NTPC LIMITED - rites. · PDF fileNTPC LIMITED (A Government of India Enterprise) ... General Conditions of Contract for NTPC Ltd. (6) Technical Specifications (7) Drawings . Signature

Signature of the tenderer

Under seal of the firm

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NTPC LIMITED (A Government of India Enterprise)

Open Tender Notice No. 118/OT/NTPC-BARH/P.Way/PKG-IIC-Part-1/2013 Dated 10.01.2013.

P.WAY WORKS INCLUDING SUPPLY OF P.WAY MATERIALS FOR MAKING NEW PRIVATE SIDING FROM IN-PLANT ENTRY KM CH 4/231 TO PUNARAKH RAILWAY STATION DEAD END KM CH 0/147.72 IN CONNECTION WITH THE PROJECT MANAGEMENT AND EXECUTION OF RAILWAY SIDING SYSTEM PACKAGE FOR BARH STPP, STAGE-I (3 X660 M.W) AT BARH, DIST. PATNA, BIHAR.

Package – II C (Part-1)

PART-1 TECHNICAL BID

CONTENTS

Section-1 : Notice Inviting Tender and Instructions to Tenderers Section-2 : Tender and Contract Form Section-3 : Special Conditions of Contract

Section-4 : Amendment / Errata to GCC Section-5: General Conditions of Contract for NTPC Ltd.

Section-6: Technical Specifications Section-7: Drawings

Issued to (Name of

Tenderer):________________________________________________

Address of tenderer:

________________________________________________________

Signature of officer issuing the

documents_______________________________________

Designation

________________________________________________________________

Date of

Issue________________________________________________________________

RITES Ltd. (A Govt. of India Enterprise)

Kolkata Project Office 56, C.R. Avenue, 2nd Floor Kolkata-700 012

e. mail: [email protected] Phone No.: 033-22367118/7146/7162/7143(Fax)



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RITES LTD (A Govt. of India Enterprise)

REGIONAL PROJECT OFFICE, 56, C.R. Ave. (2nd fl),

Kolkata-12

Phone No. 033-2236 7118/46/62 FAX-033 2236 7143

NOTICE INVITING TENDER (OPEN)

NIT NO:118/OT/NTPC-BARH/P. Way/PKG-IIC-Part-1/2013

Dated 10.01.2013.

General Manager (Projects) RITES Ltd, Regional Project Office,

Kolkata for & on behalf of NTPC Ltd. invites sealed tenders from

contractors who fulfill qualifying criteria stipulated in Tender

Documents for the following work:

Name of the work: P. Way works including supply of P. Way

materials for making new private siding from In-plant entry Km.

Ch. 4/321 to Punarakh Railway Station dead end Km. Ch. 0/147.72

in connection with the Railway Siding system Package for Barh –

STPP, Stage-I, (3x660 MW), Dist. Patna, Bihar. Estimated Cost:

Rs.296.18 Lakh (Approx), EMD: Rs.2,96,200/-, Completion

period: 03 (Three) months. Sale of Tender Documents:

11.01.2013 to 22.01.2013 from 11.00 Hrs to 16.00 Hrs on any

working days. Last date of Submission of Tender: 24.01.2013 up

to 14.00 Hrs. Date of opening of Technical Bid: From 14.30 Hrs

on 24.01.2013 in presence of the intending tenderers. Date of

opening of Financial Bid: Shall be intimated later to the technically

successful bidders only. Tender documents can be purchased from

the above address at a cost of Rs.5,000/- (Rupees five thousand) in the form of DD/PO/BC drawn on any Schedule Bank in favour of

RITES Ltd., payable at Kolkata. For complete Tender Documents

including qualifying criteria etc. please visit: (www.rites.com)

contact this office. Addendum/corrigendum, if any, would be

hoisted on the websites only.



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PART I

TECHNICAL BID

Section – 1

NOTICE INVITING TENDER & INSTRUCTIONS TO TENDERERS



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SECTION 1

NOTICE INVITING TENDER AND INSTRUCTIONS TO TENDERERS

Tender No.118/OT/NTPC-BARH/P.Way/PKG-IIC-Part-1/2013 Dated 10.01.2013.

1.0 GENERAL

1.1 Tender Notice

Sealed Tenders are invited by RITES Ltd., a Public Sector Enterprise under the Ministry of

Railways, acting for and on behalf of NTPC Ltd. (Employer) as an Agent/Power of

Attorney Holder, from working contractors (including contractors who have executed works

within the last five years reckoned from the date of opening of tenders) of Railways,

CPWD, MES, DOT, RITES, State PWD or any other Central / State Government

Undertaking Municipal Body, Autonomous Body or Public Ltd., Co. listed on BSE/NSE for

the work of P.Way works including supply of P.Way materials for making new private

siding from In-Plant Entry Km. Ch 4/231 to Punarakh Railway Station dead end Km.

Ch 0/147.72 in connection with the project management and execution of railway

siding system package for Barh STPP, Stage-I (3 x 660 M.W) at Barh, dist. Patna,

Bihar (Note : Throughout these bidding documents, the terms ‘bid’ and ‘tenders’ and their

derivatives are synonymous.)

1.2 Estimated Cost of Work

The work is estimated to cost Rs.296.18 Lakhs (Approx.). This Estimate, however, is

given merely as a rough guide.

1.3 Time for Completion

The time allowed for completion of the work will be 03 (Three) months from the 15th day

after the date of issue of Letter of Acceptance or from the first day of handing over of the

site, whichever is later, in accordance with the phasing, if any, indicated in the Tender

Documents.

1.4 Brief Scope of Work

a) P.Way Work: Laying & Linking of Track, Points & Crossings,Supply of

Ballast, P.way fittings,Turn outs,D.swithes,Welding portions ,PSC sleepers and

any other element of work required to complete the work(except rails and

balance quantity of PSC sleepers which shall be supplied free of cost by NTPC

at nominated locations/store).

1.5 Availability of Site

The site for the work is available/ shall be made available in parts, as specified

below:

Site of the work is available/shall be made available phase wise.



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2.0 QUALIFICATION CRITERIA TO BE SATISFIED

2.1 The Qualification Criteria to be satisfied are given at Annexure I enclosed.

2.2 The Qualification Criteria to be satisfied will depend on the category of works,

whether Normal or Large. Normal Works are those costing upto Rs.30 Crores each

and Large Works are those costing more than Rs.30 Crores. The work for which

the Tender is being invited falls under the category of Normal.

2.3 The Qualification Criteria to be satisfied will also depend on whether the Work falls

in Normal area or Difficult area. Difficult area includes North East States, Jammu

& Kashmir, Jharkhand, Chattisgarh and Andaman & Nicobar Islands. Normal area

covers all areas other than Difficult area. The work for which this Tender has been

invited falls under Normal area.

2.4 In this Tender Joint Venture is not allowed.

2.5 The documents to be furnished by the Bidder to prove that he is satisfying the

Qualification Criteria laid down should all be in the Bidder’s name, except in cases

where though the name has changed, the owners continued to remain the same and

in cases of amalgamation of entities.

3.0 FORMAT AND CHECK LIST FOR SUBMISSION OF INFORMATION ON

QUALIFICATION CRITERIA

3.1 Other than Joint Ventures

The Tenderer shall furnish a Letter of Transmittal as given in Annexure II A

enclosing the documents mentioned therein/listed in para 1(a) of Annexure IA.

3.2 Joint Ventures (For Large Works) : Not Applicable.

3.3 Joint ventures (For Normal Works) Not Applicable

4.0 CONTENTS OF TENDER DOCUMENT

4.1 Each set of Tender or Bidding Document will comprise the Documents listed below

and addenda issued in accordance with Para 7 :

PART – 1 :- Technical Bid Packet

SECTION No. CONTENTS

(1) Notice Inviting Tender and Instructions to Tenderers

(2) Tender and Contract Form.

(3) Special Conditions of Contract

(4) Amendment /Errata to GCC

(5) General Conditions of Contract for NTPC Ltd.

(6) Technical Specifications

(7) Drawings



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PART – 2:- Financial Bid Packet

Schedule of Quantities (Bill of Quantities)

5.0 ISSUE OF TENDER DOCUMENT

5.1 A complete set of Tender Document (Technical and Financial Bid) described in

Para 4.1 above can be seen in the office of the General Manager (Projects),

RITES Ltd., 56, C.R. Avenue, 2nd Floor, Kolkata – 700 012 between hours of

11.00 AM and 4.00 PM every day except on Saturdays, Sundays and Public

Holidays.

5.2 One set of Tender Document may be purchased from the office of the General

Manager (Projects), RITES Ltd., 56, C.R. Avenue, 2nd floor, Kolkata – 700 012

from 11.01.2013 to 22.01.2013 for a non refundable fee per set of Rs.5,000/-

(Rupees Five thousand only) in the form of Demand Draft/ Pay Order/ Banker’s

cheque drawn on any Scheduled Bank payable at Kolkata in favour of RITES Ltd.,

on submission of an application.

5.3 Tender Documents including drawings can also be downloaded from RITES

Website (www.rites.com) and in such a case, the Tenderer shall deposit the cost of

tender documents along with submission of tender, failing which his tender shall not

be opened. The cost of tender documents shall be deposited in the form of a

separate Banker’s cheque / Demand Draft / Pay Order and enclosed in the envelope

containing the Earnest Money Deposit. The amendments / clarifications to the

Tender documents will also be available on the above website.

5.4 Tender Documents downloaded from the above websites shall be considered valid

for participating in the tender process. During the scrutiny of downloaded tender

document, if any modification / correction etc. is noticed as compared to the original

documents posted on the website, the bid submitted by such a Tenderer is liable to

be rejected. In case the bid of a Tenderer who has downloaded the document from

website is accepted the contract shall be executed in the original / manual tender

document issued by the concerned RITES officer.

5.5 Clarifications on Tender Documents

A prospective tenderer requiring any clarification on the Tender Document may

notify Sri K. Haldar/SrDGM (Civil) (The official nominated for this purpose) in

writing or by telefax/cable at the address RITES Ltd, Regional Project Office,56 CR

Avenue, Kolkata -700012/FAX NO. 033-2236-7143/E-mail to [email protected]

In cases where Pre-Bid Meeting is not proposed to be held, request for clarifications

including request for Extension of Time for submission of Bid, if any, must be

received not later than 10 (ten) days prior to the deadline for submission of tenders.

Details of such questions raised and clarifications furnished will be uploaded in

RITES website without identifying the names of the Bidders who had raised the

questions. Any modification of the Tender Document arising out of such

clarifications will also be uploaded on RITES website only.



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In cases where Pre-Bid Meeting is proposed to be held, provisions in para 6.0 below

may be referred to.

6.0 PRE-BID MEETING: Not Applicable

7.0 AMENDMENT OF TENDER DOCUMENT

7.1 Before the deadline for submission of tenders, the Tender Document may be

modified by RITES Ltd. by issue of addenda/corrigendum. Issue of addenda /

corrigenda will however be stopped 7 days prior to the deadline for submission of

tenders as finally stipulated.

7.2 Addendum/corrigendum, if any, will be hosted on website only and shall become a

part of the tender document. All Tenderers are advised to see the website for

addendum/ corrigendum to the tender document which may be uploaded upto 7 days

prior to the deadline for submission of Tender as finally stipulated.

7.3 To give prospective Tenderers reasonable time in which to take the addenda/

corrigenda into account in preparing their tenders, extension of the deadline for

submission of tenders may be given as considered necessary by RITES.

8.0 TENDER VALIDITY

8.1 The Tender shall be valid for a period of 180 days from the due date for submission

of Tender or any extended date as indicated in sub para below.

8.2 In exceptional circumstances, during the process of evaluation of tenders and prior

to the expiry of the original time limit for Tender Validity, the Employer may

request that the Tenderers may extend the period of validity for a specified

additional period. The request and the tenderer’s response shall be made in writing.

A Tenderer may refuse the request without forfeiting his Earnest Money. A Tenderer

agreeing to the request will not be permitted to modify his Financial Bid to a higher

amount but will be required to extend the validity of the Earnest Money for the

period of the extension.

9.0 EARNEST MONEY

9.1 The Tender should be accompanied by Earnest Money of Rs.2,96,200/- (Rupees

Two lakh Ninetysix thousand Two hundred only) in any of the forms given

below:-

Banker’s Cheque / Pay Order/ Demand Draft payable at Kolkata , drawn in favour

of RITES Ltd.

9.2 Any Tender not accompanied by Earnest Money in an acceptable form shall be

rejected by the Employer as non-responsive.



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9.3 Refund of Earnest Money

a) Two Packet System: Applicable

The Earnest Money of the Tenderers whose Technical Bid is found not acceptable

will be returned without interest soon after scrutiny of Technical Bid has been

completed by the Employer subject to provisions of Para 9.4 (b). The Earnest

Money of the Tenderers whose Technical Bid is found acceptable but Financial Bid

is rejected will be returned without interest within 28 days of the end of Tender

Validity Period subject to provisions of Para 9.4 (b).

Single Packet System

After evaluation of the Financial Bids, the Earnest Money of unsuccessful Tenderers

will be returned without interest within 28 days of the end of Tender Validity Period

subject to provisions of Para 9.4 (b).

c) In case of both Two Packet and Single Packet System, the Earnest Money of the

successful Tenderer, without any interest, will be adjusted as a part of the Security

Deposit payable in terms of provisions in the General Conditions of Contract.

The Earnest Money is liable to be forfeited

a) if after bid opening, but before expiry of bid validity or issue of Letter of

Acceptance, whichever is earlier, any Tenderer

i) withdraws his tender or

ii) makes any modification in the terms and conditions of the tender

which are not acceptable to the Employer.

b) in case any statement/information/document furnished by the Tenderer is

found to be incorrect or false.

c) in the case of a successful Tenderer, if the Tenderer

i) fails to furnish the Performance Guarantee within the period specified

under “Clauses of Contract”. or

ii) fails to commence the work without valid reasons within the period as

specified in the tender document after the date of issue of Letter of

Acceptance or from the first date of handing over of the site,

whichever is later.

In case of forfeiture of E.M. as prescribed hereinabove, the Tenderer shall not be

allowed to participate in the retendering process of the work.



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10.0 ALTERNATIVE PROPOSALS BY THE TENDERERS

The Tenderers shall submit offers which comply strictly with the requirements of the

Tender Document as amended from time to time as indicated in Para 7.0 above.

Alternatives or any modifications shall render the Tender invalid.

11.0 SUBMISSION OF TENDER

11.1 Two Packet System and Single Packet System

(a) Two Packet System Applicable

The tenderer shall submit the Tender in original in two packets as under:-

PACKET A :- TECHNICAL BID

Envelope 1 Earnest Money & Cost of Tender Document if the bid

is submitted on the document downloaded from

RITES/NTPC website

Envelope 2 “Authority to Sign”, ‘Integrity Pact’ (when applicable)

and Qualification Information along with all

enclosures / documents as per Letter of Transmittal/

Checklist given in Annexure II A. As regards

“Authority to Sign” Para 11.2 below may be referred

to. As regards ‘Integrity Pact’, para 11.7 below may

be referred to.

Technical Bid (Part 1 and Part 3) (Refer Para 4.1)

including

signature on Tender Form (Section 2) duly witnessed

after filling up blanks therein.

Each page of the above documents including all

Drawings should bear the dated initials of the

Tenderer along with the seal of the Company, in token

of confirmation of having understood the Contents.

PACKET B :- FINANCIAL BID

Envelope 3 Schedule/Bill of Quantities.

Each page of the Financial Bid (Part 2 – Refer Para 4.1) should be signed by the

Tenderer along with the seal of the company. In the last page of Financial Bid, at the

end, the Tenderer should sign in full with the name of the Company, Seal of the

Company and Date.

All rates and amounts, both in figures and words, must be written in indelible ink.

Each Correction, Cutting, Addition and overwriting should be initialed by the

Tenderer.



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The rates must be quoted in decimal coinage. Amounts must be quoted in full

rupees by ignoring fifty paise and less and considering more than fifty paise as rupee

one. If the same item figures in more than one section/part of Schedule of

Quantities, the Tenderer should quote the same rate for that item in all sections/parts.

If different rates are quoted for the same item, the least of the different rates quoted

only shall be considered for evaluation of that item in all sections/parts of the

Schedule of Quantities.

Instructions contained in subsequent Para 17.6 (a) on “Item rate tender” and 17.6 (b)

on “Percentage rate tender” may be carefully studied and complied with.

b) Single Packet System : Both Technical Bid (including signature on Tender Form in

Section 2 duly witnessed) and Financial Bid Documents will be submitted in one

Packet. Precautions as described above for Two Packet System shall be observed by

the tenderers. – Not Applicable

11.2 Authority to Sign

a) If the applicant is an individual, he should sign above his full type written

name and current address.

b) If the applicant is a proprietary firm, the Proprietor should sign above his full

type written name and the full name of his firm with its current address.

c) If the applicant is a firm in partnership, the Documents should be signed by

all the partners of the firm above their full type written names and current

addresses. Alternatively the Documents should be signed by the person

holding Power of Attorney for the firm in the Format at Annexure IV.

d) If the applicant is a limited Company, or a Corporation, the Documents shall

be signed by a duly authorized person holding Power of Attorney for signing

the Documents in the Format at Annexure IV.

e) If the applicant is a Joint Venture, the Documents shall be signed by the Lead

Member holding Power of Attorney for signing the Document in the Format

at Annexure V. The signatory on behalf of such Lead Partner shall be the

one holding the Power of Attorney in the Format at Annexure IV.

11.3 Items to be kept in mind while furnishing details

While filling in Qualification Information documents and the Financial Bid,

following should be kept in mind:

i) There shall be no additions or alterations except those to comply with the

instructions issued by the Employer or as necessary to correct errors, if any,

made by the Tenderers.

ii) Conditional Offer/ Tender will be rejected. Unconditional rebate/ discounts

in the Financial offer will however be accepted.

iii) The Employer reserves the right to accept or reject any conditional

rebate/discounts. While evaluating the Bid Price, the conditional

rebates/discounts which are in excess of the requirements of the bidding



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documents or otherwise result in accrual of unsolicited benefits to the

Employer, shall not be taken into account.

11.4 Sealing and Marking of Tenders

11.4.1 Two Packet System – Applicable

(a) PACKET A – TECHNICAL BID

Envelopes 1 & 2 as described in Para 11.1 (a) above should be sealed separately

superscribing “Technical Bid” with Envelope Number, Name of the work and

Name of the tenderer. In addition, the following should also be superscribed on the

respective envelopes.

Envelope 1 i) Earnest Money

ii) Cost of Tender Document if the Bid is

submitted on the document downloaded from

RITES/NTPC website.

Envelope 2 i) Authority to Sign, ‘Integrity Pact’ (when

applicable as per para 11.7 below) and

Qualification Information/ documents as per

checklist in Annexure IIA / IIB(L)/ II B (N).

ii) Technical Bid including Drawings

Both the envelopes should be put in a packet which should be sealed. The following

should be superscribed on the packet:

i) Packet A – Technical Bid

ii) Name of the Work

iii) Name of the Tenderer

(b) PACKET B – FINANCIAL BID

Envelope 3 – Financial Bid should be put in Packet B which should be sealed. The

following should be superscribed on the packet.

i) Packet B - Financial Bid

ii) Name of the work

iii) Name of the tenderer

(c) Both packets A and B should be put inside an outer envelope and sealed. This

envelope should be superscribed with the following details:

i) Tender for (Name of work)

ii) Tender number

iii) Date and time of opening of Tender

iv) From (Name of Tenderer)

v) Addressed to ---- (RITES Officer inviting the Tender)



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11.4.2 Single Packet System : Not Applicable

Two envelopes of Technical Bid and one of Financial Bid shall be made out as

stipulated in Para 11.4.1 (a) and (b) above with the Name of the work and Name

of the Tenderer superscribed on each of the envelopes. All the three envelopes shall

be put in a Single Packet which shall be superscribed in the same manner as given in

Para 11.4.1 (c) above.

11.4.3 If the envelopes and packets are not superscribed and sealed as indicated in Paras 11.4.1/ 11.4.2 above, the Employer will assume no responsibility for the

misplacement or premature opening of the Tender.

11.5 Deadline for submission of Tender

11.5.1 Tenders must be received by the Employer at the following address not later than

14.00 Hrs. on 24.01.2013. In the event of the specified date for the submission of the

Tender being declared a holiday due to Strike/Bandh or on any account by the

Employer, the Tenders will be received up to the appointed time on the next working

day.

Address for submission of Tender: Office of the General Manager (Projects),

RITES Ltd., 56, C.R. Avenue, 2nd Floor, Kolkata – 700 012.

11.5.2 The Employer may extend the deadline for submission of Tenders by issuing an

amendment in writing in accordance with Para 7.3 in which case all rights and

obligations of the Employer and the Tenderer previously subject to the original

deadline will be subject to new deadline.

11.6 Late Tender / Delayed Tender

Any Tender received by the Employer after the specified date and time of receipt of

Tender will be returned unopened to the Tenderer.

11.7 Integrity Pact

(i) The Bidder/Contractor is required to enter into an Integrity Pact with the

Employer, in the Format at Annexure VIII. The Integrity Pact enclosed as

Annexure VIII will be signed by RITES for and on behalf of Employer as

its Agent/Power of Attorney Holder at the time of execution of Agreement

with the successful Bidder. While submitting the Bid, the Integrity Pact shall

be signed by the duly authorized signatory of the Bidder/Lead Member of

JV. In case of failure to submit the Integrity Pact duly signed and witnessed,

along with the Bid, the Bid is likely to be rejected.

(ii) In case of any contradiction between the Terms and Conditions of the Bid

Document and the Integrity Pact, the former will prevail.

Provided always that provision of this para 11.7 – Integrity Pact, shall be

applicable only when so provided in para 11.7A below which will also



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stipulate the name and address of the Independent External Monitor as well

as the Name, designation and address of the official nominated by the

Employer to act as the Liaison Officer between the Independent External

Monitor and the Engineer-in-Charge as well as the Contractor.

11.7A Whether para 11.7 (Integrity Pact) shall be applicable NO

11.8 Modification and Withdrawal of Bids

11.8.1 Tenderers may modify or withdraw their bids by giving notice in writing before the

deadline prescribed in para 11.5 for submission of Bids.

11.8.2 Each modification or withdrawal notice shall be prepared, sealed, marked and

delivered in accordance with paras 11.1, 11.2 and 11.4 with the outer envelopes

additionally marked ‘Modification’ or ‘Withdrawal’ as appropriate.

The envelopes for modifications on ‘Technical Bid’ and ‘Financial Bid’ shall be

submitted in separate sealed envelopes and marked as ‘Modifications of Technical

Bid’ or ‘Modifications of Financial Bid’ as the case may be.

11.8.3 No bid may be modified after the deadline for submission of Bids except as

indicated below. If a Bidder makes a suo moto offer of rebate / discount in his

Financial Bid after the deadline for submission of Bids, such offer will not be

considered for Financial evaluation of Tenders. But if the Tenderer is successful in

the Bid based on his original offer without considering the suo moto offer, the

rebate / discount offered will be taken into account for incorporation in the Contract

Agreement.

11.8.4 Withdrawal or modification of a Bid, subject to provisions in Para 11.8.3 above,

after the deadline for submission of Bids shall result in forfeiture of the Earnest

Money.

12.0 TENDER OPENING, EVALUATION AND CLARIFICATIONS OF

APPLICATIONS

12.1 The Employer will open all the Tenders received (except those received late or

delayed)as described in para 12.2/12.3 below, in the presence of the Tenderers or

their representatives who choose to attend at 14.30 Hrs. on 24.01.2013 in the office

of the General Manager (Projects), RITES Ltd., 56, C.R. Avenue, 2nd Floor, Kolkata

– 700 012. In the event of the specified date of the opening being declared a holiday

by the Employer, the Tenders will be opened at the appointed time and location on

the next working day.



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12.2 Two Packet System

(a) (i) The PACKET A will be opened and Envelope 1 containing Earnest Money and

Cost of Tender Document (where Bid is submitted in the document downloaded

from RITES/NTPC website) of all the Tenderers will be opened first and

checked. If the Earnest Money furnished is not for the stipulated amount or is

not in an acceptable form and where applicable, the cost of Tender Document

has not been enclosed for the correct amount and in an acceptable form, the

Envelope 2 of PACKET A (TECHNICAL BID) and PACKET B will be

returned to the Tenderer concerned unopened at the time of opening of the

Tender itself. The Envelopes 2 of PACKET A (TECHNICAL BID) of other

Tenderers who have furnished Earnest Money of correct amount in acceptable

form and where applicable the cost of Tender Document for the correct amount

and in an acceptable form will then be opened. The Tenderer’s name, the

presence of Earnest Money and Authority to sign and such other details as the

Employer may consider appropriate will be announced by the Employer at the

time of opening of Packet A. PACKET B (FINANCIAL BID) of the Tenderers

whose Technical Bids have been accepted for evaluation will be checked to see

if the seals are intact. All such PACKETS B will be put in an envelope and

sealed. The Employer’s official opening the Tender will sign on this envelope

and will also take the signatures of preferably atleast two Tenderers or their

representatives present. This envelope will be kept in safe custody by the

Employer.

(b) The Employer will scrutinise the Technical Bids accepted for evaluation to

determine whether each Tenderer

(i) has submitted `Authority to sign’ as per para 11.2 above and Integrity Pact

(where applicable) duly signed and witnessed as per para 11.7 above;

(ii) meets the Qualification Criteria stipulated in Para 2.0; and

(iii) conforms to all terms, conditions and specifications of the Tender Document

without any modifications or conditions.

(c) If required, the Employer may ask any such Tenderer for clarifications on his

Technical Bid. The request for clarification and the response from the Tenderer will

be in writing. If a Tenderer does not submit the clarification/document requested, by

the date and time set in the Employer’s request for clarification, the bid of such

Tenderer is likely to be rejected. Tenderers whose Technical Bids are not found

acceptable will be advised of the same and their Earnest Money and PACKET B

(FINANCIAL BID) will be returned unopened. Tenderers whose Technical Bids

are found acceptable will be advised accordingly and will also be intimated in

writing of the time and date and place where and when the PACKET B (Financial

Bid) will be opened.

(d) At the appointed place, time and date, in the presence of the Tenderers or their

representatives who choose to be present, the Employer will open the envelopes

containing the PACKET B (FINANCIAL BID). The Tenderer’s name, the tender

amount quoted and such other details as the Employer may consider appropriate

will be announced by the Employer.



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12.1 Single Packet System

(a) Envelope 1 of all the Tenders will be opened first and checked. If the Earnest

Money furnished is not for the stipulated amount or is not in an acceptable form and

where applicable the Cost of Tender Document has not been furnished for the

correct amount and in an acceptable form, the remaining envelopes will be returned

to the tenderer concerned unopened at the time of opening of the Tender itself. The

Envelopes no. 2 of Technical Bid and no. 3 of Financial Bid of other Tenderers who

have furnished Earnest Money and where applicable the Cost of Tender Document,

in acceptable form will then be opened. The Tenderer’s name, the presence of

Earnest Money, the Authority to Sign the Tender, amount quoted and such other

details as the Employer may consider appropriate will be announced by the

Employer.

13.0 INSPECTION OF SITE BY THE TENDERERS

Tenderers are advised to inspect and examine the site and its surroundings and

satisfy themselves before submitting their Tenders, as to the nature of the ground

and sub-soil (as far as is practicable), the form and nature of the site, the means of

access to the site, the accommodation they may require and in general shall

themselves obtain all necessary information as to risks, contingencies and other

circumstances which may influence or affect their Tender. A Tenderer shall be

deemed to have full knowledge of the site whether he inspects it or not and no extra

charges consequent on any misunderstanding or otherwise shall be allowed. The

Tenderer shall be responsible for arranging and maintaining at his own cost all

materials, tools & plants, water, electricity, access, facilities for workers and all

other services required for executing the work unless otherwise specifically provided

for in the contract documents. Submission of a tender by a Tenderer implies that he

has read this notice and all other contract documents and has made himself aware of

the scope and specifications of the work to be done and of conditions and rates at

which stores, tools and plant etc. will be issued to him by the Employer and local

conditions and other factors having a bearing on the execution of the work.

14.0 EMPLOYER’S RIGHT ON ACCEPTANCE OF ANY TENDER

(i) If required, the Employer may ask any Tenderer the breakdown of unit rates. If

the Tenderer does not submit the clarification by the date and time set in the

Employers request for clarification, such Tender is likely to be rejected.

(ii) The competent authority on behalf of the Employer does not bind himself to

accept the lowest or any other Tender and reserves to himself the authority to

reject any or all the Tenders received without the assignment of any reason. All

Tenders in which any of the prescribed conditions is not fulfilled or any

condition is put forth by the Tenderer shall be summarily rejected.

15.0 CANVASSING PROHIBITED

Canvassing whether directly or indirectly, in connection with tenders is strictly

prohibited and the tenders submitted by the Contractors who resort to canvassing

will be liable to rejection.



16

16.0 EMPLOYER’s RIGHT TO ACCEPT WHOLE OR PART OF THE TENDER

The competent authority on behalf of the Employer reserves to himself the right of

accepting the whole or any part of the tender and the Tenderer shall be bound to

perform the same at the rates quoted.

17.0 MISCELLANEOUS RULES AND DIRECTIONS

17.1 The Tenderer shall not be permitted to tender for works if his near relative is posted

as Associated Finance Officer between the grades of AGM(F) and J.M (F) in the

concerned

SBU Unit of RITES or as an officer in any capacity between the grades of

GGM/GM and Engineer (both inclusive) of the concerned SBU of the Employer.

He shall also intimate the names of persons who are working with him in any

capacity or are subsequently employed by him and who are near relatives to any

Gazetted officer in the organization of the Employer. Any breach of this condition

by the Tenderer would render his Tender to be rejected.

No Engineer of Gazetted rank or other Gazetted Officer employed in Engineering or

Administrative duties in an Engineering Department of the Organisation of the

Employer is allowed to work as a contractor for a period of one year after his

retirement from the Employer’s service without the previous permission of the

Employer in writing. The contract is liable to be cancelled if either the Contractor or

any of his employees is found any time to be such a person who had not obtained the

permission of the Employer as aforesaid before submission of the tender or

engagement in the Contractor’s service.

17.2 If required by the Employer, the Tenderers shall sign a declaration under the

officials Secret Act 1923, for maintaining secrecy of the tender documents drawings

or other records connected with the work given to them. The unsuccessful Tenderers

shall return all the drawings given to them.

17.3 Use of correcting fluid anywhere in tender document is not permitted. Such tender is

liable for rejection.

17.4 a) In the case of Item Rate Tenders, only rates quoted shall be considered. Any

tender containing percentage below/above the rates quoted is liable to be rejected.

