be joined/ vulcanised as per manufacturer's specifications and directions of the Engineer-in-Charge. Jigs manufactured out of reinforcing bars may be used for fixing the water stop. The jigs shall be measured and paid under reinforcement item.

5.2.4 Expansion joints shall be filled up with non-absorbent compressible sheet/bitumen impregnated fibre board (as per IS:1838) except the top 12rnm depth on the water faces(or as shown on the drawings) which shall be filled with two part liquid polysulphide sealant (as per IS: 12 1 18).In case of contraction and/or construction joints, such polysulphide sealant shall be used for 12rnrn depth on the water faces (or as shown on the drawings) after forming suitable grooves in concrete.

5.3 Items Embedded in Concrete

5.3.1 All sleeves, inserts, anchors and embedded items required for the work shall be available at site prior to start of concreting. These shall be accurately placed and embedded as described in GAIL specification no. 6-68-004. In case any protective coating for such elements is shown, Contractor shall coat the same prior to embedment, which shall be paid separately.

5.3.2 Every precaution shall be taken to keep all embedments and water stops in position as shown on drawings during pouring and compacting concrete. Work in such areas shall be carried out under strict supervision.




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6.0 RENDERING

6.1 Rendering by cement-sand mortar of same proportion as in original concrete shall be used with the object of covering weak patches in the construction, as per the direction of the Engineer-in-Charge. The rendering shall be applied to the concrete only after the inspection by the Engineer-in-Charge and if approved by him. The concrete surface shall be well wetted and if necessary, hacked prior to the application of mortar. The mortar shall be steel trowelled and finished with a wooden float.

7.0 SLIDING LAYER

7.1 Wherever shown on drawings, a sliding layer shall be provided between the lean concrete and the bottom raft/slab of the underground liquid retaining structure. This layer shall consist of bitumenized kraft paper or alkathene sheet as shown on the drawings or any other suitable material as directed by the Engineer-in-Charge. The top surface of lean concrete shall be finished smooth with a wooden trowel to receive the sliding layer. Joints in the sliding layers shall be lapped as shown on drawings. All care shall be taken to keep the sliding layer in position while progressing with further work above.

8.0 FORM WORK

8.1 GAIL specification no. 6-68-0004 for Plain & Reinforced Cement Concrete shall be applicable together with the following:

8.2 Detailed dimensioned drawing showing the arrangement of form work including its design if so required by the Engineer-in-Charge shall be furnished to the Engineer-in-Charge before the form work is erected. The work shall be as per the directions and approval of the Engineer-in-Charge. No concrete element of the liquid retaining structure shall be loaded with any support for further form work unless it has aged for minimum 21 days. After that if any form work rests on such element, adequate external support shall be provided so that any unequal loading on the element does not cause any local deformation.

9.0 CURING

Concrete shall be cured in accordance with the GAIL specification no. 6-68-0004 for Plain & Reinforced Cement Concrete.

10.0 FINISHES

10.1 All the form work shall be so done that no plastering or other external finish is required. All burrs shall be rubbed smooth with carborandum stone and the finished work shall




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present a uniform shade and finish. All the exposed surfaces shall be provided with a coat of cement wash free of cost if the rendered surfaces are not of acceptable standard as per the sole discretion of the Engineer-in-charge. Quantity of cement actually used for this purpose may be considered for reconciliation of materials.

11.0 HYDRAULIC TESTING

11.1 Liquid retaining structures shall be tested strictly in accordance with IS:3370 for water tightness in addition to the structural tests as mentioned in GAIL specification no. 6-68-0004. The total maximum drop in water surface level shall not exceed 6mm in 24 hours in case of covered reservoirs and 12mm in 24 hours in case of open reservoirs.

11.2 If the test proves that the structure is defective, the Contractor shall rectify/repair the same at his own cost as per the approved scheme as agreed to by the Engineer-in-Charge. The required structure shall again be tested as per 11.1 above. If the structure is still not found to satisfy the acceptance criteria, the same shall be dismantled and rebuilt.

11.3 All testing after construction and remedial treatments shall conform to the provision of IS : 6494.

11.4 Backfilling around underground structures shall be allowed only after the test results are found satisfactory by the Engineer-in-Charge.

12.0 PAYMENT

This clause shall apply to Item Rate tender only.

12.1 Payment shall be made on cubic metre (m3) basis of the volume of the actual finished concrete work done or as per approved construction drawings, whichever is less. The rate shall be inclusive of all labour, material, curing, cost of leaving pockets, blockouts for pipes/electric conduits, recesses of all sizes, embedding fixtures, vibrating, rendering, hacking and washing old concrete faces, applying mortar/grout on them, etc . but exclusive of reinforcement, formwork, embedded fixtures, water stops and sealing compound which shall be paid under separate items. In case the Contractor proposes to use any admixture in concrete for making it water Tight/leakproof, no separate payment for such admixtures shall be made and the rate quoted for concrete under liquid retaining structures shall be inclusive of such admixtures. However, when such admixtures are used under GAIL specific requirements mentioned in the drawings/GAIL specifications, these shall be separately measured and paid for, under respective item, provided in the Schedule of Rates.

12.2 No separate payment shall be made for testing and report making which is deemed to




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be included in the quoted concrete rate, including cost of hydraulic tests and structural tests, all appliances and rectifications, if any.

12.2.1 If the test proves that the structure is defective, the Contractor shall develop and execute with the approval of the Engineer-in-Charge, suitable methods for making the structure, water tight/leakproof at his own cost. Even after this if the test fails, the Contractor shall have to dismantle and rebuild the structure within the specified time schedule, at his own cost.

12.2.2 Cost of initial and subsequent testing, inclusive of cost of water, shall be borne by the Contractor. The Contractor shall make his own arrangement for filling as well as emptying the reservoir after the completion of the test and no payment shall be made on this account.

12.3 Payment for sliding layer shall be based on the actual surface area in square metres (m2). The Contractor shall include in his rate all allied works viz. cleaning, preparing of surfaces, laying etc. all materials complete.


STANDARD SPECIFICATIONCIVIL & STRL WORKS FOR STRUCTUTAL

STEEL S-11-02-006 Page 1 of 28



STRUCTURAL STEEL WORKS





CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 MATERIALS

4.0 FABRICATION DRAWINGS

5.0 FABRICATION

6.0 MARKING FOR IDENTIFICATION

7.0 SHOP ERECTION

8.0 INSPECTION & TESTING OF STRUCTURES

9.0 SHOP PAINTING

10.0 PACKING

11.0 TRANSPORTATION

12.0 SITE (FIELD) ERECTION

13.0 SAFETY & SECURITY DURING ERECTION

14.0 FIELD CONNECTIONS

15.0 GROUTING

16.0 SCHEME AND SEQUENCE OF ERECTION

17.0 PAYMENT

18.0 PAINTING AFTER ERECTION

ANNEXURE -'A'

ANNEXURE -'B'





1.0 SCOPE

This specification covers the requirements for material, storage, preparation of fabrication drawings, fabrication, assembly, tests/examinations, transportation, erection and painting of all types of bolted and/or welded structural steel works for general construction work. Fabrication of structures shall also include fabricating:

(a) Built up sections/plate girders made out of rolled section and/or plates.

(b) Compound sections made out of rolled sections.

2.0 REFERENCE

2.1 BIS Codes

IS: 800, 816, 819, 822, 919, 1024, 1261, 1323, 1477, 1852, 2074, 7205, 7215, 7307, 73 10, 73 18, 9595 and other relevant BIS Codes.

SP: 6(1)

2.2 GAIL Specifications

S-11-02-002- MaterialsS-04-02-014- Shop & Field Painting

2.3 In case of conflict between the clauses mentioned in this specification and those in the Indian Standards, this specification shall govern. Any special provision as shown or noted on the design drawings shall govern over the provisions of this specification.

3.0 MATERIALS

3.1 General

All materials shall conform to their respective specifications given in GAIL Specification no. 6-68-0002. The use of equivalent or alternative materials shall be permitted only in very special cases and for all such cases prior written approval of the Engineer-in-Charge shall be obtained.

3.2 Receipt & Storing of Materials

3.2.1 Each section shall be marked for identification and each lot shall be accompanied by manufacturer's quality certificate, chemical analysis and mechanical characteristics.

3.2.2 All sections shall be checked, sorted out and arranged by grade and quality in the store.





Any instruction given by the Engineer-in-Charge in this respect shall be strictly followed.

3.2.3 All material shall be free from surface defects such as pitting, cracks, laminations, twists etc. Defective material shall not be used and all such rejected material shall be immediately removed from the store/site. The decision of the Engineer-in-Charge in this regard shall be final and binding.

3.2.4 Welding wires and electrodes (packed in their original cartons) shall be stored separately by quality and lots inside a dry and enclosed room in compliance with IS:9595 and as per the instructions given by the Engineer-in-Charge. Electrodes shall be kept perfectly dry to ensure satisfactory operation and weld metal soundness.

3.2.5 Each lot of electrodes, bolts, nuts etc. shall be accompanied by manufacturer's Quality/test certificates.

3.2.6 All bolts (including nuts & washers) shall be checked, sorted out and arranged diameter-wise by grade and quality in the store.

3.3 Material Tests

3.3.1 The Contractor shall submit manufacturers' quality certificates for all the materials supplied by him. In case, quality certificates are not available or are incomplete or when material quality differs from standard specifications, such materials shall not be used in the construction. However, the Contractor shall get all appropriate tests conducted in approved test houses for such materials as directed by the Engineer-in-Charge, at no extra cost, and submit the same to Engineer-in-Charge for his approval. The Engineer-in-Charge may approve the use of such materials entirely at his discretion.

3.3.2 The Contractor shall ensure that all materials brought to site are duly approved by the Engineer-in-Charge. Rejected materials shall not be used and shall be removed from site forthwith. Any material of doubtful quality for which specific tests are to be carried out as per the instruction of the Engineer-in-Charge shall be separately stacked and properly identified and shall not be used. These shall be removed from site forthwith.

4.0 FABRICATION DRAWINGS

4.1 Fabrication and erection drawings shall be prepared by the Contractor on the basis of "Approved for Construction (AFC)" design drawings, GAIL Standards issued to the Contractor. These drawings shall be prepared by the Contractor or by an agency appointed by the Contractor and approved by the Engineer-in-Charge.

4.2 Fabrication and erection drawings shall be thoroughly checked, stamped "Approved for Construction" and signed by the Contractor's own responsible Engineer irrespective of the fact that such drawings are prepared by the Contractor or his approved agency, to





ensure accuracy and correctness of the drawings. Unchecked and unsigned drawings shall not be used for the purpose of proceeding with the work. The Contractor shall proceed with the fabrication and erection work only after thoroughly satisfying himself in this regard.

4.3 All fabrication and erection drawings shall be issued for construction by the Contractor directly to his worksite. Six copies of such drawings shall simultaneously be submitted to the Engineer-in-Charge who may check/ review some or all such drawings at his sole discretion and offer his comments for incorporation in these drawings by the Contractor.

However, the Contractor shall not proceed with the fabrication of such structures whose fabrication drawings are required to be reviewed before taking up the fabrication work as noted on "Approved for Construction (AFC)" design drawings issued to the Contractor or as conveyed by the Engineer-in-Charge. The fabrication of such structures shall be done only as per the reviewed fabrication drawings.

The review of such drawings by GAIL shall be restricted to the checking of the following only:

i) Structural layout, orientation and elevation of structures/members.

ii) Sizes of members.

iii) Critical joint details.

4.4 Fabrication drawings shall be drawn to scale and shall convey the information clearly and adequately. Following information shall be furnished on such drawings:

- Reference to design drawing number (along with revision number) based on which fabrication drawing has been prepared.

- Structural layout, elevations & sections (with distinct erection marking of all members).

- Framing plans, member sizes, orientation and elevations.

- Layout and detailing of rain water pipes and gutters showing all necessary levels, connections and provisions wherever required.

- Detailing of shop/field joints, connections, splices, for required strength and erection.

- Location, type, size and dimensions of welds and bolts.





- Shapes and sizes of edge preparation for welding.

- Details of shop and field joints/welds.

- Bill of materials/D.O.D. Lists.

- Quality of structural steel, plates etc., welding electrodes, bolts, nuts and washers to be used.

- Erection assemblies identifying all transportable parts and sub-assemblies with special erection instructions, if required.

- Method of erection and special precautions to be taken during erection as required.

4.5 The Contractor shall additionally ensure accuracy of the following and shall be solely responsible for the same:

i) Provision for erection and erection clearances.

ii) Marking of members

iii) Cut length of members

iv) Matching of joints and holes.

v) Provision kept in the members for other interconnected members.

vi) Bill of materials/D.O.D. Lists.

4.6 Connections, splices and other details where not shown on the design drawings shall be suitably designed and shown on the fabrication drawings based on good engineering practice developing full member strength. Design calculations for such connections/splices shall be submitted to the Engineer-in-Charge along with the fabrication drawings.

4.7 Any substitution or change in section shall be allowed only when prior written approval of the Engineer-in-Charge has been obtained. Fabrication drawings shall be updated incorporating all such substitutions/changes by the Contractor at no extra cost to the Owner.

4.8 In case during execution of the work, the Engineer-in-Charge on review of drawings considers any modifications / substitutions necessary to meet the design parameters /





good engineering practice, these shall be brought to the notice of the Contractor who shall incorporate the same in the drawings and works without any extra cost to the owner. The Contactor will be totally responsible for the correctness of the detailed fabrication drawings and execution of the work.

4.9 Contractor shall incorporate all the revisions made in the design drawings during the course of execution of work in his fabrication drawings, and resubmit the drawings at no extra cost to the Owner. All fabrication shall be carried out only as per the latest AFC design drawings and corresponding fabrication drawings.

4.10 The Contractor shall supply two prints each of the final/as built drawings alongwith their transparencies to Engineer-in-Charge for reference and record. The rates quoted shall include for the same.

5.0 FABRICATION

5.1 General

5.1.1 Fabrication of structures shall be done strictly as per "Approved for Construction" fabrication drawings (prepared by the Contractor based on the latest design drawings) and in accordance with IS:800, 9595 & other relevant BIS Codes and BIS Hand Book SP:6(1).

5.1.2 Prior to commencement of structural fabrication, undulations in the fabrication yard, if any, shall be removed and area levelled and paved by the Contractor.

5.1.3 Any defective material used in the work shall be replaced by the Contractor at his own expense. Necessary care and precautions shall be taken so as not to cause any damage to the structure during any such removal and replacement.

5.1.4 Any faulty fabrication pointed out at any stage of work by the Engineer-in-Charge, shall be made good or replaced by the Contractor at his own cost.

