TECHNICAL SPECIFICATIONtenders.hpcl.co.in/tenders/tender_prog/TenderFiles/879/Tender/5423... · ... portland cement. IS 1489 - Specification for portland - pozzolona cement. ... -

TECHNICAL SPECIFICATIONS

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TECHNICAL SPECIFICATION A. MATERIALS WATER: Water to be used shall conform to IS-456 Latest Edition. Water used shall be clean. Generally potable water is considered satisfactory for construction and curing purpose. CEMENT: Cement used shall be any one of the following 1. Sulphate Resistant Cement conforming to IS 12330- Latest edition 2. Portland Pozzolona Cement conforming to IS 1489 - Latest edition 3. Portland Slag Cement conforming to IS 455 - Latest edition 4. Ordinary Portland Cement may be used for Superstructure Work only BRICKS Common burnt clay having minimum compressive strength of 50 kg/ Sq. cm conforming to IS 1077-1976 shall be used. Bricks shall be hand or machine moulded and free from cracks and flaws and nodules of free lime. Bricks shall be provided with frog 1 to 2 cm deep on one of its flat side. AGGREGATES: Coarse aggregates for cement concrete works shall be locally available hand broken/ crushed stone aggregates conforming to IS:383-1970. Fine aggregates shall be naturally occurring river sand with other properties conforming to IS:383-1970. SAND Sand used for plastering purposes shall be hard, durable clean, free from adherent organic matters and shall conforms to IS 1542-1977. Coarse sand shall be sieved at site if sand of 1542 quality is not available at site. Sand used for concrete shall conform to Grading Zone 1.11 or 111 of IS 383-1970. but in no case to zone IV. PAINTS: : (for external surfaces) Berger (Weather Coat smooth) or equivalent approved make. Enamel Paint & Zinc Phosphate Primer: Asian/ Berger/ Jenson & Nicholson/ Shalimar B. MATERIAL SPECIFICATIONS



EARTHWORK: SETTING OUT AND MAKING PROFILE: Masonry pillars will be erected at suitable points. These bench marks shall be connected to standard bench mark. In addition to these pillar center line pillars shall also be erected by the Contractor and footing positions shall be marked with the help of these pillars. The necessary profile shall be set out. The level shall be taken at a interval as directed by IEC. The levels shall be recorded in field books and plotted on plan before starting the excavation. EXCAVATION FOR FOUNDATION: The cutting shall be done to minimum depths as per drawings and as advised by EIC. Any excess excavation carried out by the Contractor without proper permission from EIC shall not be paid and the excess depth shall be made good by the Contractor by PCC 1:4:8 at contractor’s own cost. BACKFILLING: In case water is encountered during the excavation for foundation, or flooding of pits due to any other reasons the contractor shall arrange for dewatering the same at his own cost. EXCAVATION IN HARD ROCK:

CUTTING

Where hard rock is met, generally excavation by chiseling and wedging shall be carried out. Excavation by blasting shall be done only after obtaining written approval from Engg.-in-Charge/Architects. In case of excavation by blasting all the provisions of explosive rules 1940 (Corrected upto date) shall be complied with storing, transportation and handling of explosive materials. The blasting operation shall be carried out under the supervision of a responsible authorized agent of the contractor. Blasting work shall not be carried out within 200 metres of an existing structure unless otherwise permitted by the Engg.-in-Charge / Architects. MEASUREMENT

Where ordinary rock and hard rock is mixed, the measurement of the excavation shall be carried out by stacking both the types of excavated rock separately. The net quantity of rock shall be arrived at by applying reduction of 50% for looseness in stack. If the sum of net quantity of two kinds of rock exceeds the total quantity of excavated material, then the quantity of each type of rock shall be in the ratio of net quantities in stack measurements of the two types of rocks. REINFORCED CEMENT CONCRETE: SCOPE:



This specification covers the general requirements for concrete to be used on jobs using on-site production facilities including requirments in regard to the quality, handling, storage of ingredients, proportioning, batching, mixing and testing of concrete and also requirements in regard to the quality, storage, bending and fixing of reinforcement. This also covers the transportation of concrete from the mixer to the place of final deposit and the placing, curing, protecting, repairing and finishing of concrete. APPLICABLE CODES AND SPECIFICATIONS; The following specifications, standards and codes are made a part of this specification. All standards, tentative specifications, specifications, codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. In case of discrepancy between this specification and those referred to herein, this specification shall govern. APPLICABLE IS SPECIFICATIONS AND CODES OF PRACTICE: IS 269:- Specification for ordinary, rapid hardening and low heat portland cement. IS 8112:- Specification for high strength ordinary, portland cement. IS 1489 - Specification for portland - pozzolona cement. IS 383:- Specification for coarse and find aggregates from natural source for concrete. IS 2386:- Methods of test for aggregates for concrete. (Part I to VIII) IS 516:- Method of test for strength of concrete. IS 1199:- Method of sampling and analysis of concrete. IS 3025:- Methods of sampling and test (Physical and chemical) water used in industry. IS 432:- Specification for mild steel and medium tensile steel (parts I & II) bars and hard drawn steel wire for concrete reinforcement. IS 1139:- Specification for hot rolled mild steel and medium tensile steel deformed bars for concrete reinforcement.