Rates quoted by the Tenderer in item rate tender in figures and words shall be

accurately filled in so that there is no discrepancy in the rates written in figures and

words. However, if a discrepancy is found, the rates which correspond with the

amount worked out by the Tenderer shall unless otherwise proved be taken as

correct. If the amount of an item is not worked out by the Tenderer or it does not

correspond with the rates written either in figures or in words then the rates quoted

by the Tenderer in words shall be taken as correct. Where the rates quoted by the

Tenderer in figures and in words tally but the amount is not worked out correctly,

the rates quoted by the Tenderer will, unless otherwise provided, be taken as correct

and not the amount. In the event that no rate has been quoted for any item(s),

leaving space both in figure (s) or word(s) and the amount blank, it will be

presumed that the Tenderer has included the cost of this/ these item (s) in other items

and rate for such item (s) will be considered as zero and work will be required to be

executed accordingly.



17

b) In case of percentage Rate Tender only percentage quoted shall be considered. Any

tender containing item rates is liable to be rejected. Percentage quoted by the

Tenderer in percentage rate tender shall be accurately filled in figures and words so

that there is no discrepancy. If, for any Schedule in Financial Bid, the total amount

has been indicated by the Tenderer and if discrepancy is noticed in the percentages

quoted in words and figures, then the percentage which corresponds with the total

amount, shall, unless otherwise proved be taken as correct. If the total amount is not

worked out or if worked out, it does not correspond with the percentages written

either in figures or in words, then the percentage quoted by Tenderer in words shall

be taken as correct. When the percentages quoted by the Tenderer in figures and in

words tally but the total amount is not worked out correctly, the percentage quoted

by the Tenderes shall be taken as correct, unless proved otherwise and the total

amount worked out accordingly.

17.5 In the case of any Item rate tender where unit rate of any item/items appears

unrealistic, such tender will be considered as unbalanced and in case the Tenderer is

unable to provide satisfactory explanation, such a tender is liable to be disqualified

and rejected.

17.6 (a) In Item rate Tender, all rates shall be quoted on the tender form. The amount for

each item should be worked out and requisite totals given. Special care should be

taken to write the rates in figures as well as in words and the amount in figures only,

in such a way that interpolation is not possible. The total amount in each Schedule

should be written both in figures and in words. In case of figures, the word ‘Rs.’

should be written before the figure of rupees and word ‘P’ after the decimal figures,

e.g. Rs.2.15 P and in case of words, the word, ‘Rupees’ should precede and the word

‘Paise’ should be written at the end. Unless the rate is in whole rupees and followed

by the word ‘only’ it should invariably be up to two decimal places. While quoting

the rate in schedule of quantities, the word ‘only’ should be written closely

following the amount and it should not be written in the next line.

(b) In Percentage Rate Tender, the Tenderer shall quote percentage below / above

(in figures as well as in words) at which he will be willing to execute the work. He

shall also work out the total amount of his offer and the same should be written in

figures as well as in words in such a way that no interpolation is possible. In case of

figures, the word “Rs” should be written before the figure rupees and word ‘P’ after

the decimal figures (eg.) Rs.2.15 P and in case of words the word “Rupees” should

precede and the word “Paisa” should be written at the end.

17.7 Sales-tax/VAT (except Service Tax), purchase tax, turnover tax or any other tax/

Cess on material, labour and Works in respect of this Contract shall be payable by

the Contractor and the Employer will not entertain any claim whatsoever in respect

of the same. However, in respect of Service Tax, same shall be paid by the

Contractor to the concerned department on demand and it will be reimbursed to him

by the Engineer-in-Charge after satisfying that it has been actually and genuinely

paid by the Contractor.

17.8 Each Bidder shall submit only one Bid either as an individual or as a Proprietor in a

Proprietary firm or as a Partner in a Partnership firm or as a Director of a limited

Company/Corporation or as a Partner in a Joint Venture. Any Bidder who has



18

submitted a Bid for a work, shall not be a witness for any other Bidder for the same

work. Failure to observe the above stipulations would render all such Tenders

submitted as a Bidder and / or as a witness, liable to summary rejection.

17.9 The Contractor shall be fully responsible for all matters arising out of the

Performance of the Contract and shall, at his own expense, comply with all laws/

acts/ enactments/ orders/ regulations/ obligations whatsoever of the Government of

India, State Government, Local Body and any Statutory Authority.

18.0 SIGNING OF CONTRACT AGREEMENT

18.1 The Tenderer whose tender has been accepted will be notified of the award by the

Employer by issue of a `Letter of Acceptance’ ‘ prior to expiration of the Bid

Validity period, in the form at Annexure VI.

The Letter of Acceptance will be sent to the Contractor in two copies one of which

he should return promptly, duly signed and stamped. The Letter of Acceptance will

be a binding Contract between the Employer and the Contractor till the formal

Contract Agreement is executed.

18.2 Within the period as specified in `Clause of Contract’, of the date of issue of Letter

of Acceptance, the successful Tenderer shall deliver to the Employer, Performance

Guarantee and Additional Performance Guarantee (where applicable) in the format

prescribed.

18.3 The Tenderer whose Tender is accepted shall be required to submit at his cost stamp

papers of appropriate value as per the provisions of Indian Stamp Act within 15 days

of the date of issue of Letter of Acceptance.

18.4 At the same time the Employer notifies the successful Tenderer that his Tender has

been accepted, the Employer will direct him to attend the Employer’s office within

28 days of issue of Letter of Acceptance for signing the Agreement in the proforma

at Annexure VII. The Agreement will however be signed only after the Contractor

furnishes Performance Guarantee and Additional Performance Guarantee (where

applicable) and hence, where justified, the period of 28 days stipulated above will

be extended suitably.



19

ANNEXURE – I

QUALIFYING CRITERIA FOR WORKS CONTRACTS

1. Annual Financial Turnover

The bidder should have achieved a minimum annual financial turnover of Rs.296.18

Lac in any one of the last 5 Financial Years.

Notes :

i) The financial turnover will be taken as given under the head “Income” in audited

Profit and Loss Account and excluding non-recurring income, income from other

sources and stock. It is clarified that the Financial Turnover means relevant revenue

as recorded in the Income side of Profit and Loss Account. It does not mean Profit.

ii) Closing stocks in whatsoever manner should not form part of turnover.

iii) Weightage of 5% (compounded annually) shall be given for equating the financial

turnover of the previous years to the current year.

iv) For considering the Financial Years, for example for a work for which the Tender is

being opened in Financial Year 2011-12, the last five Financial Years shall be 2010-

11, 2009-10, 2008-09, 2007-08 and 2006-07. For a Tender opened on (say) 06.06.11

(F.Y. 2011-12), with weightage of 5% compounded annually, the weightages to be

applied on the Turnover of the previous five Financial Years will be : F.Y. 2010-11

= 1.050; F.Y. 2009-10 = 1.103; F.Y. 2008-09 = 1.158; F.Y. 2007-08 = 1.216; F.Y.

2006-07 = 1.276.

v) The Bidder should furnish Annual Financial Turnover for each of the last 5

Financial Years in tabular form and give reference of the document (with page no.)

relied upon in support of meeting the Qualification Criterion.

vi) The Bidder should submit self attested copy of Auditor’s Report along with Balance

Sheet and Profit and Loss Statement along with Schedules for the relevant Financial

Year in which the minimum criterion is met. Provisional audit reports or certified

statements will not be accepted.

vii) If the Audited Balance Sheet for the immediately preceding year is not available in

case of tender opened before 30th Sept., audited Balance Sheets, Profit and Loss

Statements and other financial statements of the five Financial Years immediately

preceding the previous Financial Year may be adopted for evaluating the credentials

of the Bidder.

2. WORK EXPERIENCE

a) Similar Works Experience

The Bidder should have satisfactorily completed in his own name or proportionate

share as a member of a Joint Venture, at least one similar work of minimum value of

Rs.236.94 Lac OR at least two similar works each of minimum value of Rs.148.09

Lac OR at least three similar works each of minimum value of Rs.118.47 Lac

during the last 5 (five) years prior to the last stipulated date for submission of the

Bid. Works completed prior to the cut off date shall not be considered.



20

Similar Works

Similar Works shall mean the work of Laying of BG Railway track/Track linking

work in Apron/Carrying out gauge conversion/Complete track renewal/Through Rail

renewal/Through sleeper renewal/Complete renewal of Points & Crossings with or

without supply of P. Way fittings.

Notes :

i) A weightage of 5% (compounded annually from the date of completion of the work

to the submission of the Bid) shall be given for equating the value of works of the

previous years to the current year.

ii) Only such works shall be considered where physical completion of entire work is

over or commissioning of work has been done, whichever is earlier.

iii) The Bidder should submit the details of such similar completed works as per the

format at Proforma-1 enclosed.

iv) Works carried out by another Contractor on behalf of the Bidder on a back to back

basis will not be considered for satisfaction of the Qualification Criterion by the

Bidder.

v) Credential certificates issued by Govt. Organizations/ Semi Govt. Organizations of

Central or State Government; or by Public Sector Undertakings/ Autonomous bodies

of Central/State Government; or by Public Ltd. Companies listed in Stock Exchange

in India or Abroad shall only be accepted for assessing the eligibility of a Tenderer.

vi) The cut off date shall be calculated backwards from the last stipulated date for

submission/ opening of Tender i.e. for a Tender which is being opened on

06.08.2011, the cut off date shall be 07.08.06.

b) Construction Experience in key activities/specified components

Not Applicable

3. SOLVENCY CERTIFICATE

A Solvency Certificate of minimum solvency of Rs 118.47 Lac (suggested format at

Proforma 2) from a Scheduled Bank issued not earlier than 6 months from the last

date for submission of tender is required to be submitted by the bidder.

Notes:

The certificate so produced by the Bidder may be got verified from the issuing Bank.

4. PROFITABILITY

The applicant firm shall be a profit (net) making firm and shall have made profit in

each of the last two Financial Years and in atleast one out of the three Financial

Years immediately preceding the last two Financial Years.



21

The Bidder should furnish figures of net profit of last 5 years in a tabular form and

submit attested copies of Auditor’s Reports along with audited Balance Sheets and

Profit and Loss Statements for the last Five Financial Years. In case the firm is

profit making for the last three Financial Years continuously, the Bidder may submit

the above documents for last three Financial Years only. Specific reference with

page no. of document which proves satisfaction of this Qualifying Criterion should

be indicated in the tabular statement.

5. POINTS TO NOTE ON SATISFACTION OF QUALIFYING CRITERIA IN

CASE OF BOTH LARGE AND NORMAL WORKS

a) Sub-Contractor’s Experiences and Resources

Sub-Contractors’ Experiences and Resources will not be taken into account

in determining the Bidder’s compliance with the qualifying criteria.

a. Experiences and Resources of the Parent Company and other subsidiary

companies

If the Bidder is a wholly owned subsidiary of a company, the experience and

resources of the owner/parent company or its other subsidiaries will not be

taken into account. However, if the Bidder is a Company, the Experience

and Resources of its subsidiaries will be taken into consideration.

6. DECLARATION BY THE BIDDER

Even though the Bidders may meet the above qualifying criteria, they are subject to

be disqualified if they have

a) Made misleading or false representation in the forms, statements and

attachments in proof of the qualification requirements. In such a case,

besides Tenderer’s liability to action under para 9.4 of Instructions to

Tenderers, the Tenderer is liable to face the penalty of banning of business

dealings with him by RITES.

b) Records of poor performance such as abandoning the work, not properly

completing the contract, inordinate delays in completion, litigation history or

financial failures etc.

c) Their business banned or suspended by any Central/State Government

Department/ Public Undertaking or Enterprise of Central/State Government

and such ban is in force.

d) Not submitted all the supporting documents or not furnished the relevant

details as per the prescribed format.

A declaration to the above effect in the form of affidavit on stamp paper of Rs. 10/-

duly attested by Notary/Magistrate should be submitted as per format given in

Proforma 3 enclosed.



22

Proforma-1

LIST OF SIMILAR WORKS SATISFYING QUALIFICATION CRITERION

COMPLETED DURING THE LAST 5 YEARS

S.

No.

Client's

Name

and

Address

Name of

the Work &

Location

Scope of

work

carried

out by

the

Bidder

Agreement

/ Letter of

Award No.

and date

Contract Value Date of start Date of Completion Reasons for

delay in

completion

if any

Ref. of

document

(with page

no.) in support

of meeting

Qualification

Criterion

Awarded Actual on

completion

As per

LOA/

Agreement

Actual

SEAL AND SIGNATURE OF THE BIDDER

Note :

1. In support of having completed above works, attach self attested copies of the

completion certificate from the owner/client or Executing Agency / Consultant

appointed by owner / Client indicating the name of work, the description of work

done by the Bidder, date of start, date of completion (contractual & actual) and

contract value as awarded and as executed by the Bidder . “Contract Value” shall

mean gross value of the completed work including cost of materials supplied by the

owner/client but excluding those supplied free of cost.

2. Such Credential certificates issued by Govt. Organizations/ Semi Govt.

Organizations of Central or State Government ; or by Public Sector Undertakings /

Autonomous bodies of Central or State Government or by Public Ltd. Companies

listed in Stock Exchange in India or Abroad shall only be accepted for assessing the

eligibility of a Tenderer.

In case of a Certificate from a Public Limited Co., the Bidder should also submit

documentary proof that the Public Ltd. Co. was listed in Stock Exchange in India or

Abroad when the work was executed for it.



23

3. Information must be furnished for works carried out by the Bidder in his own name

or proportionate share as member of a Joint Venture. In the latter case details of

contract value including extent of financial participation by partners in that work

should be furnished.

4. If a Bidder has got a work executed through a Subcontractor on a back to back basis,

the Bidder cannot include such a work for his satisfying the Qualification Criterion

even if the Client has issued a Completion Certificate in favour of that Bidder.

5. Use a separate sheet for each partner in case of a Joint Venture.

6. Only similar works completed during the last 5 years prior to the last stipulated date

for submission of Bid, which meet the Qualification Criterion need be included in

this list.



24

Proforma 2

SOLVENCY CERTIFICATE FROM A NATIONALISED

OR A SCHEDULED BANK

This is to certify that to the best of our knowledge and information, M/s

____________________, having their registered office at _____________, a customer of

our Bank, is a reputed company with a good financial standing and can be treated as solvent

to the extent of Rs. ___________. This certificate is issued without any guarantee or risk

and responsibility on the Bank or any of its officers.

Signature with date

Senior Bank Manager (Name of Officer issuing the

Certificate)

Name, address & Seal of the Bank/ Branch

Note:

Banker’s Certificate should be on letter head of the Bank.



25

Proforma 3

DECLARATION BY THE BIDDER

(Affidavit on Non-Judicial Stamp Paper of Rs.10/- duly attested by Notary / Magistrate)

This is to certify that We, M/s. __________________________, in submission of this offer

confirm that:-

i) We have not made any misleading or false representation in the forms, statements

and attachments in proof of the qualification requirements;

ii) We do not have records of poor performance such as abandoning the work, not

properly completing the contract, inordinate delays in completion, litigation history

or financial failures etc.

iii) No Central / State Government Department/ Public Sector Undertaking or

Enterprise of Central / State Government has banned/suspended business dealings

with us as on date.

iv) We have submitted all the supporting documents and furnished the relevant details

as per prescribed format.

v) List of Similar Works satisfying Qualification Criterion indicated in Proforma 1

does not include any work which has been carried out by us through a Subcontractor

on a back to back basis.

vi) The information and documents submitted with the Tender and those to be

submitted subsequently by way of clarifications / making good deficient documents

are correct and we are fully responsible for the correctness of the information and

documents submitted by us.

vii) We understand that in case any statement/information/document furnished by us or

to be furnished by us in connection with this offer, is found to be incorrect or false,

our EMD in full will be forfeited and business dealings will be banned.

SEAL, SIGNATURE & NAME OF THE BIDDER

signing this document



26

Proforma- 4

SITE FAMILIARIZATION CERTIFICATE

Certificate that I/we have visited the site of the work tendered and get

acquainted with the site conditions regarding availability of materials, lead of

materials, access roads etc before submission of this tender.

SEAL AND SIGNATURE & NAME OF THE BIDDER

Signing this document



27

ANNEXURE I A

CHECK LIST OF DOCUMENTS TO BE SUBMITTED

1. a) BY BIDDERS OTHER THAN JOINT VENTURES

i) Annual Financial Turnover

- Annual financial turnover for each of the last 5 Financial Years in

tabular form.

- Self attested copies of Auditor’s Report along with the Balance Sheet

and Profit and Loss Statement for the relevant Financial Year in

which the minimum criterion is met (Refer Notes under Para 1 of

Annexure I).

ii) Work Experience

- Similar Work Experience : Proforma 1 of Annexure I with details

of 1, 2 or 3 works as the case may be, which satisfy requisite

qualification criterion with self attested copies of supporting

document (Refer Para 2a of Annexure I).

- Construction Experience in Key Activities/Specialised Components:

Tabular Statement giving contract-wise quantities executed in last 5

years along with documentary proof in support of having met the

criterion (Refer Para 2b of Annexure I).

iii) Solvency Certificate.

Suggested format at Proforma 2 of Annexure I (Refer Para 3 of Annexure

I)

iv) Profitability

- Net profit of last 5 Financial Years in tabular form.

ii) Self attested copies of Auditor’s Report along with the Balance Sheets

and Profit and Loss Statements for last 5 or 3 Financial Years, as the

case may be (Refer Para 4 of Annexure I).

v) Declaration by Bidder

Proforma 3 (Refer Para 6 of Annexure I)

vi) Integrity Pact (where applicable) : duly signed and witnessed in the format

at Annexure VIII (Refer para 11.7 of NIT & Instructions to Tenderers)

Not Applicable



28

ANNEXURE II A

QUALIFICATION INFORMATION/CHECKLIST OF DOCUMENTS

--LETTER OF TRANSMITTAL BY OTHER THAN JOINT VENTURES

(on letter head of the Applicant)

From To

_____________ RITES Ltd._________

(Authority Inviting Tender)

Sir,

Sub: Submission of Qualification information /documents as per Checklist.

1. I/We hereby submit the following documents in support of my/our satisfying the

Qualification Criteria laid down for the work:-

a) Self attested copy of a certificate, confirming that the applicant is a working

contractor or has executed any work within the last five years reckoned from the

date of opening of Tender, issued by Railways, CPWD, MES, DOT, RITES,

State PWD or any other Central/State Government Undertaking, Municipal

Body, Autonomous Body of Central or State Government or Public Limited

Company listed on NSE/BSE.

b) Annual Financial Turnover

(i) Annual financial turnover for each of the last 5 Financial Years in a tabular

form.

(ii) Self attested copy of Auditor’s Report along with the Balance Sheet and

Profit and Loss Statement and Schedules for the relevant Financial Year in

which the minimum criterion is met, with calculations in support of the

same.

c) Work Experience

i) Similar Work Experience :- In Proforma 1 with details of 1 / 2 / 3

works as applicable and self attested copies of supporting documents

as mentioned therein.

ii) Construction experience in key activities / specialised components:

Tabular Statement giving contract wise quantities executed in last 5

years with documentary proof.

d) Solvency Certificate - Proforma 2.

e) Profitability - Net profit of last 5 Financial years in tabular form with self

attested copies of Profit and Loss Statements for the last 5 or 3 Financial

Years as applicable.

2. In addition the following supporting documents are also enclosed.

a) Self attested copy of Partnership Deed/Memorandum and Articles of

Association of the Firm.



29

b) Self attested copies of PAN/TAN issued by the Income Tax Department.

c) Declaration – Proforma 3

d) Self attested copy of Sales Tax, Works Contract Tax, Service Tax

Registration Certificate (as applicable).

e) Self attested copy of Registration under Labour Laws, like PF, ESI etc.

f) Self attested copy of ISO 9000 Certificate ( if any)

g) Integrity Pact (where applicable) : duly signed and witnessed.

3. I authorize you to approach any Bank, Individual, Employer, Firm or Corporation,

whether mentioned in the enclosed documents or not, to verify our competence and

general reputation.

4. I also enclose written Power of Attorney of the signatory of the Tender on behalf of

the Tenderer.

Yours faithfully,

Encl: As in Paras 1, 2 & 4

Signature of Applicant

with Name _________________

Date with seal



30

ANNEXURE II B (L)

QUALIFICATION INFORMATION /CHECKLIST OF DOCUMENTS

– LETTER OF TRANSMITTAL BY JOINT VENTURE

Deleted



31

ANNEXURE II B (N)

QUALIFICATION INFORMATION /CHECKLIST OF DOCUMENTS

- LETTER OF TRANSMITTAL BY JOINT VENTURE

Deleted



32

ANNEXURE III

DRAFT MEMORANDUM OF UNDERSTANDING

EXECUTED BY MEMBERS OF THE CONSORTIUM / JOINT VENTURE

(On each firm’s Letter Head)

Deleted



33

ANNEXURE IV

FORMAT FOR POWER OF ATTORNEY TO AUTHORISED SIGNATORY

POWER OF ATTORNEY

(To be executed on non-judicial stamp paper of the appropriate value in accordance with

relevant Stamp Act. The stamp paper to be in the name of the firm/ company who is issuing

the Power of Attorney).

We, M/s.______ (name of the firm/company with address of the registered office) hereby

constitute, appoint and authorise Mr./Ms.______ (Name and residential address) who is

presently employed with us and holding the position of ______ and whose signature is

given below as our Attorney to do in our name and our behalf all or any of the acts, deeds or

things necessary or incidental to our bid for the work _____ (name of work), including

signing and submission of application / proposal, participating in the meetings, responding

to queries, submission of information / documents and generally to represent us in all the

dealings with RITES or any other Government Agency or any person, in connection with

the works until culmination of the process of bidding, till the Contract Agreement is entered

into with RITES and thereafter till the expiry of the Contract Agreement.

We hereby agree to ratify all acts, deeds and things lawfully done by our said Attorney

pursuant to this Power of Attorney and that all acts, deeds and things done by our aforesaid

Attorney shall always be deemed to have been done by us.

(Add in the case of a Consortium/Joint Venture)

Our firm is a Member/Lead Member of the Consortium of ___________, _________ and

___________.

Dated this the _____ day of ______ 20

(Signature and name of authorized signatory being given Power of Attorney)

___________

(Signature and name in block letters of *All the partners of the firm, * Authorized Signatory

for the Company)

(* Strike out whichever is not applicable)

Seal of firm/ Company

Witness 1: Witness 2:

Name: Name:

Address: Address:

Occupation: Occupation:



34

Notes:

- In case the Firm / Company is a Member of a Consortium/ JV, the authorized

signatory has to be the one employed by the Lead Member.

- The mode of execution of the Power of Attorney should be in accordance with the

procedure, if any, laid down by the applicable law and the charter documents of the

executant(s) and when it is so required the same should be under common seal

affixed in accordance with the required procedure.



35

ANNEXURE V

FORMAT FOR POWER OF ATTORNEY TO LEAD MEMBER OF CONSORTIUM

/ JOINT VENTURE

Deleted



36

ANNEXURE VI

(FORM OF LETTER OF ACCEPTANCE)

(By REGD POST / ACK.DUE)

(On the letter head of RITES)

NO. : RITES/ Dated :

To

_________________aggregate

(Name & Address of the Contractor)

Dear Sirs,

Sub: TENDER No. FOR THE WORK OF

Ref: Your Tender dated _________________ and letters dated _____________

and this office letter Nos. ___________ dated___________ in reply to the same.

This is to notify you that your Tender for the work under reference has been accepted by the

Competent Authority of RITES LIMITED for a total Contract Price of Rs. _______

(Rupees _____________only) in its capacity as an Agent /Power of Attorney

Holder acting for and on behalf of ______ (the Employer).

Pursuant to Clause of the Contract, you are required to furnish irrevocable Performance

Guarantee for an amount equivalent to 5% (Five percent) of the Contract Price and an

Additional Performance Guarantee for an amount of Rs. ------------ (if applicable). The

Guarantee Bonds aggregating for an amount of Rs.______________ are required to be

submitted within ___ days of issue of this Letter of Acceptance. Bank Guarantees issued by

the following Banks will not be acceptable _____________________ (Names of Banks

_________)

The time of ________months allowed for execution of the work will be reckoned from the

date of start as defined in Schedule F or from the first day of the handing over of the site,

whichever is later, in accordance with phasing, if any, indicated in tender document.

You are requested to contact _________ (complete designation and address of the Project

Coordinator) for carrying out the contract.

You are also requested to attend this office within Twenty Eight days from the date of issue

of this letter for execution of the formal agreement. It may be noted that no payment shall

be made for any work carried out by you till the Agreement is executed and till such time

the Performance Guarantee and Additional Performance Guarantee (where applicable)

has/have been submitted by you.



37

This Letter of Acceptance is being sent to you in duplicate and you are requested to return

without delay one copy of the letter duly signed and stamped, as a token of your

acknowledgement.

Kindly note that this Letter of Acceptance thereof shall constitute a binding Contract

between us pending execution of formal Agreement.

Your letters as well as this office letters referred to above shall form part of the Contract.

Yours faithfully,

RITES LIMITED

Agent / Power of Attorney Holder

For and on behalf of______ (The Employer)

Copy to :

1. ___________ (The Employer) for information.

(To be included on the Original sent to the Contractor)

2. Project Coordinator (Complete designation and address)

3. Associated Finance (Not in original)



38

ANNEXURE VII

FORM OF AGREEMENT

(ON NON JUDICIAL STAMP PAPER OF APPROPRIATE VALUE)

Agreement No. ________ dated _________

THIS AGREEMENT is made on ________ day of ______ Two thousand ________

between RITES Ltd. a Government of India Enterprise and a Company registered under

Companies Act, 1956 having its registered office at SCOPE Minar, Laxmi Nagar, Delhi -

110092 and its Corporate Office at RITES BHAWAN, Plot No.1, Sector 29, Gurgaon

(Haryana) representing through ____________, RITES LIMITED acting for and on behalf

of and as an Agent /Power of Attorney Holder of _____ hereinafter called the Employer

(which expression shall, wherever the context so demands or requires, include their

successors in office and assigns) on one part and M/s.______ hereinafter called the

Contractor (which expression shall wherever the context so demands or requires, include

his/ their successors and assigns) of the other part.

WHEREAS the Employer is desirous that certain works should be executed

viz.___________ (brief description of the work) and has by Letter of Acceptance dated

____ accepted a tender submitted by the Contractor for the execution, completion,

remedying of any defects therein and maintenance of such works at a total Contract Price of

Rs. ______ (Rupees ______________ only)

NOW THIS AGREEMENT WITNESSETH as follows:-

1. In this agreement words and expressions shall have the same meaning as are

respectively assigned to them in the Conditions of Contract hereinafter referred to.

2. The following documents in conjunction with addenda/ corrigenda to Tender

Documents shall be deemed to form and be read and construed as part of this

agreement viz.

a) The Letter of Acceptance dated______.

b) Priced Schedule (Bill) of Quantities

c) Notice Inviting Tender and Instructions to Tenderers.

d) Tender and Contract Form

e) Special Conditions

f) Amendment/Errata to GCC.

g) General Conditions of Contract of NTPC Ltd.

h) Technical Specifications

i) Amendments to Tender Documents if any

j) Drawings if any

3. In consideration of the payment to be made by the Employer to the Contractor as

hereinafter mentioned, the Contractor hereby covenants with the Employer to

execute, complete, remedy defects therein and maintain the works in conformity in

all respects with the provisions of the Contract.



39

4. The Employer hereby covenants to pay to the Contractor in consideration of the

execution, completion, remedying of any defects therein and maintenance of the

works, the contract price or such other sum as may become payable under the

provisions of the contract at the time and in the manner prescribed by the Contract.

IN WITNESS whereof the parties hereto have caused their respective common seals to be

hereinto affixed (or have herewith set their respective hands and seals) the day and year first

above written.

SIGNED, SEALED AND DELIVERED BY

____________________________

In the capacity of _____

On behalf of M/s. _________

(The Contractor)

In the presence of

Witnesses (Signature, Name &

Designation)

1.

2.

______________________________

representing RITES LIMITED

In the capacity of Agent / Power of

of Attorney Holder

For and on behalf of _________

(The Employer)

In the presence of

Witnesses (Signature, Name &

Designation)

1.

2.



40

ANNEXURE VIII

INTEGRITY PACT

Between

RITES LTD. acting for and on behalf of and as an Agent / Power of Attorney Holder of

____________hereinafter called the “Employer” AND

____________ hereinafter referred to as "The Bidder/Contractor"

Deleted



41

ANNEX-A

Guidelines on Banning of Business Dealings

1. Introduction

1.1 RITES, being a Public Sector Enterprise and ‘State’, within the meaning of Article

12 of Constitution of India, has to ensure preservation of rights enshrined in Chapter

III of the Constitution. RITES has also to safeguard its commercial interests. It is not

in the interest of RITES to deal with Agencies who commit deception, fraud or other

misconduct in the execution of contracts awarded / orders issued to them. In order to

ensure compliance with the constitutional mandate, it is incumbent on RITES to

observe principles of natural justice before banning the business dealings with any

Agency.

1.2 Since banning of business dealings involves civil consequences for an Agency

concerned, it is incumbent that adequate opportunity of hearing is provided and the

explanation, if tendered, is considered before passing any order in this regard

keeping in view the facts and circumstances of the case.

2. Scope

2.1 The procedure of (i) Suspension and (ii) Banning of Business Dealing with

Agencies, has been laid down in these guidelines.

2.2 It is clarified that these guidelines do not deal with the decision of the Management

not to entertain any particular Agency due to its poor / inadequate performance or

for any other reason.

2.3 The banning shall be with prospective effect, i.e., future business dealings.

3. Definitions

In these Guidelines, unless the context otherwise requires:

i) `Bidder / Contractor / Supplier' in the context of these guidelines is indicated

as ‘Agency’.

ii) ‘Competent Authority’ and ‘Appellate Authority’ shall mean the following:

a) The Director shall be the ‘Competent Authority’ for the purpose of

these guidelines. MD, RITES shall be the ‘Appellate Authority’ in

respect of such cases.

b) MD, RITES shall have overall power to take suo-moto action on any

information available or received by him and pass such order(s) as he

may think appropriate, including modifying the order(s) passed by

any authority under these guidelines.



42

iii) ‘Investigating Department’ shall mean any Department, Division or Unit

investigating into the conduct of the Agency and shall include the Vigilance

Department, Central Bureau of Investigation, the State Police or any other

department set up by the Central or State Government having powers to

investigate.

4. Initiation of Banning / Suspension:

Action for banning / suspension business dealings with any Agency should be

initiated by the department/ unit having business dealings with them after noticing

the irregularities or misconduct on their part.