5.l.5 Tolerances for fabrication of steel structures shall be as per IS:7215.

5.2 Fabrication Procedure

5.2.1 Straightening & Bending

5.2.1.1 All materials shall be straight and, if necessary, before being worked shall be straightened and/or flattened (unless required to be of curvilinear form) and shall be free from twists.

5.2.1.2 Bending of rolled sections and plates shall be done by cold process to shape/s as





shown on drawings.

5.2.2 Clearances

The erection clearance for cleated ends of members shall be not greater than 2mm at each end. The erection clearance at ends of beams without web cleats and end plates shall be not more than 3mm at each end but where for practical reasons, greater clearance is necessary, suitably designed seatings approved by the Engineer-in-Charge shall be provided.

5.2.3 Cutting

5.2.3.1 Prior to cutting, all members shall be properly marked showing the requisite cut length/width, connection provisions e.g. location and dimensions of holes, welds, cleats etc. Marking for cutting shall be done judiciously so as to avoid wastages or unnecessary joints as far as practicable. Marking shall be done by placing the members on horizontal supports/pads in order to ensure accuracy. Marking accuracy shall be limited to + lmm.

5.2.3.2 Cutting may be affected by shearing, cropping or sawing. Gas cutting by mechanically controlled torch shall be permitted for mild steel. Hand flame cutting may be permitted subject to the approval of the Engineer-in-Charge.

5.2.3.3 Except where the material is subsequently joined by welding, no loads shall be transmitted into metal through a gas cut surface.

5.2.3.4 Shearing, cropping and gas cutting shall be clean, square, free from any distortion & burrs, and should the Engineer-in-Charge find it necessary, the edges shall be ground afterwards, to make the same straight and uniform at no extra cost to the Owner.

5.2.4 Holing

5.2.4.1 Holes for bolts shall not be formed by gas cutting process.

5.2.4.2 Holes through more than one thickness of material of members such as compound stanchions and girder flanges shall, where possible, be drilled after the members are assembled and tightly clamped/bolted together. Punching may be permitted before assembly, provided the thickness of metal is less than 16mm and the holes are punched 3mm less in diameter than the required size and reamed, after assembly, to the full diameter. Punching shall not be adopted for dynamically loaded structures.

5.2.4.3 Holes may be drilled in one operation through two or more separable parts and burrs removed from each part after drilling.





5.2.4.4 Holes in connecting angles and plates, other than splices, also in roof members and light framing, may be punched full size through material not over 12mm thick, except where required for close tolerance bolts or barrel bolts.

5.2.4.5 All matching holes for black bolts shall register with each other so that a gauge of 2mm less in diameter than the diameter of hole shall pass freely through the assembled members in the direction at right angle to such members. Finished holes shall be not more than 2mm in diameter larger than the diameter of the black bolt passing through them, unless otherwise specified by the Engineer-in-Charge.

5.2.4.6 Holes for turned and fitted bolts shall be drilled to a diameter equal to the nominal diameter of the shank or barrel subject to H8 tolerance specified in IS:919. Parts to be connected with close tolerance or barrel bolts shall be firmly held together by tacking bolts or clamps and the holes drilled through all the thicknesses in one operation and subsequently reamed to size. Holes not drilled through all the thicknesses in one operation shall be drilled to a smaller size and reamed out after assembly. Where this is not possible, the parts shall be drilled and reamed separately.

5.2.4.7 To facilitate grouting, holes shall be provided in column bases or seating plates exceeding 300mm in width for the escape of air.

5.2.4.8 To avoid accumulation of water in gussetted column bases of laced, battened or box type stanchions, suitable reverse U-type holes shall be provide at the junction of base plate and column section in the vertical gussets for draining out of any water.

5.2.5 Assembly

The component parts shall be assembled and aligned in such a manner that they are neither twisted nor otherwise damaged, and shall be so prepared that the required camber, if any, is provided. Proper clamps, clips, jigs and other fasteners (bolts and welds) shall be placed in a balanced pattern to avoid any distortion in the members and to ensure their correct positioning (i.e. angles, axes, nodes etc.). Any force fitting, pulling/stretching of members to join them shall be avoided. Proper care shall be taken for welding shrinkage & distortion so as to attain the finished dimensions of the structure shown on the drawings.

5.2.6 Welding

5.2.6.1 General

a) All joints shall be welded unless noted otherwise on the design drawings,

b) Welding shall be in accordance with IS:8 16, IS:8 19, IS: 1024, IS: 126 1, IS: 1323 and IS:9595 as appropriate.



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c) The Contractor shall make necessary arrangement for providing sufficient number of welding sets of the required capacity, all consumables, cutting and grinding equipment with requisite accessories/ auxiliaries, equipment & materials required for carrying out various tests such as dye penetration, magnetic particle, ultrasonic etc.

d) Adequate protection against rain, dust, snow & strong winds shall be provided to the welding personnel and the structural members during welding operation. In the absence of such a protection no welding shall be carried out.

e) It shall be the responsibility of the Contractor to ensure that all welding is carried out in accordance with the terms of this specification and relevant BIS codes. The Contractor shall provide all the supervision to fulfil this requirement.

5.2.6.2 Preparation of Member for Welding

a) Edge Preparation

Edge preparation/bevelling of fusion faces for welding shall be done strictly as per the dimensions shown in the drawings. In case, the same are not indicated, edges shall be prepared (depending on the type of weld indicated in the drawing) as per the details given in IS:9595. Bevelling of fusion faces shall be got checked and approved by the Engineer-in-Charge. The tolerances on limits of gap, root face & included angle shall be as stipulated in IS:9595.

b) Cleaning

Welding edges and the adjacent areas of the members (extending upto 20mm) shall be thoroughly cleaned of all oil, grease, scale and rust and made completely dry. Gaps between the members to be welded shall be kept free from all foreign matter.

c) Preheating

Preheating of members, shall be carried out as per IS:9595 when the base metal temperature is below the requisite temperature for the welding process being used. Preheating shall be done in such a manner that the parts, on which the weld metal is being deposited, are above the specified minimum temperature for a distance of not less than 75mm on each side of the weld line. The temperature shall be measured on the face opposite to that being heated. However, when there is access to only one face, the heat source shall be removed to allow for temperature equalization (1 minute for each 25mm of plate thickness) before measuring the temperature.



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d) Grinding

i) Column splices & butt joints of struts and compression members (depending on contact for load transmission) shall be accurately ground and close-butted over the whole section with a tolerance not exceeding 0.2mm locally at any place. In column caps & bases, the ends of shafts together with the attached gussets, angles, channels etc., shall be accurately ground so that the parts connected butt over minimum 90% surface of contact. In case of connecting angles or channels, care shall be taken so that these are fixed with such accuracy that they are not reduced in thickness by grinding by more than 2mm.

ii) Ends of all bearing stiffeners shall be ground to fit tightly at both top and bottom. Similarly bottom of the knife edge supports along with the top surface of column brackets shall be accurately ground to provide effective bearing with a tolerance not exceeding 0.2mm locally at any place.

iii) Slab bases and caps shall be accurately ground over the bearing surfaces and shall have effective contact with the ends of stanchions. Bearing faces which are to be grouted direct to foundations need not be ground if such faces are true & parallel to the upper faces.

5.2.6.3 Welding Processes

Welding of various materials under this specification shall be carried out using one or more of the following processes.

- Manual Metal Arc Welding Process (MMAW)

- Submerge Arc Welding Process (SAW)

- Gas Metal Arc Welding Process (GMAW)

- Flux Cored Arc Welding Process (FCAW)

The welding procedure adopted and consumables used shall be specifically approved by the Engineer-in-Charge. A combination of different welding processes or a combination of electrodes of different classes/makes may be employed for a particular joint only after qualifying the welding procedures to be adopted and obtaining the written approval of the Engineer-in-Charge.

5.2.6.4 Approval & Testing of Welders



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The Contractor shall satisfy the Engineer-in-Charge that the welders are suitable for the work upon which they will be employed. For this purpose the welders shall have satisfied the relevant requirements of IS:7318. If the welders will be working to approved welding procedures, they shall have satisfied the relevant requirements of IS:7310.

Adequate means of identification shall be provided to enable each weld to be traced to the welder by whom it was made. The Contractor shall intimate the Engineer-in-Charge sufficiently in advance, the commencement of tests, to enable him to be present to witness the same.

5.2.6.5 Approval & Testing of Welding Procedures

The Contractor shall carry out procedure tests in accordance with IS:7307 to demonstrate by means of a specimen weld of adequate length on steel representative of that to be used, that he can make welds with the welding procedure to be used for the work to the complete satisfaction of the Engineer-in-Charge. The test weld shall include weld details from the actual construction and it shall be welded in a manner simulating the most unfavourable instances of fit-up, electrode condition etc., which are anticipated to occur on the particular fabrication. Where material analysis are available, the welding procedure shall be carried out on material with the highest carbon equivalent value.

After welding, but before the relevant tests given in IS:7307 are carried out, the test weld shall be held as long as possible at room temperature, but in any case not less than 72 hours, and shall then be examined for cracking. The examination procedure shall be sufficiently rigorous to be capable of revealing significant defects in both parent metal and weld metal.

After establishing the welding method, the Contractor shall finally submit to the Engineer-in-Charge for his approval the welding procedure specification in standard format given in IS39595 before starting the fabrication.

5.2.6.6 Sequence of Welding

a) As far as practicable, all welds shall be made in a sequence that will balance the applied heat of welding while the welding progresses.

b) The direction of the general progression in welding on a member shall be from points where the parts are relatively fixed in position with respect to each other towards points where they have a greater relative freedom of movement.

c) All splices in each component part of a cover-plated beam or built up member shall be made before the component part is welded to other component parts of



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the member.

d) Joints expected to have significant shrinkage shall be welded before joints expected to have lesser shrinkage.

e) Welding shall be carried continuously to completion with correct number of runs.

f) The Contractor shall choose the welding sequence after carefully studying eachcase such as to minimize distortion and shrinkage & submit the same to the Engineer-in-Charge for comments and approval.

5.2.6.7 Welding Technique

a) After the fusion faces are carefully aligned and set with proper gaps, the root pass of butt joints shall be executed properly so as to achieve full penetration with complete fusion of the root edges.

b) On completion of each run, all slag and spatters shall be removed and the weld and the adjacent base metal shall be cleaned by wire brushing and light chipping. Visible defects such are cracks, cavities and other deposition faults, if any, shall be removed to sound metal before depositing subsequent run of weld.

c) All full penetration butt welds shall be completed by chipping/gouging to sound metal and then depositing a sealing run of weld metal on the back of the joints. Where butt welding is practicable from one side only, suitable backing steel strip shall be used and joint shall be arranged in such a way as to ensure that complete fusion of all the parts is readily obtained.

d) While welding is in progress care shall be taken to avoid any kind of movement of the components, shocks, vibrations to prevent occurance of weld cracks.

e) Any deviation desired from the recommended welding technique and electrodes shall be adopted only after obtaining written approval of the Engineer-in-Charge.

5.2.6.8 Inspection & Testing of Welds

The method of inspection shall be according to IS:822 and extent of inspection and testing shall be in accordance with the relevant applicable standard or, in the absence of such a standard, as specified by the Engineer-in-Charge. Welds shall not be painted or otherwise obscured until they have been inspected, approved and accepted.

The Engineer-in-Charge or his representative shall have access to the Contractor's work at all reasonable times and the Contractor shall provide him with all facilities necessary for inspection during all stages of fabrication and erection with, but not limited to, the



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following objectives.

i) To check the conformity with the relevant standards and suitability of various welding equipments and their performance.

ii) To witness/approve the welding procedure qualification.

iii) To witness/approve the welders performance qualification.

iv) To check whether shop/field welding being executed is in conformity with the relevant specifications and codes of practice.

Inspection and testing of all fabricated structures shall be carried out by the Contracator by any, or, a combination of all the following methods as directed by the Engineer-in-Charge and no separate payment shall be made, unless otherwise mentioned, for inspection and testing of welds/fabricated structures:

A. Visual Inspection

All finished welds (i.e. 100 percent) shall be visually inspected for identification of the following types of weld defects & faults.

a) Weld defects occurring at the surface such as blow holes, exposed porosity, unfused welds etc.

b) Surface cracks in the weld metal or in the parent metal adjacent to it.

c) Damages to the parent metal such as undercuts, burning, overheating etc.

d) Profile defects such as excessive convexity or concavity, overlapping, unequal leg lengths, excessive reinforcement, incompletely filled grooves, excessive penetration beads, root grooves etc.

e) Distortion due to welding i.e., local shrinkage, camber, bowing, twisting, rotation, wariness etc.

f) Linear eccentric, angular and rotational misalignment of parts.

g) Dimensional errors.

B. Mechanical Tests

The mechanical testing (such as tensile load tests, bend tests, impact tests etc.) shall be done in accordance with the relevant standards and as per the instructions of the



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Engineer-in-Charge.

C. Magnetic Particle/Dye Penetration/Ultrasonic Examination:

The examination shall be done at random as directed by the Engineer-in-Charge. Whenever such tests are directed, the tests shall be carried out on joints chosen by him. The tests shall be carried out by employing approved testing procedure in accordance with IS:822.

D. Radiographic Examination

Radiographic examination shall be carried out only in special cases for random joints as directed by the Engineer-in-Charge. The Contractor shall be paid extra for such examination except for penalty radiographic tests for which the cost shall be borne by him. The Contractor shall make necessary arrangement at his own expense for providing the radiographic equipment, films and all other necessary materials required for carrying out the examination. The tests shall be carried in the presence of the Engineer-in-Charge by employing approved testing procedure in accordance with IS:822. The Contractor shall fulfil all the statutory safety requirements while handling X-ray and Gamma-ray equipment and provide the Engineer- in-Charge all the necessary facilities at site such as dark room, film viewer etc., to enable him to examine the radiographs.

5.2.6.9 Repair of Faculty Welds

No repair of defective welds shall be carried out without proper permission of the Engineer-in-Charge and his approval for the corrective procedure.

Welds not complying with the acceptance requirements (as specified by BIS Codes & the Engineer-in-Charge), as revealed during inspection & testing of welds or erection or in-situ condition, shall be corrected either by removing & replacing or as follows:

a) Excessive convexity - Reduced to size by removal of excess weld metal.

b) Shrinkage cracks, - Defective portions removed down to sound cracks in parent plates metal and rewelded.and craters

c) Under cutting. - Additional weld metal deposited.

d) Improperly fitted/ - Welding cut & edges suitably prepared andmisaligned parts. parts.

e) Members distorted - Member straightened by mechanical means or



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by the heat of careful application of limited amount of heat,welding temperature of such area not to exceed 650

degree Centigrade dull red heat).