IS 1566:- Specification for plain hard drawn steel wire fabric (Part I) for concrete reinforcement. IS 1786:- Specification for cold twisted steel bars for concrete reinforcement. IS 2645:- Specification for integral cement waterproofing compound. IS 456:- Code of practice for plain and reinforced concrete. IS 3370:- Code of practice for concrete structures for storage of liquids (Part I to IV) IS 2502:- Code of practice for bending and fixing of bars for concrete reinforcement. IS 2571:- Code of practice for laying in situ cement concrete flooring. IS 3596:- Safety code for scaffolds and ladders. (Part I & II) IS 1200:- Method of measurement of building works. In the event that state, city or other Government bodies have requirements, more stringent than those set forth in this specification, such requirements shall be considered part of this specification and shall supersede this specification where applicable. The quality of materials , method and control of manufacture and transportation of all concrete works irrespective of the mix , whether reinforced or otherwise, shall conform to the applicable portion of this specification. Engineer shall have the right to inspect the source/s of material/s, the layout of operations of procurement and storage of materials, the concrete batching and mixing equipment and quality control system. Such an inspection shall be arranged and approval of Engineer-In-Charge shall be obtained prior to starting of concrete work. Concrete shall be mixed by mechanical mixer only and no hand mixing shall be allowed for RCC works. GENERAL: The quality of materials and method and control of manufacture and transportation of all concrete work irrespective of mix, whether reinforced or otherwise, shall conform to the applicable portions of this specification. Engineer shall have the right to inspect the source/s of material/s, the layout and operation of procurement and storage of materials, the concrete batching and mixing



equipment, and the quality control system. Such an inspection shall be arranged and Engineer’s approval obtained, prior to starting of concrete work. MATERIALS FOR STANDARD CONCRETE: The ingredients to be used in the manufacture of standard concrete shall consist solely of a standard type portland cement, clean sand, natural coarse aggregate, clean water and admixtures, if specially called for on drawings or specifications. CEMENT The use of bulk cement will be permitted only with the approval of Engineer. Changing of brands or type of cement within the same structure will not be permitted. CONTRACTOR will have to make his own arrangements for the storage of adequate quantity of cement. If supplies are arranged by owner, cement will be issued in quantities to cover work requirements of one month or less, as deemed fit by the engineer and it will be the responsibility of contractor to ensure adequate and proper storage. Cement bags shall be stored in a dry enclosed shed (storage under tarpaulin will not be permitted), well away from the outer walls and insulated from the floor to avoid contact with moisture from ground and so arranged as to provide ready access. Damaged or reclaimed or partly set cement will not be permitted to be used and shall be removed from the site. Not more than 12 bags shall be stacked in any tier. The storage arrangement shall be approved by engineer. Consignment of cement shall be stored as received and shall be consumed in the order of their receipt at site. Cement held in storage for a period of Ninety (90) days or longer shall be tested. Should at any time Engineer have reasons to consider that any cement is defective, then irrespective of its origin, date of manufacture and/or manufacturer’s test certificate, such cement shall be tested immediately at Contractor’s cost at a national Test such tests are found satisfactory, it shall not be used in any work. Contractor shall not be entitled to any claim of any nature on this account. CONSISTENCY: The consistency of the concrete shall be such that it flows sluggish into the forms and around the reinforcement without any segregation coarse aggregate from mortar. The slump tests are mandatory and shall be carried out at regular intervals so that the consistency concrete can be monitored. PLACING OF CONCRETE: Concreting shall commence only after inspection and written approval by EIC. Shuttering shall be clean and free from deposits of foreign materials and proper de-shuttering agent shall be applied to the surface. Proper arrangements shall be provided for conveying the concrete the place of deposition without disturbing the reinforcement.



COMPACTION: Concrete shall be compacted immediately after placing by means of mechanical vibrators. All RCC works shall be cured for a minimum period of 14 days or more as advised by EIC. INSPECTION AND RECTIFICATION OF DEFECTS: Immediately on removal of forms, the RCC works shall be examined by the Engg. -

In-Charge / Architects before any defects are made good.

The work that has sagged or contains honey combing to an extent detrimental to the

structural safety or architectural concept shall be rejected.

Surface defects on a minor nature may be accepted and the same shall be rectified as

follows:

a) Bulges due to movement of forms, ridges at forms, ridges at form joints shall be

carefully chipped and then rubbed with a grinding stone.

b) Honeycombed and other defective areas must be chipped out, the edges being out

as straight as possible and perpendicular to the surface. Shallow patches are first

treated with a coat of thin grout (1 cement: 1 sand) and then filled with mortar

similar to that used in concrete. Large and deep patches shall be filled up with

concrete held in place by forms and shall be reinforced.

c) Holes left by bolts shall be filled carefully with mortar. Holes extending right

through the concrete shall be filled with mortar with a pressure gun.

d) The same amount of care to cure the material in patches should be taken as with

the whole structure.