5. Suspension of Business Dealings

5.1 If the conduct of any Agency dealing with RITES is under investigation by any

department, the Competent Authority may consider whether the allegations under

investigation are of a serious nature and whether pending investigation, it would be

advisable to continue business dealing with the Agency. If the Competent Authority,

after consideration of the matter including the recommendation of the Investigating

Department/Unit, if any, decides that it would not be in the interest to continue

business dealings pending investigation, it may suspend business dealings with the

Agency. The order to this effect may indicate a brief of the charges under

investigation. The order of such suspension would operate for a period not more

than six months and may be communicated to the Agency as also to the

Investigating Department.

The Investigating Department/Unit may ensure that their investigation is completed

and whole process of final order is over within such period.

5.2 As far as possible, the existing contract(s) with the Agency may be continued unless

the Competent Authority, having regard to the circumstances of the case, decides

otherwise.

5.3 If the Agency concerned asks for detailed reasons of suspension, the Agency may be

informed that its conduct is under investigation. It is not necessary to enter into

correspondence or argument with the Agency at this stage.

5.4 It is not necessary to give any show-cause notice or personal hearing to the Agency

before issuing the order of suspension. However, if investigations are not complete

in six months time, the Competent Authority may extend the period of suspension

by another three months, during which period the investigations must be completed.

6. Grounds on which Banning of Business Dealings can be initiated

6.1 If the security consideration, including questions of loyalty of the Agency to the

State, so warrants;

6.2 If the Director / Owner of the Agency, proprietor or partner of the firm, is convicted

by a Court of Law for offences involving moral turpitude in relation to its business



43

dealings with the Government or any other public sector enterprises or RITES,

during the last five years;

6.3 If there is strong justification for believing that the Directors, Proprietors, Partners,

owner of the Agency have been guilty of malpractices such as bribery, corruption,

fraud, substitution of tenders, interpolations, etc;

6.4 If the Agency employs a public servant dismissed / removed or employs a person

convicted for an offence involving corruption or abetment of such offence;

6.5 If business dealings with the Agency have been banned by the Govt. or any other

public sector enterprise;

6.6 If the Agency has resorted to Corrupt, fraudulent practices including

misrepresentation of facts;

6.7 If the Agency uses intimidation / threatening or brings undue outside pressure on

the Company (RITES) or its official in acceptance / performances of the job

under the contract;

6.8 If the Agency indulges in repeated and / or deliberate use of delay tactics in

complying with contractual stipulations;

6.9 Based on the findings of the investigation report of CBI / Police against the Agency

for malafide / unlawful acts or improper conduct on his part in matters relating to the

Company (RITES) or even otherwise;

6.10 Established litigant nature of the Agency to derive undue benefit;

6.11 Continued poor performance of the Agency in several contracts;

(Note: The examples given above are only illustrative and not exhaustive. The

Competent Authority may decide to ban business dealing for any good and sufficient

reason).

7. Banning of Business Dealings

7.1 A decision to ban business dealings with any Agency shall apply throughout the

Company.

7.2 If the Competent Authority is prima-facie of view that action for banning business

dealings with the Agency is called for, a show-cause notice may be issued to the

Agency as per paragraph 8.1 and an enquiry held accordingly.

8. Show-cause Notice

8.1 In case where the Competent Authority decides that action against an Agency is

called for, a show-cause notice has to be issued to the Agency. Statement containing

the imputation of misconduct or mis-behaviour may be appended to the show-cause



44

notice and the Agency should be asked to submit within 30 days a written statement

in its defence. If no reply is received, the decision may be taken ex-parte.

8.2 If the Agency requests for inspection of any relevant document in possession of

RITES, necessary facility for inspection of documents may be provided.

8.3 After considering the reply of the Agency and other circumstances and facts of the

case, a final decision for Company-wide banning shall be taken by the Competent

Authority. The Competent Authority may consider and pass an appropriate speaking

order:

a) For exonerating the Agency if the charges are not established;

b) For banning the business dealing with the Agency.

8.4 The decision should be communicated to the Agency concerned along with a reasoned

order. If it decided to ban business dealings, the period for which the ban would be

operative may be mentioned.

9. Appeal against the Decision of the Competent Authority

9.1 The Agency may file an appeal against the order of the Competent Authority

banning business dealing, etc. The appeal shall lie to Appellate Authority. Such an

appeal shall be preferred within one month from the date of receipt of the order

banning business dealing, etc.

9.2 Appellate Authority would consider the appeal and pass appropriate order which

shall be communicated to the Agency as well as the Competent Authority.

10. Review of the Decision by the Competent Authority

Any petition / application filed by the Agency concerning the review of the banning

order passed originally by Competent Authority under the existing guidelines either

before or after filing of appeal before the Appellate Authority or after disposal of

appeal by the Appellate Authority, the review petition can be decided by the

Competent Authority upon disclosure of new facts /circumstances or subsequent

development necessitating such review.

11. Circulation of the names of Agencies with whom Business Dealings have been

banned.

11.1 Depending upon the gravity of misconduct established, the Competent Authority of

RITES may circulate the names of Agency with whom business dealings have been

banned, to the Ministry of Railways and PSUs of Railways, for such action as they

deem appropriate.

11.2 If Ministry of Railways or a Public Sector Undertaking of Railways request for more

information about the Agency with whom business dealings have been banned a

copy of the report of Inquiring Authority together with a copy of the order of the

Competent Authority/ Appellate Authority may be supplied.



45

12. Restoration

12.1 The validity of the banning order shall be for a specific time & on expiry of the

same, the banning order shall be considered as "withdrawn".

12.2 In case any agency applies for restoration of business prior to the expiry of the ban

order, depending upon merits of each case, the Competent Authority which had

passed the original banning orders may consider revocation of order of suspension

of business/lifting the ban on business dealings at an appropriate time. Copies of the

restoration orders shall be sent to all those offices where copies of Ban Orders had

been sent.



46

Annexure – B

Form of Performance Security Bank Guarantee Bond

In consideration of the Employer having agreed under the terms and conditions of

agreement No…………………………………… dated ………………. made between

………………………….( the employer ) represented by RITES Ltd for and on

behalf of the employer as an agent/Power of Attorney Holder and

……………………………… (hereinafter called “the said Contractor(s)”) ………. for

the work ……………………………(herein after called the said agreement”) the

Contractor having agreed to production of a irrevocable bank guarantee for Rs.

…………………. (Rupees ……………………. Only) as a Security/Guarantee for

compliance of his obligations in accordance with the terms and conditions in the said

agreement,

1. We …..……………………………………………. (hereinafter referred to as “ the

(indicate the Name of the Bank) Bank”) hereby undertake to pay to the RITES LTD for

and on behalf of the employer as an agent/ Power of Attorney Holder an amount not

exceeding Rs. ……………………………… (Rupees

…………………………………………only) on demand by RITES Ltd for and on

behalf of the employer as an agent/ Power of Attorney Holder.

2. We …………………….……… do hereby undertake to pay the (indicate the Name of

the Bank) amounts due and payable under this guarantee without any demur, merely

on a demand from by RITES Ltd for and on behalf of the employer as an agent/

Power of Attorney Holder stating that the amount claimed is required to meet the

recoveries due or likely to be due from the said Contractor(s). Any such demand

made on the bank shall be conclusive as regards the amount due and payable by the

bank under this guarantee. However, our liability under this guarantee shall be

restricted to an amount not exceeding Rs………….. (Rupees

…………………………………… only).

3. We, the said Bank further under take to pay to the employer represented by RITES Ltd.

for and on behalf of the employer as an agent/ Power of Attorney Holder any money

so demanded not withstanding any dispute or disputes raised by the Contractor(s) in

any suit or proceeding pending before any court or Tribunal relating there to our

liabilities under this present being absolute and unequivocal. The payment so made by

us under this bond shall be a valid discharge of our liability for payment thereunder and

the Contractor(s) shall have no claim against us for making such payment.

4. We …………….……………………….. further agree that the guarantee herein

(indicate the Name of the Bank) contained shall remain in full force and effect during

the period that would be taken for the performance of the said agreement and that it

shall continue to be enforceable till all dues of the employer represented by RITES Ltd

for and on behalf of the employer as an agent/ Power of Attorney Holder under or by

virtue of the said agreement have been fully paid and its claims satisfied or

discharged or till Engineer-in-charge on behalf of the employer represented by

RITES Ltd for and on behalf of the employer as an agent/ Power of Attorney Holder



47

certified that the terms and conditions of the said agreement have been fully and

properly carried out by the said Contractor (s) accordingly discharges this guarantee.

5 We …………………..……… further agree with the employer (indicate the Name

of the Bank) represented by RITES Ltd for and on behalf of the employer as an

agent/ Power of Attorney Holder that the employer shall have the fullest liberty

without our consent and without affecting in any manner our obligations hereunder

to vary any of the terms and conditions of the said agreement or to extend time of

performance by the said Contractor (s) from time to time or to postpone for any time

or from time to time any of the powers exercisable by the Employer against the said

Contractor (s) and to forbear or enforce any of the terms and conditions relating to

the said agreement and we shall not be relieved from our liability by reason of any

such variation, or extension being granted to the said Contractor (s) or for any

forbearance, act of omission on the part of the Employer or any indulgence by the

Employer to the said Contractor (s) or by any such matter or thing whatsoever which

under the law relating to sureties would, but for this provision, have effect of so

relieving us.

6. This guarantee will not be discharged due to the change in the constitution of the

Bank or the Contractor (s).

7. This guarantee will neither be cancelled nor revoked by the bank without the written

authorization of the beneficiary (RITES Ltd.). For this purpose the beneficiary

would inform the Bank of their authorized signatories together with the specimen

signatures.

8. This guarantee shall be valid up to ………………………… unless extended on

demand by the employer represented by RITES Ltd for and on behalf of the

employer as an agent/ Power of Attorney Holder. Not withstanding anything

mentioned above, our liability against this guarantee is restricted to

Rs…………………….(Rupees ……………………………………. Only) and

unless a claim in writing is lodged with us within six months of the date of expiry or

the extended date of expiry of this guarantee, all our liabilities under this guarantee

shall stand discharged.

Dated the …………………….. day of ……………………….. for

……………………… (indicate the name of the Bank)”.



48

ANNEXURE `C’

PROFORMA FOR BANK GUARANTEE FOR MOBILIZATION ADVANCE

(On Non-Judicial Stamp Paper of Appropriate Value)

To,

RITES LTD.

________

1. In consideration of, RITES Ltd. acting for and on behalf of as Agent/ Power of

Attorney Holder of _____ (hereinafter called “the Employer”) (which expression

shall unless repugnant to the subject or context include its successors and assigns

having agreed under the terms and conditions of the Contract Agreement No.

_______ dated ___________ with * ______ in connection with the work of

“____________________________” (hereinafter called “the said Contract”) to

make at the request of the Contractor a lumpsum advance of Rs.______/- (Rupees

____________ only) for utilizing it for the purpose of the Contract on his furnishing

a guarantee acceptable to the Employer, we, ______ Bank incorporated under

_________ and having one of our branches at ___________________ (hereinafter

referred to as “the said Bank”) do hereby guarantee the due recovery by the

Employer of this said advance with interest thereon as provided according to the

terms and conditions of the Contract. If the said Contractor fails to utilize the said

advance for the purpose of the Contract and / or the said advance together with

Interest thereon as aforesaid is not fully recovered by the Employer, we,

___________ Bank hereby unconditionally and irrevocably undertake to pay to

RITES Ltd. on demand and without demur to the extent of the said sum of Rs.

________/- (Rupees ____________ only), any claim made by the Employer on us

for the loss or damage caused to or suffered by the Employer by reason of the

Employer not being able to recover in full the said sum of Rs. _____/- (Rupees

________________ only) with interest as aforesaid.

2. We, ___________ Bank further agree that the Employer shall be the sole judge of

and as to whether the said Contractor has not utilized the said advance or any part

thereof for the purpose of the Contract and the extent of loss or damage caused to or

suffered by the Employer on account of the said advance together with interest not

being recovered in full and the decision of the Employer that the said Contractor has

not utilized the said advance or any part thereof for the purpose of the Contract and

as to the amount or amounts of loss or damage caused to or suffered by the

Employer shall be final and binding on us.

3. We, the said Bank, further agree that the Guarantee herein contained shall remain in

force and effect during the period that would be taken for the performance of the

said Contract and till the said advance with interest has been fully recovered and its

claims satisfied or discharged and till the Employer certifies that the said advance

with interest has been fully recovered from the said Contractor, and accordingly

shall have no claim under this Guarantee after 30 (thirty) days from the date of

satisfactory completion of the said Contract (as per the mutually agreed Work

Schedule) i.e. upto and inclusive of _______ (date) unless a notice of the claim

under this Guarantee has been served on the Bank before the expiry of the said

period i.e. _______ (date) in which case the same shall be enforceable against the



49

Bank notwithstanding the fact, that the same is enforced after the expiry of the said

period.

4. The Employer shall have the fullest liberty without affecting in any way the liability

of the Bank under this Guarantee or Indemnity, from time to time, to vary any of the

terms and conditions of the said Contract or the advance or to extend time of

performance by the said Contractor or to postpone for any time and from time to

time any of the powers exercisable by it against the said Contractor and either to

enforce or forbear from enforcing any of the terms and conditions governing the said

Contract or the advance available to the Employer and the said Bank shall not be

released from its liability under these presents by any exercise by the Employer of

the liberty with reference to the matters aforesaid or by reasons of time being given

to the said Contractor or any other forbearance, act or omission on the part of the

Employer or any indulgence by the Employer to the said Contractor on any other

matter or thing whatsoever which under the law relating to sureties would, but for

this provision, have the effect of so releasing the Bank from its such liability.

5. It shall not be necessary for the Employer to proceed against the Contractor before

proceeding against the Bank and the Guarantee herein contained shall be enforceable

against the Bank notwithstanding any security, which the Employer may have

obtained or obtain from the Contractor shall at the time when proceedings are taken

against the Bank hereunder, be outstanding or unrealized.

6. We, the said Bank, lastly undertake not to revoke this Guarantee during its currency

except with the previous consent of the Employer in writing and agree that any

change in the Constitution of the said Contractor or the said Bank shall not discharge

our liability hereunder.

If any further extension of this Guarantee is required the same shall be extended to

such required periods on receiving instructions from M/s.________________ on

whose behalf this Guarantee is issued.

Notwithstanding anything contained herein before our liability under this Guarantee is

restricted to Rs._____ (Rupees ___________ only) together with interest ____. Our

undertaking shall commence from the date of execution and shall remain in force upto

______

Dated this __________ day of _________

In presence of For and on behalf of (the Bank)

WITNESS Signature ____________________________

1.______________________ Name________________________________

2.______________________ Designation ___________________________

Authorization No._______________________

Seal of the Bank ________________________

The above guarantee is accepted by the Employer

For RITES Ltd.________________

For and on behalf of ______________ (the Employer)



50

---NOTES

*For Proprietary Concerns

Shri _____________ son of ______________ resident of _____________________

_________________________ carrying on business under the name and style of

_________ at _____________ (hereinafter called ”the said Contractor” which expression

shall unless the context requires otherwise include his heirs, executors, administrators and

legal representatives).

For Partnership Concerns

*M/s. ________________ a partnership firm with its office __________ (hereinafter called

“the said Contractor” which expression shall unless the context requires otherwise include

their heirs, executors, administrators and legal representatives); the names of their partners

being

i) Shri ______________________ S/o__________________________

ii) Shri ______________________ S/o _________________________ etc.

For Companies

* M/s. ______________ a company under the Companies Act, 1956 and having its

registered office at ____ in the State of _______ (hereinafter called “the said Contractor”

which expression shall unless the context requires otherwise include its administrators,

successors and assigns).



51

PART I

TECHNICAL BID Section - 2

TENDER & CONTRACT FORM



52

SECTION 2

TENDER AND CONTRACT FOR WORKS To

The Accepting Authority.

TENDER

1. I/We have read and examined the Notice Inviting Tender and Instructions to

Tenderers, Special Conditions, Technical Specifications, Drawings, Schedule / Bill

of Quantities, Amendments/Errata no.to GCC and General Conditions of Contract as

well as other documents and rules referred to in GCC and all the details contained

in the Tender Document for the work.

2. I/We hereby tender for the execution and completion of the work and remedy any

defects therein, specified in the Schedule of Quantities within the time specified in,

and in accordance in all respects with the specifications, designs, drawings and

instructions in writing referred to in Notice Inviting Tender and Instructions to

Tenderers and in Clause of the Clauses of Contract and with such materials as are

provided for, by, and in respects in accordance with, such conditions so far as

applicable.

3. We agree that our tender shall remain valid for a period of 180 days from the due

date of submission thereof and not to make any modifications in its terms and

conditions.

4. A sum of Rs. __________ is hereby forwarded in the form of Banker’s

cheque/Demand Draft drawn on any Schedule Bank issued in favour of RITES

Ltd.,payable at Kolkata as the Earnest Money.

5. If I/We withdraw my/our tender during the period of tender validity or before issue

of Letter of Acceptance which ever is earlier or make modifications in the Terms

and Conditions of the Tender which are not acceptable to the Employer, then the

Employer shall, without prejudice to any other right or remedy, be at liberty to

forfeit entire Earnest Money absolutely.

6. If I/We fail to furnish the prescribed Performance Guarantee within prescribed

period, I/We agree that the said Employer shall, without prejudice to any other right

or remedy, be at liberty to forfeit the said Earnest Money absolutely.

7. If, I/We fail to commence the work within the specified period, I/We agree that the

Employer shall, without prejudice to any other right or remedy available in law, be

at liberty to forfeit the Earnest Money and Performance Guarantee absolutely.

8. Further, I/We hereby agree that in case of forfeiture of Earnest Money or both

Earnest Money & Performance Guarantee as aforesaid in Paras 5 to 7, I/We shall be

debarred for participation in re-tendering process of the work.

9. On issue of Letter of Acceptance by the Employer, I/We agree that the said Earnest

Money shall be retained by the Employer towards Security Deposit, to execute all



53

the works referred to in the Tender document upon the Terms and Conditions

contained or referred to therein and to carry out such deviations as may be ordered,

upto maximum of the percentage mentioned in the document, and those in excess of

that limit at the rates to be determined in accordance with the provisions contained

in Clause 12.2 and 12.3 of the tender form.

10. I/We hereby agree that I/ We shall sign the Formal Agreement with the Employer

within 28 days from the date of issue of Letter of Acceptance. In case of any delay,

I/We agree that we shall not submit any Bill for Payment till the Contract

Agreement is signed.

11. I/We hereby declare that I/We shall treat the tender documents, drawings and other

records connected with the work as secret/confidential documents and shall not

communicate information derived there from to any person other than a person to

whom I/We am/are authorized to communicate the same or use the information in

any manner prejudicial to the safety of the Employer/State.

12. I/We hereby declare that I/We have not laid down any condition/deviation to any

content of Technical Bid and/or Financial Bid. I/We agree that in case any condition

is found to be quoted by us in the Technical and/or Financial Bid, my/our Tender

may be rejected.

13. I/We understand that the Employer is not bound to accept the lowest or any tender

he may receive. I/We also understand that the Employer reserves the right to accept

the whole or any part of the tender and I/We shall be bound to perform the same at

the rates quoted.

14. Until a formal agreement is prepared and executed, this bid together with our written

acceptance thereof shall constitute a binding contract between us and RITES.

15. I am/We are signing this Tender offer in my / our capacity as one/those authorized to

sign on behalf of my/our company/as one holding the Power of Attorney issued in

my favour as Lead Member by the Members of the Joint Venture.

Signature of Authorized Person/s

Date

Name/s & Title of Signatory

Name of Tenderer

Postal Address

Seal

Witness

Signature

Name

Postal Address

Occupation



54

PART I

TECHNICAL BID

Section - 3

SPECIAL CONDITIONS OF CONTRACT



55

Section - 3

SPECIAL CONDITIONS OF CONTRACT (SCC)

FOR

P.WAY WORKS INCLUDING SUPPLY OF P.WAY MATERIALS FOR MAKING

NEW PRIVATE SIDING FROM IN-PLANT ENTRY KM CH 4/231 TO

PUNARAKH RAILWAY STATION DEAD END KM CH 0/147.72 IN

CONNECTION WITH THE PROJECT MANAGEMENT AND EXECUTION OF

RAILWAY SIDING SYSTEM PACKAGE FOR BARH STPP, STAGE-I (3 X660

M.W) AT BARH, DIST. PATNA, BIHAR.

1 DESCRIPTION OF SITE. 1.1 The National Thermal Power Corporation (NTPC) is India’s premier institution in the

field of thermal power generation. Putting up new power plants and augmenting the

capacity of its existing ones is a continuous process in NTPC. One mega project planed is a

Super Thermal Power Plant of 3 x 660 MW capacities near Barh town in Patna district of

Bihar.

The Project site is located east of Barh town near village Bariyapur at latitude 16° 28’ North

and longitude 85° 47’ east. The power plant is bound by villages Purani Barh on the West,

Bariyapur on the North, Punarakh on the East and East Central Railway main line in the

South. It is approachable by Mokama-Bakhtiapur National Highway, No 31 running at

about 160m to its north. The City of Patna which is the nearest airport is about 67km from

the site. East Central Railway’s main line from Mokama to Mughalsarai runs at about 100m

to its south. Barh and Punarakh are the nearest railway stations on this line.

1.2 The Permanent Way works are to be carried out in accordance with the provision of the

specifications and agreement along with the schedules attached. The relevant Codes,

Manuals and Specifications applicable for such works.

2 SCOPE OF WORK.

(a) Supply & fixing of P.Way small fittings & PSC Sleeper.

(b) Supply, delivery & spreading of machine crushed stone ballast.

(c) Supply of 52 Kg. BG 1 in 8.5 & 1 in 12 turn outs along with PSC sleepers.

(d) Packing of track ballast.

(e) Welding of rail joints 52/60 Kg. from single rail to panel by SKV process.

(f) P-way work: Supply and fixing of Grooved Rubber Pad, insulated leading &

following streacher bar, slide chair, MS plate, insulated tie plate, plate screw,

coil washer, bolts & nuts with coil spring washer, GFN Liner, cutted liner,

juggle fish plate etc.

(g) Fabrication, manufacture, supply & fixing in position of glued insulated joint

52/60 Kg.

(h) Making adjustment for proper housing of switch with stock rail upto the

sufficient length by ZIM crowing.



56

As per the provisions of the bidding documents, Contractor will be responsible for the

entire scope of work for P-Way works including P-Way materials for P.Way works

including supply of P.Way materials for making new private siding in connection with the

project management and construction of railway siding system package for Barh STPP,

Stage-I (3 x 600 M.W) at Barh, dist. Patna, Bihar.

2.1 The contractor in accordance with the design, technical specifications and

drawings prepared by the consultant M/s. VCC shall execute all the above

works.

2.3 The detailed scope of work covered under this package has been specified in

relevant clauses of Technical Specification.

2.4 Contractor shall obtain license for storage of blasting material and conducting

controlled blasting through an authorized expert.- Not Applicable

2.5 The contractor shall provide a site office for RITES Personal with a size of

minimum 21 sqm. including Office Furniture, Toilet and Internal electrical

fittings. - Not Applicable

2.6 In case of any conflict between General Conditions of Contract and Special

Conditions of Contract, provisions of Special Conditions of Contract shall

prevail.

3 GENERAL INSTRUCTIONS

3.1 Contractor is advised to visit the site to familiarize him with the site conditions

before quoting the rates.

3.2 Before starting the work contractor/s has to prepare an execution chart (BAR

CHART) and PERT CHART and get it approved from the competent authority

and the same shall be displayed in office. This chart shall be reviewed after

every 15 days.

3.3 The contractor/s will remove dismantled materials/bushes, trees, branches and

leaves of trees etc. immediately from the site of work to avoid hindrance or

inconvenience to the agencies working in adjoining site/road vehicles/traveling

public as per instructions of the Engineer and useful materials released will be

the property of the NTPC. Contractor will lead and hand over the same at

NTPC’s store/godown at Barh. The dismantled materials which are classified by

Engineer as not useful will be disposed off by The Contractor irrespective of

any lead as per instructions of the Engineer-in-charge. Nothing extra on account

of leading, loading, unloading etc. of such materials will be paid. This aspect

while quoting rates may be kept in view by the contractor/s.

3.4 Dismantled track structure (P. Way materials) shall be kept in safe custody of

the Contractor. Any shortages/losses will have to be made up by the contractor

at his own cost. The dismantled material shall be lead and handed over to NTPC

store godown at Barh by the contractor at own cost.

3.5 In case any material is rejected at site due to its not conforming to the

Specification, the contractor shall arrange to remove all such material from site

of work at his own cost within 7 days of the receipt of the notice. Safe custody

of the materials at site is the responsibility for the contractor.



57

3.6 The work will be carried out in some cases under traffic conditions; therefore

contractor is required to follow the road/railways traffic rules. He is advised that

this aspect may be kept in view by the contractor/s while quoting rates.

3.7 The materials to be supplied by the contractor shall comply with relevant IS/IRS

Specifications.

3.8 Samples of the materials, which the contractor would be intending to

supply/shall, are got approved in advance from the Engineer before

commencing the supply of the same.

3.9 The land and place where materials are to be stacked shall be made fit for

stacking of materials by the contractor at own cost; nothing extra will be paid

for this purpose.

3.10 The contractor will also himself/themselves arrange and pay for the cost of land

use for such working facilities as he/they need (i.e. land for labour camps,

contractor’s office, approach road to site(s) of work etc.) the contractor will be

deemed to have included this element of compensation in their through tendered

rates and will not be entitled to any extra payment. They are advised to see the

site of work before tendering.

3.11 The rate quoted by contractor/s shall be inclusive through rate. No leads, lifts,

loading, unloading, handling, re-handling, stacking at site, toll tax, octroi, sale

tax and royalty or any other charges levied or leviable by the State Government

or by Local bodies will be paid by the NTPC.

3.12 The contractor will be responsible for the security of the staff and the labour

deployed by him.

4 SETTING UP OF FIELD LABORATORY - DELETED

4.1 The contractor shall set up field laboratory at his own cost at work site which

should be open for use and inspection by the NTPC Engineer at any time, the

laboratory shall be equipped with necessary equipments to carry out the various

tests for classification of soils and compaction, sieve analysis, compression tests

on cubes, slump test, workability test etc. on aggregates, cement, water and

concrete required for ensuring the required quality and standard conforming to

codal provision and special specifications. The tenederer shall render all

reasonable assistance and help in making the check and test.

4.2 All the equipments, machineries etc. shall be kept in good working condition.

The cost of setting up the laboratory, equipping and maintaining the same,

conducting all tests on materials and cubes etc. shall be borne by the contractor.

4.3 As part of the Contract the contractor shall provide and maintain a site laboratory

for the testing of construction materials under the direction and general

supervision of the Engineer-in-charge.

4.4 The laboratory building shall be constructed and installed with the appropriate

facilities. Temperature and humidity controls shall be available wherever

necessary during testing of samples.

4.5 All equipments shall be provided by the Contractor so as to be compatible with

the testing requirements specified. The Contractor shall maintain the equipment

in good working condition for the duration of the Contract.



58

4.6 The Contractor shall provide approved qualified personnel to run the laboratory

for the duration of the Contract. The number of staff and equipment available

must at all times be sufficient to keep pace with the sampling and testing

programme as required by the Engineer-in-Charge.

4.7 The Contractor shall fully service the site laboratory and shall supply everything

necessary for its proper functioning, including all transport needed to move

equipment and samples to and from sampling points on the site, etc.

4.8 The Contractor shall re-calibrate all measuring devices whenever so required by

the Engineer-in-Charge and shall submit the results of such measurements

without delay.

5 MACHINERY AND PLANT

5.1 The contractor will be entirely responsible to arrange all necessary machinery

including inches, gauges, dredgers, derricks, cranes, staging materials, vehicles,

trailers, tools and plant and their spare parts required for efficient and methodical

execution of the work and transport them to the site of work. Delay in procurement

of such items due to their non-availability as excuse for import difficulties or any

other cause whatsoever will not be taken as excuse for slow or non-performance of

the work. Safety of plants and machinery will be the responsibilities of the

contractor and for any loss in cases of wash way any type of contractor’s materials,

tools & plants in floods, or otherwise no claim will be entertained on this account,

whatsoever.

5.2 The minimum equipment and machinery to be deployed by the Contractor for the

execution of work shall be as given in Part-C of Technical Specification.

6 AS BUILT DRAWING

6.1 After completion of the works contractor should submit dimensional completion /

as built drawings – 3sets and soft copy (CD).

7 SECURITY DEPOSIT

7.1 The existing condition 9 of General conditions of contract shall be treated as deleted

and substituted with the following sub clauses of Special Conditions of Contract.

7.2 The total security deposit to be furnished by the Contractor whose tender(s) may be

accepted (hereinafter called the contractor) including the amount of Earnest money

deposited with the tender shall be 5% (Five Percent) of the contract value.

7.3 Recovery of Security Deposit The person/persons whose tender(s) may be accepted (hereinafter called the

Contractor) shall permit the Employer at the time of making any payment to him for

work done under the Contract to deduct a sum at the rate of 5% of the gross amount

of each running bill till the sum along with the sum already deposited as earnest

money will amount to Security Deposit of 5% of the tendered value of the work.

Earnest money shall be adjusted first in the Security Deposit and further

recovery of Security Deposit shall commence only when the up-to-date amount of Security Deposit starts exceeding the Earnest Money. Such deductions will be

made and held by the RITES for & on behalf of Employer by way of Security

Deposit unless he/ they has/ have deposited the amount of Security at the rate



59

mentioned above in cash or fixed deposit receipts. In case a fixed deposit receipt of

any Bank is furnished by the Contractor to the RITES as part of the security deposit

and the Bank is unable to make payment against the said fixed deposit receipt, the

loss caused thereby shall fall on the Contractor and the Contractor shall forthwith on

demand furnish additional security to the Employer to make good the deficit.

All compensations or the other sums of money payable by the Contractor under the

terms of this Contract may be deducted from, or paid by the sale of a sufficient part

of his security deposit or from the interest arising there from, or from any sums

which may be due to or may become due to the Contractor by the RITES for & on

behalf of Employer on any account whatsoever and in the event of his Security

Deposit being reduced by reason of any such deductions or sale as aforesaid, the

Contractor shall within 10 days make good in cash or fixed deposit receipt tendered

by the State Bank of India or by Scheduled banks endorsed in favour of the

Engineer-in-Charge, any sum or sums which may have been deducted from, or

raised by sale of his security deposit or any part thereof. The security deposit shall

be collected from the running bills of the Contractor at the rates mentioned above

and the Earnest Money deposited at the time of tenders will be treated as part of the

Security Deposit.