In removing defective parts of a weld, gouging, chipping, oxygen cutting or grinding shall not extend into the parent metal to any substantial amount beyond the depth of weld penetration, unless cracks or other defects exist in the parent metal. The weld or parent metal shall not be undercut in chippping, grinding, gouging or oxygen cutting.

Any fabricated structure or its component which, in the opinion of Engineer-in-Charge, is defective and/or beyond any corrective action shall be removed forthwith from the site as instructed by the Engineer-in-Charge without any extra claim. The owner reserves the right to recover any compensation due to any loss arising out of such rejections.

5.2.7 Bolting

5.2.7.1 All bolts shall be provided such that no part of the threaded portion of the bolts is within the thickness of the parts bolted together. Washers of suitable thickness shall be used under the nuts to avoid any threaded portion of the bolt being within the thickness of parts bolted together.

5.2.7.2 The threaded portion of each bolt shall project through the nut at least one thread.

5.2.7.3 Flat washers shall be circular and of suitable thickness. However, where bolt Heads/nuts bear upon the bevelled surfaces, they shall be provided with square tapered washers of suitable thickness to afford a seating square with the axis of the bolt.

5.2.8 Splicing

5.2.8.1 Splicing of built up/compound/latticed sections shall be done in such a fashion that each component of the section is joined in a staggered manner.

5.2.8.2 Where no butt weld is used for splicing, the meeting ends of two pieces of joist / channel / built up section shall be ground flush for bearing on each other and suitable flange and web splice plates shall be designed and provided for the full strength of the flange1 web of the section and welds designed accordingly.

5.2.8.3 Where full strength butt weld is used for splicing (after proper edge preparation of the web and flange plates) of members fabricated out of joist/ channel / angles / built up section, additional flange and web plates shall be provided, over and above the full strength butt welds, to have 40% strength of the flange and web.

5.2.8.4 Where a cover plate is used over a joist/channel section the splicing of the cover



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plate and channel/joist sections shall be staggered by minimum 500mm. Extra splice plate shall be used for the cover plate and joist/channel section as per clause 5.2.8.2 or 5.2.8.3.

5.2.8.5 Prior approval shall be obtained by the Contractor for locations of splices where not shown on design drawings. Only a single splice at approved location shall be allowed for members upto a length of 6 to 7m. Maximum two numbers of splices shall be allowed for members exceeding this length.

5.2.9 Machining & Grinding

5.2.9.1 All slab bases and slab caps shall be accurately machined over the bearing surfaces and shall be in effective contact with the ends of column sections (shafts).

5.2.9.2 For slab bases and slab caps, ends of column shafts shall be accurately machined. However, for gussetted bases and caps, the column shafts shall be ground flush for effective contact with parts connected together.

5.2.9.3 Gussetted bases and caps shall be ground flush for effective contact with ends of column sections.

5.2.9.4 End of all bearing stiffeners shall be machined or ground to fit tightly at top and bottom without any air gap.

5.2.9.5 While machining or grinding care shall be taken so that the length or thickness of any part does not get reduced by more than 2.0mm.

5.2.9.6 For all machining or grinding works for gassetted base and cap plates, the clearance between the parts joined shall not exceed 0.2mm at any location.

6.0 MARKING FOR IDENTIFICATION

6.1 Each component shall be distinctly marked (with paint) before delivery in accordance with the marking diagrams and shall bear such other marks as will facilitate erection.

6.2 For small members which are delivered in bundles or crates, the required marking shall be done on small metal tags securely tied to the bundle.

7.0 SHOP ERECTION

The steel work shall be temporarily shop erected complete or as directed by the Engineer-in-Charge, so that the accuracy of fit may be checked before despatch.

8.0 INSPECTION & TESTING OF STRUCTURES



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8.1 The Engineer-in-Charge (or his authorised representative) shall have free access at all times to those parts of the Contractor's works which are concerned with the fabrication of the steel work and shall be provided with all reasonable facilities for satisfying himself that the fabrication is being undertaken in accordance with the provisions of these specifications & other relevant BIS Codes.

8.2 Should any structure or part of a structure be found not to comply with any of the provisions of this specification (or relevant BIS Codes as referred to), it shall be liable to rejection. No structure or part of the structure, once rejected shall be resubmitted for inspection, exception cases where the Engineer-in-Charge or his authorised representative considers the defect as rectifiable.

8.3 Defects which may appear during/after fabrication / erection shall be made good only with the consent of the Engineer-in-Charge and procedure laid down by him.

8.4 All necessary gauges and templates shall be supplied free to the Engineer-in-Charge by the Contractor whenever asked for during inspection. The Engineer-in-Charge, may at his discretion, check the test results obtained at the Contractor's works by independent tests at a test house, and the cost of such tests shall be borne by the Contractor.

9.0 SHOP PAINTING

9.1 All components and members of steel work shall be given one shop coat of red oxide zinc chromate primer (conforming to IS:2074) or any other primer as specified, in the tender, immediately after the surfaces have been properly prepared (i.e. degreased, derusted, descaled & cleaned) in accordance with IS:1477 or 6-44-0004, as applicable. The primer coat shall be applied over completely dry surfaces (using brushes of good quality) in a manner so as to ensure a continuous and uniform film without "holidaying". Special care shall be taken to cover all the crevices, comers, edges etc. However, in areas which are difficult to reach by brushing, dauberslmops shall be used by dipping the same in paint and then pulling pushing them through the narrow spaces. The primer coat shall be air dried and shall have a minimum film thickness of 25 microns or as per GAIL Specification no. 6-44-0004 (tolerance + 10%) after drying, as applicable.

9.2 Surfaces which are inaccessible after shop assembly, shall receive the full specified protective treatment before assembly (this shall not apply to the interior of sealed hollow sections).

9.3 Steel surfaces shall not be painted within a suitable distance of any edges to be welded if the paint specified would be harmful to welders or impair the quality of the welds.

9.4 Welds and adjacent parent metal shall not be painted prior to deslaggipg, inspection



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and approval by the Engineer-in-Charge.

9.5 Parts to be encased in concrete shall have only one coat of primer and shall not be painted after erection.

10. PACKING

10.1 All items shall be suitably packed in case these are to be despatched from the fabrication shop to the actual site of erection so as to protect them from any damage/distortion or falling during transit. Where necessary, slender projecting parts shall be temporarily braced to avoid warping during transportation.

10.2 Small parts such as gussets, cleats etc., shall be securely wired on to their respective main members.

10.3 Bolts, nuts washers etc. shall be packed in crates.

11.0 TRANSPORTATION

Loading and transportation shall be done in compliance with transportation rules. In case, certain parts can not be transported in the lengths stipulated on the drawings, the position details of such additional splice joints shall be got approved by the Engineer-in-Charge.

12.0 SITE (FIELD) ERECTION

12.1 Plant & Equipment

The suitability and capacity of all plant and equipment used shall be to the complete satisfaction of the Engineer-in-Charge.

12.2 Storing & Handling

All steel work shall be so stored and handled at site so that the members are not subjected to excessive stresses and any damage.

12.3 Setting Out

Prior to setting out of the steel work, the Contractor shall get himself satisfied about the correctness of levels, alignment, location of existing concrete pedestals / columns/ brackets and holding down bolts/pockets provided therein. Any minor modification in the same including chipping, cutting and making good, adjusting the anchor bolts etc., if necessary, shall be carried out by the Contractor at his own expense. The positioning and levelling of all steel work including plumbing of columns and placing of every part



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of the structure with accuracy shall be in accordance with the drawings and to the complete satisfaction of the Engineer-in-Charge.

12.4 Tolerances

Tolerances for erection of steel structures shall be as per Annexure 'A'

13.0 SAFETY & SECURITY DURING ERECTION

13.1 The contractor shall comply with IS:7205 for necessary safety and adhere to safe erection practices and guard against hazardous as well as unsafe working conditions during all stages of erection.

13.2 During erection, the steel work shall be securely bolted or otherwise fastened and when necessary, temporarily braced/guyed to provide for all loads to be carried by the structure during erection till the completion, including those due to the wind, erection equipment & its operation etc. at no extra cost to the owner. For the purpose of guying, the Contractor shall not use other structure in the vicinity without prior written permission of the Engineer-in-Charge.

13.3 No permanent bolting or welding shall be done until proper alignment has been achieved.

13.4 Proper access, platform and safety arrangement shall be provided for working and inspection, (at no extra cost to the owner) whenever required.

14.0 FIELD CONNECTIONS

14.1 Field Bolting

Field bolting shall be carried out with the same care as required for shop bolting.

14.2 Field Welding

All field assembly and welding shall be executed in accordance with the requirements for shop assembly and welding. Holes for all erection bolts – where removed after final erection shall be plugged by welding. Alternatively erection bolts may be left and secured.

15. GROUTING

15.1 Prior to positioning of structural columns/girders/ trusses over the concrete pedestals/columns/brackets, all laitance & loose material shall be removed by wire brushing & chipping. The bearing concrete surfaces shall be sufficiently levelled, hacked



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with flat chisels to make them rough, cleaned (using compressed air) and made thoroughly wet. All pockets for anchor bolts shall also be similarly cleaned and any excess water removed. Thereafter, the structural member shall be erected, aligned & plumbed maintaining the base plates/shoe plates at the levels shown in the drawings, with necessary shims/pack plates/wedges.

15.2 After final alignment and plumbing of the structure, the forms shall be constructed alround and joints made tight to prevent leakage. Grouting (under the base plates/shoe plates including grouting of sleeves & pockets) shall be done with non-shrink grout having compressive strength (28 days) not less than 40Nlsq.mm Non shrink grout shall be of free flow premix type and of approved quality and make. It shall be mixed with water in proportion as specified by the manufacturer. Ordinary 1 :2 cement/sand mortar grout shall be used only for small, isolated structures e.g. operating platforms not supporting any equipment, pipe supports, cross overs, stairs & ladders. The thickness of grout shall be as shown on the drawings but not less than 25 mm nor more than 40mm in any case.

15.3 The grout mixture shall be poured continuously (without any interruption till completion) by grouting pumps from one side of the base plate and spread uniformly with flexible steel strips and rammed with rods, till the space is filled solidly and the grout mixture carried to the other side of the base plate.

15.4 The grout mixture shall be allowed to harden for a period as decided by the Engineer-in-Charge. At the end of this period, the shims/wedges/pack plates may be removed and anchor bolts tightened uniformly. The alignment of the structure shall now be rechecked and if found correct, the voids left by the removal of shims/wedges/pack plates (if removed) must be filled up with a similar mixture of grout. In case after checking, serious misalignment is indicated, the grout shall be removed completely and fresh grouting done after making appropriate correction of alignment.

16.0 SCHEME AND SEQUENCE OF ERECTION

The Contractor shall furnish the detailed scheme and sequence of erection to match with the project schedule and get the same approved by the Engineer-in-Charge. All necessary co-ordination and synchornization shall be done with the Civil contractor where Civil works are not included in the scope of structural contractor at no extra cost so as to match with the project schedule.

17.0 PAYMENT


17.1 Payment for structural steel works shall be made on the basis of admissible weight in metric tons (determined as described in clause 17.2 and 17.3) of the structure accepted



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by the Engineer-in-Charge. The rate shall include supplying (as per supply conditions given in the Tender) fabricating, erecting in position (at all levels & locations), testing/examining (excluding radiography only) of bolted and/or welded structural steel works of all types (including all built up/compound sections made out of rolled sections and/or plates) including all handling, transporting, storing, straightening if required, cutting, edge preparation, preheating, bolting and welding of joints (including sealing the joints of box sections with continuous welding), finishing edges by grinding/machining as shown, fixing in line & level with temporary staging & bracing and removal of the same after erection, grouting with nonshrink/ordinary grout as specified, preparation of fabrication & erection drawings, & erection schedule and getting them reviewed, preparation and submission of as built drawings, as built drawings, preparing the surfaces for painting, surface cleaning, wire brushing, removal of mill scale, dust, rust, oil or grease and applying one coat of red oxide zinc chromate primer or any other primer as specified after fabrication, return of surplus materials to owner's stores and material reconciliation in the case of materials supplied by the owner as per relevant contract conditions etc. all complete for all the operations mentioned in the foregoing clauses.

17.2 The weight for payment shall be determined from the fabrication drawings and respective bill of materials prepared by the Contractor. The bill of materials shall be checked and approved by the Engineer-in-Charge before making the payment. The Contractor shall prepare full scale template in order to supplement/verify the actual cutting dimensions where so directed by the Engineer-in-Charge. The weight shall be calculated on the basis of BIS Hand Book wherever applicable. In case sections used are different from BIS sections, then Manufacturers' Hand Book shall be adopted. No allowance in weight shall be made for rolling tolerances.

17.3 Welds, bolts, nuts, washers, shims, pack plates, wedges, grout and shop painting shall not be separately measured. The quoted rate shall be deemed to include the same.

17.4 The rate shall include all expenses related to safety & security arrangements during erection and all plants & tools required for fabrication, transportation & erection.

18.0 PAINTING AFTER ERECTION

18.1 General

18.1.1 The scope of painting after erection shall be at the sole discretion of the Engineer-in-Charge and the Contractor shall obtain written instruction in this regard sufficiently prior to taking up any procurement of paint and execution of painting work after erection of steel structures.

18.1.2 The Contractor shall carry out the painting work in all respects with the best quality of approved materials (conforming to relevant BIS Codes or relevant Specification, as



STEEL S-11-02-006 Page 23 of 28


applicable) and workmanship in accordance with the best engineering practice. The Contractor shall furnish characteristics of paints (to be used) indicating the suitability for the required service conditions. The paint manufacturer's instructions supplemented by Engineer-in-Charge's direction, if any, shall be followed at all times. Particular attention shall be paid to the following:

- Proper storage to avoid exposure & extremes of temperature.

- Surface preparation prior to painting.

- Mixing & thinning.

- Application of paint and the recommended limit on time intervals between consecutive coats.

18.1.3 Painting shall not be done in frost or foggy weather, or when humidity is such as to cause condensation on the surfaces to be painted.

18.1.4 Surface which shall be inaccessible after site assembly shall receive the full specified protective treatment before assembly.

18.1.5 Primers & finish coat paints shall be from the same manufacturer in order to ensure compatibility. Painting colour code shall be as per Annexure-'B'.

18.2 Rub Down & Primer Application

The shop coated surfaces shall be rubbed down thoroughly with emery/abrasive paper to remove dust, rust, other foreign matters and degreased, if required, in accordance with IS:1477 or GAIL specification no. 6-44-0004, as applicable, cleaned with warm fresh water and air dried. The portions, from where the shop coat has peeled off, shall be touched up and allowed to dry.