POST TREATMENT OF SURFACE:

The surface which has to receive plaster or where it has to be joined with brick

masonry walls shall be properly roughened immediately after the shuttering is

removed.

.

MEASUREMENT



All measurements shall be as per IS 1200

PLASTERING PREPARATION OF SURFACE: The following surface preparation shall be made for both single and double coat plasters. The surface shall then be thoroughly washed with water, cleaned and kept wet before plastering is commenced. In case of concrete the surface shall be chipped by chiseling and wire brushing, cleaning the surface and erecting scaffolding it required. CEMENT PLASTER (SINGLE COAT) APPLICATION: Plastering shall be started from the top and worked down towards the floor. All holes shall be properly filled in advance of the plastering as the scaffolding is being taken down. To ensure even thickness and a true surface, plaster of about 15 x 15cm shall be first applied horizontally and vertically, at 3 metres intervals over the entire surface to serve as gauges. The surfaces of these gauged areas shall be truly in the plane of the finished plaster surface. The mortar shall then be laid on the wall, between the gauges with trowel. The mortar shall be applied in a uniform manner slightly more than the specified thickness and brought to true surface by working a wooden straight edge reaching across the gauges with small upward and sideways movements at a time. All corners, arises, angles and junctions shall be truly vertical or horizontal as the case may be and shall be carefully finished. Rounding or chamfering corners, arises, junctions, etc. where required shall be done without any extra payment. Such rounding or chamfering shall be carried out with proper templates to the sizes required. Horizontal joints in plaster shall not occur on parapet tops and copings as these invariably lead to leakages. Good quality lime neroo shall be applied to plastered surface with steel trowel to a thickness slightly more than specified and rubbed down to give overall thickness of 12mm and polished to a perfectly smooth and even finish working from top to bottom. Curing shall be commenced as soon as the plaster has hardened sufficiently. This shall be done by spraying water at regular intervals. CEMENT PLASTER (TWO COAT WORK):



The plaster shall be applied in two coats as detailed below: - Apply 12mm thick coat of CM 1:4 mixed with CICO / ACCO Proof water

proofing compound mixed as per manufacturer’s specifications as 1st cost leaving the surface rough.

When the plaster has been brought to true surface with a wooden straight edge the surface shall be left rough with 2mm deep furrows shall be made with a scratching tool to form key for the finishing coat. The surface shall be kept wet till the finishing coat is applied. Apply 2nd coat of 8mm thick of CM 1:3 and finishing the surface by rubbing with sponge till uniform texture is obtained. The finishing coat shall be applied after the undercoat has sufficiently set but not dried and in any case within 48 hours of laying the first coat. STEEL REINFORCEMENT For super structure item mentioned in the job schedule only cold twisted HYS bars conforming to IS: 1786-1979 shall be used. For Piles & Pile Caps job mentioned in the job schedule only thermo mechanically treated reinforcement bars having high strength and superior corrosion resistance bars conforming to IS: 1786-latest edition shall be used. Providing and fixing in position, steel (CRS) reinforcement bars of various diameters for RCC piles as per detailed designs, drawings and schedule including cutting, bending, hooking the bars, binding with wires, tack welding and placing the reinforcement cage in position with concrete cover blocks as required etc. complete. PLAIN CEMENT WORKS: Mixing: It shall be done in mechanical mixers. Mixing by hand shall not be permitted unless specific prior permission of the EIC has been obtained in writing. In such a case, proportion of cement shall be increased as per IS:456. CONSISTENCY: The quantity of water to be used for each mix of 50 Kg cement to obtain the required consistency shall not be more than 34 litres for 1:3:6 mix.30 Ltrs for 1:2:4 mix. In case of vibrated concrete, the limits specified shall be suitably reduced to avoid segregation. The quantity of water shall be regulated by carrying out regular slump tests. LAYING: The concrete shall be laid gently in layers not exceeding 150mm. Mechanical vibrators shall be used for compaction. Hand compaction may be carried out if permitted by IEC. Hand compaction shall be done with the help of tamping