7.4 Security Deposit shall be released to the contractor as per scheduled given below:

1 50% (fifty percent) of total

security deposit (release of

security deposit in the form of

BG and EMD).

After satisfactory completion of the

work as certified by the Engineer-

in-charge.

2. Balance 50% (fifty percent)

of total security deposit

(release of security deposit in

the form of cash).

After successful completion of

defect liability/maintenance period.

7.5 No interest will be payable on the Earnest Money or the Security Deposit or the

amount payable to the contractor under the contract.

7.6 Security Deposit shall not be released/refunded to the contractor till the

contractor obtains clearance certificate from the Labour office.

8 PERFORMANCE GUARANTEE

8.1 The contractor shall provide RITES with a financial guarantee for the due and

faithful performance of the contract for a sum equal to 05% (five per cent) of

the Tendered Value. Such guarantee shall be in the form of a bank guarantee

from a Schedule Bank or the State Bank of India located in India, on the format

already agreed upon. The Bank guarantee shall be furnished within 21 days

from the date of issue of Letter of Acceptance. This period can be further

extended by the Engineer-in-Charge up to a maximum period 10 day on written

request of the Contractor stating the reason for delays in procuring the Bank

Guarantee, to the satisfaction of the Engineer-in-Charge.



60

8.2 In case the performance of the contractor is not found satisfactory at any stage in

the opinion of Engineer-in-charge, the performance guarantee of the contractor shall

be forfeited after giving due notice to the contractor. The decision of the Engineer-

in-chare shall be final and binding on the contractor in this regard.

8.3 The Performance Guarantee shall be initially valid upto the stipulated date of

completion plus 60 days beyond that. In case the time for completion of work gets

enlarged, the Contractor shall get the validity of Performance Guarantee extended to

cover such enlarged time for completion of work. The Performance Guarantee

shall be released after satisfactory completion of defect liability period.

(i) The Engineer-in-charge shall not make a claim under the Performance Guarantee

except for amounts to which the Employer is entitled under the Contract

(notwithstanding and/or without prejudice to any other provisions in the Contract

agreement) in the event of :

a) Failure by the Contractor to extend the validity of the Performance

Guarantee as described herein above, in which event the Engineer-in-charge

may claim the full amount of the Performance Guarantee.

b) Failure by the Contractor to pay the Employer any amount due, either as

agreed by the Contractor or determined under any of the Clauses/ Conditions

of the agreement, within 30 days of the service of notice to this effect by

Engineer-in-charge.

ii) In the event of the Contract being determined or rescinded under provisions of

any of the clause/condition of the agreement, the performance guarantee shall

stand forfeited in full and shall be absolutely at the disposal of the Employer.

8.4 The Contractor’s All Risk Policy (C.A.R) shall be incorporated by the Contractor up

to completion of the work.

9 SALES TAX ON WORKS CONTRACT, SERVICE TAX, OTHER TAXES,

DUTIES, & LEVIES ETC.

9.1 The award of work under this Contract shall be on “Works Contract Basis”. The

Contractor shall be responsible for payment of any tax levied on the transfer of

property or goods involved in the “Works Contract” under Bihar State Government

Sales Tax Act and the rules made hereunder including amendments if any. This

liability shall be to the Contractor’s account and it shall not be reimbursed by RITES

Ltd., Tax deductions at source shall be made as per laws prevalent in the country.

It will be incumbent upon the Contractor to obtain a registration certificate as a

dealer under the Local Sales Tax Act and the Central Sales Tax Act and necessary

evidence to this effect s hall be furnished by the Contractor to RITES Ltd., Sales Tax

on the transactions between the Contractor and his Sub contractors/Vendors etc shall

not be reimbursed by RITES Ltd.

9.2 The Contractor shall be responsible for any taxes that may be levied hereinafter on

the transaction between Contractor and RITES Ltd.,

9.3 The Contractor, shall be liable and responsible for the payment wherever payable,

of the taxes, import duties, tolls, octroi duties, excise duty, levies, entry tax, service



61

tax, Cess, Royalty, Seinorage charges etc. on all services, material and articles’ that

he may use for this work. Any increase in the aforesaid taxes, import duties, tolls,

octroi duties, excise duty, levies, entry tax, service tax, Cess, Royalty, Seinorage

charges etc that may arise during the currency of the contract shall be entirely on the

Contractor’s accounts.

9.4 NTPC will provide form C and way bill to the contractor for availing of Sales Tax rebate wherever applicable. In case RITES/NTPC fails to provide form ‘C’

and way bill additional sales tax as paid by the contractor on account of non issue of

Form ‘C’, will be reimbursed to the contractor on production of proof of payment of

Sales Tax by the Contractor.- NOT APPLICABLE

9.5 The item rates quoted shall be inclusive of all taxes such as Sales Tax (against issue

of Form ‘C’) Excise Duty, Entry Tax, Toll Tax, Turnover Tax on works contract,

Octroi, Royalty and any other tax of levy etc. as applicable. However sales tax on

work contract, if paid by RITES/NTPC directly, the same amount shall be recovered

from the contractor’s on account bills and no exemption claims on this account shall

be entertained by RITES Ltd.

10 CONTRACT PRICE ADJUSTMENT. (REFER CLAUSE 53 OF GCC) -

NOT APLICABLE

10.1 Price adjustment against this contract shall be available to the contractor only on

“Fuel component of the work elements, this Price adjustment shall not be available

to the contractor on any other components as defined in clause 10.3”

10.2 The Contractor shall be required to produce necessary "Price List" for H.S. Diesel

Oil and "Monthly Bulletins" issued by office of Economic Adviser/labour Bureau,

Simla for receiving payments from, RITES/Refund to be made to RITES as required

in the Price Adjustment formula mentioned above.

10.3 The percentage of various components in contract price on which variation in prices

shall be admissible are indicated below. However, for the contract price adjustment

shall be available only on Fuel Component.

a. Labour Component - 30 %

b. Fuel Component - 15 %

c. Materials Component - 40 %

d. Fixed Component - 15% (will not be considered for any

price variation)

11 PAYMENT ON ACCOUNT

11.1 Add the following in clause 51.1 (b) of GCC.

11.2 For the purpose of this clause, the material component is defined as follows:

"The sum of all the percentages for various factors, stipulated in price adjustment

Clause except the percentage stipulated for the labour component and fixed

component".



62

12 TIME SCHEDULE

12.1 The condition no. 13 under Schedule-A (i.e. Reference to General Conditions of

Contract) “The time allowed for execution of work or time schedule” may be

read as deleted and modified as under.

The entire scope of work covered under this contract shall be completed within

03(Three) months from the date of commencement of work. The date of

commence of work shall be reckoned from the 15th day of issue of Letter of

Award The work shall be performed in time and to achieve the targets, the

Contractor shall have to plan adequate mobilization of all resources. List of

equipment, construction methodology, Site Organization Set-up and a detailed Work

Schedule shall be discussed with the successful tenderer before award of the

Contract and agreed to and such agreed Work Schedule shall form a part of the

Letter of Award. All the Contractor's activities shall be performed and completed

strictly in accordance with agreed Work Schedule. The Engineer-in-charge, shall

however, have the right to review the progress and modify the Work Schedule

suiting the site conditions and the Contractor shall be required to complete his

activities in accordance thereof without any extra cost to the Owner.

13 WATER & POWER SUPPLY

13.1 Clause No. 46 and 48 of Section-III of General Conditions of Contracts (GCC):

13.2 Water Supply

13.2.1 Replace the existing clause 46 (a), (b), (c) of Section-III of GCC by the following:

13.2.2 No water will be supplied by RITES/NTPC for any purpose. The Contractor shall

make his own arrangement at his own cost. No claim will be entertained on this

account.

13.3 Power Supply

13.3.1 Delete the GCC clause: 48.

13.3.1.1No power will be supplied by RITES/NTPC for any purpose. The Contractor shall

make his own arrangement at his own cost. No claim will be entertained on this

account.

14 QUALITY ASSURANCE PROGRAMME – Followed by RITES Specifications

for Railway Track and Bridge Works September-2010

14.1 All costs associated with testing of materials required as per technical specifications

shall be borne by Contractor.

15 TEMPORARY & ENABLING WORKS AND DELAYING WORKS

15.1 The sitting and nature of all offices, huts, access road to the work - areas, access

tracks to work areas, bunds, sumps, channels and all other temporary works as may

be required for the proper execution of the works shall be subject to the' approval of

the Engineer-in-Charge. These works shall be executed by the Contractor at his own

cost. Hard crusting for pre-assembly/fabrication yard shall be in line with Part-A of

Technical Specification.

15.2 All the equipments, labour, materials required for the enabling works associated with

the entire Contract-shall have to be arranged by the Contractor only. Nothing extra

shall be paid to the Contractor on this account and the unit rates quoted by the



63

Contractor for various items in the Schedule of Items shall be deemed to include the

cost of enabling works.

15.3 The Contractor shall make his own arrangement at his own cost for approach to the

work site including borrow I disposal area and for movement of men, machinery,

other requirement etc. required for carrying out the work included under this

Contract.

16 SHIFT WORK

16.1 To achieve the required progress, two or more shifts a day may be necessary for

executing the work. The period of completion and number of working days shall not

be affected by the number of shifts each day. No extra amount on account of any

shift work is payable to the Contractor.

16.2 Wherever, the work is carried out at night, adequate lighting of working areas and

access paths should be provided by the Contractor at his own cost. Sufficient notice

should be given by the Contractor to the Engineer-in-Charge regarding the details of

works in shifts so that necessary supervision could be provided.

17 OBSERVANCE OF LABOUR LAWS

17.1 In addition to the observance of provision in clauses 16.0 and 34-A, of Section III of

General Conditions of Contract, the following provisions will also hold good:

17.2 The Contractor shall be liable to make payment to all the employees and make

compliance with labour laws. If the OWNER, is held liable as 'PRINCIPAL

EMPLOYER' to pay contribution etc- under ESI Act or any other legislation of

Government or Court decision, in respect of the employees of the Contractor, then

the-latter would reimburse, the amount of such contributions so paid by

RITES/NTPC.

18 COOPERATION WITH OTHER AGENCIES

18.1 The Contractor shall attend at his cost, all the meetings with the Engineer-in Charge,

other Contractors and the Consultants of the Owner for the Contract. The Contractor

shall attend such meetings as and when required and fully cooperate with such

persons and agencies involved.

19 DEFECT LIABILITY /MAINTENANCE PERIOD

19.1 The Defect Liability/Maintenance period shall be 12 months reckoned from the date of issue of handing over of works to RITES/NTPC on completion. Also

through out the defect liability period of 12 months sufficient staff and

materials/equipments etc. will be arranged by the contractor to enable to carry out

the repairs/rectification immediately whenever pointed out by RITES/NTPC.

19.2 In case the defect liability are such that can not be rectified or the contractor fails to

rectify completely to the satisfaction of Engineer-in-charge, then RITES/NTPC

reserves the right to accept the work at reduced rates or to get the rectification work

done at the risk and cost of the contractor. The decision of RITES/NTPC in this

regard shall be final and binding on the contractor and shall be beyond purview of

the “Settlement of disputes and Arbitration” clause of General Conditions of

Contract.



64

19.3 The contractor shall be responsible for rectification of defects arising out of defective

workmanship / defective materials for this period of twelve months and shall be

responsible for replacement of all defective materials and for rectification of all

defects at his own cost. The assets shall be handed over to Engineer-in-Charge /

NTPC at the end of the maintenance period as per stipulations given in Technical

Specifications.

20 CONTRACT COORDINATION PROCEDURES, MEETINGS & PROGRESS

REPORTING COORDINATION

20.1 The Contractor shall prepare and finalize in consultation with RITES Ltd /NTPC, a

detailed Contract coordination procedure within 21 days from the date of issue of

Letter of Award for the purpose of execution of the Contract.

20.2 During the execution of the work, Contractor shall submit at his own cost a detailed

monthly progress report to the Engineer-in-Charge in three copies by 7th of every

month.

21 QUANTITY VARIATION LIMIT

21.1 The quantity variation shall be as per Clause 10 (iv) of Schedule-A enclosed with the

GCC.

22 HANDING OVER OF SITE

22.1 Efforts will be made by the Owner to hand over the site to the Contractor free of

encumbrance. However, in case of any delay in handing over of the site to the

Contractor, the Owner shall only consider suitable extension of time for the

execution of the work. It should be clearly understood that the Owner shall not

consider any other compensation whatsoever viz. towards idleness of contractor’s

labour, equipment etc.

22.2 The Contractor shall make his own arrangement at his own cost for approach to the

work site including borrow / disposal area and for movement of men, machinery,

other equipment etc. required for carrying out the work included under this Contract.

22.3 The Owner reserves the right to hand over the site in parts progressively to the

Contractor. The Contractor will be required to do the work on such released-fronts

in parts without -any reservation whatsoever.

22.4 The access roads near to the work site may not be available at the time of Mobilisation

of the Contractor. The Contractor shall plan his work within the plant area as per

available roads at site. All drainage of works area and all other weather

truckable/haulage roads as required by the Contractor shall be constructed and

maintained during the construction period by the Contractor at his own cost.

23 STAFF QUARTER

23.1 Staff quarters & labour hutment at Barh STPP, RITES/NTPC, if available, may be

provided to the contractor on chargeable basis at the discretion of the Engineer-in-

Charge on mutually agreed terms & conditions.

24 SITE ORGANISATION

24.1 The contractor shall depute well qualified and experienced personnel for

administration and execution of the Contract at site in the area of planning,



65

procurement & contracts/construction, electrical, mechanical, quality assurance,

personnel, finance, safety etc.

25 PREVENTION OF POLLUTION.

25.1 Contractor shall make necessary arrangement to prevent pollution of the water in any

stream, springs, nallah, river and lakes.' The Contractor shall be solely responsible

and liable for all damage caused by any pollution that may take place during the

execution of the work.

26 EXPLOSIVES

26.1 Permission for the use of explosives shall be obtained from the Engineer-in-Charge

and shall be used only under close supervision.

26.2 It shall be responsibility of the Contractor to seek and obtain any necessary permits

and to ensure that the requirements of the authorities are complied with in all

respects. Failure to do so may result in the Engineer-in-Charge withdrawing

permission to use explosives.

26.3 Under no circumstances shall blasting be permitted at night. The indemnification

provided for under the General Condition of Contract shall include indemnification

against all claims in respect of any incident arising from the use of explosives.

26.4 The Owner reserves the right to award the work to a single Party or to Split the work

amongst two or more parties as deemed necessary without assigning any reason.

27 PROCUREMENT OF P.WAY MATERIALS AND INSPECTION

27.1 All the materials and equipments received for track construction shall be procured

from the suppliers/manufacturers approved by RDSO/Railway/RITES.

27.2 Any materials for which approved manufacturers or suppliers are not available shall

be procured from sources after getting approved from RITES prior to procurement.

27.3 All the materials shall be got inspected and passed from Railway authorized inspecting

agencies such as RDSO/Railway/RITES/DGS&D and certificates obtained to this

effect shall be submitted to RITES before acceptance of that material.

27.4 Procurement of Rails:-

i) 52 Kg (90 UTS) 1st quality rails (required for tracks only) are available at NTPC

stock yards inside plant at Barh.

ii) Depending upon the requirements of work, the contractor shall give his requirement

schedule of rails to RITES sufficiently in advance of the date of requirement of rails

(at least one (1) month in advance of the requirement), so that necessary

arrangements are made by RITES for issue of rails to the contractor in time. Any

failure on this account resulting in stoppage/delay in execution of work shall be

solely on contractor’s account. The decision of the Engineer in charge of the work,

in this regard, shall be final and binding on the contractor.

iii) Upon receipt of requirement of rails from the contractors, RITES shall issue

authorization letter to the contractor to draw rails (1st quality only) as required for

the work. However, before issue of authorization letter by RITES to the contractor,

the contractor will have to furnish a Indemnity bond to cover cost of these rails on

the proforma placed as Proforma-XIII. Such indemnity bond shall be available for



66

the period upto payment of ‘Final Bill’ to the contractor. However, the Indemnity

bond shall be released by RITES on measurement, reconciliation and finalisation of

the quantity of rails issued to the contractor against the concerned Indemnity bond,

in addition the contractor shall also provide insurance cover for the rails covering

cost of rails.

iv) On receipt of the authorization letter from RITES, the contractor to collect rails from

Rail stock yard of NTPC/Barh. Thereafter, the contractor shall be solely and fully

responsible for the safe custody of rails.

v) Handling and leading of Rails.

The contractor shall as explained above, collect the rails from Rail stock yard of

NTPC/Barh and then lead them to site of work where they are required to be used.

All costs towards handling, loading, leading, unloading, lifting, crossing of rivers,

nalah etc, including spreading, pairing etc of the rails as required for the work shall

be solely borne by the contractor which will be considered included in the relevant

item of work of the Schedule of Quantities and nothing extra shall be payable to the

contractor on any account.

vi) Use of Rails

The rails so collected by the contractor against the authorization letter of RITES (as

stipulated above) shall be used only in laying of plain tracks, in accordance with the

Technical Specifications. The contractor shall not use these rails for Points &

Crossing, Derailing Switches, making guard rails for bridges, check rails for level

crossings, manufacture of various types of posts etc. for which rails as required as

per specifications shall be arranged and procured by the contractor at his level and

cost and then used.

vii) Account of Rails:

a) The rails will be issued to contractor from Rail Stock yard of NTPC/Barh in

Metric Tones.

b) One meter rail shall be considered to weigh 52 Kg.

c) Scale of consumption:

For each track meter laid, 52x2= 104 Kg. rail shall be considered consumed.

NOTE: - No allowance shall be provided for wastage.

viii) Calculation of consumption of rails:

The quantity of rails used on the works shall be calculated as follows:-

Sl. No.

Item of work

done and

measured

Unit

Quantity of

work

done

Quantity of Rails consumed (in

Kg)

Rate of usage

unit (Kg) Quantity (Kg)

1 2 3 4 5 6

1

Linking of track

as per item in

Schedule of

Quantity

Track

Metre 104 = Col 4 x 104



67

ix) Reconciliation of quantities:

a) As detailed above, the total quantity of rails consumed by the contractor for the work

shall be calculated without making any allowance for wastage.

b) The aforesaid quantity of rails as worked out above, shall be taken as consumed on

work and shall be issued to the contractor free of cost.

c) If the quantity of consumption of rails so worked above, falls short of the quantity

issued to the contractor from Rail Stock Yard, the excess quantity issued shall have

to be returned back by the contractor to RITES in rail lengths not less than (4) four

meters. Rails lesser in length than Four (4) meters shall not be accepted. Such

surplus rails will have to be handed over by the Contractor to Engineer-in-Charge of

the work at his store at Barh. All cost of handling, leading, lifting etc on this account

shall be fully borne by the contractor and no payment, whatsoever, shall be payable

to the contractor on this account

d) If the contractor fails to return the excess quantity of Rails as calculated above, a

recovery at the rate of Rs.50,000/- (Rupees fifty thousand) only per metric tone for

1st quality rails shall be made for the excess quantity not returned back by the

contractor from his bills.

27.5 Procurement of PSC Sleepers:

i) PSC Sleepers has already been purchased by RITES for & on behalf of NTPC.

Balance quantity of Normal & special sleepers as per the schedule is to be procured

by the agency.

ii) Depending upon the requirements of work, the contractor shall give his requirement

schedule of sleepers to RITES sufficiently in advance of the date of requirement of

sleepers (at least one (1) month in advance of the requirement), so that necessary

arrangements are made by RITES for issue of sleepers to the contractor in time. Any

failure on this account resulting in stoppage/delay in execution of work shall be

solely on contractor’s account. The decision of the Engineer in charge of the work,

in this regard, shall be final and binding on the contractor.

iii) Upon receipt of requirement of sleepers from the contractors, RITES shall issue

authorization letter to the contractor to draw sleepers as required for the work.

However, before issue of authorization letter by RITES to the contractor, the

contractor will have to furnish an Indemnity bond to cover cost of these sleepers on

the proforma placed as Proforma-11. Such indemnity bond shall be available for the

period upto payment of ‘Final Bill’ to the contractor. However, the Indemnity bond

shall be released by RITES on measurement, reconciliation and finalisation of the

quantity of sleepers issued to the contractor against the concerned Indemnity bond,

in addition the contractor shall also provide insurance cover for the sleepers

covering cost of sleepers.

iv) On receipt of the authorization letter from RITES, the contractor to collect sleepers

from stock yard of NTPC/Barh and transport them to the site at his own cost.

Thereafter, the contractor shall be solely and fully responsible for the safe custody of

rails.



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v) Handling and leading of Sleepers.

The contractor shall as explained above, collect the sleepers from stock yard of

NTPC/Barh and then lead them to site of work where they are required to be used.

All costs towards handling, loading, leading, unloading, lifting, crossing of rivers,

nalah etc, as required for the work shall be solely borne by the contractor which will

be considered included in the relevant item of work of the Schedule of Quantities

and nothing extra shall be payable to the contractor on any account.

28 PAYMENT TOWARDS SUPPLY OF ORDINARY PSC SLEEPERS & PSC

SLEEPER FOR POINTS & CROSSINGS

a) 70% payment will be made on receipt of materials at site and balance 30% payment

will be made after laying the track. Actual quantity of materials received at site will

be considered for the purpose of effecting payment.

b) No payment will be made unless current and valid STCC (wherever applicable) is

submitted prior or along with the bills and also without obtaining insurance policies

for the work such as CAR policy, Workmen compensation policy, Plant &

Equipment policy etc.

29 RETURN OF UN-USED SURPLUS MATERIALS

29.1 In case the materials issued by RITES/NTPC are left surplus then the surplus material

should be returned by the contractor in good condition to the representative of

RITES/NTPC at specified depot at the time of completion of determination of

contract.

29.2 In case the contractor fails to return the un-used excess materials (over the actual

requirement plus 3% for wastage of consumed quantity) as indicated above, the cost

of surplus materials will be recovered from the contractor at the rate to be arrived at

as per relevant para below.

29.3 The rate at which the material is procured by RITES/NTPC through

supplier/contractor (±) 25% overhead charges approximately.

29.4 The contractor shall not be entitled for any cartage and incidental charges for

returning the surplus materials to the specified stores.

30 Following Specifications, Drawings and Codes with latest corrections/revisions

are required to be followed:

(i) Authorized drawings and plans if issued for this work from time to time by

RITES.

(ii) Other standard RDSO drawings and specifications for item as quoted in

schedule of Rates or otherwise applicable.

(iii) IS Codes and Specifications as applicable.

(iv) IRS Codes and Specifications as applicable.

(v) IRC Codes and Specifications as applicable.

(vi) RDSO Guidelines for Track Ballast



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(vii) Indian Railway Manuals including Permanent Way Manual, Bridge Manual,

Works Manual etc.

(viii) Eastern Railway Specifications as applicable.

(ix) Rites reserve the right to issue any drawing/instructions progressively.

(x) RITES Specifications for Railway Track & Bridge Works, September-2010

31 COMPLETION CERTIFICATE

31.1 The Contractor shall maintain a logbook at site incorporating therein the progress of

work during the execution of contract. During execution of the work, Contractor

shall submit monthly progress reports and on completion shall intimate the

Engineer-in-charge in writing. Within 21 days of receipt of such information the

Engineer-in-charge shall physically inspect the works and logbook and shall furnish

Contractor with a certificate of completion indicating

31.1.i Date of completion.

31.1.ii Defects to be rectified by Contractor. The Contractor shall remain liable for

rectifying defects etc. in the work executed by him and his sub-contractor upto 12

months after issue of completion certificates.

31.1.iii Part of work completed for which payment may be authorized towards the charges

claimed by them.

31.2 For the purpose of this clause the work shall be considered completed in full on the

day when the contractor has completely removed from the premises, all sheds

surplus material, rubbish etc.

32 TERMINATION

32.1 TERMINATION FOR DEFAULT

32.1.i The owner may without prejudice to any other remedy for breach of Contracts, by

written notice of default sent to the contractor, terminate the contract in whole or in

part.

32.1.ia If the Contractor fails to deliver any or all of the services within the time period(s)

specified in the contract or any extension thereof granted by the owner in writing.

32.1.ib If the Contractor fails to perform any other obligation(s) under the contract or.

32.1.ic If the contractor, in either of the above circumstances, does not cure its failure

within a period of twenty one (21) days after receipt of the default notice from the

owner.

32.1.id In the event the Owner terminates the Contract in whole or in part, pursuant to para

32.1.i, the owner may get the works done, upon such terms and in such manners as it

deems appropriate, similar to those not carried out by the Contractor, and the

Contractor shall be liable to the Owner for any excess costs for such similar works.

However, the Contractor shall continue performance of the Contractor to the extent

not terminated.



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32.2 TERMINATION FOR CONVENIENCE

32.2.i The owner may be written notice sent to the Contractor terminate the contract, in

whole or in part, at any time for its convenience. The notice of termination shall

specify that termination is for owner’s convenience, the extent to which performance

of work under the contract is terminated and the date upon which such termination

becomes effective.

32.2.ii The items of work those are completed and ready for final inspection within twenty

one (21) days after the contractor’s receipt of notice of termination shall be accepted

by the Owner at the Contract terms and price. For the remaining items of works the

Owner may elect.

32.2.iia To have any portion completed and delivered at the contract terms and prices

and/or.

32.2.iib To cancel the reminder and pay to the Contractor an agreed amount for partially

completed works.

32.3 TERMINATION FOR INSOLVENCY

32.3.i The owner may any time terminated the Contract by giving written notice to the

Contractor, without compensation to the Contractor, if the Contractor becomes

bankrupt or otherwise insolvent, provided that such termination will not prejudice or

affect any right action or remedy which has occurred or will accrue thereafter to the

Owner.

32.4 Upon termination of the contract at any time for whatever reason by RITES/NTPC

compensation shall be payable to the Contractor for all items of works performed

satisfactorily until the date of termination. In addition the Contractor will be paid

for such of those items of work, which have been partially completed as conditions

stipulated under clause 30.2.ii. The contractor shall provide available documentary

evidence to this effect, acceptance to RITES/NTPC.

32.5 Following issuance by RITES/NTPC of a notice of termination and prior to the

effective date of such termination, the Contract shall:

32.5.i Terminate performance of work in progress under the contract on the date and to the

extent specified in the notice of termination.

32.5.ii Incur no further costs for services except as necessary to complete performance of

any portion of the work under the contract not terminated by the said notice.

32.5.iii Terminate all outstanding order, service contracts and sub-contracts to the extent

that they relate to the performance of work terminated by the notice.

32.5.iv Transfer title and deliver to RITES/NTPC in the manner, at the times and to the

extent, if any, as directed, by RITES/NTPC in the completed or partially completed

items of work which, if the contract has been continued, would have been required

to be furnished to RITES/NTPC.

32.6 The termination of the contract shall not relieve the contractor of its responsibilities

and liabilities as per the contract for the portion of the work performed prior to the

effective date of termination.



71

33 ARBITRATION

33.1 Except where otherwise provided for in the contract all questions and disputes

relating to the meaning of the specifications, designs, drawings and instructions

herein before mentioned and as to the quality of workmanship or material used on

the works or as to any other question, claim, right matter or thing whatsoever in any

way arising out of or relating to the contract, designs drawings, specifications,

estimates, instructions orders or these conditions or otherwise concerning the works,

or the execution or failure to execute the same whether arising during the progress of

the work or after the completion or abandonment thereof shall be referred to the sole

arbitration of the General Manager of NTPC Ltd. (Barh, STPP) and if General

Manager of NTPC Ltd. (Barh, STPP) is unable or unwilling to act, some other

person appointed by the Chairman & Managing Director, NTPC Ltd., will act as

such arbitrator. There will be no objection if the arbitrator so appointed is an

employee of NTPC Ltd., and that he had to deal with the matters to which the

contract relates and that in the course of his duties as such he had expressed views

on all or any of the matters in dispute or difference. The arbitrator to whom the

matter is originally referred being transferred or vacating his office or being unable

to act for any reasons as aforesaid at the time of such transfer, vacation of office or

inability to act, Chairman & Managing Director, NTPC Ltd., shall appoint another

person to act as arbitrator in accordance with the terms of the Contract. It is also a

term of this contract that no person other than a person appointed by Chairman &

Managing Director, NTPC Ltd., shall appoint another person to act as arbitrator in

accordance with the terms of the Contract. It is also a terms of this Contract that no

person other than a person appointed by Chairman & Managing Director, NTPC

Ltd., as aforesaid should act as arbitrator and if for any reason, that is not possible

the matter is not to be referred to arbitrator at all. Subject as aforesaid the provision

of Indian Arbitration and Conciliation Act, 1996, the rules framed there under and

any statutory modifications thereof shall apply to the arbitration proceeding under

this clause.

33.1.1 It is a term of the contract that the party invoking arbitration shall specify the dispute

or disputes to be referred to arbitration under this clause together with the amount or

amounts claimed in respect of each such dispute.

The arbitrator (s) may from time to time with consent of the parties enlarge the time

for making and publishing the award.

The work under the Contract shall, if reasonably possible, continue during the

arbitration proceedings and no payment due or payable to the Contractor shall be

withheld on account of such proceedings.

The Arbitrator shall be deemed to have entered on the references on the date he

issue notice to both the parties fixing the date of the first hearing. The Arbitrator

shall give a separate award in respect of each dispute or difference referred to him.

The venue of arbitration shall place as may be fixed by the Arbitrator in his sole

discretion.

The cost of arbitration shall be borne by the parties to the dispute, as may be decided

by the arbitrator(s).

In the event of disputes or differences arising between one Public Sector Enterprise

and a Govt. Department or between two Public Sector Enterprise the above



72

stipulation shall not apply and the provisions of BPE office memorandum No.

BPE/GL-0017/MAN/2/110-75-BPE/GMI dated 01.01.1976 or its amendments for

arbitration shall be applicable.

33.1.2 Notwithstanding the existence of any dispute or difference and/or reference for the

arbitration the Contractor shall proceed with and continue without hindrance with

the performance of the work under the contract with due diligence and expedition in

a professional manner and the payment due to the contractor shall not be withheld

by the Owner on account of such difference or arbitration proceedings unless such

payment is subject matter of the arbitration.

34 LAWS GOVERNING THE CONTRACT

34.1 This Contract shall be governed by the Indian Laws for the time being in force.

35 APPOINTMENT OF SAFETY OFFICER.

35.1 The Contractor or Contractor’s Engineer or Contractor’s Supervisor who is directly

engaged in supervision of the work should go through General Safety awareness

training programme at least for two days at any reputed organization or Training by

NTPC before the start of the work. A certificate in this respect has to be obtained

and submitted to Engineer-in-Charge. The EIC should not allow the work to start

without this training as well as training to his workmen. Such designated safety

officer can discharge the responsibility of ensuring safety at work site. Besides

above daily PEP talks to be conducted at workplace for refreshing awareness.