Primer coat of red oxide zinc chromate primer (conforming to IS:2074) or any other primer as per GAIL specification no. 6-44-0004, as specified, shall be applied by brushing/ spraying over the shop coat in a manner so as to ensure a continuous and uniform film throughout. Special care shall be taken to cover all the crevices, comers, edges etc. The final primer coat shall be air dried and shall have a minimum film thickness of 25 microns or as per GAIL Specification no. 6-44-0004 (tolerance 2 10%) after drying, as applicable.

In case a different cleaning procedure & primer specifications are specified in the drawing / Tender, the same shall be adopted.



STEEL S-11-02-006 Page 24 of 28


18.3 Final Paint Application

After the primer is hard dry, the surfaces shall be dusted off and one coat of synthetic enamel paint of approved colour & shade (conforming to IS:2932) or any other paint as per GAIL specification no. 6-44-0004, as specified, shall be applied by brushing/spraying so that a film free from "holidaying" is obtained. The colour & shade of first coat of paint shall be slightly lighter than the second coat in order to identify the application of each coat. The second coat of paint shall be applied after the first coat is hard dry. The minimum thickness of each film shall be 20 microns (2 10% tolerance) after drying.

In case a different type of paint & painting procedure are specified in the drawing/tender, the same shall be adopted.

18.4 Inspection & Testing of Painting Works

18.4.1 All painting materials including primers & thinners brought to site by the Contractor for application shall be procured directly from reputed and approved manufacturers and shall be accompanied by manufacturer's test certificates. Paint formulations without certificates shall not be accepted.

18.4.2 The Engineer-in-Charge at his discretion may call for additional tests for paint formulations. The Contractor shall arrange to have such tests performance including batch wise test of wet paints for physical & chemical analysis. All costs shall be borne by the Contractor.

18.4.3 The painting work shall be subject to inspection by the Engineer-in-Charge at all times. In particular, the stage inspection will be performed and Contractor shall offer the work for inspection and approval at every stage before proceeding with the next stage. The record of inspection shall be maintained. Stages of inspection are as follows:

(a) Surface preparation(b) Primer application(c) Each coat of paint

18.4.4 Any defect noticed during the various stages of inspection shall be rectified by the Contractor to the entire satisfaction of the Engineer-in-Charge before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work the Contractor shall be responsible for making good any defects found during final inspection/guarantee period/defect liability period, as defined in General Conditions of Contract. Dry film thickness (DFT) shall be checked and recorded ater application of each coat. The thickness shall be measured at as many locations as decided by the Engineer-in-Charge. The Contractor shall provide standard thickness measuring instrument such as elkometer (with appropriate range for measuring dry film thickness of each coat) free of cost to the Engineer-in-Charge whenever asked for.



STEEL S-11-02-006 Page 25 of 28


18.5 Payment

Payment for painting of structural steel works shall be made on the basis of admissible weight in metric tons of the painted structures accepted by the Engineer-in-Charge.

The rate shall include supplying & applying two coats of synthetic enamel paint or any other paint specified in the tender of approved quality and shade over a coat of red oxide zinc chromate primer or any other primer specified in the tender over one coat of shop primer already applied to structural steel works of all types/shapes at all levels, locations & positions including storage, surface preparation, degreasing, cleaning, drying, touching up of shop primer coat, providing temporary staging, testing etc. all complete to the entire satisfaction of the Engineer-in-Charge.



STEEL S-11-02-006 Page 26 of 28


ANNEXURE – ‘A’(Clause 12.4)

Maximum Permissible Erection TolerancesA. Columns

1. Deviation of column axes at foundation toplevel withrespect to true axes.

i) In longitudinal direction + 5mm

ii) In lateral direction + 5mm

2. Deviation in the level of bearing surface of columns atfoundation top with respect to true level + 5mm

3. Out of plumb (Verticality) of column axis from true verticalaxis, as measured at top:

i) Upto and including 30m height +H/1000 or +25mm whichever is less.

ii) Over 30m height +H/1200 or +35mm whichever is less.

4. Deviation in straightness in longitudinal & transverse planesof column at any point along the height. +H/1000 or +10mm

whichever is less.

5. Difference in the erected positions of adjacent pairs of columnsalong length or across width of building prior to connectingtrusses/beams with respect to true distance. +5mm

6. Deviation in any bearing or seating level with respect to true level. +5mm

7. Deviation in difference in bearing levels of a member onadjacent pair of columns both across & along the building. +5mm

Note: 1. Tolerance specified under 3 should be read in conjunction with 4 & 5.Note: 2. 'H' is the column height in mm.

B. Trusses



STEEL S-11-02-006 Page 27 of 28


1. Shift at the centre of span of top chord member +1/250 of height ofwith respect to the vertical plane passing through truss in mm at centrethe centre of bottom chord. of span or +5mm

whichever is less.

2. Lateral shift of top chord of truss at the centre of span +1/1500 of span offrom the vertical plane passing through the centre of truss in mm or +10mmsupports of the truss. whichever is less.

3. Lateral shift in location of truss from its true position. +10mm

4. Lateral shift in location of purlin from true position +5mm

5. Deviation in difference of bearing levels of truss from +1/1200 of span oftruss in mm or 20mmwhichever is less

C. Gantry Girders & Rails

1. Shift in the centre line of crane rail with respect + [{web thickness(mm)}+2mm]to centre line of web of gantry girder 2

2. Shift of alignment of crane rail (in plan) with respectto true axis of crane rail at any point. +5 mm

3. Deviation in crane track gauge with respect to truegauge.



STEEL S-11-02-006 Page 28 of 28


ANNEXURE-'B '(Clause 1 8.2)

PAINTING COLOUR CODE FOR STRUCTURAL STEEL

1 GANTRY GIRDER & MONORAIL DARK GREEN

2 GANTRY GIRDER & MONORAIL STOPPER SIGNAL RED

3 BUILDING STRUCTURAL STEEL COLUMNS, DARK ADMIRALITYBRACKETS, BEAMS, BRACINGS, ROOF TRUSS, GREYPURLINS, SIDEGIRTS, LOUVERS, STRINGERS

4 PIPE RACK STRUCTURE & TRESTLE DARK ADMIRALITYGREY

5 CHEQUERED PLATE (BOTH FACES) BLACK

6 GRATING BLACK

7 LADDER RUNGS - BLACKVERTICALS & CAGERED

8 HAND RAILING

- HANDRAIL, MIDDLE SIGNAL REDRAIL, TOE PLATE

- VERTICAL POST BLACK


STANDARD SPECIFICATIONCIVIL & STRL WORKS FOR

MISCELLANEOUS STEEL WORK S-11-02-007 Page 1 of 14


TECHNICAL SPECIFICATION CIVIL & STRUCTURAL WORKS

MISCELLANEOUS STEEL WORK





CONTENTS

1.0 GENERAL

2.0 REFERENCES

3.0 MATERIAL

4.0 ANCHOR BOLTS

5.0 METAL INSERTS

6.0 CHEQUERED PLATES

7.0 GRATINGS

8.0 TUBULAR HAND RAILING

9.0 MILD STEEL RUNGS

9.0 LIGHT GAUGE STEEL STRUCTURALSECTIONS EXPANSION FASTENERS SPECIFICATION





1.O GENERAL

1.1 All materials supplied by the Contractor shall conform to their respective specifications given in GAIL Specification no S-11-02-011

1.2 The Contractor shall furnish test certificates for all materials prior to their use in the works.

1.3 Other requirements not covered under this specification shall be in accordance with

specification no S-11-02-006 Structural Steel Works.

2.0 REFERENCES


3.0 MATERIAL


3.1 Plain and Reinforcement cement Concrete work shall con firm to Indian Standard for Plain and reinforced Concrete – Code of practice

4.0 ANCHOR BOLTS

4.1 Material

Materials for anchor bolts, nuts, locknuts, washers, pipe sleeves and anchor plates shall conform to their respective specification given in GAIL Specification

4.2 Fabrication

Fabrication of anchor bolts and their complete assemblies shall be strictly in

compliance with the specifications and drawingslstandards. Anchor bolts shall

have coarse type threads conforming to IS :421 8.

4.3 Placement

Anchor bolt assemblies shall be placed in position strictly as per drawings and securely held during pouring and vibrating of concrete with necessary templates and other dummy structures to prevent their dislocation.

4.4 Tolerances





Tolerances allowed for anchor bolts positioning shall be:

- For sleeved bolts, one tenth of the bolt nominal diameter. -F or bolts without sleeves, one twentieth of the bolt nominal diameter.

4.5 Protection

The exposed surfaces of bolts shall be properly covered (after greasing of bolts and packing of sleeves) with jute cloth so as to protect them from damage till final erection of structure equipment is over.

4.6 Payments


4.6.1 Payment shall be made on the basis of actual weight in metric tons of the anchor bolt/anchor bolt assembly. The rate shall include supply (as per scope of supply of all transporting tender material handling, fabrication, turning from available size MS round to required diameter, threading, welding, fixing in position, at all levels and locations, providing necessary templates, greasing, packing of sleeves, covering with jute cloth and other protective measures etc. all complete. The rate shall cover bolt of any diameter and nomenclature. Payment for fixing in position anchor bolt assembly (already fabricated and supplied by the Owner as free issue) shall be made on the basis of actual weight of anchor bolts/bolt assemblies in metric tons. The rate shall include handling, transporting, fixing in position, welding if required, providing necessarytemplates, greasing, packing of sleeves, covering with jute cloth and other protective measures etc . all complete. No separate payment shall be made for templates, dummy structures, supports etc. and the rate quoted shall be inclusive of all cost related to such provision required for correct and accurate installation of anchor bolts/assembly.

5.0 METAL INSERTS

5.1 Material

Materials required for fabricating metal inserts shall conform to their respectivespecification given in relevant GAIL Specification.

5.2 Fabrication

Fabrication of inserts shall be done strictly as per drawingshtandards and in compliance with the requirements given in relevant GAIL Specification for Structural Steel Works.





5.3 Placement

Metal inserts shall be correctly embedded (in plain concrete/reinforced concrete) as per their location shown on the drawings. Care shall be taken that these are securely held in position and do not get disturbed during concreting. Where necessary, these may be welded to the reinforcement bars. Suitable templates, spacers, dummy structures and temporary staging shall be provided. Necessary cutting in the formwork and adjustment of reinforcement bars shall be done for the placement of metal inserts where required.

5.4 Painting

The exposed surfaces of metal inserts shall be cleaned with wire brush and given one coat of red oxide zinc chromate primer (conforming to IS: 2074) or any other primer as per relevant Specification after fabrication.

5.5 Payments


5.5.1 Payment shall be made on the basis of actual weight in metric tons of the metal inserts. The rate shall include supply (as per supply conditions given in the tender) of all materials, handling, transporting, fabrication, welding, fixing in position, at all levels and locations, providing necessary templates, spacers, dummy structures, adjusting the formwork and reinforcement, staging,

preparation of surface for painting, applying one coat of red oxide zinc chromate primer or any other primer, as specified, etc. all complete.

6.0 CHEQUERED PLATES

6.1 Material

Chequered plates shall be of mild steel and conforming to IS:3502. Chequering shall be closed or open-ended or of any other pattern as shown on drawings.

6.2 Fabrication Drawings

Refer Specification for -Structural Steel Works.

6.3 Fabrication

Chequered plates shall be fabricated as per the "Approved for Construction" fabrication drawings (prepared by the Contractor based on design drawings).





These shall be perfectly flat and without any dents / deformations and shall be cut to the required size and shape. Holes/notches/openings of the required size, if any, shown on drawings shall be made. Nosing for staircase treads shall be made by cold bending of chequered plates. All edges shall be made smooth and even. All chequered plate units shall be given distinct erection marks in accordance with the marking drawings. Stiffeners of any description shall be welded with the chequered plates where shown on drawings.

6.4 Erection/fixing Chequered plates shall be fixed to the bearing members by welding/ bolting1 screwing as shown on drawings. All bolts screws shall be of counter-sunk type so that the heads remain flush with the top of plate. Where welding is used for fixing, stitch welds of minimum 50mm length with a pitch of 150mrn shall be used. Continuous sealing run of weld shall be provided along the junction of two consecutive chequered plates parallel to the span. For removable flooring, details as shown on drawings shall be followed.

6.5 Painting Chequered plates shall be cleaned (both the surfaces) with wire brush and given one coat of red oxide zinc chromate primer (conforming to IS: 2074) or any other primer as per GAIL Specification as specified, on both surfaces.

6.6 Payment


6.6.1 Payment shall be made on the basis of admissible weight in metric tons (determined as described in clause 6.6.2) of the chequered plates accepted by the Engineer-in-Charge. Where stiffeners are used, weight of the same shall be included in arriving at admissible weight.

The rate shall include supplying (as per supply conditions given in the tender), fabricating, erecting M.S. chequered plates including transporting, handling, straightening if required, cutting to required size and shape, making holes/notches/opening of required size and nosing, smoothening the edges, fixing by welding/ bolting /screwing, at all levels and locations, preparing detailed fabrication drawings, surface cleaning, removal of rust, scale, grease and applying one coat of red oxide zinc chromate primer or any other primer as per GAIL Specification no, as specified, etc. all complete.

In any stiffening sections are provided below the chequered plates for strengthening, the same shall be separately measured & paid under Structural Steel item (Viz. relevant GAIL Specification.)





6.6.2 The weight for payment shall be determined from the fabrication drawings and respective bill of materials prepared by the Contractor. The bill of materials shall be checked and approved by the Engineer-in- Charge before making the payment.

The weight shall be calculated on the basis of BIS Handbook. No allowance in weight shall be made for rolling tolerances. Welds, bolts, nuts, screws, washers, clips

7.0 GRATINGS

7.1 Categories

The gratings shall be of two categories:

i) Category 'A' - Fabricated by the Contractor as per GAIL design drawings/standards.

ii) Category 'B' -Ready made bought out from an approved manufacturer.

7.2 Material

Materials for fabrication and fixing of Gratings shall conform to their respective specification given in GAIL Specification no.


Refer GAIL Specification for Structural Steel Works.

7.4 Fabrication

7.4.1 Category 'A' Gratings

These shall be fabricated strictly as per the "Approved for Construction" fabrication drawings prepared by the Contractor based on design drawings and standards. All units shall be given distinct erection marks in accordance with he marking drawing. All notchings in the flats shall be punched and not flame-cut. Continuous around welding shall be done along the contact-lines between two flats on both the surfaces. All fabrication shall be done in a shop under strict supervision. Clamps shall be fabricated as shown on drawing standard.