rods. Next layer of concrete shall be carried out before initial setting starts in the previous layer. When the concreting is suspended, necessary removal of laitance and roughening of surface for jointing shall be done before concrete sets. On the resumption of work the joint shall be thoroughly cleaned, roughened, watered and a grout of neat cement slurry (1 kg of cement in 2 Ltrs of water) shall be applied uniformly. CURING: Green work shall be protected form rain by suitable covering. After about 1 to 2 hours of concreting, the surface of concrete shall be protected from drying. The following methods shall be adopted for curing. All foundation PCC strips shall be cured by spraying water and keeping the surrounding soil moist. The curing shall continue for minimum 14 days or more as advised by EIC. The masonry work can be started after 48 hours of concreting, but the curing shall continue for minimum 14 days along with masonry. STRUCTURAL STEEL Fabrication shall be generally done as per IS 800-1962. The steel sections as specified shall be straightened and cut, square to correct lengths. The cut ends exposed to view shall be finished smooth. No two pieces shall be welded or otherwise jointed to make up the required length of the member unless specifically approved by the engineer in charge. Bending or cutting shall be done in such a manner as not to impair the strength of the metal. ASSEMBLY: Before making holes in individual members, the steel work to be bolted together shall be assembled and clamped properly and tightly so as to ensure close abutting or lapping of the surface of the different members. All traces of slag shall be removed from the deposit by chipping and the deposit and the adjoining base metal shall be wire brushed and cleaned. The welds shall be free from cracks, discontinuity in welding and other defects such as undersize, oversize, undercutting and over-cutting in case of fillet welds. VISUAL INSPECTION: The height of spacing of the ripples shall be uniform. In case of butt and corner welds, the profile shall be slightly convex and in case of fillet welds it shall be slightly concave.



The welded joints shall be free from undercuts but slight intermittent occurrences shall be disregarded provided that such undercuts are not in the form of sharp notch. The joints in the weld run shall be smooth and shall show no pronounced lump or crater in the weld surface. The surface of the weld shall be free from porosity, cavity and scale. ERECTION: Steel work shall be hoisted and erected in position carefully, without any damage to itself, other structures and equipments and injury to workman. Proper equipment like derricks, lifting tackles, winches, ropes, etc. shall be used. Fabricated members shall be lifted at such points to avoid the deformation or excessive stress in the members. The structure or part of it erected in position shall be secured against overturning or collapse by suitable means. Trusses shall be lifted only at nodes. After the trusses are placed in position, purlins and wind bracings shall be fixed as soon as possible. PAINTING ON STRUCTURAL STEEL All structural steel items mentioned in the job schedule unless otherwise mentioned shall be painted with two coats of anti corrosive zinc phosphate primer before any other paint is applied. The first coat shall be applied immediately after the entire fabrication is completed but before erection. The second coat shall be applied after the components are erected on to their places. After the primer is applied the following colour code shall be adopted for various members: The roof trusses, purlins, runners, bracings and the base plates shall be painted with two coats of AL paint. The top surface of the bracings and trusses shall be painted completely before laying the AC sheets as these portions cannot be painted after laying. APPROVED MAKES: 1. JENSON & NICHOLSON 3. GARWARE PAINTS 2. ASIAN PAINTS 4. SHALIMAR PAINTS 3. BERGER PAINTS 5. NEROLAC PAINTS



SPECIFICATIONS FOR PIPELINE WORK MATERIALS: ELECTRODES Electrodes for welding of pipelines shall strictly conform to AWS SPECIFICATION AWS-1.5.1.69-E 6013 and be of the following make/brand INDIAN OXYGEN ADVANI ORLIKON D&H SECHERON PHILIPS WELDCRAFT GEE LTD PIPING Pipe and pipe fittings, wherever required to be supplied by the contractor, shall conform to IS: 1978-latest edition. FLANGES MS plate ring flanges wherever required to be supplied by the contractor shall conform to ASA class 150, ANSI B-16.5 Specification, unless otherwise mentioned. BOLTS AND NUTS Bolts and nuts shall conform to the requirement of turned gauge bolts of symbol 4D, 5D and 5S, specifications in IS:1367-1962 technical supply conditions for threaded fasteners. The screw thread shall conform to coarse series medium class referred in IS:1367-1962. JOINTING MATERIALS (GASKETS) The details of the gaskets to be used shall be as given below: QUALITY: As mentioned in Job schedule. Manufacturer: Champion or Equivalent approved by Engineer In-Charge SERVICE: For use on all pipelines, flange joints, etc.



PREPARATION OF PIPE END The fabrication of pipeline shall conform to IS:10234 The pipes supplied will be in random lengths of 5-7 meters generally with beveled ends. However, in case any ends are damaged cutting / beveling shall be done by the contractor at no extra cost. Cutting/ beveling will also be required to be done before welding my cut piece of pipeline. For pipes that are intended to be in axial alignment the place of the pipe ends shall be square with the axis of the pipe. The pipes which are intentionally out of axial alignment, the plane of the joint shall bisect the angle between adjacent pipes. All tack welded but joint assemblies shall be inspected to ensure root gap, alignment, quality of tack welds, their root penetration section, cleaning and free from cracks. Any substandard tack weld shall be cut and remade upto the standard before starting the welding. Contractor shall arrange to maintain register for stage wise inspection and clearance by site in-charge for above and any other checks as desired by site in charge. LAYING OF PIPELINES: Above ground pipeline: Above ground pipelines shall laid on RCC pedestals. Pipelines shall follow the general alignment of the ground. The height of the pedestal shall be adjusted in such a way that clearance from the ground to the bottom of the pipeline shall not be more than 400 mm. No flange or valve joint shall fall on support. UNDERGROUND PIPES A) The trench shall be excavated to proper width as decided by site in charge. b) It should be ensured that while laying the pipes no. foreign material like stones, sand, gunny bags, bits of welding rods, weld materials etc. are left inside the laid pipes. At the end of each day’s work the free end of the laid pipes must be kept properly closed with dry gunny bags. C) The trenches shall not be backfilled till the final inspection by radiography/hydrostatic tests are completed, and all the defects pointed out by the Engineer-in-charge are rectified to the satisfaction of the Engineer-in-charge.