36 ACCIDENTS

36.1 If any accident occurs in the project area under the charge of the contractor during

the period of construction or during the defect liability / maintenance period of 12

months after the commissioning of works, causing damage to the works / assets, an

inquiry shall be conducted by RITES / NTPC and if it is found in the inquiry that the

accident was caused due to any negligence / failure on the part of the contractor / his

staff /defective workmanship /defective material etc. attributable to the contractor,

he shall be responsible to carry out all required repairs / replacement / works to the

assets being maintained by him, solely at his cost. The decision of the inquiry

committee in this regard, shall be final and binding. In addition, the contractor shall

compensate the Railway/RITES/NTPC by payment of Rs. 5 Lacs (Rs. Five lacs) per

accident in cases where the contractor / his staff / defective workmanship /defective

material etc. are found responsible for the accident.

36.2 If, however, it is found in the inquiry that the contractor was not responsible in any

way for the accident and the accident occurred due to any fault on the part of

Railway/RITES/NTPC any other cause, the contractor shall not be responsible for

carrying out the require repairs / replacements/ works at his cost.

36.3 Not withstanding as to who is responsible for the accident, the contractor, if required

by RITES / NTPC shall immediately carry out all the required repairs / replacements

/ works to the assets being maintained by him, at accident site and in case he is not

found responsible for the accident as indicated in para (ii) above, he shall be paid for

the works / replacements/repairs as per schedule of rates as accepted in Schedule of

Quantities. For additional items if any, the payment shall be governed by provisions



73

of para – 39 of General Conditions of Contract. In any case, the contractor shall

not delay the restoration work at accident site and shall carry them out

immediately on instructions from RITES. Any failure in this regard (delay in

restoration work) shall be treated as breach of contract and the contractor shall

be liable to pay a penalty of Rs. 16000/- per day for the days the restoration

work is not taken up by the contractor to the satisfaction of the Engineer-in-

Charge.

37. EXECUTION OF EXTRA ITEMS

Any other item, which has not been covered under items mentioned in BOQ,

shall be executed on SOR of E.C. Rly. 2012 and DSR 2012 rates.

(Signature} ..................

(Printed Name} ..........................................................

(Designation) ................... .......

(Firm Seal} ... ....

The person having Power of Attorney of the bidder, is required to sign and stamp at

each and every page including Annexures.



74

List of Minimum Plants, Equipments and Machinery required to be deployed by Contractor at Site. – NOT APPLICABLE

Sl.No Descriptions Nos

1. Bull Dozer (Heavy Duty) 2

2. Excavator(Poclain) minimum 0.90 cum capacity 2

3. Dumpers 20

4. Roller( 10 Ton Capacity) 2

5. Vibro Compactor 2

6. Water Tankers 2

7. Diesel Generator Set 1

8. Survey Equipment:- Total Station & Auto Levels 1 Set each

9. Lab. Equipment for testing of Soil, Concrete etc As per Contract Requirement

10. Mixer 4

11. Vibrators Needle Type 5

12 De-Water Pumps (i) 5 HP (ii) 10 HP to 50 HP

2 2

13. Weigh Batcher 12

NOTES:-

a) These requirements and capacity of the equipment are indicative only and not exhaustive and deployment of the equipment, machinery and labour shall be suitably augmented to achieve the timely completion of the work as per the programme and directions of the Engineer. Without any additional cost to owner.

b) Other equipment through required for timely completion of the job, but not listed

above shall be deployed by the contractor, as per the job requirement and as directed by the Engineer.

c) The contractor shall make suitable provisions for repairs and maintenance of the

equipment mobilized and always keep them in good working conditions, as the repair facilities for such equipment are not available at the project site.



75

PART-1

SECTION-4

TECHNICAL BID

AMENDMENT/ERRATA TO GCC



76

AMMENDMENT/ERRATA NO.

Sl.No Page

No

Clause No Line of

Reference

Fill/Add/Delete

1. -- All

Clauses in

GCC.

-- Replace the word “National Thermal Power Corporation

Ltd.” or “NTPC” or “Corporation”

by “NTPC/RITES”.

2. 2. NIT 3. Fill “NTPC/BARH”.

3. 2. 1. -- Delete the entire existing clause and

Replace by: Tenders are invited by RITES Ltd. on behalf of

the National Thermal Power Corporation Ltd. for

Construction of new power plants and augmenting the

capacity of its existing ones is a continuous process in

NTPC. One mega project planed is a Super Thermal

Power Plant of 3 x 660 MW capacity near Barh town in

Patna district of Bihar. for NTPC Barh Super Thermal

Power Project.

4. 2. 4. 1 Replace “free of charge, two”

by “one”.

5. 2. 5. 1 Replace the word “The CMD, NTPC Ltd.”

by “The Competent Authority of RITES”.

6. 2. 9 -- Fill:

RITES Limited, Office of the Group General Manager

(P)/General Manager (P)

56, C.R.Avenue, 2nd

Floor,

Kolkata- 70 012

7. 4 20 3 Replace the line “of contract services … been returned”

by “for refund of EMD by tender cell”.



77

8. 6 3.a -- Delete the entire Clause.

Replace by as “Owner” or “NTPC” or “Client” shall mean

the “National Thermal Power Corporation Ltd., New

Delhi, India (A Government of India Enterprises) and shall

include their legal representative, successor and

permitted assigns”.

“RITES Ltd.” (RITES) has been engaged as “Construction

Agency” to supervise the above project by the owner

(NTPC). RITES, shall, therefore be signing the contract

and working on the project, for and on behalf of its

Principal (NTPC) who is the owner & employer of the

Project to be constructed, under a Redeemable Power of

Attorney. The

Contract signed by RITES Ltd., is to be treated as the

Contract signed by “NTPC”.

9. 6 3.c -- Delete the entire Clause.

Replace by “Contract” shall mean the Contract

agreement entered into between RITES and the

Contractor, together with the Contract Documents

referred to therein, they shall constitute the Contract

and the term Contract shall in all such documents be

construed accordingly.

10. 6 3.d -- Delete the entire Clause.

Replace by “Contractor” shall mean the

Bidder whose bid has been accepted by RITES for the



78

award of the work and shall include his legal

representatives, successors and permitted assigns.

11. 7 3.g -- Delete the entire Clause.

Replace by “Engineer–In – Charge” or “EIC” shall mean

the Officer appointed in writing by RITES to act as

Coordinator from time to time on behalf of NTPC in all

matters pertaining to this Contract. RITES shall authorize

“Engineer–in–Charge for direction, supervision,

inspection, security and approval of sum or all of the

services rendered by the Contractor under this Contract.

12. 7 3.j -- Delete the entire Clause.

Replace by Schedule(s) refer to in these condition shall

mean the relevant Schedule annexed to the tender

papers issued by RITES.

13. 7 3.k -- Delete the entire Clause.

Replace by “The ‘Project’ or “Site” or Barh Super Thermal

Power Project shall mean and include the Land and other

places on or over or into or through which the Railway

Siding System and it’s associated Sub – System between

Barh and Punarakh including the proposed Railway Line

and In plant yard such as Signaling and

Telecommunication System etc. are to be constructed by

the RITES through Contractor on behalf of NTPC as

specified in the Scope of work. It shall also include any

adjacent land, path street, river or a reservoir which may



79

be allocated or used by the RITES or Contractor in

performance of the Contract”.

14. 7 3.n -- Delete the entire Clause.

Replace by “ A Week shall mean continuous period of

seven (7) days”.

15. 3.p Add new Clause:

“Specification” shall mean the terms and conditions of

contract and detail project report for mean a part of bid

documents and contract such other schedules and

drawings as may be mutually agreed upon.

16. 3.q Add new Clause:

“Notice of Award of Contract”/”Letter of Award” shall

mean the official intimation from the RITES notifying the

successful bidder that it’s proposal has been accepted

and that the bidder is required to sign the contract

agreement”.

17. 3.r Add new Clause:

“Date of Contract” shall mean the date on which both

parties have signed the contract agreement or any other

date mentioned in Contract/Letter of Award, as the

effective date of Contract, whichever is earlier.

18. 3.s Add new Clause:

Add new Clause “Indian Rupees” or the sign “Rs.” shall

mean the currency of the Government of India.

19. 3.t Add new Clause:



80

“The Government” shall mean the “Government of

India” or “Government of State of Bihar” or an

authorized representative / agency / department of the

Government of India or an authorized representative /

agency / department of the Government of State of

Bihar”.

20. 3.u Add new Clause:

“Starting Date” shall mean the date from which the

period specified for various activities are measured and

set forth in completion schedule. The stating date for

each schedule, unless otherwise agreed, shall be as

indicated in the respective schedule.”

21. 3.v Add new Clause:

“Month” shall mean calendar month, “day” or “days”

unless herein otherwise expressly defined shall mean

calendar day or day of 24 hours each.

22. 3.w Add new Clause:

The “Title” or “Heading” shall not alter or affected the

indent or scope of the clause or articles of the

documents.

23. 3.x Add new Clause:

The “Date of Completion of Contract” – unless otherwise

terminated under the provisions of any other relevant

Clause of the document, the Contract shall be deemed to

have been completed after issuance of the certification

from Engineer – In – Charge that there is no demand out

standing against the Contractor and all liabilities under

the Contract have been satisfactorily fulfilled by the

Contractor.”



81

24. 3.y Add new Clause:

Word pertaining “Person” shall include firms, companies,

corporations and association or bodies of individuals,

whether incorporated or not.

25. 3.z Add new Clause:

“Consultant to NTPC” – NTPC have appointed M/S Vouge

Construction and Consultancy Services Pvt Ltd. New

Delhi (VCC) as the Engineering Consultant for doing the

Design and Engineering, preparing technical

specifications and drawings for the work of Construction

of Railway Siding System and it’s associated Sub–

Systems. The Contractor in accordance with the design,

technical specifications and drawings prepared by VCC

shall execute all the works.

26. 3.aa Add new Clause:

BOQ or SOQ or SOR shall be read as “Schedule of

Quantities”.

27. 10 9

--

Delete the entire clause.

Refer, Clause 7 of SCC

28. 15 12.b.i 21 Add:

Subject to the approval of Engineer-In-Charge.

29. 21 15.b Delete the Entire Clause.

30. 25 16.7.1

and

16.7.2

-- Add the following as Clause No.:16.7.1(i) after the Clause

No.:16.7.1 “Failure to comply with model rules for

Labour Welfare and/or provisions relating to report on

accidents and/ or to grant of maternity benefits to

female workers shall make the Contractor liable to pay to

the RITES as Liquidated Damages an amount of Rs.

1000/- ( Rs. One Thousand only) for each default or

materially incorrect statement. The decision of the

Engineer-in-Charge in such matters based on reports

from the Inspecting Officers as defined in the Contractors

Labour Regulations as appended to these conditions shall

be final and binding and deductions for recovery of such

liquidated damages will be made from any amount

payable to the Sub-Contractor.

31. 25 16.7.2 -- Delete the entire existing Clause 16.7.2 and Add the

SAFETY PROVISIONS Clause:16.7.2 as

SAFETY PROVISIONS

A Contractor employing more than 250 workmen

whether temporary, casual, probationer, regular or

permanent or on contract, shall employ atleast one full



82

time officer exclusively as safety officer to supervise

safely aspects of the equipment and workmen, who will

co-ordinate with project safety officer. In case of work

being carried out through agency‘s employees/workmen

will also be considered as the Sub-Contractor’s

employees/workmen for the above purpose. The name

and address of such safety officer of Contractor will be

promptly informed, in writing to Engineer-in-Charge with

a copy to safety officer-in-charge of NTPC/RITES before

he starts work or immediately after any change of

incumbent is made during currency of the contract.

In case any accident occurs during the

construction/erection or other associated activities

undertaken by the Contractor thereby causing any minor

or major or fatal injury to his employee due to any

reason, whatsoever, it shall be the responsibility of the

Contractor to promptly inform the same to NTPC/RITES

Engineer-in-Charge in prescribed form and also to all the

authorities envisaged under the applicable laws.

The Engineer-in-Charge shall have the right at his sole

discretion to stop the work, if in his opinion the work is

being carried out in such a way that it may cause

accidents and endanger the safety of the persons and/or

property and/or equipment. In such cases, the

Contractor shall be informed in writing about the nature

of hazards and possible injury/accident and he shall

comply to remove shortcomings promptly. The

Contractor after stopping the specific work can, if felt

necessary, appeal against the order of stoppage of work

to the Engineer-in-Charge within 3 days of such stoppage

of work and the decision of Engineer-in-Charge in this

respect shall be conclusive and binding on the Sub-

Contractor.

The Contractor shall not be entitled for any

damages/compensation for stoppage of work due to

safety reasons as provided in para 16.7.2 (iii) above and

the period of such stoppage of work will not be taken as

an extension of time for completion of work and will not

be the ground for waiver of levy of liquidated damages.

The Contractor shall follow and comply with all NTPC and

RITES safety rules, relevant provision of applicable law

pertaining to the safety of workmen, employees, plant

and equipment as may be prescribed from time to time

without any demur, protest or contest or reservation. In

case of any non-conformity between statutory

requirement and NTPC and RITES safety rules referred to

above, the latter shall be binding on the Contractor

unless the statutory provisions are stringent.

If the Contractor fails in providing safe working

environment as per NTPC and RITES Safety rules or



83

continues the work even after being instructed to stop

work by the Engineer-in-Charge as provided in para

16.7.2 (iii) above, the Contractor shall promptly pay to

NTPC/RITES, on demand by the owner, compensation

@Rs.5000/- per day or part thereof till the instruction are

complied with and so certified by the Engineer-in-Charge.

However, in case of accident taking place causing injury,

to any individual, the provisions contained in para 16.7.2

(vii) below shall also apply in addition to compensation

mentioned in this para.

If the Contractor does not take all safety precautions

and/or fails to comply with the safety rules as prescribed

by NTPC and RITES or under the applicable law for the

safety of equipment and plant and for the safety of

personnel and the Contractor does not prevent

hazardous conditions which cause injury to his own

employees or employees of other Sub-Contractor, or

NTPC/RITES employees or any other person who are at

site or adjacent thereto, the Contractor shall be

responsible for payment of compensation to NTPC/RITES

as per the following schedule:

Fatal injury or accident causing death compensation 2

two percent (2%) of contract value or Rs.100, 000/-

(Rupees one lakh only) whichever is less, per person.

Major injury or accident causing 25% or more

permanent disablement To workmen or employees:

Compensation@ one half of one percent (1/2 %) of

contract value or Rs. 20,000/- (Rupees twenty thousand

only) whichever is less, per person.

Note: This compensation is applicable for death/ injury to

any person whatsoever.

Permanent disablement shall have the same meaning as

indicated in workmen Penalty Act. The compensation

mentioned above shall be in addition to the

compensation payable to the workmen/ employees

under the relevant provisions of workmen’s

compensation act and rules framed thereunder or any

other applicable laws as applicable from time to time. In

case the owner is made to pay such compensation then

Contractor is liable to reimburse the owner such amount

in addition to the penalty/ compensation indicated

above.

If the Contractor observes all the safety rules and codes,

statutory laws and Rules during the currency of the

contract awarded by the owner and no accident occurs

then NTPC may consider the performance of the

Contractor and award suitable “ACCIDENT FREE SAFETY

MERITORIOUS AWARD” as per scheme as may be

announced separately from time to time.



84

32. 31

to

34

34 to

34.10

-- Delete the entire existing Clause.

33. 39 40 -- Add:

This will also be applicable for individual partnership of

JV.

34. 43 44 1 Replace “partnership” by “partnership or joint-venture”.

35. 44 46.a to

46.c

Delete the entire existing Clause.

Add: Also Refer clause 13 of SCC

36. 44 46.e 1 Delete the word “Where”.

37. 45 48 -- Add: Also Refer clause 13 of SCC

38. 47 51.1.b -- Replace “75% of the cost, as assessed by Engineer-in-

charge of” by “75% of the cost, as assessed by Engineer-

in-charge or 75% of the material component of the item

rate or 75% of the item rate whichever is lowest for”.

39. 50 56 -- Delete the entire existing clause.

40. 77 Schedule

– “B” and

“C”

-- Delete the entire existing Schedule.

41. 79

to

93.

-- -- Delete the entire existing Proforma.



85

PART- 1

SECTION-5

TECHNICAL BID

GENERAL CONDITIONS OF CONTRACT (G.C.C.)



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Signature of the tenderer Under seal of the firm

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186

SCHEDULE ‘A’

REFERENCE TO GENERAL CONDITIONS OF CONTRACT

This schedule will be applicable instead of Schedule – A (Page No. 74 to 75) of GCC. Condition No. 3(b) Accepting Authority Competent Authority of RITES Ltd

3(i) Market Rate-percentage addition to cover

overheads and profit

10% (Ten percent)

9.1 Earnest Money/Security Deposit Rs.2,96,200 /-

(a) Estimated cost of the Works Rs.296.18 Lac (Approx.)

10(iii) Schedule of Rates applicable SOR EC Rly-2012 and CPWD-DSR-2012

10(iv) DEVIATION LIMIT FOR ITEMS OF

WORK OTHER THAN THOSE BELOW

GROUND SURFACE

10(vi)A (a) Permissible deviation limit for any contract

item, substituted item or contract-cum-

substituted item in excess of the original

Value of item

20% (twenty percent)

(b) Permissible deviation limit for items of

work not already included in the Contract

20% (twenty percent)

DEVIATION LIMIT FOR ITEM OF WORK

BELOW GROUND SURFACE

10(vi)B Permissible deviation limit for an individual

trade item

100% (Hundred percent)

12 Suspension of Work

(b)(ii) Percentage payable to cover Contractor’s

indirect expenses for suspension exceeding

thirty days and not exceeding 3 months

5% (five percent)

(c) Percentage payable to cover Contractor’s

indirect expenses for suspension exceeding 3

months

5% (five percent)

13. Time allowed for execution for execution of

work or Time Schedule

03 months

13(h) Authority competent to decide if “ any other

cause” of delay is beyond Contractor’s control

Competent Authority of RITES Ltd

16. Distribution return of number and description

by trades of workmen employed on Works to be submitted to Engineer-in-Charge

FORTNIGHTLY

32. Authority competent to reduce compensation

amount


33. Defects Liability Periods 12 months

51. Interim bills Monthly

54. Loans –

(a) Interest per annum on sum advanced

for purchase of Plant & Equipment

(b) Ditto-as lumpsum advance Recovery

of Loans to be effected

12% (twelve percent)

12% (twelve percent ) monthly

56. i) Authority for appointing Arbitrator

ii) Authority for nominating the name of

Arbitrator


Competent Authority of NTPC Ltd


187

Section - 6

TECHNICAL SPECIFICATIONS


188

NATIONAL THERMAL POWER CORPORATION LIMITED

BARH SUPER THERMAL POWER PROJECT


189


190


191


192


193

SPECIFICATION FOR TRACK BALLAST

1. SCOPE: These specifications will be applicable for stone ballast to be used for

all types of sleepers on normal track, turnouts, tunnels and deck slabs etc on all

routes.

2. DETAILED SPECIFICATIONS:

2.1 GENERAL

2.1.1 Basic Quality: Ballast should be hard durable and as far as possible angular

along edges/corners, free from weathered portions of parent rock, organic

impurities and inorganic residues.

2.1.2 Particle shape: Ballast should be cubical in shape as far as possible.

Individual pieces should not be flaky and should have generally flat faces with not

more than two rounded/ sub rounded faces.

2.1.3 Mode of manufacture: Ballast for all BG main lines and running lines,

except on ‘E’ routes but including ‘E’ special routes, shall be machine crushed. For

other BG lines and MG/NG routes planned/sanctioned for conversion, the ballast

shall preferably be machine crushed. Hand broken ballast can be used in

exceptional cases with prior approval of Chief Track Engineer/CAO/C. Such

approval shall be obtained prior to invitation of tenders.

On other MG and NG routes not planned/sanctioned for conversion hand broken

ballast can be used for which no approval shall be required.

2.2 PHYSICAL PROPERTIES

2.2.1 Ballast sample should satisfy the following physical properties in accordance

with IS:2386 Pt.IV-1963 when tested as per the procedure given in Annexure-I & II.

BG, MG & NG(planned/sanctioned NG & MG(other than those For conversion) planned for conversion)

Aggregate 30% Max.* 35% Max.

Abrasion value

Aggregate 20% Max.* 30% Max.

Impact value

* In exceptional cases, on technical and/or economic grounds relaxable upto 35%

and 25%respectively by CTE in open line and CAO/C for construction projects. The

relaxation in Abrasion and Impact values shall be given prior to invitation of tender

and should be incorporated in the Tender document.


194

2.2.2 The ‘Water Absorption’ tested as per IS 2386 Pt.III-1963 following the

procedure given in Annexure III should not be more than 1%. This test however, to

be

prescribed at the discretion of CE/CTE in open line and CAO/Con. For construction

projects.

2.3 SIZE AND GRADATION

2.3.1 Ballast should satisfy the following size and gradation:

a) Retained on 65mm Sq.mesh sieve 5% Maximum

b) Retained on 40mm Sq.mesh sieve* 40%-60%

c) Retained on 20mm Sq.mesh sieve Not less than 98% for machine crushed

Not less than 95% for hand broken

* For machine crushed ballast only.

2.3.2 Oversize ballast

i) Retention on 65mm square mesh sieve.

A maximum of 5% ballast retained on 65mm sieve shall be allowed without

deduction in payment.

In case ballast retained on 65mm sieve exceeds 5% but does not exceed

10%, payment at 5% reduction in contracted rate shall be made for the full

stack. Stacks having more than 10% retention of ballast on 65mm sieve

shallbe rejected.

ii) In case ballast retained on 40mm square mesh sieve (machine crushed

case only) exceeds 60% limit prescribed in 2.3.1 (b) above, payment at the

following reduced rates shall be made for the full stack in addition to the

reduction worked out at i) above.

· 5% reduction in contracted rates if retention on 40mm square mesh sieve is

between 60% (excluding) and 65% (including).

· 10% reduction in contracted rates if retention on 40mm square mesh sieve

is between 65% (excluding) and 70% (including).

iii) In case retention on 40mm square mesh sieve exceeds 70%, the stack

shall be rejected.

iv) In case of hand broken ballast supply, 40mm sieve analysis may not be

carried out. The executive may however ensure that the ballast is well

graded between 65mm and 20mm size.


195

2.3.3 Under Size Ballast: The Ballast shall be treated as undersize and shall be rejected if

i) Retention on 40mm Sq. Mesh sieve is less than 40%.

ii) Retention on 20mm square mesh sieve is less than 98% (for machine

crushed) or 95% (for hand broken).

2.3.4 Method of Sieve Analysis:

i) Sieve sizes mentioned in this specification are nominal sizes. The following

tolerances in the size of holes for 65, 40 and 20mm nominal sieves sizes

shall be permitted.

65mm Square Mesh Sieve Plus Minus 1.5mm



Mesh sizes of the sieves should be checked before actual

measurement.

The screen for sieving the ballast shall be of square mesh and shall not be

less than 100cm in length, 70cm in breadth and 10cm in height on sides.

ii) While carrying out sieve analysis, the screen shall not be kept inclined, but

held horizontally and shaken vigorously. The pieces of ballast retained on

the screen can be turned with hand to see if they pass through but should

not be pushed through the sieve.

iii) The percentage passing through or retained on the sieve shall be

determined by weight.

3. CONDITIONS FOR SUBMISSION OF TENDER

3.1 Each tenderer at the time of tendering shall submit the test report of Impact

Value.

Abrasion Value, Water Absorption Value from approved laboratories and the

list of these laboratories shall be mentioned in the tender documents.

3.2 The tenderer shall also furnish an undertaking as incorporated in the tender

document that the ballast supply at all times will conform to Specifications

for Track Ballast as specified by Railway.

4. METHOD OF MEASUREMENT

4.1 Stack Measurement

Stacking shall be done on a neat, plain and firm ground with good drainage.

The height of stack shall not be less than 1m except in hilly areas where it

may be 0.5m. The height shall not be more than 2.0m. Top width of stack

shall not be less than 1.0m. Top of stack shall be kept parallel to the ground

plane. The side slopes of stack should not be flatter than 1.5:1 (Horizontal :

Vertical). Cubical content of each stack shall normally be not less than 30

cum in plain areas and 15 cum in hilly areas.


196

4.2 Wagon Measurement

4.2.1 In case of ballast supply taken by direct loading into wagons, a continuous

white line should be painted inside the wagon to indicate the level to which

the ballast should be loaded. The cubical content in cubic meter

corresponding to white line should also be painted on both sides outside the

wagon.

4.2.2 In addition to painted line, mentioned in para 4.2.1, short pieces of flats (cut

pieces of tie bars or otherwise) with cubical contents punched shall be

welded at the centre of all the four sides as permanent reference. In case

the supply is taken in general service wagon, actual measurements will be

taken. Welded Flat White line

4.3 Shrinkage Allowance

Payment shall be made for the gross measurements either in stacks or in

wagons without any deduction for shrinkage/voids. However, when ballast

supply is made in wagons, shrinkage upto 8% shall be permitted at

destination while verifying the booked quantities by the consignee.

5. SAMPLING AND TESTING

5.1 A minimum of 3 samples of ballast for sieve analysis shall be taken for

measurement done on any particular date even if the numbers of stacks to

be measured are less than three.

5.2 The test viz. Determination of Abrasion Value, Impact Value and Water

Absorption should be got done through approved laboratories or Railway’s

own laboratories (List of these laboratories shall be mentioned in the tender

document).

5.3 In order to ensure supply of uniform quality of ballast, the following norms

shall be followed in respect of sampling, testing and acceptance.

5.3.1 On supply of the first 100 cum, the tests for size gradation, Abrasion value,

Impact value and water absorption (if prescribed) shall be carried out by

Railway. Further supply shall be accepted only after this ballast satisfies the

specifications for these tests. Railway reserves the right to terminate the

contract as per GCC at this stage itself in case the ballast supply fails to

conform with any of these specifications.


197

5.3.2 Subsequent tests shall be carried out as follows

Supply in stacks Supply in Wagons

For stack of

volume less than

100 cum

For stack of

volume more than

100 cum

a) Size and

Gradation

Tests.

- No. of Tests

- Size of one

sample

One for each

stack.

** 0.027 cum

One for each

stack.

** 0.027 cum for

every 100 cum or

part thereof.

One for each

wagon.

** 0.027 cum

b) Abrasion Value,

Impact Value and

Water Absorption

test @Testing

Frequency

One test for every 2000 cum

** This sample should be collected using a wooden box of internal dimensions

0.3m x 0.3m x 0.3m from different parts of the stack/wagon.

@ These tests shall be done for the purpose of monitoring quality during

supply. In case of the test results not being as per the prescribed

specifications at any stage, further supplies shall be suspended till suitable

corrective action is taken and supplies ensured as per specifications.

The above tests may be carried out more frequently if warranted at the

discretion of Railway.

5.3.3 All tests for Abrasion value Impact value and water absorption conducted

subsequently to award of contract shall be done at Railway’s cost.


198

ANNEXURE-I

Aggregate Abrasion Value

(Based on IS:2386 Part IV-1963)

1. Apparatus

1.1 The abrasion test for track ballast shall be carried out using Los-Angles

Machine as per fig.1.

1.2 The abrasive charge shall consist of 12 nos. cast iron or steel spheres

approx. 48mm dia and each weighing between 390 and 445 gm ensuring

total weight of charge as 5,000 ± 25gm.

1.3 IS sieves of sizes 50mm, 40mm, 25mm and 1.70mm.

1.4 Drying Oven

2. Test Sample

2.1 The test sample of 10,000gm shall consist of clean ballast conforming to the

following grading:

· Passing 50mm and retained on

40mm square mesh sieve 5,000 gm@

· Passing 40mm and retained on

25mm square mesh sieve 5,000 gm@

@ tolerance of ±2% permitted.

2.2 The sample shall be dried in oven at 100 – 110 °C to a constant weight and

weighed (Weight ‘A’).

3. Test Procedure

The test sample and the abrasive charge shall be placed in the Los-Angeles abrasion testing machine and the machine rotated at a speed of 20-33 revolutions/minute for 1000 revolutions. At the completion of test, the material shall be discharged and sieved through 1.70mm IS sieve.

4. Analysis and reporting of the Result

4.1 The material coarser than 1.70mm IS sieve shall be washed, dried in oven

at 100 -110°C to a constant weight and weighed (weight B).

4.2 The proportion of loss between Weight “A” and Weight “B” of the test

sample shall be expressed as a percentage of the original weight of the test

sample. This value shall be reported as:

A-B

Aggregate Abrasion Value = ------------------- X 100

A

-6-


199

ANNEXURE-II

Aggregate impact value

(Based on IS:2386 Part IV-1963)

1. Apparatus The apparatus shall consist of the following

a) Impact testing machine conforming to IS:2386 part IV-1963 as per fig.2.

b) IS Sieve of sizes 12.5mm, 10mm and 2.36mm.

c) A cylindrical metal measure of 75mm dia & 50mm depth.

d) A tamping rod 10mm circular cross section and 230mm length, rounded at one

end.

e) Drying Oven

2. Test Sample

2.1 The test sample shall be prepared out of track ballast so as to conform to following

grading:

- Passing 12.5mm IS sieve 100%

- Retention 10mm IS sieve 100%

2.2 The sample shall be oven dried for 4 hours at a temperature of 100-110°C and

cooled.

2.3 The measure shall be filled about one-third full with the prepared aggregate and

tamped with 25 strokes of the tamping rod. A further similar quantity of aggregate

shall be added and a further tamping of 25 strokes given. The measure shall finally

be filled to overflowing, tamped 25 times and the surplus aggregate struck off,

using and tamping rod as a straight edge. The net weight of the aggregate in the

measure shall be determined to the nearest gm (weight ’A’).

3. Test Procedure

3.1 The cup of impact testing machine shall be fixed firmly in the position on the base

of the machine and the whole of the test sample placed in it and compacted by 25

strokes of the tamping rod.

3.2 The hammer shall be raised 380mm above the upper surface of the aggregate in

the cup and allowed to fall freely on to the aggregate. The test sample shall be

subjected to a total of 15 such blows, each being delivered at an interval of not less

than one second.

4. Analysis and Reporting of the result

4.1 The sample shall be removed and sieved through 2.36mm IS sieve. The fraction

passing through shall be weighed ( Weight ‘B’ ). The fraction retained on the sieve

shall also be weighed ( Weight ‘C’ ) and if the total weight (B+C ) is less than the

initial weight ( Weight ‘A’ ) by more than one gm, the result shall be discarded and

a fresh test made.