7.4.2 Category 'B' Gratings

These shall be as per manufacturer’s details designed to carry loads as specified on the design drawing supplied to the contractor. The deflection shall not exceed span1200 or 6mrn whichever is minimum. The maximum clear size of voids in the grating shall be limited to 30mm x 55mm. Thickness of grating shall be 25mm. The Contractor shall make necessary notches1 opening in the gratings as





shown in the drawings. All edges affected by such notches/ openings shall be suitably stiffened by welding additional flats of the requisite size. All units shall be given distinct erection marks in accordance with the marking drawings. Before procurement the Contractor shall submit the design calculations, drawings and manufacturer’s literature1 catalogues and get the same reviewed by the Engineer-in- Charge. The Contractor shall submit sample gratings for inspection and approval by the Engineer-in-Charge whenever asked for.

7.5 Gratings shall be fixed to the bearing members by welding /clamping and bolting as indicated in the drawings. Minimum length and maximum pitch of welds shall be 50mm and 150mm respectively where stitch welding is used for fixing along the lines of supports. The edges of two consecutive gratings shall be bolted with minimum two bolts on each side of the grating panel.

7.6 Galvanising Gratings and the fixing clamps, bolts, nuts shall be cleaned with wire brush and galvanisation shall be done in accordance with IS:2629 and tested as per IS:2633 & 6745. Quantity of zinc coating shall be minimum 900 gms1sq.m. of surface area (0.12mm uniform thickness).

7.7 Payment


7.7.1 Payment shall be made on the basis of admissible weight in metric tons (determined as described in clause 7.7.2) of the gratings accepted by the Engineer- in-Charge. The rate shall include supplying, fabricating, erecting MS gratings (of the specified category) including transporting, handling, cutting to required size and shape, making holes/notches/ openings, smoothening the edges, fabricating clamps, fixing by welding/clamping/ bolting, at all levels and locations, preparing detailed fabrication drawings, surface cleaning, removal of rust, scale, grease and applying one coat of red oxide zinc chromate primer or any other primer as per GAIL Specification no. , as specified, or galvanising as required.

7.2 The weight for payment shall be determined from the fabrication drawings and respective

bill of materials prepared by the Contractor. The bill of materials shall be checked and approved by the Engineer-in- Charge before making the payment. The weight, shall be calculated on the basis of BIS Handbook as mentioned above. No allowance in weight shall be made for rolling tolerances.

7.7.3 Welds, bolts, clamps, nuts and washers shall not be measured. The quoted rate shall be deemed to include the same.





8.0 TUBULAR HAND RAILING

8.1 Material

Materials for fabrication and fixing of Tubular Hand Railing shall confirm to their respective specification given in GAIL Specification no


Refer clause 4.0 of GAIL Specification no. -Structural Steel Works.

8.3 Fabrication

Handrailing shall be fabricated strictly as per the "Approved for Construction" fabrication drawings prepared by the Contractor based on design drawings and standards. All tubes shall be straight and without any dents/ deformations. Tubes shall be cut and ends shall be prepared to a neat and workman-like finish. All elements shall be directly welded. All welded joints shall be cleaned and filed or ground smooth, if required, to have a smooth surface and aesthetically pleasant appearence. Splicing of top rail shall not be allowed. Tubes shall be coldbent to shape and curvature in case of discontinuous ends of handrails. Ripples, kinks andlor dents at bends shall not be accepted.

Lower ends of vertical posts shall be cut and splayed (for grouting in pockets in the concrete members). For removable type of handrailing, suitable base plates (with provision for bolting) shall be welded to the lower end of vertical posts. All units shall be given distinct erection marks in accordance with the marking drawing.

8.4 Erection/ fixingHandrailing, shall be fixed to the bearing members by welding1 bolting1 grouting as indicated on the drawings. Local notching shall be made in the floor plate/ grating to accomodate vertical postsltheir base plates which shall always be welded to the main supporting member. When the posts are to be fixed in concrete members, suitable pockets shall be made in concrete for grouting as shown on drawingdstandards.

8.5 Painting

Tubes shall be cleaned with wire brush and given one coat of red oxide zinc chromate primer (conforming to IS:2074) or any ,other primer as per GAIL Specification no. 6-44-0004? as specified, after fabrication.





8.6 Payment


8.6.1 Payment shall be made on the basis of measured length in meters (m) of top rail only (Horizontal andlor inclined lengths). The rate shall include preparation of fabrication drawings, supply of all materials, handling, transporting, straightening if required, cutting to required size, bending, welding, bolting, fixing in position at all levels and locations, grouting with 1:2 (cement:sand) mortar, surface cleaning, removal of rust, scale, grease and applying one coat of red oxide zinc chromate primer (conforming to IS 2074) or any other primer as per GAIL Specification no. , as specified, after fabrication etc. all complete.

8.6.2 The rate shall include making suitable notches in floor plates/ gratings and pockets in concrete structures for fixing the vertical posts.

9.0 MILD STEEL RUNGS

9.1 Material

All materials shall conform to their respective specifications given in GAIL Specification no.

9.2 Fabrication

Rungs shall be fabricated as per GAIL standards/drawings. Mild steel bars shall be straightened if required, cut, bent to shape and given one coat of red oxide zinc chromate primer on exposed portions.

9.3 Fixing

Rungs shall be fixed in position as per detailed drawing and firmly tiedlwelded with reinforcement to prevent their displacement during vibrating of concrete.

9.4 Payment


9.4.1 Payment shall be made on the basis of actual weight in kilograms (Kgs.) of the M.S. rungs. The rate shall include supply of all materials handling, transporting, straightening if required, cutting to required size, bending to shape, tying /welding with reinforcement bars, fixing at all levels and locations, adjustment of formwork, applying one coat of red oxide zinc chromate primer (conforming to IS 2074) or any other primer as per GAIL Specification no. , as specified, and two coats of anti-corrosive paint or any other paint, as specified, on the exposed portion of rungs etc. all complete.





10.0 LIGHT GAUGE STl3EL STRUCTURAL SECTIONS

10.1 Material

All materials required for fabrication and fixing in position of Light Gauge Steel Structural Sections shall conform to their respective specification given in GAIL Specification no.


Refer GAIL Specification for -Structural Steel Works.

10.3 Fabrication

Fabrication of members shall be done strictly as per the "Approved for Construction" fabrication drawings prepared by the Contractor based on the latest design drawings and in accordance with IS: 800, IS: 801 and other relevant BIS Codes.

All members shall be straight and free from any dents/deformations/ twists. Members shall be cut to the required sizes and ends prepared to a neat and workman like finish. Holes (for sag rods and cleat bolts) of appropriate size shall be drilled and all members/ components shall be given distinct erection marks in accordance with the marking drawings. Holes shall not be formed by gas cutting process.

10.4 Erection

Structural members shall be erected in proper sequence and aligned properly without causing any twist. Permanent bolting/welding shall be done only after proper alignment has been achieved. Proper access, working platforms and safety arrangements shall be provided by the Contractor for working and inspection.

10.5 Painting

All structural components shall be cleaned thoroughly and given one coat of red oxide zinc chromate primer (conforming to IS:2074) or any other primer as per GAIL Specification no. , as specified, after fabrication.

10.6 Payment


10.6.1 Payment shall be made on the basis of admissible weight in metric tons (determined as described in clause 10.6.2) of the structure accepted by the Engineer-in-Charge. The rate shall include supplying, fabricating, erecting, at all levels and locations, testing of bolted and/or welded Light Gauge structural steel works including cleats, crook bolts, splices/sleeves, all other fixtures and accessories, straightening if required, cutting, edge





preparation, welding and bolting of joints, fixing in line and level with temporary staging and removal of the same after final alignment, handling, transporting, storage, preparation of detailed fabrication drawings and getting them reviewed by the Engineer-in-Charge, surface cleaning, wire brushing, removal of scale, rust, oil or grease and painting as per 8.5 above etc., all complete.

10.6.2 The weight for payment shall include all structural members, cleats, splices, gussets and sag rods and shall be determined from the fabrication drawings along with respective bill of materials prepared by the Contractor. The bill of materials shall be checked and approved by the Engineer-in-Charge before making the payment. The weight shall be calculated on the basis of BIS Handbook. Manufacturer's catalogues/ charts shall be adopted in case relevant weights of sections used are not covered in BIS Handbook. No allowance in weight shall be made for rolling tolerances.

10.6.3 All welds, bolts, nuts washers, fixtures and accessories shall not be measured. The quoted rate shall be deemed to include the same.

10.6.4 The rate shall be applicable to all cleats, splices, sleeves and gussets. Sag rods. however, shall be separately measured and paid under structural steel item (viz.

11.0 EXPANSION FASTENERS

11.1 Material

Expansion fasteners (medium and heavy duty) shall be of mild steel high tensile steel with rust proof coating including both mechanical & chemical fasteners.

11.2 Classification

The expansion fasteners shall be designated as medium and heavy duty depending on their usage. The broad classification is given below for general guidance.

11.2.1 Medium Duty (Mild steel/High tensile steel)

-Ladders and stairs supports.

-Cables and cable trays supports.

-Electrical panels and fixtures.

-Hangers for pipes and cable trays.

-Pipe supports.

11.2.2. Heavy Duty (Mild steel1High tensile steel).

-Platform supports (beam and columns)





-Knee brackets for pipeslmulti tiers cable trays/ walkways etc.

Note:-Expansion fasteners shall not be used for

1. Members supporting equipment and pipes subjected to vibrations.

2. Cantilever connections designed to cater for effective cantilever spans greater than lOOOrnrn and 1000Kgs. of concentracted load at the free end.

11.3 Selection

The Contractor shall submit to the Engineer-in-Charge manufacturer's catalogues along with the specimens of expansion fasteners (proposed to be used for the job) for his selection and approval. Selected fasteners shall be capable to carry the specified loads.

11.4 Testing

If so desired by the Engineer-in-Charge, the Contractor shall carry out all the requisite tests (pullout test, torque test etc.) of specimen expansion fasteners (representative of those to be used) from approved laboratory1 test house and submit the report to him for approval.The decision of the Engineer-in-Charge regarding the adequacy of strength and load carrying capacity of the expansion fastener shall be final and binding to all. The cost of all such tests shall be borne by the Contractor.

11.5 Installation

The Contractor shall install the expansion fasteners at their correct location (to suit the requirement of fixtures as shown in drawings) as per the procedure laid down by thhe manufacturer. Location of all holes shall be pre-marked on the concrete surfaces and then holes drilled carefully with an electric drill to the correct recommended size and depth. Holes shall be exactly round and true perpendicular to the concrete surface. Edge distance and pitch of fasteners shall be as recommended by the manufacturer. The contractor shall suitably shift the hole with the approval of the Engineer-in-Charge in case any reinforcement bar is met with while drilling the hole in RCC structure. Necessary staging shall be provided for working and the Contractor shall take requisite safety precautions so as not to cause any damage to the existing structure1 equipment. Any damage done while executing the job shall be made good by the Contractor at his cost.

11.6 Protection

The exposed surfaces of expansion fasteners shall be properly greased & covered with jute cloth so as to protect them from damage.

11.7 Payment






11.7.1 Payment for installing rust proof expansion fasteners shall be made on number basis (each). The rate shall include supply of complete assembly, handling, transporting, providing necessary temporary staging, installing (as per manufacturer's specifications) in PCCIRCC structures, at all levels and locations, testing, drilling, cleaning, covering with jute cloth, relocating and redrilling in case of any obstruction, making good any damage done to the structure, grouting the abandoned holes and any gap left between the contact surfaces of PCC/RCC.


STANDARD SPECIFICATIONCIVIL & STRL WORKS FOR BRICK

MASONRY S-11-02-008 Page 1 of 9



BRICK MASONRY





CONTENTS

SL. NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCES

3.0 MATERIALS


5.0 CONSTRUCTION PROCEDURE

6.0 PAYMENT





1.0 SCOPE

This GAIL specification establishes the materials, dressing, laying, joining, curing, workmanship etc. for brick masonry works. Brick masonry shall also comply with all the requirements of IS:2212.

2.0 REFERENCES

2.1 BIS Codes

IS:2212, 2250

2.2 GAIL specifications

S-11-02-002 : Materials

3.0 MATERIALS

Refer GAIL specification no. S-11-02-002 : Materials


4.1 Cement Mortar

Cement mortar shall meet the requirements of IS2250 and shall be prepared by mixing cement and sand by volume. Proportion of cement and sand shall be 1 :6 (1 part of cement and 6 parts of sand), or as directed by the Engineer-in-Charge/shown on the drawing, for brick masonry of one brick thickness or more, while 1:4 cement mortar (1 part of cement and 4 parts of sand) shall be used for brick masonry of half brick thickness. The sand being used for mortar shall be sieved. The mortar shall be used as soon as possible after mixing and before it has begun to set and in any case within initial setting time of cement after water is added to the dry mixture. Mortar unused for more than initial setting time of cement, shall be rejected and removed from the site of work.

4.1.1 Proportioning

The unit of measurement for cement shall be a bag of cement weighing 50 kgs and this shall be taken as 0.035 cubic meter. Sand shall be measured in boxes of suitable size on the basis of its dry volume. In case of damp sand, its quantity shall be increased suitably to allow for bulkage.

4.1.2 Mixing





The mixing of mortar shall be done in a mechanical mixer operated manually or by power. The Engineer-in-Charge may, however, permit hand-mixing as a special case, taking into account the magnitude, nature and location of work. The Contractor shall take the prior permission of Engineer-in-Charge, in writing, for using hand-mixing before the commencement of work.

4.1.2.1 Mixing in Mechanical Mixer

Cement and sand in specified proportions, by volume, shall be thoroughly mixed dry in a mixer. Water shall then be added gradually and wet mixing continued for atleast one minute. Care shall be taken not to add more water than that which shall bring the mortar to the consistency of stiff paste. Wet mix from the mixer shall be unloaded on water-tight masonry platform, made adjacent to the mixer. Platform shall be atleast 150 mm above the levelled ground to avoid contact of surrounding earth with the mix. Size of the platform shall be such that it shall extend atleast 300rnm alround the loaded wet mix area. Wet mix, so prepared, shall be utilized within initial setting time [thirty (30) minutes either for ordinary portland cement conforming to IS:269 or for portland slag cement conforming to IS:455] after addition of water. Mixer shall be cleaned with water each time before suspending the work.

4.1.2.2 Hand Mixing

The measured quantity of sand shall be levelled on a clean water-tight masonry platform and cement bags emptied on top. The cement and sand shall be thoroughly mixed dry by being turned over and over, backward and forward, several times till the mixture is of uniform colour. The quantity of dry mix which can be consumed within initial setting time of cement shall then be mixed with just sufficient quantity of water to bring the mortar to the consistency of stiff paste.