WELDING: A) Only welders proficient in the vertical and overhead positions as per the stipulations of ISI-817 shall be allowed to weld these pipelines. Preferably welders with proficiency certificates from Govt. test house or equivalent recognized authority should be deployed for the job. Optionally welders will be tested at site and the test pieces shall be tested by radiography in an approved laboratory. All expenses for this shall be borne by the contractor. If a welder is found to perform a type of welding or in a position for which he is not qualified he shall be debarred from doing further work. All welds performed by an unqualified welder shall be cut and re welded by a qualified welder at the expense of the contractor. It shall be contractor’s responsibility to arrange for and bear all costs towards testing of welders for pre qualification. Welding shall be manual shielded metal arc process. Standard quality line up jigs and fixtures which will ensure sound welds shall be used. The cutting of pipes and welding shall conform to IS specifications and to the satisfaction of Engineer-in-charge. The pipe shall be butt welded with three or more runs of weld. Welding shall not be performed when surfaces to be welded are wet, when rain is falling on which such surface or during the period of high winds unless the welder and the works are shielded in an approved manner. Joint preparation for welding shall be so as to leave a smooth finished profile free of cavities and conforming to standard practice. Edges shall be cleaned of paint, rust, scale, slag, dirt and other foreign materials before welding. The thickness of the tack welds shall be similar to that of the initial root run to be deposited in the groove and where necessary, the extremities of the tack welds shall be dressed by grinding, chipping and flame gauged to facilitate proper fusion when they are incorporated in the initial root run. All slag and scales etc. shall be removed from the surface of each completed bead before depositing the next bead. The finished weld shall present a smooth bright and shiny surface of constant width and uniformly spaced ripples. The welds shall be free from slag pockets, porosity, undercutting, incomplete penetration and fusion and other weld defects. The weld shall not project beyond the plain surface in butt weld by more than 2 mm.



All welds protrusions spatter etc. on the weld surface and adjacent area shall be removed so as to leave the surface smooth and clean. All valves, flanges risers, bends and other fittings shall be in perfect plumb and plane. Care shall be taken to align the pipelines and bends properly to keep the symmetry of the pipeline layout. To maintain the specified alignment and gap during welding the pipes shall be securely held in position by mechanical means and not by tack welding or by welding on bridge place. Electrode or filler rods used for tack welding shall be of the same quality as those used for the first run of the weld. INSPECTION OF WELDS The methods of inspection shall be as under: Visual inspection shall be done for all weld joints of pipelines as well as flanges. Dimensions of weld deposits: The dimensions of weld shall be checked. The size of weld shall be as specified and it may be slightly over but not undersize. Shape of Profile: The profile of the weld is affected by position of the joint but shall be uniform. In the case of butt and corner welds the profile shall be slightly convex and in the case of fillet weld it is usually slightly concave. Uniformity of Surface: The height and spacing of the ripples shall be uniform these being indicative of quality of workmanship. Degree of Undercuts: The welded joints shall be free from undercuts, but slight intermittent occurrences may be disregarded provided that such undercuts is not in the form of sharp notch. Smoothness of joints where welding is recommended: The joints in the weld run shall be as smooth as possible and shall show no pronounced lump or crater in the weld surface. Freedom from surface defects:



The surface of the weld shall be free from porosity, cavities and burnts or scale. Penetration bead in butt welds: A slight penetration bead shall be present and it shall be reasonably uniform in width and appearance. Intermittent occurrences of lack of penetration bead may be disregarded. HYDROSTATIC TESTING A) On completion of laying of entire pipeline, all open flanges except one on the line shall be blanked of with blind flanges. B) The trench shall be kept free of water and the pipeline surface dry. The pipeline shall be filled with water and the pressure built up by means of test pump with a pressure gauge to the specified pressure as per the rating of the fittings i.e. 150# & 600 #. C) The pressure shall be maintained for a minimum period of 12 hours unless otherwise specified by the Engineer-in-charge. The hydrostatic test shall be considered positive only if there is no drop in the built up pressure at the end of the specified period. D) All welded and flange joints and the seam welds on the ERW pipes shall be inspected for leak by passing a dry hand. E) Leaky joints shall be repaired by methods as approved by site in-charge. After repairing the leaky joints, the joint shall be re-radiographed and entire pipeline section shall be hydro-tested to prescribed pressure. No claims for such expenditure incurred by the contractor towards such repairs of defective work and retesting shall be entertained.

F) After hydro-testing, pipeline shall be completely emptied out and the line shall be made free of water.