4.2 The ratio of the weight of the fines formed to the total sample weight shall be

expressed as a percentage. Aggregate Impact Value = (B/A) X 100

4.3 Two such tests shall be carried out and the mean of the results shall be reported to

the nearest whole number as the Aggregate Impact Value of the tested material.


200

ANNEXURE-III

Water Absorption

(Based on IS: 2386 Part III-1963)

1. Apparatus

The apparatus shall consist of the following:

a) Wire Basket- Perforated, electroplated or plastic coated, with wire hangers

for suspending it from the balance.

b) Water tight container for suspending the basket.

c) Dry soft Absorbent cloth 75x45 cm size 2 nos.

d) Shallow Tray of minimum 650 square cm area.

e) Air tight container of capacity similar to basket.

f) Drying Oven.

2. Test Sample

A sample of not less than 2000gm shall be used.

3. Test Procedure

3.1 The sample shall be thoroughly washed to remove finer particle and dust,

drained and then placed in the wire basket and immersed in distilled water

at a temperature between 22-32°C.

3.2 After immersion the entrapped air shall be removed by lifting the basket and

allowing it to drop 25 times in 25 seconds. The basket and sample shall

remain immersed for a period of 24 ± ½ hours afterwards.

3.3 The basket and aggregate shall then be removed from the water, allowed to

drain for few minutes, after which the aggregate shall be gently emptied

from the basket on to one of dry clothes and gently surface dried with the

cloth transferring it to second dry cloth when the first will remove no further

moisture. The stone aggregate shall be spread on the second cloth and

exposed to atmosphere (away from direct sunlight) until it appears to be

completely surface dry. The aggregate then shall be weighed (Weight ‘A’).

3.4 The aggregate shall then be placed in an oven at a temperature 100 -

110°C for 24hours. It shall then be removed from oven, cooled and weighed

(weight ‘B’).

4. Analysis and Reporting of the Result

Water Absorption = {(A-B)/ B}x100

4.1 Two such tests shall be made and individual and mean results shall be

reported.


201


202


203

Correction Slip No. 1

(“Specification of Track Ballast”, IRS-GE-1, June, 2004)

Add a new para 2.3.1.1 as under :

“In exceptional cases, where it is considered necessary on technical

considerations, to reduce the maximum size of ballast for NG lines, CTE may

modify the size & gradation of the ballast as defined above. In case of such

modifications, provision given in para 2.3.2 to 2.3.4 below shall also be

suitably modified. This will be finalized before invitation of tenders and

should be incorporated in the tender documents.”

Sd./- -

(Nand Kishore)

Executive Director /GE


204

Correction Slip No. 2

(“Specification of Track Ballast”, IRS-GE-I, June, 2004)

Add a new para 5.3.4 as under:

To Carry out Impact Test on ballast, a test sample of ballast pieces (about 5

kg in weight) of size 10 mm to 12.5 mm will be required. Appropriate care

should be taken by the railways that ballast selected for breaking down to 10

mm to 12.5 mm size for Impact test should be random from the ballast supply

to avoid any subjectivity in selection of test sample. Alternatively, the test

sample in the recommended range of size be got manufactured along with

the ballast in sufficient quantity required for this test.

(Alok Kumar)

Executive Director

Geotechnical Engineering


205

MANUAL FOR

FUSION WELDING OF RAILS BY THE ALUNIINO-THERMIC PROCESS

1. Introduction

1.1 This manual supercedes "Manual for welding of rail joints by the alumino-thermic

process, April 1987"

1.2. There have been many technological improvements in the process of alumino-thermic

(AT) welding which have necessitated revision of manual issued in April 1987. Same

considerations also led to revision of Indian Railway Standard specification for fusion

welding of rails by alumino-thermic process which has now been revised and issued under

the serial No. IRS: T-19-1994.

1.3 On Indian Railways alumino-thermic welding with short pre-heating process by using

high silica sand mould (carbon dioxide dried) is being followed at present for welding rails

of different chemistry and sections. Short pre-heating is mostly being done by air-petrol

fuel mixture. Oxy-LPG and compressed air petrol fuel mixture are being developed as these

techniques take less time for pre-heating the rail ends to desired temperature resulting in

saving of block time with improved quality of joint.

1.4 AT welding is required to be done to convert flash butt-welded panels into long panels

and for repair of fracture. Normally new single rails shall not be welded by AT welding.

1.5 Conventional AT welding process which utilised green sand mould has been banned on

Indian Railways. Alumino-thermic welding techniques with short pre-heat process have

been standardised for 75R, 90 R and higher rail sections and not standardised for 60R rails.

The welding of 60R rails will be done by conventional AT welding process using green

sand mould, as the scope of such welding is very limited for which the provisions laid

down in 'Manual for welding of rail joints by the alumino-thermic process, April 1987' will

continue to be applicable.

2. Scope: This manual outlines the method of welding and the precautions and steps to be

taken before, during and after welding by short pre-heating process for achieving

satisfactory weld.

3. Selection of rails to be welded:

3.1 For both new as well as second hand rails, before welding, it should be ensured that the

end bends of the rails are within + 0.5 mm, - 0 mm in vertical and ! 0.5 mm in lateral

direction, when checked with one metre straight edge as shown in Fig. 3.1(a), (b) and (c).

3.2 New rails: Rails to be welded shall conform to the tolerances stipulated in the relevant

specification as stated in table 1 given at page 2.


206

TABLE 1

Tolerances in new rail dimensions

Grade of rail

Rail sect-ion

Specifica-tion

Head width

Height Flange width

Thick ness of web

End squareness

1. Grade 880

(90 UTS)

52 kg IRS:T-12-96

± 0.5 mm +0.8mm

-0.4mm

±

1.0mm

+1.0 mm

-0.5 mm

± 0.6mm

60 kg IRS:T-12-96

--do-- --do-- +1.2mm

-1.0mm

--do-- --do--

2. Grade 1000

(100 UTS)

52 kg IRS:T-12-96

--do-- --do-- ± 1mm --do-- --do--

60 kg IRS:T-12-96

--do-- --do-- +1.2mm

-1.0mm

--do-- --do--

3. Grade 1080

head

hardened

rails

60 kg IRS:T-12-96

--do-- --do-- +1.2mm

-1.0mm

--do-- --do--

4. Chrome- manganese & chrome-vanadium alloy steel rails(100 UTS)

60 kg

(UIC)

Clause 1.6 of UIC-860-0 (8th edition dated 1-7-86)

± 0.5mm ± 0.6mm

+1.0mm

-1.1mm

+1.0mm

-0.5mm

± 0.6mm

3.3 Second hand rails : Far conversion of existing single rails/short welded panels into

SWP/LWR/CWR or during secondary rail renewal, old serviceable rails may be welded

subject to the following conditions :

(i) Obsolete rail sections and rails older than 50 years shall not, normally, be welded.

Specific approval of the Railway Board may, however, be obtained in special cases.

(ii) The Chief Track Engineer shall satisfy himself that second hand rails have a substantial

rail life to make it a safe and economical proposal.

(iii) Rails shall be free from corrosion or excessive wear. The height of rail and width of

rail head shall not be less than the values as indicated in Table 2 given below.


207

TABLE 2

Rail section

Normal height of new rail (mm)

Minimum height of old rail (mm)

Width of head of new rail (mm)

Min. width of old rail (as measured at the gauge corner) (mm)

60 kg 172 163 72 66

52 kg 156 150 67 61

90R 143 139 67 61

75R 129 126 62 56

60R 114 112 57 51

The limit of lateral wear in the rail head as laid down in Table 2, viz. 6 mm may be

followed subject to uniform gauge without any abrupt change.

(iv) Rails shall be tested before welding, with ultrasonic flaw detector apart from visual

inspection, so that rails having cracks and internal flaws are excluded from welding. In

order to achieve satisfactory running on welded rail panels, rails with excessive scabbing;

wheel burns, corrugations and wear of rail seats shall not be used for welding. The rail

flange bottom shall be visually inspected to ensure freedom from defects like dent, notch,

corrosion, etc.

(v) Even where cracks/flaws have not been detected during visual USFD examination

before welding, the ends of second hand rails should be suitably cropped so as to eliminate

fish bolt holes.

(vi) The rail ends shall be cut by sawing or using abrasive disc cutter and not by flame

cutting.

(vii) Second hand rails shall be match-marked before releasing from track to enable

matching of the rail ends at the time of welding. Kinks, if any, in the rails shall be removed

before welding.

(viii) The rolling marks on the web of rails shall be checked before welding to ensure that

generally rails of different qualities are not welded together. However in unavoidable

circumstances, where rails of Grade 710 (72 UTS) rail chemistry and that of Grade 880 (90

UTS) chemistry are to be welded, the portion of Grade 880 (90 UTS) chemistry shall be

utilised for welding.

(xi) While using second hand rail panels for secondary renewal, released from LWR/CWR

sections, the ends should be cropped to eliminate fish bolt holes. If rail ends do not have

bolt holes, the ends may be cropped to a distance of minimum 150 mm for AT welds and

85 mm for flash butt welds from the centre of welded joint to eliminate heat affected zone

of welds. End cropping may be suitably increased so as to ensure that rail ends are within

the tolerances as specified in para 3.1.


208

4. Execution of joints at site

4.1 Technique for welding : Welding techniques approved provisionally or for regular

adoption by Railway Board/RDSO should only be adopted for welding of rails. Present

status of welding techniques, approved/provisionally approved for extended field trials, of

various AT portion manufacturing firms is given at Annexure 1 (as on 31.12.97).

4.1.1 Presently, only four firms are approved for manufacturing of portion and execution of

welding. Further, 12 firms are approved only for executing AT welds with portion and

technique developed by Thermit Portion Plant, N. Rly., Lucknow (TPP). Apart from this,

departmental welders are also trained and certified by TPP for AT welding of rails with the

technique developed by them. Following course of action may be adopted for welding of

rails through approved portions manufacturers, labour contracting firms and by

departmental welders:

(i) Large scale welding

(a) Approved portions manufacturing firms with their portions, consumables, equipment and RDSO certified welders/welding supervisors.

(b) Labour contracting firms with portions, consumables of TPP and

welders/welding supervisors certified by RDSO.

(c) Departmental welders certified by TPP with portions and consumables

manufactured by TPP only.

(ii) Casual welding

(a) Agencies as mentioned in para 4.1.l(i) (a) and (b) above.

(b) TPP certified departmental welders for welds of 25 mm gap using

portion, consumables and preferably equipment also of approved portions

manufacturers as per the approved welding parameters as given in Annexure

1.

(iii) AT welding in case of turn-key contracts : In case of turn-key contracts for gauge

conversion, new lines, doubling, open line works, etc. in which AT welding also forms a

small portion of work, suitable provisions may be kept in the contract conditions for

executing welding by the agencies as mentioned in Pam 4.1.1 (i) (a).

4.2 Portion for welding

4.2.1 The 'portion' used for welding shall conform to the technical requirements as

mentioned in IRS:T-19-1994. The suitability of the 'portion' for the welding process in

respect of the type and section of rails to be welded shall be ensured before commencing

welding. Only RDSO certified/passed portions should be used for welding.


209

4.2.2 Shelf life of portion : No specific shelf life has been indicated for AT welding

portions. Life of portions would depend on the quality of packing and storage condition.

AT portion is sensitive to moisture. Once the portion absorbs moisture, the same cannot be

removed even by drying as the ingredients react chemically. All such portion should not be

used for welding.

If packing is intact and there is no entry of moisture, the portion can be used even after a

long time. However, following procedure may be adopted for permitting use of portions

beyond two years after the date of manufacturing:

(a) One random sample per batch of 300 or part there-of may be drawn from the portions available in stores.

(b) The sample shall be tested for reaction test. If the reaction is normal, the batch

represented by the sample can be used without further tests.

(c) In case the reaction is found to be quiet or boiling, a test joint should be made

from one more sample selected from the batch. Following tests should be conducted

on the test joints.

(i) Aluminium content test (from riser of the joint)

(ii) Load deflection test

These tests should be conducted at Zonal CMTs organisation and/or the Flash Butt Welding

Plant. If the values obtained in above tests are within the specified values as given in para

4.1.3 and 4.2.3.1 of IRS: T-l 9-94, the batch represented by the sample can be used

otherwise batch should be rejected.

(d) The rejected portions are to be disposed-off by igniting five portions at a time in pit

away from the store.

4.3 Equipment and staff for welding : The list for one set of AT welding equipment by

short preheating process is given in Annexure 2. The composition of thermit welding team

is given in Annexure 3.

4.4 Preparation of rail ends to be welded : The rail end face and adjacent sides at foot

(top and bottom), web and head up to 50 mm shall be thoroughly cleaned using kerosene

oil and brushing with wire brush to remove all dirt, grease and rust before welding. Any

burrs at the rail ends shall be removed by chiseling or grinding.

Normally, no alumino-thermic welded joint shall be located closer than 4 m from any other

welded or fishplated joint.

4.5 Gap between rail ends : The two rail ends to be welded shall be held in position with a

uniform and vertical gap as per gap specified in Annexure 1. The uniformity and verticality

of the gap shall be measured by a gauge prior to welding. In case of wide gap 50 ± 1/75 ± 1

mm welding, for repairing fractured/defective welds, it shall be ensured that the end faces


210

are vertical. In LWR/CWR territory, hydraulic/mechanical rail tenser of suitable and

approved design should be used for maintaining correct rail gap during welding.

4.6 Preliminary work prior to welding

4.6.1 In case of in-situ welding the rail fastenings for at least five sleepers on either side of

the proposed weld shall be loosened. The sleepers adjacent to the joint to be welded shall

be shifted to obtain a clear working space of 250 mm on either side to accommodate the

moulds, clamps, preheating equipment, etc. The rails shall then be properly aligned, both

horizontally and vertically.

4.6.2 When the welding work is carried out on cess, full rail length shall be levelled by

supporting on at least ten wooden blocks on either side. The rails shall be properly aligned

in horizontal and vertical direction and held in position.

4.7 Alignment of rail ends before welding

4.7.1 The rail ends to be welded shall be aligned in horizontal and vertical planes to the

dimensional limits indicated below:

4.7.1.1 Lateral alignment : The two rail ends, after alignment shall be within ! 0.5 mm

when checked with a 1.0 m straight edge at rail ends [Fig. 4.7.1.1 (a) & (b)]. Any difference

in the widths of rail heads shall always be fully kept on the non-gauge side, correctly

aligning the rail ends on the gauge face.

4.7.1.2 Vertical alignment : The joint shall be kept higher by 3 to 4 mm for 72 UTS rails

and 2 to 2.4 mm for higher UTS rails when measured at the end of 1 m straight edge (as a

compensation against sagging caused by differential shrinkage on cooling) (Fig. 4.7. 1.2).

This shall be achieved by wedges applied on the rail supporting blocks on both sides of the

joint.

4.7.2 Gap between rail ends may be rechecked after completion of alignment. Datum

marks shall be made on foot of both rails as well as on joint sleepers in order to observe any

longitudinal movement of rails. If excessive longitudinal movement occurs during pre-

heating and produces a welding gap outside the prescribed limits, the welding of joint shall

be temporarily abandoned and joint allowed to cool.

4.8 Fixing of mould

4.8.1 Only prefabricated moulds supplied by the portion manufacturer shall be used for

welding. These are to be made by mixing high silica sand to IS:1987 with sodium silicate to

the required consistency, followed by passage of carbon dioxide gas. These prefabricated

moulds shall have adequate permeability for escape of mould gases and adequate

reinforcement to avoid mould crushing during transportation and welding.

4.8.2 Before mounting on the rail ends to be welded, each pair of moulds shall be

examined for defects, dampness, cracks, blocked vents, etc. and defective moulds

discarded. The prefabricated moulds shall be handled with care, as they are fragile and

liable to breakage.


211

4.8.3 During fixing the moulds, it shall be ensured that the centre line of the rail gap

coincides with the centre line of the mould to avoid cross joint. The mould jackets/shoes

holding the pre-fabricated mould in a snug fit condition, after fixing, shall be tightened by

the application of adequate pressure. Excessive pressure may cause breakage of mould and

dropping of sand inside the mould cavity. Care shall be taken during application of

adequate pressure. It is essential for the moulds to fit flush to each other across the bottom

of the rail flange, which can be checked by feeling with fingers across the junction of the

two halves of the moulds and by looking down the riser aperture. The moulds should touch

the bottom of rail foot to ensure proper size of collar at the bottom.

4.8.4 After fixing the moulds, the gap between mould and the rail shall be packed firmly

with luting sand to prevent leakage of liquid weld metal. To protect the rail top table from

metal splashes during reaction, the adjacent rail surface on either side of the moulds shall

be covered with metal cover or smeared with luting sand up to 15 cm on either side.

4.9 Preheating

4.9.1 After fixing and luting of the moulds, the rail ends shall be uniformly pre-heated

throughout the rail section with specially designed air petrol/compressed air petrol/ oxygen-

LPG burner as the case may be. The flame shall be properly adjusted to achieve the desired

rail temperature. The pre-heating shall be done from the top of the mould box for stipulated

period for welding technique adopted, so as to achieve a temperature of around 600 ± 20

C.

4.9.2 In welding process using air petrol burner, the compressor tank pressure during

operation of the burner shall be maintained at 7 ± 0.70 kg/cm2 (100 ± 10 lb. per sq. in.). In

case of per-heating by oxy-LPG process, pressure for oxygen and LPG cylinders shall be

adjusted in the range of 7.0-8.0 kg/cm2 and 2.0-2.5 kg/cm2 respectively. While preheating

with oxy-LPG burner LPG supply should be opened first and the gas ignited, thereafter

oxygen supply should be opened. While closing, oxygen supply should be stopped first

followed by LPG supply. The burner shall be properly adjusted during preheating to ensure

that the head, web and foot of both the rail ends are heated uniformly.

4.9.3 Preheating time : Preheating time would be about 10 to 12 minutes and 2 to 2.5

minutes for air-petrol and oxy-LPG preheating techniques respectively. The actual

preheating time would depend upon the rail section and welding technique adopted as given

in Annexure I.

4.9.4 Special emphasis shall be given to the tank pressure, efficiency of burner and flame

condition for achieving required rail temperature within the stipulated time. From time to

time or in case of any doubt with a view to maintain proper quality control, temperature

measuring devices like optical pyrometer, contact type pyrometer or temperature indicating

crayons may be used for measuring rail end temperature just after completion of preheating

i.e. after removal of burner.


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4.10 Welding

4.10.1 The crucible lined with refractory material (magnetite/crushed alumina slag) and

fitted with bottom stone and thimble shall be preheated before making the first weld of the

day to ensure freedom from moisture.

4.10.2 Slag shall be cleaned from the crucible after each reaction, if necessary. During

cleaning, care shall be taken not to damage the refractory crucible lining. The lining shall

be examined regularly and patch repairing, or relining as necessary shall be carried out.

4.10.3 The crucible shall be positioned relative to the pouring gate with respect to its

height from the mould after it has been placed on the stand mounted on the rail head. The

tap hole in the crucible shall be sealed with closing pin, asbestos powder and slag power.

The 'portion', for the required technique, shall be thoroughly hand mixed and poured into

the crucible striking the crucible wall so that the bottom plugging remains undisturbed. The

portion shall be coned to the centre of the crucible and a sparkler be placed at the top. The

crucible shall then be brought to the proper position over the mould in line with the pouring

gate of the mould with a vertical distance of about 50 mm between the tap hole and sand

core/ top of the pouring gate.

4.10.4 After preheating the rail joint, the sparkler shall be ignited and inserted in the

portion at the centre top to start the reaction. The reaction shall not be vigorous or boiling.

By the time the reaction is complete, the burner shall be removed quickly and the gap

closed with a dried sand core in case of central pouring to prevent loss of heat and

turbulence during flow of metal. The time period between removal of burner and tapping of

metal should be as minimum as possible. After the reaction subsides, about three seconds

shall be allowed for the separation of slag from the metal, which may be judged by looking

into the crucible through coloured glass to IS:5983. Thereafter, the molten steel shall be

tapped into the mould by striking the closing pin with a tapping rod. It shall be ensured that

since the commencement of the reaction, thermit steel is tapped within the time limit as

specified in Annexure 1. Care shall be taken to ensure that the crucible does not move from

its position during tapping. When pouring is over, the crucible and swivel stand shall be

removed and kept aside without disturbing the joint. If the reaction is found to be boiling,

the metal shall be out-tapped. Vigorous reaction and loose closing of crucible may cause

self tapping. In this case also, the metal shall be out tapped. If, in any case, self tapped

metal enters the mould, the joint shall be rejected, cut and rewelded. In cases of out tapping,

the joint should be cooled to ambient temperature and the process of welding restarted a

fresh. However if temperature can be measured, the rail end may be heated to an extent so

as to achieve temperature of about 600 ± 20 C and welding of joint may be completed.

4.10.5 After pouring, molten metal shall be allowed to cool and solidify with mould intact

for the stipulated time (mould waiting time) depending upon the rail section and ambient

temperature. In case of alloy steel rails, full rail section up to 300 mm on either side of the

joint shall be heated by using burner during this period. The mould shoes shall be removed

just prior to completion of mould waiting time. The mould waiting time is generally four to

six minutes for 25 mm gap joints and 12 minutes for 75 mm gap joints. After the mould

waiting time has elapsed, the trimming should be done by using weld trimmer of suitable


213

and approved design without knocking out the mould. List of approved manufacturers of

rail profile weld grinder and weld trimmer is given at Annexure 4.

In the eventuality of sudden failure of weld trimmer, manual chipping may be resorted to.

In case of welding of old rails, if it is not possible to use weld trimmer due to flow of metal

at rail head, manual chipping should be done.

4.10.6 During the trimming operation, it shall be ensured that the wedges used in aligning

are in their proper places without loosening, and they are not removed for at least 20

minutes after stripping. The runner and riser must not be removed until cold, and that too

only by knocking towards the rail.

4.10.7 No welding shall be carried out if it is raining. In case, the rains start while the joint

is under execution, immediate arrangement to adequately cover the site shall be made.

5.1 Post weld cooling

5.1.1 110 UTS alloy steel rail joints (chrome manganese and chrome vanadium type) are

required to be slowly cooled immediately after trimming by fixing an insulation hood

(Fig.5.1) lined with asbestos, so as to control the cooling rate of the weld zone. The hood

must be kept around the joint for at least 20 minutes.

5.1.2 In case of welding of head hardened rails, the average hardness of the HAZ of the rail

becomes considerably less than the parent rail hardness. This lower hardness is due to

transformation of rail steel occurring at cooling rate much lower than that achieved during

the original head hardening operation. Such a hardness difference can lead to differential

plastic deformation during wheel rail contact which may cause localised cupping. Head

hardened rails, therefore, must be subjected to controlled quenching for a specific time by

the arrangement approved for the technique.

5.2 Post weld packing of sleeper : Before the passage of traffic, the wedges used For

aligning should be removed and joint sleepers which were shifted to obtain the clear gap of

250 mm on either side as per para 4.6.1 shall be re-shifted to the original location and

repacked. Packing of these resifted sleepers should be carried out gently and carefully.

5.3 Passing of traffic : The first train should be allowed to pass on the newly welded joint

only after 30 minutes have elapsed since pouring of weld metal. Necessary speed restriction

shall be observed until the grinding operation is over.

5.4 Grinding

5.4.1 After the excess metal is trimmed off, the grinding of the remaining metal on the rail

table and the sides of the rail head shall be carried out only with rail profile guided grinding

trolley of approved design. Use of hand files should not be resorted to except in

unavoidable circumstances. In the case of in-situ joints, the grinding shall commence only

after the sleeper fastenings are refixed, after the removal of wedges. The rail table shall first

be ground down to original profile and checked by a one metre straight edge. This should

be followed by grinding of the sides of rail head. The accuracy of grinding shall be checked


214

by using 10 cm straight edge. While grinding, only light pressure should be applied and

grinding wheel should be moved to and fro to avoid local over heating.

5.4.2 Tolerances on finished welds : All the finished joints shall be checked to ensure that

the joint geometry is within the following tolerances:

(i) Vertical alignment: Variation not more than +1.0 mm, -0 mm measured at the end of one metre straight edge.

(ii) Lateral alignment : Variation not more than ± 0.5 mm measured at centre

of one metre straight edge.

(iii) Finishing of top surface : + 0.4 mm, -0 mm measured at the end of 10

cm straight edge.

(iv) Head finishing on sides : ± 0.3 mm over gauge side of the rail head

measured at the centre of 10 cm straight edge.

Note : In specific cases, for joint geometry, in case of old rails, dispensations may be

permitted by Chief Engineer.

The method of checking the geometry of welded joints is illustrated in Fig. 5.4.2.

5.5 Record of joint geometry : The details of geometry of each joint shall be jointly

signed by the firm's and Railway's representative and kept as record. Any joint found not

conforming to the above stipulations shall be cut and rewelded, free of cost, by the firm.

5.6 Marking : Each joint shall have a distinctive mark indicating month, year, agency,

welder's code and weld number of the welded joint in the following manner:

* * * * * * * * * * * * *

Month Last two digits of Year

Agency Specific person number

Weld No

This should be done by punching on an aluminium strip of suitable thickness and

dimension of 30× 100 mm which should be fixed to the web of the rail with epoxy adhesive

at approximately 300 mm from the joint. The welded joints shall be serially numbered in a

kilometre. Repair welds/additional welds done at a later date may be given continuing weld

number in that kilometre. For example, the last thermit weld number in a particular

kilometre was 88 and subsequently a thermit weld has been executed, it shall be numbered

89, irrespective of its location in that kilometre. PWI shall maintain 'Thermit Weld Register'

as per proforma given in Annexure 5. No punch marking should be done on the rail,

5.7 Painting of thermit welds


215

5.7.1 Painting of weld collar should be done on all welds to protect them against corrosion

immediately after the welding. The procedure of painting and specification of paint is

outlined in Annexures 6 and 7.

5.7.2 In service painting (maintenance painting) of thermit welds should be carried as per

following frequency:

(i) Once in four years in areas not prone to corrosion.

(ii) Every year at locations prone to corrosion as defined in para 249 (i) of

IRPWM. The frequency may be increased depending on the site conditions.

(iii) On condition basis at locations which are prone to severe corrosion

(areas of severe corrosion to be decided by territorial Chief Engineer/Chief

Track Engineer).

5.7.3 The procedure for painting of weld collar for thermit welded rail joints to protect

against normal corrosion and severe corrosion is outlined in Annexures 6 and 7

respectively.

6. Acceptance tests

6.1 Visual inspection : All the welded joints shall be examined carefully to detect any

visible defect like cracks, blow holes, etc. Any joint, which shows any visible defect,

should be rejected.

6.2 Dimensional check : All finished joints shall be checked for dimensional tolerances

which should be within the tolerances as specified in para 5.4.2.

6.3 Ultrasonic flaw detection test : All the fusion welded joints shall be ultrasonically

tested and accepted by the purchaser or his representative as per the 'Procedure for

ultrasonic testing of thermit welded rail joints' given at Annexure 8. This testing shall be

completed as early as possible but in any case before the contractor/ welding team leaves

the welding site.

6.4 Rewelding of defective joints

6.4.1 All the joints found to be defective as per acceptance tests as given in paras 6.1, 6.2,

& 6.3 and/or joints failed in guarantee period as specified in para 7.3 will be cut and

rewelded by the firm free of cost using their portions, equipment, labour and consumables.

6.4.2 Where one bad joint is required to be replaced by two new joints, the entire cost of

both the joints shall be borne by the firm.

6.4.3 All the rewelded joints should meet the acceptance tests as indicated in paras 6.1 to

6.3


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7. Sample test joint

7.1 One out of every 100 joints welded shall be selected at random by the purchaser or by

the inspecting officer within one month of welding and subjected to hardness, transverse

load/deflection tests and porosity as per clause 4.2 of IRS:T-19-1994 (reproduced partly as

Annexure 9 for ready reference) and the joint shall comply with the provisions laid down

therein.

7.2 If the sample test joint fails to satisfy any of the requirements of specification IRS:T-19-

1994, the Railway will be at liberty to suspend further welding. However, two more

randomly selected joints from the same lot of 100 joints shall be subjected to retests as per

clause 4.2 of IRS:T-19-1994. Both the joints should clear all the tests. If this report is also

not satisfactory, further welding of joints shall be suspended until the firm's welding

technique has been examined and the same satisfies the requirements of clause 4 of IRS:T-

19-1994. The clearance for re-commencement of welding shall be given by RDSO.

7.3 Guarantee

7.3.1 Rail joints welded by a firm shall be guaranteed against failure for a period of two

years from the date of welding the joints in track or from the date such welded joints made

'in cess' are inserted in the track. Any such welded joint which fails within the guarantee

period shall be rewelded free of cost by firm as per stipulations of para 6.4.

7.3.2 In case of failure of sample test joint (refer para 7), the period of guarantee for 100

joints represented by the sample joint shall be extended for a further period of one year. In

case of failure of joints or joints exhibiting signs of failure by cracking within extended

period of guarantee, the joints shall be rewelded free of cost by the supplier as per

stipulations of para 6.4.

7.4 The welded joints with the extended period of guarantee shall be marked 'X' with

yellow paint on the outer side of the web of the rail near the joint in addition to the marking

prescribed in para 5.6. Such marked joints shall be kept under careful observation by the

purchaser.

8. Other requirements

8.1 Welding shall be supervised by trained welding supervisor and carried out by trained

welder having valid competency certificate from RDSO/TPP, NR, Lucknow in their

possession.

8.2 A welding supervisor shall supervise not more than two welding teams deployed within

50 m distance at a time.

8.3 A copy of the thermit welding manual shall be available with each PWI and at each

welding site.

9. Precautions : While carrying out welding at site, the following precautions shall be

observed :


217

(i) It should be ensured that the portion being used matches with type and chemistry of rail.

(ii) Rail ends should be square.

(iii) Alignment of rail ends should be perfect as checked by straight edge.

(iv) Rail ends should be properly cleaned with kerosene oil and wire brushes.

(v) Stop watch should be provided to the welding supervisor at each welding site.

(vi) Pressure in the tanks/cylinder should be properly maintained during pre-heating.

(vii) Correct gap between rail ends at head, web and foot shall be ensured.

(viii) Correct preheating time for rail ends shall be ensured.

(ix) Tightness of clips fitted with hose connections to compressor tank and burner shall be

checked before commencing preheating.

(x) Nozzles of burners shall be cleaned periodically to avoid back- fire.

(xi) The compressor tank shall be kept at least 2 to 3 m away from the burner to prevent fire

hazard.

(xii) The tapping shall be done within the time specified for that particular technique.