5.0 CONSTRUCTION PROCEDURE

5.1 Soaking of Bricks

Bricks shall be soaked in water before use for a period that is sufficient for the water to just penetrate the whole depth of bricks as well as to remove dirt, dust and sand. Proper soaking of bricks shall prevent the suction of water from the wet mortar as otherwise mortar will dry out soon and crumble before attaining any strength. The bricks shall not be too wet at the time of use as they are likely to slip on mortar bed and there will be difficulty in achieving the plumbness of wall as well as proper adhesion of bricks to mortar. The period of soaking shall be determined at site by a field test by immersing the bricks in water for different periods and then breaking the bricks to find the extent of water penetration. The least period that corresponds to complete soaking, will be the one, to be allowed for in the construction work.





The soaked bricks shall be removed from the tank, sufficient early, so that at the time of laying, they are skin dry. The soaked bricks shall be stacked over a clean place, wooden planks or masonry platforms to avoid earth, dirt being smeared on them.

5.2 Laying

5.2.1 Brick Work (one or more brick thickness)

Brick work (one or more brick thickness) shall be laid in English Bond unless otherwise specified. Half or cut bricks shall not be used except when needed to complete the bond. In no case the defective bricks shall be used.

A layer of average thickness of 10mm of cement mortar shall be spread on full width over a suitable length of lower course or the concrete surface. In order to check and achieve uniformity in masonry, the thickness of bed joints shall be such that four courses and three joints taken consecutively shall measure equal to four times the actual thickness of the brick plus 30mm. Each brick with frog upward, shall be properly bedded and set in position by gently tapping with handle of trowel or wooden mallet. Its inside faces shall be buttered with mortar before the next brick is laid and pressed against it. After completion of the course, all vertical joints shall be filled from top with mortar.

All brick courses shall be taken up truly plumb; if battered, the batter is to be truly maintained. All courses shall be laid truly horizontal and vertical joints shall be truly vertical. The level and verticality of work in walls shall be checked up at every one metre interval.

The masonry walls of structures shall be carried up progressively, leaving no part one metre lower than the other. If this cannot be adhered to, the brick work shall be raked back according to bond (and not left toothed) at an angle not more than 45 degrees but raking back shall not start within 60 cm of a corner. In all cases returns, buttresses, counter forts, pillars etc. shall be built up carefully course by course, and properly bonded with the main walls. The brick work shall not be raised more than fourteen (14) courses per day.

At the junction of any two walls, the bricks shall at each alternate course, be carried into each of the respective walls so as to thoroughly unite the work.

The courses at the top of plinth and sills, at the top of the wall just below the soffit of the roof slab or roof beam and at the top of the parapet, shall be laid with bricks on edge. Brick on edge course shall be so arranged as to tightly fit under the soffit of the roof beam or roof slab, restricting the mortar layer thickness upto 12mm, however, any gap between the finished brick work and soffit of roof slablbeam shall be suitably





sealed with the mortar.

52.2 Brick Work (half brick thickness)

For brick walls of half brick thickness, all courses shall be laid with stretchers. Wall shall be reinforced with 2 nos. - 6mm diameter mild steel reinforcement bars, placed at every fourth course. The reinforcement bars, shall be straightened and thoroughly cleaned. Half the mortar thickness for the bedding joint shall be laid first and mild steel reinforcement, one on each face of the wall, shall be embedded, keeping a side cover of 12mm mortar. Subsequently, the other half of the mortar thickness shall be laid over the reinforcement covering it fully.

The reinforcement bars shall be carried atleast 150mm into the adjoining walls or RCC columns. In case the adjoining wall being of half brick thickness, the length of bars shall be achieved by bending the bars in plan. During casting of reinforced concrete columns, 6mm dia. M.S. reinforcing bar shall be placed at every fourth course of brick masonry. At the junction of two walls, the brick shall, at each alternate course, be carried into each of the respective walls so as to thoroughly unite the work. The brick masonry work shall not be raised more than 14 courses per day.

Brick course under the soffit of beam or slab, shall be laid by restricting the mortar thickness to 12mm. However, any gap between the finished brickwork and soffit of slablbeam, shall be suitably sealed with the mortar.

5.2.3 Cavity Walls

Brick work in cavity walls shall be included with general brickwork. It shall consist of one wall of one or more brick thickness while the other wall shall be of half brick thickness at a clear gap of 50rnm. The brick work on either side of cavity shall conform to the specifications already stated under 5.2.1 and 5.2.2. At the base of the cavity wall, the walls shall be solidly constructed upto 300mm above the ground level. The cavity wall shall be terminated 300mm below the soffit of roof slab/beam and the courses over this shall be continued in solid brickwork.

Cavity should be continuous and free from obstructions. Mortar droppings shall be prevented from falling down the cavity by the use of laths or by hayhands which shall be drawn up the cavity as the work proceeds. Any mortar which may unavoidably fall on the wall-ties, shall be removed daily and temporary openings shall be provided to permit the daily removal of mortar droppings from the bottom of the cavity.

The outer and inner leaves shall be tied by means of wall ties. Ties shall be of mild steel round bars of 8mm dia. 200 mm long with hooks at both the ends. These shall be placed not more than 750mm clc horizontally and not more than 300mm vertically, and staggered. Additional ties shall be provided near the openings. There shall at least, be 5





ties per square meter of surface area of the wall. Ties shall be given a bituminous coat before placement, to protect them from corrosion.

In order to keep the cavity dry, air slots shall be provided in the cavity walls at bottom as well as top to the extent of 50 sq.cm area of vents to every 2.0 sq. metre area of the wall.

5.2.4 Circular Brick Work

The detailed GAIL specification for brick work covered under 5.2.1 & 5.2.2 shall apply, in so far as these are applicable. Bricks forming skew backs, shall be dressed or cut so as to give proper radial bearing. Defects in dressing of bricks shall not be covered up by extravagant use of mortar, nor shall the use of chips etc, be permitted.

The circular brick work shall be carried up from both ends simultaneously and keyed in the centre. The bricks shall be flushed with mortar and well pressed into their positions so as to squeeze out a part of their mortar and leave the joints thin and compact. All joints shall be full of mortar and thickness of joints shall be between 5mm and 15mm.

5.3 Jointing

Joints shall be restricted to a width of 10mm with brickwork of any classification. All bed joints shall be normal to the pressure upon them i.e. horizontal in vertical walls, radial in circular brick masonry and at right angles to the face in the battered retaining walls. The vertical joints in alternate courses shall come directly one over the other and shall be truly vertical. Care shall be taken that all the joints are full of mortar, well flushed up. In case no pointing is to be done, cement mortar shall be neatly struck as the work proceeds. The joints in faces which are to be plastered or pointed shall be squarely raked out to a depth of 12mm while the mortar is still green. The rake joints shall be brushed to remove loose particles. After the day's work, the faces of the brick workshall be cleaned on the same day with wire brush and all mortar droppings removed.

5.4 Curing

Green work shall be protected from rain or any other running water or accumulated water from any source, by suitable means. Masonry work, as it progresses, shall be kept thoroughly wet by sprinkling water at regular intervals, on all faces. Curing shall be done after 24 hours of completion of day's work and shall be done for atleast 10 days after completion. Proper watering cans with spray nozzles, rubber or PVC pipes shall be used for this purpose.

5.5 Staging/scaffolding

Staging/scaffolding shall be properly planned and designed by the Contractor. Use of





only steel tubes is permitted for Staging/scaffolding. Design of Staging/scaffolding shall be submitted for approval of the Engineer-in-Charge, before commencement of work.

Single scaffolding having one set of vertical support, shall be used and other end of the horizontal scaffolding member shall rest in a hole provided in the header course. The support shall be sound and strongly clamped with the horizontal pieces over which the scaffolding planks shall be fixed. The holes left in the masonry work for supporting the scaffolding shall be filled and made good with plain cement concrete of grade 1:3:6 during plastering. Suitable access shall be provided to the working platform area. The scaffolding shall be strong enough to withstand all loads likely to come upon it and shall also meet the requirements specified in IS:2750.

Double scaffolding shall be provided for pillars less than one metre in width or for the first class masonry or for a building having more than two storeys.

The following measures shall also be considered during erection of the scaffolding/ staging.

a. Sufficient sills or underpinnings, in addition to base plates, shall be provided, particularly, where scaffoldings are erected on soft grounds.

b. Adjustable bases to compensate for uneven ground shall be used.

c. Proper anchoring of the scaffolding/staging at reasonable intervals shall beprovided in each direction with the main structure wherever available.

d. Horizontal braces shall be provided to prevent the scaffolding from rocking.

e. Diagonal braces shall be provided continuously from bottom to top between two adjacent rows of uprights.

f. The scaffolding/staging shall be checked at every stage for plumb line.

g. Wherever the scaffolding/staging is found to be out of plumb line, it shall be dismantled and re-erected afresh. Efforts shall not be made to bring it in line with a physical force.

h. All nuts and bolts shall be properly tightened and care shall be taken that all the clamps/couplings are firmly tightened to avoid slippage.

i. Erection work of a scaffolding/staging, under no circumstance shall be left totally to semiskilled or skilled workmen and shall be carried out under the supervision of Contractor's technically qualified civil engineer.





5.5.2 For smaller works or works in remote areas wooden ballies may be permitted for scaffolding/staging by the Engineer-in-Charge at his sole discretion. The contractor must ensure the safety and suitability of such works as described under clause 5.5.1 above.

5.6 Embedment of Fixtures

All fixtures, pipes, conduits, holdfasts of doors and windows etc. required to be built inwalls, shall be embedded in plain cement concrete block of grade 1:3:6, at the required positions, as the work proceeds.

6.0 PAYMENT


6.1 General

The payment of brick masonry shall be inclusive of all labour, material, Scaffolding/staging sampling and testing, soaking of bricks, laying of bricks, raking of joints, cutting of bricks, providing recesses and making rectangular or round openings, sealing the gap between brick masonry and soffit of beam/slab with and including cement mortar, curing, making of masonry platform for unloading the wet mix, embedding the fittings/fixtures including providing PCC(1:3:6) etc, all as specified for all heights and depths. Deduction for rectangular or circular openings, shall be done as per relevant BIS Codes.

6.1.1 Payment for brick masonry works of one or more brick thickness, including circular brickwork, shall be made on cubic meter basis of the work done.

6.1.2 Payment for half brick masonry work shall be made on square meter basis on the area of work done and shall also include the cost of supplying and fixing of reinforcement bars in position.

6.1.3 Payment for forming the cavity, shall be in square meters and shall include the cost of laying of bitumen coated M.S. ties in position, labour required for keeping the cavity clear, providing air slots etc.


TECHNICAL SPECIFICATION FOR CIVIL & STRUCTURAL WORK

STONE MASONARY S-11-02-009 Page 1 of 9


TECHNICAL SPECIFICATION

CIVIL & STRUCTURAL WORKS STONE MASONRY





CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 MATERIALS


5.0 SPECIFIC REQUIREMENTS





1.0 SCOPE

This EIL specification establishes the materials, dressing, laying, jointing, workmanship, curing etc. for stone masonry works and shall comply with all the requirements of IS :1597.

2.0 REFERENCES

2.1 BIS Codes

IS : 269, 455, 1129, 1197, 2250, 2750

2.2 GAIL specifications for Materials

3.0 MATERIALS Refer GAIL specification on : Materials


4.1 Cement Mortar

Cement mortar shall meet the requirements of IS:2250 and shall be prepared by mixing cement and sand by volume. Proportion of cement and sand shall be 1 :6 One part of cement and six parts of sand) or as specified. The sand being used, shall be sieved before use. The mortar shall be used as soon as possible after mixing and before it has begun to set and in any case within initial setting time of cement, after the water is added to the dry mixture. Mortar unused for more than initial setting time of cement shall be rejected and removed from the site of work.

4.1.1 Proportioning The unit of measurement for cement shall be a bag of cement weighing 50 kgs and this shall be taken as 0.035 cubic meter. Sand shall be measured in boxes of suitable size on the basis of its dry volume. In case of damp sand, its quantity shall be increased suitably to allow for bulkage.





4.1.2.1 The mixing of mortar shall be done in a mechanical mixer operated manually or by power. The Engineer-in-Charge may however, permit hand mixing, as a special case, taking into account the magnitude, nature and location of work. The Contractor shall take the prior permission of the Engineer-in-Charge in writing, for using hand- mix, before the commencement of work.

4.1.2.1 Mixing in Mechanical Mixer

Cement and sand in specified proportions, by volume, shall be thoroughly mixed dry in a mixer. Water shall then be added gradually and wet mixing continued for atleast one minute. Care shall be taken not to add more water than that which shall bring the mortar to the consistency of a stiff paste. Wet mix from the mixer shall be unloaded on water-tight masonry platform, made adjacent to the mixer. Platform shall be at least 150mm above the levelled ground, to avoid contact of surrounding earth with the mix. Size of the platform shall be such that it shall extend atleas 300mrn alround the loaded wet mix area. Wet mix, so, prepared shall be utilised within initial setting time of cement [thirty (30) minutes either for ordinary portland cement conforming to IS:269 or for portland slag cement conforming to IS:455] after addition of water. Mixer shall be cleaned with water each time before suspending the work.

4.1.2.2 Hand Mixing

The measured quantity of sand shall be levelled on a clean masonry platform and cement bags emptied on top. The cement and sand shall be thoroughly mixed dry by being turned over and over, backward and forward, several times till the mixture is of uniform colour. The quantity of dry mix which can be consumed within initial setting time of cement shall then be mixed with just sufficient quantity of water to bring the mortar to the consistency of stiff paste.

4.2 Curing

Green work shall be protected from rain, running water or accumulated water from any source, by suitable means. Masonry work, as it progresses shall be kept thoroughly wet by sprinkling water at regular intervals, on all faces. Curing shall be done after 24 hours of completion of day's work and shall be done for at least 10 days after completion. Proper watering cans with spray nozzles, rubber or PVC pipes shall be used for this purpose.

Staging scaffolding shall be properly planned and designed by the Contractor. Use of





only steel tubes is permitted for staging scaffolding. Design of staging/scaffolding shall be submitted for approval of the Engineer-in-Charge, before commencement of work. 300mrn around the loaded wet mix area. Wet mix, so, prepared shall be utilized within initial setting time of cement [thirty (30) minutes either for ordinary Portland cement conforming to IS:269 or for portland slag cement conforming to IS:455] after addition of water. Mixer shall be cleaned with water each time before suspending the work.