G) Hydro-testing pressure shall be at the test pressure for the relevant rating of the pipeline.

RADIOGRAPHIC INSPECTION SCOPE This specification covers the radiographic inspection of all types of welded joints of the main pipeline and piping system. The welded joints shall include the following:



i. Full girth welds on the main line construction including double jointing of pipe, if adopted. ii. Welds for installation of block valves, insulating joints, other appurtenances and tie-ins APPLICABLE STANDARDS This specification shall apply in conjunction with the following (latest edition): i.) DNV Rules for Submarine Pipeline Systems. ii.) ASME Section V, Nondestructive Examination iii.) ASTM E 94, Standard Practice for Radiographic Testing. iv.) ASTM E 142, Method for Controlling Quality of Radiographic Testing. v.) SNT-TC-IA - Recommended Practice for Nondestructive Testing Personnel Qualification and Certification. VI) API-1104 Standard for Welding Pipelines and Related Facilities. PROCEDURE The radiographic examination procedure to be adopted shall be submitted by the Contractor. The procedure of radiographic examination shall be qualified to the entire satisfaction of Company/Company’s authorised Inspection agency. It shall include but not be limited to the following requirements. i. Manual or automatic film processing shall be done, so that they are interpretable

for atleast three years after they are produced. ii. A single- wall exposure technique shall be used for radiography whenever

practical. When it is not practical to use a single wall technique, a double wall technique shall be used. An adequate number of exposures shall be made to demonstrate that the required coverage has been obtained.

iii.The quality level required for radiography shall be atleast 2% (2-2T) iv.A densitometer shall be used to determine film density. The transmitted film

density shall be 1.8 - 2.5 throughout the weld. The Contractor shall qualify each procedure in the presence of the Company prior to use. The radiographic procedures are to be made of a weld joint using pipe of same diameter, wall thickness and of material same as that used in the pipeline system. The procedure of radiographic examination shall produce radiographs of sufficient density, clarity and contrast so that defects in the weld or in the pipe adjacent to the weld, and the outline, hole-wires and identification no. of the penetrameter wires are clearly discernible.



All the girth, welds of mainline shall be subjected to 10% radiographic examination The Contractor shall furnish all the radiographs to Company/Company’s authorised representative, immediately after processing and drying for review and approval, together with the corresponding interpretation reports on approved formats. The details of the radiographs along with the joint identification number shall be duly entered in a register and signed by the Contractor and submitted to the Company/ Company’s authorised representative for approval. When the radiation source and the film are both on the outside of the weld and located diametrically opposite to each other, the maximum acceptable length of film for exposure shall not exceed the values given as per acceptable procedure. The minimum film overlap, in each case, shall be 40 mm. The ellipse exposure technique may be used on nominal pipe sizes of 2 inch and smaller provided that the source to film distance used is a minimum of 12 inch. Three copies of each acceptable radiographic procedure (as per Exhibit- A) and three copies of radiographic qualification records shall be supplied to Company. One set of the qualifying radiographs on the job, shall be kept by the Contractor’s authorised representative, to be used as a standard for the quality of production radiographs during the job. The other two sets shall be retained by Company for its permanent record. Three copies of the exposure charts relating to material thickness, kilo voltage, source to film distance and exposure time shall also be made available to company by the Contractor. The Contractor on daily basis, record for each radiograph (i) Radiograph’s number (ii) Welder/s number (iii) Approximate chainage of weld location, (iv)Whether or not the welds meet the specified acceptance standards and (v) the nature and approximate location of unacceptable defects observed. It must be possible to relate back to a particular butt weld and welder on piping drawing and pipeline alignment drawing. Each batch production of processed radiographs shall be properly packaged separately identified by atleast the week No. and job location. The contractor shall provide all the necessary facilities at site such as a dark room with controlled temperature, film viewer etc. to enable the Company/Company’s authorised representative to examine the radiographs.



The contractor, if found necessary, may modify the procedure of radiographic examination suiting to the local conditions prevailing. This shall, however, be subject to the approval of the Company/Company’s authorised agency. Company/Company’s authorised representative shall have free access to all the Contractor’s work facilities in the field. Any approval granted by the Company/Company’s authorised representative shall not relieve the Contractor of his responsibilities and guarantees. RADIATION SOURCE Radiographic examination shall be carried out using Gamma radiations at the discretion of the Company. LEVEL OF QUALITY The quality level required for radiography shall be atleast 2% (2-2T) PENTRAMETER The image quality indication shall be used for the qualification of the welding procedure and during examination shall produce radiographs to suit the requirement of the codes. For radiographs made with the source on the outside a penetrameter shall be placed on each side of the film with the smaller wire of penetrameter turned towards the end of the film itself. When a complete weld is radiographed in a single exposure using a source inside the pipe minimum three penetrameters approximately equally spaced around the circumference shall be used. During the procedure qualification IQI shall be placed both on the source side and on the film side. The sensitivity limit may be considered to have been reached when the outline of the IQI, its identification number and the wire if the required diameter show up clearly on the radiograph. The Company/Company’s authorized representative may authorize use of types of IQI other than those planned, provided that they confirm with recognized standards and only if the contractor is able to demonstrate that the minimum sensitivity level required is obtained. For this demonstration, a test shall be carried out comparing the IQI, scheduled and the Contractor’s to show up the identification number and other details of the proposed IQI, which must be visible in the test radiograph. Material of the penetrameter shall be of equivalent radiographic density to that of the material under examination. FILM IDENTIFICATION MARKERS