Welding parameters for techniques presently being used are available at Annexure 1. For

special type of welding i.e. 75 mm gap, combination joint, etc. the time of reaction and

tapping shall be as stipulated by RDSO for that particular welding technique.

(xiii) Arrangements for giving first aid shall be available at site.

(xiv) Welders should be provided with gloves and coloured glasses.

(xv) Boiling portion shall be out tapped.

(xvi) No moist portion/torned portion bag shall be used for welding.

(xvii) Dampness in moulds can lead to porosity and early fatigue failure of welds.

(xviii) Only those contractual agencies as have clearance from the RDSO/Railway Board

can execute welding work. Supply of portions must be from sources approved by

RDSO/Railway Board.

(xix) Many weld failures show evidence of badly cut rail ends. The evenness and verticality

of a rail cut depends solely upon the skill of the welder. With portable disc cutters, very

little skill is required to produce good cut.

10. Defects in AT welding : The major types of defects which can cause weld failure

because of improper weld execution are given in Annexure 10.


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ANNEXURE 1

STATUS OF VARIOUS AT WELDING TECHNIQUES (as on 31.12.97)

I. India Thermit Corporation Ltd., Kanpur

1. Techniques with air-petrol pre-heating

S.No. Welding technique Gap

(mm)

Pre- heating time(mm)

Reaction time (sec)

Wt. of portion

(kg)± 2% Remarks

1. 60 kg (90 UTS) 25± 1 12 20± 3 13.4 Approved 2. 60 kg (72 UTS) 25± 1 12 20± 3 13.4 Approved 3. 52 kg (90 UTS) 25± 1 10 20± 3 11.8 Approved 4. 52 kg (72 UTS) 25± 1 10 20± 3 11.8 Approved 5. 90R (90 UTS) 25± 1 8 20± 3 10.6 Approved 6. 90R (72 UTS) 25± 1 8 20± 3 10.6 Approved 7. 75R (90 UTS) 25± 1 6 20± 3 8.55 Approved 8. 75R (72 UTS) 25± 1 6 20± 3 8.55 Approved 9. 52 kg (90 UTS) wide

gap 75± 1 10 20± 3 23.75 Provisionally

Approved for extended field trial

10. 60 kg (90 UTS) wide gap

75± 1 12 25± 3 25.8 Provisionally Approved for extended fieldtrial

11. 52 kg (90 UTS)/90R (72 UTS) comb.jt.

48-50 10 25± 3 19.6 Provisionally Approved for extended field trial

12. 60 kg/52kg (90 UTS) comb.jt.

50± 1 12 25± 3 21.4 Under development

2. Technique with compressed air-petrol pre-heating

S.No Welding technique Gap

(mm)

Pre-heating time (mm)

Tapping time (mm)

Wt. of portion (kg

± 2%)

Post weld heat treatment* (minutes)

Remarks

1. 60 kg (90 UTS) Head hardened(with post weld air quenching)

25± 1 4.5 20± 3 13.4 8 Provisionally Approved for extended field trial

With equipment of M/s ITC, Kanpur


219

II. Harshad Thermit Industries, Raipur 1. Techniques with air-petrol pre-heating S.No Welding technique Gap

(mm)


Reaction time (sec)

Wt. of portion (kg) ! 2%

Remarks

1. 60 kg (90 UTS) 25± 1 12 20± 3 13 Approved 2. 52 kg (90 UTS) 25± 1 10-11 20± 3 12.5 Approved 3. 52 kg (72 UTS) 25± 1 10 20± 5 12 Approved 4. 90R (90 UTS) 25± 1 8 20± 3 11 Approved 5. 90R (72 UTS) 25± 1 10 20± 5 11 Approved 6. 75R (90 UTS) 25± 1 8 20± 5 6.75 Approved 7. 75R (72 UTS) 25± 1 8 20± 5 6.75 Approved 8. 52 R (90 UTS)/90R

(72 UTS) comb. jt. 75± 1 10 20± 3 23.75 Provisionally

Approved for extended field trial

2. Technique with oxy-LPG pre-heating


(mm)

Pre-heating time (mm)

Tapping time (mm)

Wt. of portion (kg ! 2%)

Remarks

1. 60 kg (90 UTS) 25± 1 3.0 20± 1 15 Under development 2. 52 kg (90 UTS) 25± 1 2.5 19± 1 12.5 Under development III. Sagar Electric & General Industries, Hyderabad 1. Techniques with air-petrol pre-heating S.No Welding technique Gap

(mm)


Reaction time (sec)


Remarks

1. 60 kg (90 UTS) 25± 1 12 20± 5 13.8 Approved 2. 60 kg (72 UTS) 25± 1 10-12 20± 3 12.5 Approved 3. 52 kg (90 UTS) 25± 1 10 20± 3 11.0 Approved 4. 52 kg (72 UTS) 25± 1 10-11 20± 3 11.0 Approved 5. 90R (90 UTS) 25± 1 10 20± 5 10.0 Approved 6. 90R (72 UTS) 25± 1 9-11 20± 3 10.0 Approved 7. 75R (90 UTS) 25± 1 7-8 20± 3 10.21 Approved 8. 75 R (72 UTS) 25± 1 7-8 20± 5 9.72 Approved

IV. Raybon Metals Privet Limited, Bilaspur

1. Techniques with air-petrol pre-heating


(mm)


Reaction time (sec)


Remarks

1. 60 kg (90 UTS) 25± 1 10 20± 3 12.4 Approved 2. 52 kg (72 UTS) 25± 1 10 20± 3 12.2 Approved


220

ANNEXURE 2

LIST OF EQUIPMENT FOR ALUMINO-THERMIC WELDING OF RAIL JOINTS BY SHORT

PREHEATING PROCESS PER WELDING TEAM

S. No. Description

Quantity Mass

welding

Repair

Welding A. PRE-HEATING EQUIPMENT A1. Air-petrol pre-heating 1. Pressure tanks with pressure gauges complete 2 Nos. 1 No. 2. Vaporisers (burner) complete 2 Nos. 1 No. 3. Nozzle prickers 4 Nos. 2 Nos. 4. Nozzle keys 1 No. 1 No. 5. Vaporiser stand 2 Nos. 1 No. 6. Goose neck attachment to vaporiser 4 Nos. 2 nos. A2. Compressed air-petrol pre-heating 1. Suitable compressor system with pressure gauges 2 Nos. 1 No. 2. Torch (burner) complete 2 Nos. 1 No. 3. Torch (burner) keys 1 No. 1 No. 4. Torch (burner) stand 2 Nos. 1 No. 5. Goose neck attachment to vaporiser 4 Nos. 2 Nos. A3. Oxy-LPG pre-heating 1. Oxy-LPG torch (burner) 2 Nos. 1 No. 2. Oxygen cylinder with pressure gauge 2 Nos. 1 No. 3. LPG cylinder with pressure gauge 2 Nos. 1 No. 4. Torch (burner) stand 2 Nos. 1 No. 5. Connecting hose pipe 4 Nos. 2 Nos. B. OTHER EQUIPMENT 2 Nos. 1 No. 1. Crucible complete 2 Nos. 1 No. 2. Crucible caps 2 Nos. 1 No. 3. Crucible forks 2 Nos. 1 No. 4. Crucible stands 2 Nos. 1 No. 5. Crucible rings 2 Nos. 1 No. 6. Mould pressure (clamp) 2 Nos. 1 No. 7. Cleaning rod round 2 Nos. 1 No. 8. Tapping rod 1 No. 1 No. 9. Straight edge 1 m long 2 Nos. 1 No. 10. Straight edge 10 cm long 2 Nos. 1 No. 11. Aluminium steel rod for thermal plugging 2 Nos. 2 Nos. 12. Leather washers for pump 4 Nos. 2 Nos. 13. Gap gauges and height gauge 2 Nos. 1 No. 14. Filler gauge 2 Nos. 1 No. 15. Tools for punching the marking 2 Nos. 1 No. 16. Mould shoes 6 pairs 2 pairs 17. Stop watches 1 No. 1 No. 18. Pyrometer/thermal chalk for measurement of rail temperature 1 No. 1 No. 19. Wooden wedges for rail alignment 24 Nos. 1 No.


221

ANNEXURE 2(contd.)

LIST OF EQUIPMENT FOR ALUMINO-THERMIC WELDING OF RAIL JOINTS BY SHORT

PREHEATING PROCESS PER WELDING TEAM

20. First aid box filled with medicines, bandages, cotton, etc. 1 No. 12 Nos. 21. Mirror 150 x 100 mm with handle 2 Nos. 1 No. 22. Tool box containing :

(i) Hot sets (chisels) (For emergency use only) 2 Nos. 1 No.

(ii) Funnel tin (for pouring petrol) 1 No. 1 No.

(iii) Adjustable spanner 1 No. 1 No.

(iv) Hammer 1 kg 1 No. 1 No.

iv) Sledge hammer double panel 5 kg 2 Nos. 2 Nos.

(vi) Steel wire brush Blue goggles 1 No. 1 No.

viii) Paint brush 50 mm 2 pairs 1 pair

(ix) Slag container (bowl) 1 No. 1 No.

(x) Asbestos gloves 2 Nos. 1 No.

(xi) Hose clips 4 pairs 2 pairs

(xii) Pliers 4 Nos. 4 Nos.

(xiii) Rail file 350 x 40 x 6 mm (For emergency use only) 1 No. 1 No.

23 Weld trimmer 4 Nos. 2 Nos. 24. Insulation hood for control cooling (for 110 UTS rail welding) 1 No. 1 No. 25. Rail profile guided grinding trolley 1 No. 1 No. 26. To ensure quality, protective clothing, shoes gear & leather

gloves 1 No. 1 No.

ANNEXURE 3

COMPOSITION OF THERMIT WELDING TEAM (COMPRESSOR TANK-WISE)

Designation Numbers

Welder Grade I/Grade II 1

Welder Grade III/ Skilled Artisan 2

Helper Khalasi/Khalasi 5

Gangman As per work load

Note: The composition of welding team has been framed taking into account that trimming

and grinding operation would be done by weld trimmer and rail profile grinder.


222

ANNEXURE 4

LIST OF APPROVED SUPPLIERS OF RAIL PROFILE WELD GRINDER AND WELD TRIMMER

(as on 01-09-97)

S.No. Name of Machine

Approved supplier Approval granted up to

1. Rail profile weld grinder

(i) M/s Indiana Machine, D-151, Phase-VII,

S.A.S. Nagar-160 055

(Near Chandigarh).

31.3.98

(ii) M/s Phooltas Tamper Pvt. Ltd. Layak Bhavan, Canal Road, Patna-800 001.

31-12-97

(iii) M/s Rajasthan Mining & Engg. Pvt. Ltd., 65, Gopal Bari, Jaipur-302 001.

31-06-98

(iv) M/s ITC Ltd.,

• 84/22, Fazalganj,

Kanpur- 208 012.

01-12-98

2. Weld trimmer (i) M/s CTR Manufacturing Trimmer Industries Ltd., Nagar Road, Pune-411 014.

31-12-97

(ii) M/s ITC Ltd.,

84/22, Fazalganj,

Kanpur-208 012.

01-12-98


223

ANNEXURE 5

PROFORMA FOR THERMIT WELD REGISTER

Sl.

No.

Date of

welding

Location details Rail Bolt

Hole

Dist. (mm)

Block

St.

Cess/

Situ

Km TP U/

D

L/

R

Sect. UTS

1 2 3 4

Portion details Welding details

Agen.

code

Batch No. Portion

No.

Date of

manuf.

Agency code Process Super

visor

Welder

code.

5 6

Weld

No.

Block time Date of

finish grinding

Dimensional toler on finished

joint

USFD testing

After welding

From To On 1 m On 10 cm Date Result

(Pass/F) Lat Ver. Top Side

7 8 9 10 11

In service failure details Test joint

Date

removed

Repl. weld Ref. Sign. of

PWI

Weld. Failure Weld 1 Weld 2

Date Type S. No. Date S. No. Date

12 13 14 15

Date of

sending

test jt.with

refer.

Test joint results

Date of

receipt of

results

with ref.

Hardness (BHN) Transverse load Poro-

sity

(%)

Date of

marking

'X' for

extended

guarantee

Remarks

Rail Weld HAZ Load

(t)

Def.

(mm)

16 17


224

ANNEXURE 6

PROCEDURE FOR PAINTING OF WELD COLLAR FOR THERMIT WELDED

RAIL JOINTS TO PROTECT AGAINST NORMAL CORROSION

A. NEW WELDED JOINT

1. Surface preparation

1.1 Remove dust, loose rust and mill scale by wire brushing.

1.2 Scrub welded area with water to make it free from slag and other water soluble

compounds. Make it dry.

2. Painting procedure

2.1 Apply one coat of ready mixed paint; brushing, bituminous black, lead free, acid, alkali,

water and chlorine resisting, conforming to IS:9862-1981 on the welded area and 10 cm on

either side.

2.2 After eight hours drying, apply a second coat of the same paint.

2.3 Painting should be carried out by brush only.

B. MAINTENANCE PAINTING (FOR OLD PAINTED JOINTS)


1.1 Remove dust, dirt, and flaked paint from the welded joint by wire brushing.

1.2 Degrease the surface by petroleum hydrocarbon or any other suitable solvent, if oil or

grease is present. Allow it to dry.


2.1 Apply one coat of ready mixed paint; brushing, bituminous black, lead free, acid, alkali

and chlorine resistant to IS:9862-1981 or bituminous emulsion to IRS: P-30-1996 on

welded area and 10 cm on either side.

2.2 If required, a second coat of the same paint may be applied after a minimum of eight

hours drying.

2.3 Painting should be carried out by brush.

3. The list of approved manufactures for the above quality of paints is issued every year by

the Director General (M&C), RDSO, Lucknow to Zonal Railways.


225

ANNEXURE 7

PROCEDURE FOR PAINTING OF WELD COLLAR FOR THERMIT WELDED RAIL JOINTS TO

PROTECT AGAINST SEVERE CORROSION

A. NEW WELDED JOINT


1.1. Remove dust, loose rust and mill scale by wire brushing.

11.2 Scrub welded area with water to make it free from slag and other water soluble

compounds. Make it dry.


2.1 Apply one coat of high build epoxy paint(two pack) conforming to RDSO

specification No. M&C/PCN-111/88 on the welded area up to 10 cm on either side.

B. MAINTENANCE PAINTING (FOR OLD PAINTED JOINTS)


1.1 Remove dust, dirt, and flaked paint from the welded joint by wire brushing.

1.2 Degrease the surface by petroleum hydrocarbon or any other suitable solvent, if

oil or grease is present. Allow it to dry.


2.1. Apply one coat of high build epoxy paint (two pack) conforming to RDSO

specification No. M&CIPCN-............. on the welded area up to 10 cm on either

side.

3. RDSO specification No. M&C/111/88 has been circulated vide RDSO's letter No.

M&C/PCN/II/TR/3 dt. 13/ 14-5-1 991.

NOTE :

1. The epoxy based paint recommended is a two pack system with a pot life of around five

hours. Hence prepare only that much quantity of paint which can be consumed in less than

five hours.

2. The paint should be procured along with the thinner recommended by the manufacturer

of the paint. No other thinner i.e. kerosene oil, etc should be used.

3. The painting shall be carried out by brush only. Brush shall be cleaned by the thinner

after use.


226

4. The list of probable suppliers is given below as per RDSO's letter No.M&C/PCN/II/TR/3

dt. 13/14-5-1991:

(i) M/s Asian Paints (India) Ltd.,

Nirmal', 5th Floor,

Nariman Point, P.B. No. 1546,

Mumbai- 400 421.

(ii) Mis Addison Paints & Chemicals Ltd.,

'Huzur Gardens',

Sembium, Chennai-600 011.

(iii) M/s Goodlass Nerolac Paints (P) Ltd.,

Nerolac House, Ganpat Rao Kadaw Marg,

Lower Parel,

Mumbai- 400 013.

(iv) M/s Shalimar Paints Limited,

13, Camac St.,

Calcutta - 700 071.

(v) M/s Berger Paints India Ltd.,

32, Chowringee Road,

Calcutta - 700 071.


227

ANNEXURE 8

PROCEDURE FOR ULTRASONIC TESTING OF ALUMINO THERMIT RAIL

JOINTS

1. Scope : This procedure covers the requirement of ultrasonic testing of alumino themic (AT) welded rail joints immediately after execution of the weld.

2. General conditions of test

2.1 surface preparation : After execution of the AT weld, the welded zone shall be

dressed properly to facilitate placement of probes and to avoid incidence of spurious signals

on the CRT. The rail table shall be dressed to obtain reasonably flat and smooth surface.

The flange and the web, up to a distance of 200 mm on either side of the weld collar shall

be thoroughly cleaned with a wire brush to ensure freedom from dust, dirt, surface

unevenness, etc.

2.2 Couplant : Water/oil/soft grease shall be used as couplant.

2.3 Sensitivity: The equipment sensitivity shall be set for normal, 70 and 80 probes in

accordance with the procedure laid down in para 4. The sensitivity so adjusted shall be

considered as normal gain setting and shall be utilised during AT weld testing, the

sensitivity level shall not be altered during the course of testing.

3. Apparatus required

3.1 Equipment : Any model of RDSO approved rail tester shall be considered suitable for

testing of AT welded rail joints.

3.2 Probes : During ultrasonic examination of AT welded joints, the following probes shall

be utilised:

(a) Normal (0 ), 4 MHz Double crystal fitted in trolley

(b) 70 , 2 MHz Double crystal fitted in trolley

(c) 80 , 1.25 MHz Single crystal for hand probing

3.3 Cable : One co-axial cable of suitable length for connecting 80 probe to flaw detector

shall be used. The length should not exceed more than 5 m.

4. Sensitivity setting procedure

4.1 Calibration : The equipment shall be set for a depth range of 250 mm by manipulating

the depth control knob suitably. Each main scale division, therefore, shall correspond to 25

mm.


228

4.2 Test rail : The sensitivity of the ultrasonic equipment shall be set with the help of a

standard Ai welded rail piece of 1.5 m length having a simulated flaw at standard locations

as shown in Fig. 1.

4.3 Alignment of probes : The alignment of normal and 70 probes fitted with the trolley

may be checked by placing the rail tester on the test rail using water/oil as a couplant and

ensuring that the probes travel along the vertical axis of the rail.

4.4 Sensitivity setting for 70 ; probes

4.4.1 Place the trolley on the test rails shown in Fig. l. Keep the switches of all the probes

in off positions and turn the potentiometer knobs of all the probes to 50% of their highest

working range.

4.4.2 Switch on only 70 forwards probe and move the equipment towards the drilled hole

of 3 mm dia in rail head. When the probe is just in the reflecting range, a pulse

corresponding to the hole shall appear on the screen which during onward travelling shall

show higher amplitude. The pulse shall appear moving from right to left. The equipment

should be progressively moved forward till maximum height of the pulse is obtained. At

this location the height of the pulse shall be adjusted to 60 % of full screen height by

suitably manipulation of the gain knob.

4.4.3 The forward probe shall be switched off and the 70% backward probe shall now be

switched on. In this case a flaw signal shall appear moving from left to right. The signal

height in this position shall also be adjusted to 60% of full screen height. This can be

accomplished through suitable manipulation of relevant potentiometer.

4.4.4 The sensitivity setting for the normal probe has to be done while keeping all other

probes in off position. Switch on only the normal probe and bring it above 3 mm dia hole

drilled in the head of the test rail; Manipulate the potentiometer control knob to obtain echo

eight of 60% of full screen height at 1.0 division horizontal scale.

4.4.5 80 probe shall be connected to the socket available in the ultrasonic equipment. The

selectors switch may be set to single crystal mode. Move the probe towards the 3 mm dia

hole drilled at the middle of the flange through in the AT weld and manipulate knobs to

obtain a 60% full screen height on the CRT.

5. Criteria for defect classification

5.1 Any flaw signal obtained by normal probe of 40% height or more from head location

shall be treated as a defective AT welded joint and any flaw signal obtained from the

normal probe either from the web or the foot location shall also be a cause for rejection of

the AT weld.

5.2 In the case of lack of fusion, inclusions, blow holes, etc. in the rail head, moving signal

shall be obtained while testing with 70 probe. The position of onset of the signal and its


229

corresponding range on the horizontal screen as well as their maximum amplitude shall be

recorded.

A welded joint showing the moving signal of 40% or more of the full screen height shall be

considered as a defective welded joint.

5.3 80 probe shall be placed on the flange at a distance of 180 mm corresponding to

position 'L' in Fig. 2 such that ultrasonic waves are directed towards the weld. The probe

shall thereafter be moved slowly in a zigzag pattern towards the weld. A welded joint

showing a flaw echo of 40% vertical height or more with the stipulated gain setting shall be

treated as a defective welded joint. Similar testing shall be carried out on 'C' and 'U' regions

as shown in Fig. 2. In these cases also the criteria for rejection shall remain the same.

6. The defective joints based on. the criteria mentioned at para 5 shall not be allowed to

remain in service and shall be cropped, re-welded and tested again. This execution shall be

done by the contractor free of cost. The re-welded joints shall be scanned ultrasonically

again with the same set of acceptance criteria to ensure freedom from any harmful defects.


230

ANNEXURE 9

EXTRACTS FROM IRS:T-19-1994 CLAUSE 4.2 ON MECHANICAL AND

METALLURGICAL TESTS ON TEST WELDS AND RETESTS

4.2 Mechanical and metallurgical tests on test welds

1.2.1 Two new rail pieces of same section and grade, each approximately 750 mm long,

shall be used to make test weld joint. The welded joint shall be made as per the technique

offered by the manufacturer. The rail table and sides of rail head shall be finished to the

geometrical tolerances specified in para 18.1.

4.2.2 Hardness test : Brinell hardness test shall be carried out at the welded zone, heat

affected zones and parent metal of the rails in accordance with IS: 1500 "Method for

Brinell hardness test for steel". The test shall be done on the top surface of the head of the

test weld with a ball of 10 mm dia and a test toad of 3000 kg maintained for 10 sec. The

average hardness number (of two readings) determined for the weld metal at locations

shown, as 'A' in Fig. 1 given below shall be within +20-0 HB of the hardness values of rail

as shown in table 1. The average hardness number (of two readings) on each heat affected

zone at locations shown as 'B' and 'C' in Fig. 1 shall be within ! 20 HB actual hardness of

the parent rail, except in case of head hardened rail.

FIGURE

• Fig. 1


231

TABLE 1

Type of rail 72 UTS rail 90 UTS rail UIC Cr-Mn Or Cr-

V alloy steel rail

Head hardened

rail

Average

hardness(BHN)

230 265 310 365

4.2.3 Transverse breaking load test

4.2.3.1 The test weld shall be supported on cylindrical or semi-cylindrical supports

having a distance of one metre between them from centre to centre. The weld

shall be at the centre of the span and loaded in such a manner that the foot of

the rail is in tension. The diameter of mandrel and the supports shall be between 30

to 50 mm. The load shall be gradually increased (rate of loading shall not exceed

2.5 t/sec) till rupture occurs.

The test weld shall withstand a minimum load and show corresponding minimum'

deflection as stipulated in Table 2 for different sections and types of rails.

TABLE 2

Rail type Rail section Min. transverse

breaking load

(t)

Min. deflection at

the centre at the

load in col. 3

(mm)

1 2 3 4

72 UTS to

IRS:T-12-1 996

60 R 50 15

-do- 75R 60 15

-do- 90R 70 15

-do- 52kg 85 18

-do- 60 kg 95 18

90 UTS to 75R 65 15

IRS:T-12-1996/ 90R 85 18

UIC 860-0 52 kg 90 15

or equivalent 60 kg 115 15

Alloy steel 52 kg 95 10

(Cr-Mn or Cr-V 60 kg 1.15 10

type) 110 UTS

Head hardened rails 60 kg 115 15


232

4.2.3.2 it the fracture does not occur through weld, a slice shall be cut transversely

at the weld and etched in boiling 1:1 hydrochloric acid for about 20 minutes to

determine casting defects if any.

4.2.3.3 The fractured surface of the weld, or in case where macro-etching is done

on transverse section through the joint, shall not show defects such as blow holes,

porosity, inclusions, etc. exceeding total permissible area of defect shown in Table

3. However, the size of any individual defect shall not exceed 2 mm diameter. The

defects should not be interconnected and none of these shall extend upto the

outer surface of the weld. There shall not be any lack of fusion. The fractured

surface shall also not show the presence of accretions or mirror like structure and

shall be crystalline in appearance.

TABLE 3

Area of permissible defects

Rail section Permissible total area of defect (mm2)

60 R 19.0

75 R 23.7

90 R 28.5

52 kg 33.0

60 kg 38.4

4.3 Retests

4.3.1 If the results of any of the tests referred to in para 4.1 and 4.2 are found to be

unsatisfactory, the batch will stand rejected. However, restests can be carried out

at the manufacturer's request. These retests shall be carried out as per para 4.1

and 4.2 on twice the original sample size.

4.3.2 If the results of all the retest samples are satisfactory, the batch represented

by the sample portions shall be accepted. If any sample fails to meet the

requirements of any of the tests, the batch shall be rejected.


233

ANNEXURE 10

MAJOR DEFECTS IN AT WELDING BECAUSE Of IMPROPER WELD EXECUTION

S.No. Type of defect Cause of defect Preventive steps to be taken to avoid the defect

1 Longitudinal crack in rail web.

Cutting of wear resistant grade rails by flame cutting.

Flame cutting of rail ends is prohibited due to likelihood of cracking in web.

2 Lack of fusion in rail foot. Flame cutting of rail ends. When producing the welding gap, never flame cut rail ends without using a cutting guide.

3 Cold spots-lack of fusion. Gap between rail ends too wide-rail ends outside the collar formation

Maintain the welding gap between rail ends specified in the approved parameters of the technique. Never attempt to weld a gap which is too wide, with standard mould.

4 Cold spot-lack of fusion and associated local porosity.

Mould fitted vertically but off centre to the weld gap.

Take care to centralise the mould to the gap. Never try to fit both mould halves simultaneously.

5 Lack of fusion on foot of one rail end.

Mould fitted centre to the gap-but inclined to the vertical.

Take care to fit mould both vertical and central to the weld gap. Do not incline mould to the vertical

6 Gross lack of fusion on rail end.

Standard moulds fitted to rails of dissimilar depth.

Do not try to weld worn to new rail, or rails dissimilar depth with standard mould.

7 Porosity in the thermit steel.

Luting sand too wet. Luting sand must be moist but not too wet. Never use wet luting sand.

8 Sand inclusion in the rail foot and sand burn marks transversely across the rail head.

Dropping of luting sand into the mould.

Take care when sealing the mould with luting sand. It must not be allowed to drop into the mould.

9 Grass porosity throughout the whole weld section.

Use of damp crucible is detrimental to thermit reaction and results in gross porosity of weld metal.

Carefully dry out the crucible lining using the preheating burner.

10 Gross porosity throughout the whole weld section.

Use of damp portion. Moisture present in portion reacts with aluminium and its characteristics thereby affecting the thermit reaction and resultant steel. This change cannot be reversed by drying out.

It is essential only to use dry thermit portions. Never use portions which have been damped and dried out.

11 Gross inclusion of slag in the rail head.

Pouring without the plug in the position.

After preheating fit the sand core with the riser aperture of the mould and press down lightly.

12 Gross slag inclusion in rail head on one side

Pouring off centre to the plug. Ensure that the crucible is positioned centrally the over the sand core and the crucible does not move during the thermit reaction. Never allow the thermit steel to pour directly into either pouring gate.

13 Fracture through weld centre.

Immediate imposition of tensile forces on weld metal cause internal tearing of weld metal which leads to total transverse fracture.

During solidification and immediately after thermit weld should not be subjected to tensile force.

14 Cracking of weld after cooling at rail ends.

Failure to use the correct thermit portion and welds. Procedure as approved for specific rail section/rail chemistry.

Always check the chemistry and type of rail to be welded and use correct type of portion and adopt correct welding parameters at the time of welding of rail joints.


234


235


236


237


238

SALIENT FEATURES OF REVISED MANUAL FOR WELDING OF RAIL JOINTS BY THE

ALUMINO-THERMIT PROCESS (1998)

1. As conventional method of alumino-thermic (AT) welding has been discontinued on

Indian Railways except for 60R rails, accordingly the revised manual provides for only Skv AT

welding (Clause 1.5).

2. A para on 'Shelf life of portion' has been included, which brings out the importance of

proper packing and storage of AT portions. Procedure to be adopted for use of portions

beyond two years since the date of manufacture has also been laid down (clause 4.2.2).

3. Detailed instructions on painting of weld collar immediately after welding and also its in-

service painting have been laid down. In case of areas where severe corrosion is observed

epoxy painting has been provided for (Clause 5.7).

4. Course of action to be adopted for welding of rails through approved portion

manufacturer, labour contracting firms and departmental welders, in case of large scale

welding, casual welding and welding forming part of turn-key projects have been outlined

(Clause 4.1.1).

5. In case of secondary rail renewal, AT welding by end cropping so as to eliminate both

bolt holes has been specified. In case of use of rail panels released from LWR/CWR territory,

cropping of rail ends so as to eliminate heat affected zone has been specified [Clause 3.3

(xi)].

6. Use of 880 grade portions for AT welding where Grade 710 (72UTS) and Grade 880

(90UTS) rails form junctions in unavoidable circumstances has been specified [Clause 3.3

(viii)].

7. The composition of welding team has been revised keeping in view introduction of Skv

welding and use of weld trimmer and rail profile grinder (Annexure 3).

8. A list of defects giving causes and preventive action to be taken to avoid the same

have been briefly outlined (Annexure 10).

9. As only Grade 880 rails are being produced, AT welding by flame cutting/gas cutting of

rails specially for wide gap welding has been deleted and only sawing or abrasive disc

cutting has been provided (Clause 3.3 (vi)l.

10. Welding parameter of AT welding techniques (as on 31.12.97) including welding

techniques under development for various approved firms have been laid down

(Annexure 1);

11. Provision of fixing an aluminium strip with distinctive weld number an the web of rail by

epoxy based adhesive has been laid down (Clause 5.6).

12. Guarantee period and other provisions wherever required as provided in IRS:T-19-1994

have been included to update the manual in line with IRS:T- 19-1994 (Clause 7.3).

13. List of approved manufacturers of rail profile weld grinder and weld trimmer has been

included (Annexure 4).


239

NATIONAL THERMAL POWER CORPORATION LIMITED

BARH SUPER THERMAL POWER PROJECT (3 X 660 MW)

Technical Specification for Permanent Way

1.0 Materials

The track shall consist of following elements:-

1.1 Rail 52 Kg/T-12/90 UTS flat bottom (1st quality as specified in schedule of quantity) as per I.R. Specification T-12/96 with up to date amendments.