4.3 StaginglscaffoldingStaginglscaffolding shall be properly planned and designed by the Contractor. Use of only steel tubes is permitted for staginglscaffolding. Design of staging/scaffolding shall be submitted for approval of the Engineer-in-Charge, before commencement of work. Single scaffolding having one set of vertical support, shall be used and other end of the horizontal scaffolding member shall rest in a hole provided in the header ourse. The supports shall be sound and strongly clamped with the horizontal pieces over which the scaffolding planks shall be fixed. The holes left in the masonry works for supporting the scaffolding shall be filled and made good with plain cement concrete of grade 1:3:6 during plastering. Suitable access shall be provided to the working platform area. The scaffolding shall be strong enough to withstand all loads likely to come upon it and shall also meet all the requirements specified in IS:2750. Double scaffolding shall be provided for pillars less than one metre in width or for the first class masonry or for a building having more than two storeys. The following measures shall also be considered during erection of the scaffoldinglstaging

a. Sufficient sills or underpinnings, in addition to base plates, shall be provided, particularly, where scaffoldings are erected on soft grounds.

b. Adjustable bases to compensate for uneven ground shall be used.

c. Proper anchoring of the scaffolding/staging at reasonable intervals shall be provided in each direction with the main structure wherever available.

d. Horizontal braces shall be provided to prevent the scaffolding from rocking.

e. Diagonal braces shall be provided continuously from bottom to top between two adjacent rows of vertical supports.

f. The scaffolding/ staging shall be checked at every stage for plumb line.

g. Wherever the scaffolding staging is found to be out of plumb, it shall be dismantled and re-erected afresh. Effort shall not be made to bring it in line with a physical force.

h. All clamps and couplings shall be properly tightened with nuts and bolts to avoid





slippage.

i. Erection work of a scaffoldinghtaging under no circumstances shall be left totally to semiskilled or skilled workmen and shall be carried out under the supervision of contractor's technically qualified civil engineer.

4.3.2 For smaller works or works in remote areas, wooden ballies may be permitted for scaffolding staging by the Engineer-in-Charge at his sole discretion. The contractor must ensure the safety and suitability of such works as described under clause 4.3.1 above.

4.4 Embedment of Fixtures

All fixtures, pipes, conduits, holdfasts of doors and windows etc. required to be built in walls, shall be embedded in plain cement concrete of grade 1:3:6 at the required position as the work proceeds.

5.0 SPECIFIC REQUIREMENTS

5.1 Random Rubble Masonry

5.1.1 Dressing

Stone shall be hammer dressed on the face, the sides and the beds to enable it to come in proximity with the neighbouring stone. The "bushing" (projection) on the face shall not be more than 40mm on an exposed face and 19mm on the face to be plastered. It shall not have depression more than l0mm from the average wall surface. It shall also conform to the general requirements for dressing of stones covered in IS :1 129.

5.1.2 Laying

All stones shall be wetted before laying to prevent absorption of water from mortar. The stones shall be laid so that the pressure is always perpendicular to the natural bed. The courses (if any) shall be built perpendicular to the pressure which the masonry will bear. In case of battered walls, the base of stone and plane of courses (if any) shall be at right angles to the batter.

The walls shall be carried up truly plumb or to the specified batter. Every stone shall be carefully fitted to the adjacent stones, so as to form neat and close joints. Vertical joints shall be staggered as far as possible.

Stones may be brought to level course at plinth, window sills and roof level.Levelling up at plinth level, window sills and roof level shall be done with concrete comprising of one part of the mortar as used for the masonry and two parts of graded stone aggregate of 20mm nominal size.





The bond shall be obtained by fitting in closely the adjacent stones. Transverse bonds shall be provided by the use of bond stones extended from the front to the back of the wall. At angular junctions the stones at each alternate course shall be well bonded into the respective courses of the adjacent wall. Face stones shall extend and bond well in the back. These shall be arranged to break joints as much as possible, and to avoid long vertical lines of joints. The depth of stone from the face of the wall, inwards, shall not be less than the height or breadth at the face. Where there is break in masonry work, the masonry shall be raked in sufficiently long steps for facilitating joining of old and new work. The stepping of the raking shall not be more than 45 degrees with the horizontal. The masonry work shall not be raised more than 1.2 metre per day. Toothed joints in masonry shall not be permitted.

5.1.3 Hearting Stones The hearting or interior filling of the wall shall consist of rubble

stones which may be of any shape but shall not be less than 150mm on any face. These

shall be carefully laid, hammered down with a wooden mallet into position and solidly dded in mortar. The hearting should be laid nearly level with facing and backing, except that at about one metre intervals, vertical bond stones shall be firmly embedded to form a bond between successive courses.

5.1.4Insertion of Chips

The chips and spalls stones shall be used wherever necessary to avoid thick mortar beds or joints and it shall also be ensured that no hollow spaces are left anywhere in the masonry. The chips shall not be used below the hearting stone to bring these upto the level of face stones. The use of chips shall be restricted to the filling of interstices between the adjacent stones in hearting and this shall in no case exceed 20% of the quantity of stone masonry.

5.1.4 Bond Stone

Bond or through stone running across the thickness of wall shall be provided in the walls having thickness upto 600mm. If the walls are thicker than 600 rnm, two or more bond stones overlapping each other by atleast 150mm shall be provided in a line from face to back. Atleast one bond stone or a set of bond stones shall be provided for every 0.5 sq.m of wall surface. These shall be provided at 1.5m to 1.8m apart clear in every course and shall be staggered in subsequent course. An identification mark for the bond stones shall be given on both faces.

5.1.6 Quoins The quoins shall be of selected stones neatly dressed to the required angle and shall be of the same height as the course in which they occur and laid header and tretcher alternately. The quoin stone shall not be less than 0.03 cubic metre in





volume.

5.1.7 Jointing

Stones shall be so laid that all joints are fully packed with mortar. Face joints shall be minimum 20mm thick. The joints shall be struck flush and finished at the time of laying; when plastering and pointing is not required. If walls are to be plastered or pointed, joints shall be raked to a minimum depth of 20mm during the progress of work when the mortar is still green. For the faces of the wall which are not to be plastered, stone surfaces shall be cleared of mortar splashing to give uniform stone appearance.

5.2 Coursed Rubble Masonry

5.2.1 Dressing

Face stones shall be hammer dressed on all beds and joints so as to give them approximately rectangular shape. These shall be square on all joints and beds. The bed joints shall be chisel drafted for atleast 80mm back from the face and for theside joints atleast 40mm. No portion of the dressed surface shall show a depth of gap more than 6mm from a straight edge placed on it. The remaining unexposed portion of the stone shall not project beyond the surface of the bed and side joints. The bushing on the face shall not be more than 40mm on an exposed face and l 0mm on the face to be plastered.

The hammer dressed stone shall also have a rough tooling for a minimum width of 25mm along the four edges of the face of the stone for the exposed stone masonry work.

5.2.2 Laying

All stones shall be wetted before laying to prevent absorption of water from ortar. The stones shall be laid so that the pressure is always perpendicular to the natural bed. The courses shall be built perpendicular to the pressure which the masonry will bear. In case of battered walls, the base of stone and plane of courses shall be at right angles to the batter.

The walls shall be carried up truly plumb or to the specified batter. Every stone shall be carefully fitted to the adjacent stones, so as to form neat and close joints. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical. The quoin stones shall be laid stretchers and headers alternately and shall be laid square on their beds, which shall be rough chisel dressed to a depth of atleast 100mm. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical.

The tones shall be laid in horizontal courses and each course shall be of equal height of not less than 150mm and more than 300m.m.





Levelling at plinth level, window sills and roof level shall be done with concrete comprising of one part of the mortar as used for the masonry and two parts of graded stone aggregate of 20 mm nominal size.

The bond shall be obtained by fitting in closely the adjacent stones. Transverse bonds shall be provided by the use of bond stones extended from the front to the back of the wall. At angular junctions the stones at each alternate course shall be well bonded into the respective courses of the adjacent wall.


TECHNICAL SPECIFICATION FOR DEMOLITION AND DISMANTLING S-11-02-010 Page 1 of 6


TECHNICAL SPECIFICATION

CIVIL & STRUCTURAL WORKS DEMOLITION AND DISMANTLING




CONTENTS

1.0 SCOPE

2.0 GENERAL

3.0 SAFETY PRECAUTIONS

4.0 PROCEDURE

5.0 CLEANING & STACKING

6.0 DISPOSAL

7.0 PAYMENT




1.0 SCOPE

This specification covers the procedure and safety requirements for demolition and dismantling of masonry (Brick & Stone), concrete (Plain /Reinforced), structural steel (sheeted / unsheeted) works .

2.0 GENERAL

2.1 Apart from this specification, the demolition and dismantling of structures (part or whole) shall be in compliance with all statutory safety regulations and any other special requirement as shown/Noted on the drawings and General Conditions of Contract. Prior consent and approval of the Engineer-in-charge shall be obtained in writing before starting any dismantling works. Any restrictions imposed regarding working hours shall also be strictly followed by the Contractor.

2.2 All materials obtained from dismantling/demolition operations shall be the property of the Owner unless otherwise specified and shall be kept in safe custody until handed over to the Engineer-in-charge.

2.3 Where it becomes necessary to disconnect any existing service line(s) (such as eIectrica1, piping etc.) during dismantling/demolishing operation and where so required by the Engineer-in-charge, suitable alternate arrangement shall be made by the Contractor to maintain the continuity and proper functioning of the affected service line(s) with the approval of the Engineer-in-charge at no extra cost to GAIL.

2.4 Specification No S-10-02-002 (Earthwork) shall be referred to the extent applicable.

3.0 SAFETY PRECAUTIONS

3.1 The Contractor shall adhere to safe demolishing/dismantling practices at all stages of work to guard against accidents, hazardous and unsafe working procedures.

.3.2 Necessary propping ,shoring ,strutting and/or underpinning shall be done for the safety of all surrounding structures (whose safety is likely to be endangered) before taking up the demolishing and dismantling work.

3.3 Temporary enclosures made out of GI sheets, fencings, danger lights etc. shall be provided by the Contractor and got approved by the Engineer-in-charge before start of work to prevent accidents.

3.4 Contractor must ensure the availability of adequate fire fighting equipment / arrangements before starting actual demolishing/dismantling works. These facilities shall be made available throughout the entire operation of demolition and dismantling of structures.

3.5 All equipments, pipes ,fittings and instruments, underground utilities etc. located in the




vicinity shall be protected by suitable means, as decided by the Engineer-in-charge, during demolishing, dismantling operations.

3.6 Roads and working spaces shall be kept free of any debri / dismantled materials at the end of day's work.

3.7 Necessary measures shall be taken to keep the dust and noise nuisance to minimum levels.

3,8 Dismantled elements/components shall not be dropped from a height or thrown from a distance. Dismantling of elements fixed by screws/bolts/hooks etc. shall be fixtures with proper tools only. Such fixtures may be allowed to be cut by sawing or flame cutting, in the event of their being stuckup due to corrosion etc. however the decision of Engineer-in-charge in this regard shall be final and binding., Welds shall be removed by flame cutting. Tearing or ripping of elements shall not be resorted to under any condition.

4.0 PROCEDURE

4.1 Entire work of demolishing & dismantling shall be meticulously planned. Prior to start of work, the Contractor shall thoroughly understand the scope and nature of the work, and then prepare and submit the proposed work execution plan of demolishing & dismantling to the Engineer-in- charge for his review. Comments if any, shall be taken care by the contractor and execution of the work shall be done based on the revised execution plan.

4.2 Demolition and dismantling shall be restricted to the extent shown on drawings or as directed by the Engineer-in-charge.

4.3 Demolition of any structure shall be carried out in the sequence reverse to that followed at the time of its construction.

4.4 Dismantling shall be done in a systematic manner. All elements shall be carefully removed without causing any damage.

4.5 Blasting in any form shall not be permitted.

4.6 Chipping of concrete grout shall be done with precision by chiseling. The finished surfaces shall be made true to the requisite size and shape.

4.7 Pockets/holes of specified size shall be made cut by drilling/chiselling.

5.0 CLEANING & STACKING

5.1 All demolished/dismantled servicable materials such as bricks, stones, reinforcement bars, structural steel, sheeting etc. shall be separated out, cleaned and stacked in




separate lots within the plant boundary as directed by the Engineer-in-charge.

6.0 DISPOSAL

All unserviceable materials shall be disposed off in spoil heaps within or outside the plant boundary as per the directions of the Engineer-in-charge. Areas required outside the plant boundary for dumping of disposed material shall be arranged by the contractor and got approved by the Engineer-in- charge.

7.0 PAYMENT

7.1 General

Measurement of all works shall be taken prior to start of demolishing / chipping / dismantling works.

7.2 Masonry/Concrete Works (Demolition)

7.2.1 Payment shall be made on the basis of actual volume in cubic meters (cu.m.) of masonry1 concrete works demolished. The thickness of plaster bitumen felt shall be included in measurements. The rate for demolishing shall include supply of labour, tools & tackles, necessary safety measures, propping, underpinning, scaffolding, handling, cutting, straightening, scraping & cleaning of reinforcement bars and other embedment (in case of reinforced concrete works), sorting out and stacking of all serviceable materials, disposal of all unserviceable material, clearing the site, etc. all complete as specified and directed by the Engineer-in-charge.

7.3 Excavation & Backfilling

7.3.1 Excavation and backfilling shall be paid separately as per relevant clauses of Specification No. S-10-02-002 for Earth Work.

7.4 Chipping of Concrete Works

Payment shall be made on the basis of admissible area in square meters (sq.m.) of concrete surfaces chipped, pertaining to the different categories of thicknesses specified in the schedule of items.

The rate for chipping shall include supply of labour, tools and tackles, necessary safety measures, scaffolding, chiselling, handling exposing, cutting, straightening, scraping, clearing the reinforcement bars (in case of reinforced concrete works), wire brushing and washing the exposed surfaces, disposal of all unserviceable material etc. all complete as directed.

7.5 Making Pockets/Holes in Concrete Works




Payment shall be made on the basis of number (Each) of pockets/holes of sizes upto & inclusive of 200x200x500 mm, made or cut in the concrete works.

The rate for making pockets/holes shall include supply of labour, tools & tackles, necessary safety measures, scaffolding, chiselling, drilling, handling, cutting or relocating reinforcement bars, cleaning, disposal of all unserviceable material etc. all complete as directed.

7.6 Dismantling of Structural Steel Works

Payment shall be made on the basis of weight (MT) of the structure/components being dismantled. Assessment of weight shall be done as per the specifications or as per the direction of Engineer-in-charge.

The rate for dismantling shall include supply of labour, tools and tackles, equipment, consurnables, necessary safety measures, scaffolding, propping, handling, unbolting, cutting (by sawing or flame cutting) of gussets/plates/bolts/hooks/welds, cleaning, sorting out and stacking of all serviceable materials, disposal of all unserviceable material, etc. all complete as specified and directed.