All films shall be clearly identified by lead numbers, letters and/or markers. The image of the markers shall appear on the films, without interfering with the interpretation. These markers positions shall also be marked on the part to be radiographed and shall be maintained during radiography. PROTECTION AND CARE OF FILM All exposed and unexposed film shall be protected and stored properly as per the requirements of ASTM E94 and DNV rules. The exposed and unexposed film shall be protected from light, heat, dust and moisture. Sufficient shielding shall be supplied to prevent exposure of film to damaging radiation prior to and following the use of the film for radiographic exposure. RE –RADIOGRAPHY The weld joints shall be re-radiographed in case of unsatisfactory quality of radiographs. All the repaired weld joints shall be re-radiographed at repaired position in the same manner at that followed for the original welds. In addition, the repaired weld areas shall be identified with the original identification number plus the letter R to indicate the repair. When evaluating repair film radiographers shall compare each section (exposure) of the weld with the original film to assume repair was correctly marked and original defect removed. The Company/Company’s authorized representative will review prior to any repair of welds, all the radiographs of welds that contain, according to the Contractor’s interpretation, unacceptable defects. The Company/Company’s authorized representative will decide the final deposition of all unacceptable welds. QUALIFICATION OF RADIOGRAPHERS As a minimum, all personnel conducting radiographic examination shall be certified to Level- I in accordance with ASNT document SNT-TC-IA. All qualification certification should have current validity. Radiography will be performed under jurisdiction of a certified ASNT Level-II Supervisor. Interpretation of radiographs shall be carried out only by certified ASNT-Level II Personnel. All the records of NDT Personnel such as background and experience records, training course records, certification records and fitness records shall be submitted to the Company for review and approval before the NDT personnel are permitted to perform production radiography and interpret films. PRESERVATION OF RADIOGRAPHS



The radiographs shall be processed to allow storage of films without any discoloration for atleast three years. All the radiographs shall be presented in suitable folders for preservation along with necessary documentation. All radiographs shall become property of the Company. EQUIPMENT AND ACCESSORIES Contractor shall make necessary arrangement at his own expense, for providing the radiographic equipment, radiographic films and all the accessories for carrying out the radiographic examinations for satisfactory and timely completion of the job. For carrying out the radiographic examination contractor shall be equipped with film processing units, film viewer, density meter etc. RADIATION PROTECTION Contractor shall be responsible for the protection and personal monitoring of every man with or near radiation sources. The protection and monitoring shall comply with local regulations. In view of visual hazards, in the handling of Radioactive source of material, Contractor shall be solely responsible for complying with all rules and regulations set forth by Atomic Energy Commission or any other Government agencies of India in this regard and Company shall not be responsible and shall be kept indemnified by the Company for all necessary personnel shall be made available for use and maintained for immediate and proper use by the Contractor.

TESTING OF MATERIALS

The contractor shall carryout the following tests at his own expense and as directed by

the Engg.-in-charge. Also Engineer-In-Charge reserves their right to ask the

contractor to carry out any further tests on any material which is being used in the

project.

1. WATER: Suitability for construction/ concreting purposes as per IS 456-2000

Periodicity: One test at the beginning of the project and once in every 3 months as

per IS code

2. SAND

Tests to be conducted

a. Particle size - Lab

b. Silt content - Field



c. Bulking of sand-Field

d. Percentage of Deleterious material / Organic impurities - lab

Is code for material - IS-383-1970

IS code for testing - IS-2386 (Part I) to IS-2386 (Part VIII)

Periodicity of testing

Whenever there is a change in source of supply or as directed by the Engineer-in-

Charge.

Remarks

1. Silt content should not exceed 8%.

2. For sand pad foundation no need of particle size distribution. Only silt & bulk

content to be carried out.

Sand (for plastering)


a) Particle size - Lab

b) Silt content - Field

c) Percentage of Deleterious /organic impurities - Lab.

IS code for material - IS-1542

IS code for testing - IS-1727

Periodicity of testing

Same as above, Test shall be repeated for Minimum qty. 500 sq. m of plastering.

Remarks

1. Silt content not to exceed 5%

2. Sand to be sieved in sieve size 4.75 mm

3. COARSE AGGREGATE


a. Percentage of Soft deleterious materials- Field (Visual)

b. Particle size distribution

c. Aggregate value:

1. Crushing - Lab

2. Impact - Lab



3. Abrasion - Lab (Only for Roads)

IS code for material - IS-383-1970

IS code for testing - IS-2386 (Part I) to IS 2386 (Part VIII)

Periodicity of Testing

Minimum 45 cum. Tests to be repeated for every 45 cum of coarse aggregate or part

thereof.