1.1.1 60 KG PSC Sleeprs.

1.2

Rail fastenings

1.2.1 52kg Fish Plates to RDSO Drg. No. T-090 (M) Cor. 6 of July 92, in length of 610mm to IRS specifications No. T 1-1966.

1.2.2 Fish Bolts 25mm Dia with nuts to RDSO Drg. No, 11501 – IRS Specification T-23/67.

1.3 Mono block Pre-stressed concrete sleepers as per IRS Specification T-39/1996.

1.3.1 For plain track on straight & curves of radius > 350m to Drg. No. T-2496 with modifications, if any.

1.3.2 For curves laid on sharper than 50 (Radius <350m) with check rails as per Drg. No. RDSO/T-5738 to T-5740 for track gauge of 1675, 1677, 1679 & 1681 with uses of liners.

1.3.3 For level crossing to RDSO Drg. No. T-4783 with modifications, if any sleepers drawing no., T-4148 – A.

1.3.4 For ballasted deck bridges as per RDSO drawing no. T-4088-4097.

1.3.5 For 3 rail panel (SWP). Joint Sleepers will be as per RDSO Drg. No. T-4322 for 52 kg with ERC clips as per RDSO Drg. L No. T-4158.

1.3.6 For bridge approaches of Girder bridges for provision of Guard rails as per RDSO Drg. No. T-4088 to 4097.

1.4 PSC Sleeper Fittings: The sleepers shall be normally 60 kg as per RDSO drg. No. T-2496 and sleeper fittings shall be for 52 kg rail section on 60 kg sleepers as per specifications and drawings.

1.4.1 Grooved Rubber Sole Plate 6mm thick to RDSO Drg. No. T-3711.

1.4.2 Elastic Rail Clips to RDSO Drg. No. T-3701. IRS Specification T-31/1992.

1.4.3 Glass Filled Nylon (GFN) Liners (GFN-66 insulating liners for 52 kg Rails on 60 kg sleepers as per RDSO Drg. No. T-2496.) as per RDSO drawing no. T-3707 (GS) & T-3708 (NGS) as per IR Specification.

1.4.4 Metal Liners as per RDSO drawing no. T-3741 (GS) & RDSO/T-3742 (NGS). 1.5 Steel channel sleepers for girder bridges and track fittins as per RDSO Drg. No. BA

1636 / R2, BA 1636 / 1 / R2, BA 1636 / 2 and rail fastening assembly and guard rail as per RDSO Drg. No. T-5155 to T-5164.

1.6 Ballast

Track ballast machine crushed, conforming to RDSO specifications of Track ballast, June 2004 with up to date modifications thereto, shall be procured and used on the


240

work.

Note:

The word IRPWM where ever used in these specifications shall mean `Indian Railway Permanent Way Manual’ 1986 reprinted in 2004 with up to date correction slip.

(B) Technical Specifications for laying of Permanent Way

1.0 Track Structure

1.1 Components

The track shall consist of the following elements.

i) Rails 52 kg/T-12, 90 UTS flat bottom (1st quality) ii) Rail fastenings – Fish plates 52 kg, with bolts and nuts. iii) Monoblock pre-stressed concrete sleepers for plain tracks, level crossings,

bridges, fish plated joints, girder bridge approaches, fan type turnouts. iv) Guard rails on bridges, check rail on level crossings. v) Fittings for sleepers – grooved rubber sole plates, elastic rail clips Mark – III

(RDSO drawing no. T-3701) for normal track and Elastic rail – J-clips for fish plated rail joints to RDSO Drg No. T-4158, GFN liners, metal liners.

vi) Track Ballast as per RDSO Specifications of June 2004 vii) Gradient posts, KM posts, curve monuments, curve boards, whistle boards,

W/L broadly creep posts and other boards and indicators etc., as per IRPWM. viii) Points and crossings. ix) Steel Channel sleepers for girder bridges and track fittings. x) Glued Joints.

1.2 The track will be laid on monoblock PSC Sleeper as specified in Schedule of Quantities. The ballast cushion will consist of Track ballast as per RDSO specifications to a depth of 250mm below the bottom of sleepers as measured under the rail seat.

1.3 The mono block PSC sleepers shall be laid @ 1540 nos/km as specified in chapter XIV of IRPWM for main line and @ 1340 nos./km for loops and sidings in yards.

1.4 Guard rail to be provided at all major bridges as per para 275 of IRPWM.

1.5 Check Rail at level crossings.

2.0 Procurement of Materials:

2.1 All the materials and equipment required for track construction shall be procured from the suppliers/manufactures approved by Rly./RDSO duly inspected by RITES/RDSO.

2.2 Other track materials for which approved manufacturers/suppliers are not available, shall be procured from sources after getting them approved/inspected from RITES.

2.3 All the materials shall be got inspected and passed from the Railway’s authorized inspecting agencies such as RDSO/Rly/RITES etc. and certificates obtained to this effect which will be submitted to site Engineer-in-charge.

2.4 Ballast

a) The Contractor shall procure, at his own cost, track ballast conforming to RDSO’s `specifications for Track Ballast, June 2004 with up to date correction slips, of


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approved quality for use on all lines with 250mm cushion. The test reports for the ballast for quality as required, should be submitted to NTPC before ballast is brought to site. Ballast should be supplied in stacks on levelled ground along the proposed alignment.

3.0 Linking

3.1 The formation shall be constructed and mechanical compaction shall be done as per RDSO `Guidelines for Earthwork in Railway Projects’.

Track ballast be then compacted by at least 2 passes of 5 to 10 t roller before laying the PSC sleepers and rails.

3.1.1 Dismantling & Re-linking

Dismantling of existing track structure with 52 kg single rail 3 rail panel (SWP) & stacking the same duly segregated as per direction of site Engineer within in 50m of track and relaying the same after construction of new bridges, raising of existing bridges including formation duly recouping the missing/damaged fittings i.e. sleepers, fish plate with bolts & nuts, liners, ERC, GR Pad etc. nothing extra shall be paid for recouped materials/fittings. Contractors to please note that existing track structure is in good working condition & it is assumed that all fittings are also in good condition so contractor’s are advised to dismantle the track carefully and keep the same in safe custody. Before re-linking all the materials/fittings to be checked by the authorized Engineer, rejected fittings/materials shall be replaced by new of same standard & specification. This aspect may be kept in view while quoting the rates.

3.2 Curves

i) The alignment of track on certain locations is on curved alignment as per index plan. While laying track on such locations, the layout of the curve shall be done accurately with deflection angle, degree of curvature, transition length and curve length and laid to required super elevation for each curve as directed by Engineer Incharge.

ii) The design of curves specifying all parameters (transition length, total length of curve, super elevation etc.) shall be done by Engineer Incharge and advised to the contractor who shall then lay the curves accordingly as indicated in the above para so that it conforms to the designed parameters.

iii) The station numbers, SE & Versine shall be marked, starting from zero at TP (i.e from the start of curve) at 10 meter interval on the inside web of outer rail of the curve and shall be continued over the entire length of the curve with figures in white paint over black back ground.

iv) Curve posts as per Railway’s design shall be fixed at both ends of curves, at TP (Transition Point) and TTP (Transition Tangent Point), and the details of the curve shall be written on TP post of both ends mentioning curve no: degree of curvature, transition length, curve length and super elevation with appropriate painting scheme as followed by Railways.

3.3 Longitudinal level of Track

The longitudinal level of the track shall be in accordance with the gradients as indicated in L-Section supplied by Engineer –Incharge Gradient posts at each change of gradient shall be provided as per approved design and shall be engraved with the values and arrow indicating rise, fall or level as the case may be, on both faces with figures in black on white back ground.


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• The gradient post shall be provided as per L-Section.

• Sketch of gradient post and km post is placed as Annexure PW-VI.

3.4

Kilometer & Gradient Posts

RCC kilometer and gradient posts as per drawing, (Annexure PW-VI) shall be casted and fixed at each kilometer / Point of change of gradient on cess and number engraved on both faces and surface painted with white and engraved figure written with black.

3.5 Ballasting

i) Once the central line and level pegs have been provided, the ballast should, on clearance by the Engineer in charge/his authorized representative, be lead out from the stacks and spread on the track formation. The ballast layer shall be consolidated by running of heavy rollers (5-10 tonne). The ballast cushion which is to be finally achieved shall be 250mm. Hence about 8% more cushion shall be provided initially, which on consolidation, shall come down to the required dimensions. The profile of ballast, finally to be provided shall be as per IRPWM para 263, for SWR.

ii) On all flat top, arch and pre-stressed concrete girder bridges with deck slab, where guard rails are not provided, the whole width of the bridge between the parapet walls shall be filled with ballast up to the top of the sleeper level.

iii) The payment for supply of ballast will be made on the basis of stack measurement of ballast without deduction for any shrinkage, as laid down in RDSO specifications, June 2004. The measurement and passing of ballast in stacks shall be done by Engineer -Incharge.

iv) Ballast under dismantled (existing) track – Total ballast under dismantled (existing) track shall be removed, screened & stacked as per direction of site Engineer, after raising the bank the same screened ballast shall be spread on raised bank. Approx 70% of calculated ballast under dismantled track to be taken into account & to be deducted from required ballast & the same to be paid for spreading ballast under respective item.

3.6 Concrete Sleepers

i) Concrete sleepers are very heavy and prone to develop cracks/ chipping, if handled roughly. Manual handling of these sleepers is, therefore, not desirable. The sleepers directly received at site through road trucks shall be unloaded using mechanical gantries/cranes, whereas those received on railway BFRS shall be unloaded through cranes/mechanical unloading equipment. One such device is Jib crane attachable to BFR/BRH for handling concrete sleepers. The shifting of sleepers shall be done using slings which should lift the sleepers through hooks fixed to inserts.

ii) Unloaded sleepers shall be kept at site of placement, properly supported underneath.

iii) On the ballast already laid and consolidated PSC sleepers 60 kg to RDSO drg no. T-2496 shall be laid at specified spacing. All care be taken in handling the sleepers so as to avoid breakage. The sleepers shall be laid to a density of 1540 nos/km/or 1340 nos./km as specified. For fish plated joints, the spacing shall be 40 cms (centre to centre). The sleeper spacing at welded joints shall


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be the same as intermediate sleeper spacing as per para 244 (h) of IRPWM. No damaged sleepers will be accepted.

iv) To get proper track alignment, it is necessary that the centre line of the sleepers coincides with the centre line of the alignment marked.

v) Greasing of Elastic rail clips and MCI/SGCI Inserts: All the Elastic rail clips and inserts fixed in the concrete sleepers shall be thoroughly cleaned and grease to IS specification IS 15:408 – 1981 (Specification for Grease No. “O” Graphited) should then be applied on the central leg of ERC and eye of the insert and then the clip be driven at the time of assembly of the rail with the sleeper as per provisions of para 1411 (5) (a) of IRPWM. ERCs shall be provided with anticorrosive treatment before putting in track. Nothing extra shall be payable for any of the elements stated above.

3.7 Rails

3.7.1 a)

Rails to the extent required shall be supplied by the employer at NTPC nominated store godown. The contractor at its own cost shall lead the same to site for use on the work.

b) The rails and other fittings from depot area/complex be lead to site of actual laying in track by any means convenient to the contractor depending upon the site conditions and be placed at places where these are to be laid. The rails shall be adjusted in pairs along the alignment on the cess. The contractor will remove kinks from each rail, if any, with the help of jim Crow, etc. Handling of rails shall be done as per instructions issued by RDSO.

c) Single rails so brought to site shall be converted into 3 rail welded panels by Short Pre Heat process of Thermit Welding by the contractor at his own cost on the cess or at site.

d) The cutting of rails, where required shall be done using Abrasive rail cutting Machines and the holes drilled with rail drilling machines approved by Railways/NTPC. All the holes drilled in rails shall be chamfered using approved chamfering kit in terms of para 251 (5) of IRPWM (CS No. 51 dated 21.4.00)

e) All rails after pairing to be ultransonically tested by the contractor at his own cost and only defect free rails shall be used. The contractor shall submit the test report to the Engineer-in-charge.

3.7.2 Welding of Rail Joins:

a) The rail joints shall be welded with Alumino Thermit welding of rail joints by short pre-heating (SKV) process to IR Specification no. T-19-1994 as detailed in RDSO `Manual for Fusion welding of Rails by the Alumino, Thermic Process `September 1998’

b) The welding shall be got done only from approved portion manufacturing firms with portions, consumables, equipment and RDSO certified welders/welding supervisors.

c) The portion shall conform to IRS specification no. T-19-1994. (para 4.2.1 of AT welding Manual).


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d) For field welding of rail ends provisions of para 4.4 to 4.10 of the “Alumino Thermic welding “ 1998 referred above shall be followed. Post welding operations shall be carried out as per para 5 and tests as per para 6 of the aforesaid manual. Sample tests of welds done shall be carried out as per para 7 of AT welding manual.

e) The finishing tolerances of the weld must conform to provision of para 5.4.2 indicated below:-

• Vertical alignment : Variation not more than +1.00mm, -0mm measured at the end of 1.0metre straight edge.

• Lateral alignment : Variation not more than + 0.5mm measured at the centre of 1.0metre straight edge.

• Head Finishing: top table surface

: +0.4mm, -0mm, measured at the end of 10cm straight edge.

f) While welding, adequate precautions as laid down in para 9 of the Manual shall be followed.

g) Welds found defective shall be replaced by the contractor as per para 6.4 of the Manual.

h) Flame cutting / gas cutting of 52 kg 90 UTS (1st quality) rail ends for welding them is not permitted. Rail ends for welding shall be cut by sawing or by abrasive disc cutter as laid down in para 3.3 (vi) of A.T. Welding Manual.

i) All thermit welds shall be ultra sonically tested by the contractor at his cost and all welds, found defective in such testing, shall be replaced by the contractor at his cost. The contractor shall remove all welds found defective either in ultrasonic testing or any other tests or failure of welds or welds found defective on any other account, by cutting the rail on both sides of the defective weld including the heat effected zone, and then welding the rail joints so created. In certain locations, two welds may have to be done to replaced one defective weld. All these works of replacement of defective welds including all materials, equipment, machinery and labour etc. shall be done by the contractor at his cost.

j) All Thermit welds shall be painted as per para 5.7 of Manual for fusion welding of rails by Alumino Thermic Process, September 1998 issued by RDSO.

k) Guarantee against failures : All the rail joints welded by Thermit welding technique shall be guaranteed against failure for a period of twelve months from the date of commissioning of project (para 7.3 of thermic Welding Manual 1998 is modified for this project). Any such welded joint which fails within the guarantee period be re-welded free of cost by the contractor as per stipulations of para 6.4.

l) The acceptance tests required for accepting the Thermit welds shall be as per para 6 and 7 of Thermit welding manual.


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m) Sample test Joints

i) One out of every 100 joints welded, shall be selected at random by the purchaser or by the inspecting officer with in one month of welding and subjected to hardness, transverse load/deflection tests and porosity as per clause 4.3 of IRS:T-19-1994.

ii) If the sample test joint fails to satisfy any of the requirements of specification IRS:T-19-1994. Engineer Incharge will be at liberty to suspend further welding. However, two more randomly selected joints from the same lot of 100 joints shall be subjected to re-tests as per clause 4.2 of IRS: T-19-1994. Both the joints should clear all the tests. If this report is also not satisfactory, further welding of joints shall be suspended until the firm’s welding technique has been examined and the same satisfies the requirement of clause 4 of IRS: T-19-1994. The clearance for re-commencement of welding shall be given by the Engineer-in-charge.

3.7.3 Short Welded Rails (SWR)

i) The laying and maintenance of short welded rails shall conform to provisions of para 505 to 510 of Part `B’ of chapter V of IRPWM. Special care shall be taken to provide expansion gaps at fish plated joints as per IRPWM para 508 table 1 for initial laying and para 510(3), table II for maintenance.

ii) The fishing planes of fish plates and rails shall be lubricated with a paste of workable consistency (Plumbago and kerosene oil) in the following proportions and fish bolts be oiled. The material for lubrication of joints shall be arranged by the contractor. No extra payment will be made for the same.

Plumbago (Dry Graphie) - 5 kg Kerosene oil (2nd quality) - 3.5 ltrs for 100 joints Black or reclaimed oil - 2.75 ltrs

3.7.4 Bridges

a) The rail joints on girder bridges with opening less than 6.1m shall be avoided. For other spans, the preferred position of rail joints is at 1/3rd of span from either end as per para 272(3) of IRPWM.

b) Guard rails shall be provided on bridges as per para 275 of IRPWM. c) The design of guard rails on the bridge and its approaches shall be as per para

275(2) of IRPWM. d) PSC sleepers to RDSO drg. No. T-4089 to Drg. No. T-4097 with complete fittings

as shown in the drawings, shall be used on ballasted deck bridges with guard rails and their approaches. The fixing of guard rails shall be done as per RDSO drg. No. T-4088 to Drg. No, T-4097 as per para 275(3) of IRPWM, CS no. 63 dated 27.1.2003 M.S. flat/tie bars for tying PSC sleepers together at ends is not required. (CS 63 dated 27.1.2003 to IRPWM).

e) Gang path as per para 276 of IRPWM, shall be provided on the sleepers on the bridge only in case of unballasted girder bridges.

3.7.5 Level Crossings

i) Asphalting of road surface between gate posts to full width of road on level crossings shall be provided by the contractor at his cost. The road shall be provided complying with instructions contained in items 12 to 15, of Annexure 9/1 para 904, Chapter IX of IRPWM.


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ii) Gate posts made out of 52 kg rails shall be provided at the level crossing to hold the chain as per sketch, Annexure – PW-VIII chain shall also be provided by the contractor.

iii) Whistle boards (W/L), Stop boards shall be provided for the approaching trains at a distance of 600m and 30m from the level crossing respectively (as per Annexure-PW-IX). Similarly, Level Crossing indicator boards and Speed breaker indicator boards (as per Annexure – PW-IX) shall be fixed on the road approaches as per IRPWM para 916.

3.7.6 Points and Crossings

(i) Points and crossings shall conform to RDSO Drawings and specifications and shall be procured form manufactures / vendors approved by RDSO duly inspected by RDSO/RITES as per direction of Engineer-in-charge.

(ii) 52 kg 1 in 8 ½ turnout shall conform to RDSO Drg. No. T-4865, Switch sub assembly drg. No. T-4866 and crossing sub assembly drg. No. T-4867. Switches shall be 6400 mm overriding curved switches for 1 in 8 ½ BG (1673 mm) for 52 kg on PSC sleepers with all parts and fittings as per drg. No. T-4866 with latest alteration. CMS Crossings for PSC layout to RDSO drg. no. T-4867 with latest alterations complete with all fittings shall be used.

(iii) 52 kg 1 in 12 turnout shall conform to RDSO Drg. No. T-4732, Switch sub-assembly drg. No. T-4733 and crossing sub-assembly drg. No. T-4734. Switches shall be 10125 mm overriding curved switches for 1 in 12 BG (1673 mm) for 52 kg on PSC sleepers with all parts and fittings as per drg no. T-4733 with latest alteration. CMS Crossing for PSC layout to RDSO drg. No. T-4734 with latest alterations complete with all fittings shall be use.

(iv) Only lead Rails will be supplied by NTPC at Barh Depot.

3.7.6.1 Fan type turnouts

Turnout sleepers shall conform to Indian Railway Standard Specification for pre tensioned concrete sleepers serial no. T-45-96 (latest revision) as per RDSO Drawings. The same shall be procured from RDSO approved manufacturers / vendors duly inspected by NTPC as per direction of the Engineer-in-charge.

Salient aspects of fan shape layout are :

(i) The sleepers under switch portion are having dowels in which slide chairs are fixed with the help of screws. These sleepers are laid perpendicular to the main line and therefore, can be used for left hand and right hand turnouts.

(ii) The sleepers between the switch and the crossing (lead portion) are designed and laid at an angle of Q/2 with respect to main line where Q is the angle between the main line and the lead rail at that particular location. The same sleeper of left hand turnout rail at that particular hand turnout by laterally shifting the sleepers by an angle of Q.

(iii) The sleepers under crossing are laid perpendicular to the center line of the crossing and as such the same sleeper can be used for left hand and right hand by lateral shifting.

(iv) For laying sleepers in the lead portion correctly, spacing of sleepers on left rail seat and right rail seat on main straight track are given which define the center line of the sleepers.


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PRC fan shape layouts have curved switches. Before laying the turnouts, the correctness of the switch as well as its curvature should be checked in advance by pre-assembling and then once again after laying it in track.

This layout needs efficient drainage and adequate ballast cushion.

It may be noted that the sleepers are the same for 52 kg as well as 60 kg rails.

A mark ‘RE’ is provided on fan shape PRC turnout sleepers at one end. The sleepers should be laid in a manner that the end having the mark ‘RE’ is always laid on the right hand side.

The dowel fixed in the PRC sleepers should be cleared with the help of a suitable diameter soft brush so that all dirt/muck is removed. All the screws required to be fixed in the dowels should be greased before being put in.

Fan Shape Layout Assembly

(A) 1 in 8 ½ Turnout

Main drg. of Turnout

Switch sub-Assembly (T-4805)

Crossing sub - Assembly

52 Kg RDSO/T-4865 (T-4805)

RDSO/T-4866 – 60kg RDSO/T-4867 (T-4967 – 60 kg )

(B) 1 in 12 Turnout

52 Kg RDSO/T-4732 (T-4218 – 60 kg).

RDSO/T-4733 (T-4219 – 60 kg)

RDSO/T-4734 (T-4720 – 60 kg)

Disposition of Sleepers

Type of layout

Sleeper under switch which are to be perpendicular to main line

Sleeper Nos. which are to be laid at angle Q/2 where Q is inclination of outer lead rail with respect to main line at that location

Sleeper Nos. to laid perpendicular to centre line of crossing

1 in 12

1 to 20 21 to 64 65 to 83

1 in 8 ½

1 to 13 14 to 41 42 to 54

Approach sleepers

Type of layout

Entry Exit

1 in 8 ½

5 Nos. : 60-S, 60-4A, 60-3A, 60 2AS & 60-1AS

8 Nos. : (4 sleepers on main line and 4 on turnout side.)

1 in 12

5 Nos. : 60-S. 60-4A, 60-3A, 60-2AS & 60-1AS

8 Nos. : (4 sleepers on main line and 4 on turnout side.)

Long sleepers shall be provided for point machines to meet the requirement of S&T.


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It shall be ensured that the turnout is perfectly in line and duly packed both for the main lines as well as the siding served/connected by the turnout. Any adjustments as required shall be carried out by the contractor so that the layout and the connections meet the standard requirements. Nothing extra shall be payable for the same.

3.7.6.2 Fouling Marks made out of Cement concrete shall be provided as per approved drawing at locations as required as per directions of the Engineer-in-charge.

3.7.7 Glued Joints

Supply and fixing of 52 kg Glued Insulated Rail joint G3(L) as per RDSO Drg. No. T-1276 along with welding is to be provided in running/non-running lines as per direction of the Engineer-in-charge. The welds are to be ultrasonically tested as per RDSO manual of Sept. 1998.

These joints consist of web fitting fish plates glued to the rails with a high polymer adhesive and bolted with high tensile steel bolts. The insulation is provided by special type of insulating side channels, bushes and end posts made of fiber glass cloth roving. The instructions for fabrication and installation of glued insulated rail joints should be strictly followed as given in the manual for glued insulated rail joints 1998 issued by RDSO. In this type of joint 1m long fish plates with 6 HTS bolts are used. The pull out strength should be more than 160 tonnes.

The insulation resistance tests should satisfy the following criteria.

(i) In Dry Condition : After glued insulated joint is prepared, maggering voltage of 100 VDC shall be applied across the joint. The value of the insulation resistance shall not be less than 25 Mega ohms.

(ii) In Wet Condition : The value of resistance shall not be less than 3 Kilo ohms.

4.0

Follow up Packings

i) The track shall be lifted to the correct profile as directed by the Engineer’s representative.

ii) The sleepers shall be well packed with the ballast under them taking care that the ballast shall be worked under throughout the length of the sleepers without damaging the bottom edges of the sleepers and sleepers repacked till no more ballast can be packed in and or as directed by Engineer/his representatives.

iii) Stone ballast from the stacks along the alignment shall be lead and dumped over the track to correct profile as indicated in para 263 of Indian railway permanent way manual 1986 reprint to 1999 and as directed by the Engineer or his representative.

iv) Correct track parameters i.e. Gauge, alignment of rails, square ness of the sleepers, longitudinal and cross levels, expansion gaps at rail joints etc. shall be achieved as directed by the Engineer’s representative.

5.0 Final Adjustment and Packing

i) Any sleeper which has been shifted from correct spacing or gone out of square shall be moved back and squared after loosening the fastenings, care being taken not to cause damage to PRC Sleepers while slewing the sleeper. The fastenings shall be tightened again after squaring.

ii) The track shall be slewed to correct alignment by sighting along the rail head of the base rail. It should be ensured that track does not get lifted in the process of slewing. Any defects developed in gauge shall be rectified by adjusting the liners.


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iii) The track shall then be given a final packing. For this, sighting shall be done along the base rail and any dip or low joint lifted correctly and packed, attending the adjacent sleepers also. After the base rail is thus packed for 2 or 3 rail lengths, the cross levels should be checked and the opposite rail lifted wherever necessary and sleepers under the rail seat packed.

iv) The joint and shoulder sleepers shall be repacked and cross levels adjusted. The ballast section shall be dressed neatly as directed by Engineer’s representative to uniform height and width with correct side slopes.

v) Testing – The track completed as above will be rolled with a light, diesel engine for rolling complete with fuel and crew to be supplied by M/s NTPC free of cost. After 4 such movements of the engine, the contractor will attend to the defects developed, by packing, aligning, levelling and gauging the track. No extra payment will be made for this.

6.0 Specifications for Finished Work

a) Ballast Profile

i) The ballast profile should be in conformity with para 263 of IRPWM and brought to specified section, as directed by the Engineer’s representative.

ii) The ballast cushion shall be checked at three places in each km at random locations (these locations shall be recorded) and the average value shall be considered for acceptance.

iii) The expression “Ballast Cushion” wherever used in these specifications, shall mean depth of clean layer of ballast below the bottom of sleepers and above the finished top of formation, measured under the rail seat of the sleeper.

b) New Track Tolerances The new track shall conform to the following track standards. The track measurements should be taken in floating conditions.

S.N. Track Parameter Items for measurement Value

1 Gauge • Gauge

• Sleeper to sleeper variation

1673mm + 3mm 2mm

2 Expansion Gap Maximum deviation from the prescribed gap (Average gap worked out by recording 20 successive gaps)

+ 2mm

3 Joints • Low joints not permitted. ---

• High joints not more than 2mm

• Maximum out of Squareness of joints on straight

+ 10mm

• Maximum out of squareness of joints on curves

½ pitch of fish bolts holes

4 Spacing of Sleeper With respect to theoretical spacing

+ 20mm

5 Cross level To be recorded on every 4th sleeper

+ 3mm


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6 Alignment • On straight on 7.5m chord

• On curves – variation over theoretical versions.

(on curves station to station variation in versine shall not be more than 10mm)

+ 5mm* + 5mm**

*Values up to 10mm can be accepted at

few isolated locations

• ** Values upto 7mm can be accepted at few isolated locations

7 Longitudinal level • Variation in longitudinal level with reference to approved longitudinal sections

50mm

• Unevenness (variation in longitudinal profile of track as measured on 3.5m chord at the centre.

Not more than 6mm values of 10mm can be tolerated at few locations

7.0 Maintenance /Defect liability period

i) The maintenance of all assets / works of the project handed over to the contractor by client/constructed by the contractor will be the responsibility of the contractor, during the period of construction. Defect liability period shall be 12 months from the date of issue of completion certificate/commissioning of the works, whichever is earlier.

ii) The contractor shall be responsible for rectification of defects arising out of defective work man-ship/defective materials for this period of twelve months from the date of commissioning of the work and shall be responsible for replacement of all defective materials and for rectification of all defects at his own cost. The assets shall be handed over to NTPC at the end of the defect liability period as per stipulations given below .

8.0 Handing over of track by the contractor to NTPC

8.1 On completion & commissioning of work, the contractor shall handover the track to

NTPC for operation and maintenance after rectification of defects noticed during the joint inspection by the Engineer.

8.2 Performance security shall be released to the contractor on expiry of defect liability period and rectification of defects, if any.


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Technical Specifications for laying of Ballastless Track on Track Hopper Inside Plant

9.0 Ballastless Track on Track Hopper Inside Plant

9.1 The Epoxy leveling layer shall be of (minimum 13.4mm thick at the center of Rails) and should have a cross slope 1 in 20 (to give the necessary tilt to the rails) with proper Longitudinal levels/grades over the RCC beams. The insert shall be so fixed as to keep the bottom of its head flush with top of the leveling layer as shown in the drawing.

9.2 For the leveling layer M/s CIBA (India’s) Araldite GY-257, Hardner HY-840, Hardner HY-960 and qarts sand mix no. 10 in the proportion of 100:45:2:800-900 by weight or any other equivalent manufacturer.

9.3 The insert shall be housed in the concrete using resin mortar with M/s CIBA (India’s) Araldite GY-257, Hardner HY-840, Quarts sand mix no. 10 in the proportion of 100:50:350 by weight or any other equivalent suitable synthetic composition to match the desired technical specification.

9.4 The material/fittings to be supplied by the contractor for fixing the Rails to the RCC beams shall comply with the following specifications and drawings :

(i) CI inserts to IRS Specifications no. T-32 and to RDSO Drg. no. T-381 or T-2071

(ii) MS Composite Insulating Liners to IRS Specification & to RDSO Drg. no. T-1895

(iii) Grooved Rubber Sole Plate to IRS Specifications and to RDSO Drg. no. T-2052.

(iv) Pandrol Clips to IRS Specification no. T-32 and to RDSO Drg. no. T-1892.

9.5 All the small fittings as per specifications and drawings mentioned are to be supplied and fixed in position by the contractor in full for completion of the work at his own cost.

All the small fittings mentioned should be procured from the RDSO approved manufacturers. Manufacturers test certificates should be submitted for NTPC verification and record. The materials shall be rejected if they are not manufactured as per specification and drawings.

9.6 The track on the track hopper should be laid to the standards prescribed at para 316 of IRPWM. The details of the salient parameters are given here under :

(i) Gauge Variation : 0 to -3mm (sleeper to sleeper variation ± 1mm)

(ii) Cross level variation : Generally the track should be laid to zero variation. However, variation up to 3mm permitted.

(iii) Alignment variation : On straight on 10 M chord ± 2)


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PART-1

SECTION -7

DRAWINGS, IF ANY

Not Enclosed