7.7 Dismantling of Roof & Wall Sheeting

Payment shall be made on the basis of dismantled sheeted area in square metreS (sq.m.) of plan area in case of roof sheeting and area in elevation in case of side and louver sheeting.

The rate for dismantling shall include supply of labour, tools and tackles, equipments, consumables, necessary safety measures, handling, scaffolding, unbolting, cutting (by saw or flame cutting) of hook bolts, removal of ridges, gutters, flashings, transporting, stacking of all serviceable materials, disposal of all unserviceable material, etc. all complete as directed.


TECHNICAL SPECIFICATION FOR CIVIL & STRUCTURAL WORKS MISCELLANEOUS ITEMS S-11-02-011

Page 1 of 9


TECHNICAL SPECIFICATION FOR CIVIL & STRUCTURAL WORKS

MISCELLANEOUS ITEMS



Page 2 of 9


CONTENTS

1. SCOPE

2. REFERENCES

3. MATERIALS

4. GENERAL REQUIREMENTS

5. PRE-CONSTRUCTIONAL ANTI-TERMITE TREATMENT

6. ANTI-CORROSIVE LAYER

7. DRESSING & TRIMMING

8. CUTTING PILE HEADS

9. BUILDING-UP PILE HEADS

10. HARD CORE

11. SAND FILLING IN PLINTHIFOUNDATIONS

12. DAMP PROOF COURSE - (DPC)



Page 3 of 9


1.0 SCOPE

The scope shall be as specified separately for different items below.

2.0 REFERENCES

2.1 BIS CodesGAIL specifications

S-11-02-002: Materials

S-11-02-004: Plain and Reinforced Cement Concrete

3.0 MATERIALS

The materials shall be as specified separately for different items below.


4.1 The Contractor shall test the materials, where applicable, in approved laboratory as required by the Engineer-in-Charge and furnish test certificates for materials and obtain the approval of the Engineer-in- Charge prior to the use of such materials in the works. All tests shall be in accordance with relevant Indian Standards.

5.0 PRE-CONSTRUCTIONAL ANTI-TERMITE TREATMENT

5.1 Scope

This GAIL specification establishes the materials and method of accomplishing pre-constructional anti-termite treatment of soil for protection of buildings against attack by subterranean termites with the usage of chemical emulsions in accordance with the procedure laid down.

5.2 Materials

Refer GAIL specification no. S-11-02-002

5.3 Procedure for Treatment

5.3.1 The treatment shall be carried out by an approved agency specialised in the field. Apart from this specification, the work shall be carried out in compliance with IS:6313. In case of any contradiction, this EIL specification shall govern.

5.3.2 Site Preparation



Page 4 of 9


Prior to start of chemical treatment, area(s) shall be made free from logs, stumps, timberoffcuts, leveling pegs, roots of planted trees etc. Soil treatment shall start when foundationtrenches pits are ready to take concrete/masonry in foundations and plinth area ready for laying the subgrade. Treatment shall not be carried out when it is raining or the subsoil water level is at the same or higher than the level of treatment. In the event of water-logging of foundations, the water shall be pumped out and the chemical emulsion applied when the soil is absorbent.

5.3.3 Treatment of the excavated pitsltrenches and backfill for Foundations

a) The bottom surface and the lower 300 mm side surfaces of the excavated pitsltrenchesfor foundations of masonry works and RCC plinth beams supporting such masonryworks, shall be treated with specified chemical emulsion @ 5 litres /m2 of the surfacearea. However, no such treatment shall be required in case of pitsltrenches made forRCC foundations supporting RCC walls and/or columns.

b) On completion of construction of masonry foundations, the backfill in immediate contact with the substructure shall be treated in layers, of 300mrn, with emulsion @ 7.5 litres/m2 of the vertical surface of the substructure (i.e. 7.5 x 0.300 = 2.25 Litre/ meter of perimeter) for each side. The treatment shall be given after ramming

of each layer of soil, by rodding the earth at 150mm centres close to the wall surfaceand working the rod backward and forward (parallel to the wall surface) and thenspraying the specified dosage of emulsion. The emulsion shall be directed towards themasonry surfaces so that the soil in contact with these surfaces is well treated with thechemical. After the treatment, the soil shall be tamped back into place. This shall bedone for full depth of the fill.

c) For RCC walls and columns, the treatment as specified in (b) shall start from a depth 500 mm below the finished ground level, and shall be done upto the FGL.

5.3.4 Treatment of Plinth / Basement and Apron

The top surface of the consolidated earth below the non-suspended floor slabs and theperipheral aprons of widths upto 750mm, the bottom surface and side surfaces of theexcavated pits for the basements shall be treated with chemical emulsion @ 5 litres/m2of the surface area. Holes 50 to 75mm deep at 150mm centres, both ways, shall bemade on the surface with 12mm diameter mild steel rod and then emulsion shall besprayed uniformly over the area. At expansion joint locations, anti-termite treatmentshall be supplemented by treating through the expansion joint @ 2.0 litres per linearmeter of joint after the subgrade has been laid.

Treatment of Junctions of plinth filling and wall/column faces shall be done aftermaking a small channel 30rnrnx30mm, by making rod holes 150mm apart (upto theground level) in the channel and then by moving the rod backward and forward tobreak up the earth. The chemical emulsion shall be poured along the channel @ 7.5



Page 5 of 9


litres/m2 of the vertical wall/column surface so as to soak the soil right to the bottom.The soil shall be tamped back into place after the treatment.

5.3.5 Treatment of Sol along External Perimeter of Bulding

After the building is complete, the earth along the external perimeter shall be rodded at intervals of 150mm and to depth of 300mm. The rod shall be moved backward and forward parallel to the wall to break up the earth and chemical emulsion poured along the wall @ 7.5 litres/m2 of vertical surface (i.e. 7.5 x 0.300 = 2.25 litreslmetre of perimeter). After the treatment, the earth shall be tamped back into place.

5.4 Payment


Payment for pre-constructional anti-termite treatment shall be made on square metre (sq.m.) basis of plinth area of the building at ground floor only. The rate shall include supplying all materials, spray pumps, tools, tackles & other accessories, labour, site preparation, rodding, tamping, mixing, spraying the specified chemical emulsion at prescribed dosage, storage facilities, handling, transporting etc. all complete as directed & specified.

6.0 ANTI-CORROSIVE LAYER

6.1 Scope

This EIL specification covers the requirement of materials, method of preparation andprocedure for laying an anticorrosive layer over top surface of tank foundations for protection of bottom plates of steel tanks against corrosion attack.

6.2 Materials

6.2.1 Sand shall be clean, dry, coarse, hard, angular, free from coatings of clay, dust and mix ofvegetable and organic matter and shall conform to IS:383 - Grade 111.

6.2.2 Bitumen shall be of grade A 90 conforming to IS:73.

6.3 Mixing and Laying

The bitumen shall be heated to a temperature of 175OC to 190•‹C with 3 % kerosene if required and sand ( 8 to 10% by volume) shall be thoroughly mixed with it in a mixing drum to give a uniform mixture and shall be laid over clean and dry surface of tank foundation to line, grade and levels as shown on the drawings and directed by the Engineer-in-Charge. Bitumen shall not be heated beyond the specified temperature limits. The layer shall be tamped to form hard mass of specified compacted thickness.



Page 6 of 9


6.4 Payment


The payment shall be made on square metre (sq.m.) basis of the area covered with theanticorrosive layer. The rate shall include supplying all materials, tools, plants, labour, transportation, handling, heating, mixing, laying, tamping etc. all complete as specified.

7.0 DRESSING & TRIMMING

7.1 Scope

This GAIL specification covers the procedure for dressing, trimming and paving with earth the peripheral area around the completed building/structure.

7.2 Procedure

The ground all around the completed buildinglstructure for 3 metres width or as specified by the Engineer-in-Charge, shall be cleaned and dressed to suitable slope. Over the prepared ground a layer of approved earth shall be spread, watered and well consolidated so as to achieve an average thickness of 75mm.

7.3 Payment


Payment shall be made on square metre (sq.m.) basis of the actual area dressed and paved with earth.The rate shall include supplying all materials, labour including cleaning, dressing the ground to required slope, spreading of earth, watering, ramming, consolidating etc. all complete as directed.

8.0 CUTTING PILE HEADS

8.1 Scope

This GAIL specification covers procedure for cutting pile heads of cast-in-situ RCC piles.

8.2 ProcedureHead of already cast RCC piles shall be cut after 28 days of casting up to a length and elevation as shown on the drawing by chiseling taking all necessary safety precautions. Care shall be taken that pile reinforcement is not cut or damaged during chiseling operation. All debris and loose or cracked concrete in the pile shall be removed and disposed off within the plant boundary as per the directions of the Engineer-in-Charge and



Page 7 of 9


site shall be left clean for casting of pile caps. The surface of reinforcement bars shall be cleaned, if required by wire brushing so that no old concrete sticks to them.

8.3 Payment


Payment shall be made per pile basis for the actual number of pile heads cut. The rate shall include supplying a11 tools and tackles, labour including disposal of debris, bending the pile reinforcements for proper anchorage within the pile cap etc. all complete as directed.

9.0 BUILDING-UP PILE HEADS

9.1 Scope

This GAIL specification covers requirements of materials and procedure for building-up of RCC Pile Heads.

9.2 Materials

9.2.1 Concrete shall be of the same grade & GAIL specification as that for the pile.

9.2.2 Reinforcement shall be of the same grade and GAIL specification as that for the pile.

9.2.3 Type of cement shall be same as that used for the pile.

9.3 Procedure

Concrete in existing piles shall be chiseled off minimum upto the lap-length of thereinforcements in the pile. In cases where reinforcements are longer than the concreted piles, the top concrete of the existing piles shall be chiseled off upto a length of 800mm.

Concrete surface and reinforcement of pile shall be cleaned of any dirt, grease, debris etc. and concrete surface shall be made rough by hacking. Reinforcement shall be lapped/welded as per the direction of the Engineer-in-Charge. Neat cement slurry shall be applied on top surface of concrete and using approved formwork concreting shall be done upto the level shown on the drawing or as directed by the Engineer-in-Charge.

9.4 Payment


Payment shall be made on cubic metre basis for the total quantity of concrete actually poured for achieving the level as shown on drawings.The rate shall include supply of all materials (except reinforcement which shall be paid



Page 8 of 9


separately as per respective item) labour, cleaning, welding, shuttering, vibrating, finishing,curing etc. all complete. Cutting of pile heads and excavation including backfilling shall bepaid separately as per respective item.

10.0 HARD CORE

10.1 Scope

This GAIL specification covers the requirements of materials and procedure for laying of hard core.

10.2 Materials

Hard core shall consist of brokenlcrushed stones of 150mm and down size. Stones shall besound, angular, hard and free from flakes, dust and other impurities.

10.3 Procedure

Hard core shall be laid to the grade, level and thickness as shown on the drawing. Brokenstones of required height shall be vertically placed and blinded with approved murrum /sand and consolidated with roller including watering, dressing etc. However, areas inaccessible by roller may be compacted by hand rammer.

10.4 Payment


The hard core shall be measured on the basis of volume in cubic metres (cu.m.) of compacted hard core laid. The rate shall include all labour, materials, consolidation byrammer/roller, watering, dressing etc. all complete.

11.0 SAND FILLING IN PLINTH/FOUNDATIONS

11.1 Sand filling in plinth / foundation shall be as per relevant standard specifications.

11.2 Filling shall be carried out in layers not exceeding 15cms and shall be compacted mechanically or by saturation to specified grade and level and to obtain 90% laboratory maximum dry density or as specified in schedule of rates.

11.3 Compaction by flooding may be accepted at the discretion of the Engineer-in-Charge, provided the required compaction is achieved.

11.4 The Contractor shall not commence filling in and around any work until it has been permitted by the Engineer-in-Charge.

11.5 Payment



Page 9 of 9



Payment shall be made on cubic metre (cam.) basis of the finished compact volume. The rate shall include cost of sand for any compacted thickness, wastage if any, all handling, transport for all leads, tamping, watering, flooding, dressing etc. Any brick work requiredfor ponding shall be paid separately under relevant item.

12.0 DAMP PROOF COURSE - (DPC)

12.1 All materials used for Damp Proof Course shall as per relevant standard specifications.

12.2 The 40mm thick Damp Proof Course shall consist of plain cement concrete of grade M-20,unless otherwise specified.

12.3 The Damp Proof Course shall be laid at plinth level of masonry walls, flush with the floorsurface and shall not be carried across doorways.

12.4 Before laying, the top surface of wall shall be thoroughly cleaned and watered. The D.P.C. shall be laid in layers of 20mm thickness retaining the edges by necessary formwork and shall be well tamped and troweled to smooth finish. The layer shall be cured by keeping the surface wet for 40 hours and after it has dried, two coats of hot bitumen of grade A120lS120 conforming to IS:73 shall be applied over it at the rate of 1.7 ~g./m'. Over this, the second layer of 20mm thick concrete shall be laid and cured as described in case of the first layer and two coats of hot bitumen at the rate of 1.7 Kg./m2 shall be applied again in a similar manner.Over this, dry sharp sand shall be sprinkled evenly before hardening of second coat of bitumen paint.

12.5 Payment


Payment shall be made on square metre (sq.m.) basis of the area laid. The rate shall beinclusive of formwork, curing, providing and laying bitumen, supplying and spreading sandover bitumen etc. complete.

STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI FLOORING DETAILS FOR BUILDINGS S-11-01-001 Page 1 of 2


STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI FLOORING DETAILS FOR BUILDINGS S-11-01-001 Page 2 of 2


STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI METAL INSERT PLATES S-11-01-002 Page 1 of 7














STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI STANDARD LINTELS S-11-01-003 Page 1 of 5










STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI M.S. ANCHOR BOLTS ASSEMBLIES S-11-01-004 Page 1 of 7














STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI HANDRAIL S-11-01-005 Page 1 of 10



















HANDRAILS-11-01-005

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STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI STEEL STAIR S-11-01-006 Page 1 of 7












STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI STANDARD GRATING DETAIL S-11-01-007 Page 1 of 6













SMALL OPERATING FORMS ON GRADE/RCC ELEVATED STRUCTURE S-11-01-008 Page 1 of3








STANDARD DRG. NO. REV-0 GAIL (INDIA) LTD NEW DELHI PIPESLEEPER CROSSOVER S-11-01-009 Page 1 of 10














HANDRAIL ON HORIZONTAL LANDING








CABLE TRENCHS-11-01-010

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