Remarks

Percentage of soft deleterious materials. Usually visual inspection shall be carried out.

If Engg.-in-Charge / Architects have doubts, the same may be tested in Lab.

4. CEMENT


a. fineness - Lab

b. Soundness - Lab

c. Setting Time - Lab

d. Compressive strength - Lab


Minimum qty. 20 MT, Tests to be repeated for every 50 MT or part thereof or change

of supplier.

Remarks

Cement to be tested if supplied by the contractor. Cement to be tested if stored for

more than 3 months.

5. CEMENT CONCRETE


a. Slump test - Field

b. Cube strength - Lab/field


a. Once for minimum 5 cum.

b. Minimum 15 cum of part thereof.

Remarks



Cube strength to be taken for both 7 days as well as 28 days. Cubes of critical

members (decided by Engg.-in-Charge) shall be tested at lab.

6. REINFORCEMENT STEEL


a. Free from defects - Field (Visual)

b. Weight - Lab

c. Size - Lab

d. Ultimate tensile stress - Lab

e. Yield stress - Lab

f. Elongation percentage - Lab

g. Bend Re-bend test - Lab

IS code for material

• IS-432 for mild steel

• IS-1786 for Tor steel

IS code for testing - IS-1608


Minimum qty. 10 MT, tests shall be repeated for every 10 MT of each size (dia) or

part thereof.

Remarks

a. Steel shall be tested if supplied by contractor.

b. Steel shall be tested if stored in open yard for more than one year.

NOTE: All the testing equipments/ machines like Sieve, Compression testing machine etc. required for field tests shall be arranged by the party at site. In case of failure of machine, testing to be carried out by the Contractor at lab at no extra cost

7. BRICKS


a. Compressive Test - Lab

b. Water absorption - Lab

c. Efflorescence - Lab



d. Percentage of Deleterious material - Lab.

e. Dimension test-Lab

IS code for material - IS-1077-1986

IS code for Testing - IS-3495 (Part I) to IS-3495 (Part III)


Minimum 20000 bricks but tests shall be repeated for every 40000 or part thereof

depending on the volume of work.

10. CEMENT: 10.1 Cement required for execution of jobs contained in this tender shall be arranged by the contractor at his own cost. Cement shall be procured and brought at site at least 15 days in advance. Sample from every batch of cement brought to site shall be tested for standard tests as per specifications in approved laboratory and the test certificates shall be submitted to engineer-in-charge for verification. Only after obtaining approval of engineer-in-charge the cement shall be put in to use. Manufacturer’s batch test certificate backed by factory’s invoice for the batch will also be acceptable for approval of cement. Contractor shall bring cement well in advance before full consumption of previous lot. No claims for extension of completion period for stoppage of works on account of non-availability of cement/delays in testing procedures will be entertained / accepted by HPCL. 10.2 For all computation purposes, the theoretical cement consumption shall be considered as per CPWD standards. Cement cost shall be recovered for under cement consumption as per clause 10.4 below. 10.3 The contractor will be required to maintain a stock register for receipt, issuance and daily construction of cement at site. Cement shall be regulated on the basis of FIRST RECEIPT to go as FIRST ISSUE. Cement not consumed within three months after bringing to site, shall not be used and shall be removed from site with prior written permission of engineer-in-charge. 10.4 Empty cement bag shall be the property of the contractor. Contractor shall be penalised for any UNDER consumption of cement. The penal rate shall be Rs. 5600 per MT.



10.5 All the running bills as well as the final bills will be accompanied by cement consumption statements giving the detailed working of the cement used. 10.6 Contractor shall construct suitable temporary godown at site for storage of cement under his lock and key. The contractor will be fully responsible for safe custody of cement. HPCL will not entertain any claims by the contractor for theft, loss or damage to cement. The contractor shall not remove from the site any cement bags at any time. 12.0 WATCHING & LIGHTING: The contractor shall provide and maintain at his own expense all lights, guards, fencing and watching when and wherever deemed necessary by the Site Incharge for protection of the works or for the safety and convenience of those employees on the works or public. 13.0 STORAGE OF MATERIALS SUPPLIED BY HPCL: The contractor shall provide and maintain proper temporary sheds of adequate capacity for storage of all project materials, free issue items and his own stores in good and water tight conditions at site. Contractor shall also protect adequately all other materials including tools and tackles supplied by the corporation during execution of work. Any damage / loss for material in the contractor's custody will be on his account and will be recovered from his running bill. 14.0 Drawings Drawings enclosed with the tender are typical drawings & is given for general guidelines for quoting and may vary at the time of execution depending on the site condition

Documents

TECHNICAL SPECIFICATIONtenders.hpcl.co.in/tenders/tender_prog/TenderFiles/879/Tender/5423... · ... portland cement. IS 1489 - Specification for portland - pozzolona cement. ... -