01.

Survey
General:
Surveying work is most important activity in construction work and shall be carried out by
skilled personals. The scope includes the guidelines to be adopted for setting out and surveying
works. -BOQ, Drawing, Specification shall be used as reference documents.

Equipment:
Calibrated auto-level, total station / theodolite and other appropriate survey equipment and
accessories.

Procedure:
1. Prior to use, ensure that all survey equipment’s (including hire equipment) have valid
calibration certificates.
2. Take over base co-ordinates furnished by clients /
consultants and set up benchmark datum.
3. Establish 2 station points (having specific
Northing and Easting) at accessible locations
away from
4. periphery of the building to be constructed. Ensure
that benchmark shall remain undisturbed till the
completion of project.
5. Construct masonry pillars for the established permanent benchmarks with embedded steel
plates at top. Plaster and finish the top surface neatly.
6. Drive 20 mm dia. rebar’s to at least 1.50 m depth all around the pillars and barricade the pillars
to protect the pillars from displacement.
7. Recheck the benchmark co-ordinates and put paint, punch marks on top.
8. Establish control pillars for individual structures as above with reference to benchmarks.
9. Run the traverse on all sides of structure and establish set out stations on grid lines.
10. Mark grid lines with reference to temporary benchmarks in both X and Y direction with paint.
11. Plot detail survey plan showing site boundary, all reference points / pillar locations in Auto-
cad.
12. Superimpose building points given in architectural points over the plotted survey plan.
13. Refer this auto-cad drawing transfer center line and out-lines points of walls, columns and
footings on the PCC.
14. Also transfer reduced levels from temporary benchmark for such at footing, tie- beams etc.
Records:

Records of surveying and levelling works.

Any other records as per contract requirements.
 02. Excavation, Backfilling & Anti-termite
Procedures for excavation and backfilling works including anti-termite
treatment Excavation:
It shall be ensured that all necessary equipment, tools, instruments, material and consumables
including temporary facilities like platform, walkways etc. as mentioned are available at site.
All skilled / unskilled manpower along with supervisory personnel for carrying out work
shall have sufficient experience on similar works.
Excavation drawings shall clearly indicate in plan (preferably by dotted line) the part of soil
to be excavated and levels to which excavation needs to be carried out.
For the purpose of understanding terminology used for soil to be excavated, soil shall be
classified in accordance with IS-1200 part I as under:
a) Ordinary soils:
These shall include all kinds of soils containing sand, silt, hard and soft murrum, shingles,
gravel, clay, ash, etc. which can generally be excavated by spades, pick axes and shovels.
Removal of the same shall be done by mechanical excavators, shovels, draglines etc.
b) Soft and decomposed rock:
This shall include rock, boulders, chalk, slate, laterite and all other materials which does not
need blasting and can be removed with picks, hammers, crow bars, wedges and pneumatic
breaking equipment like Jack Hammers.
c) Hard rock:
This shall include all rock, occurring in large continuous masses, which cannot be removed
except by blasting.
Boulders of rock occurring in such sizes and not classified under (a) and (b) above shall also
be classified as hard rock. Excavation in reinforced cement concrete works shall be treated as
excavation in hard rock.
During excavation procedures:
The excavation shall be done to correct lines, dimensions and levels as per drawing.
Adequate side slopes shall be maintained during excavation of loose soil to prevent soil from
sides of excavated pits from falling back into the pits.
Wherever required, proper shoring and strutting shall be provided to maintain and prevent
sides of excavations from collapsing.

No heavy equipment shall be allowed within 6m from edge of excavation or within a

distance equal to depth of excavation, whichever is less.
Excavated materials shall not be deposited within 1.5 m from edge of the excavation. Any
material obtained from the excavation which in the opinion of the Site Engineer is useful,
shall be stacked separately in regular stacks as directed by Site Engineer.
Any excavated material, which is not suitable for backfilling shall be carted away from the
workplace as per directions of Site Engineer.

Planks placed over trenches for crossing shall not be slippery and of width not less than 75
mm wide.
Necessary barricades shall be erected and maintained around excavated areas. Also warning
lamps at night shall be provided to ensure safety.

Pits shall not be excavated to final founding level, if concreting work is not to be carried out
immediately. Last 15 cm shall be excavated prior to providing blinding layer with lean
concrete (PCC). PCC shall be of proportion 1:2:4 or as specified by Consultant.

If by mistake, excavation is carried out below the level mentioned on the drawing, the same
shall be made up to correct level by filling with concrete.

If any bottom of excavation is left exposed and is deleteriously affected by atmosphere or

water, it shall be dewatered and excavated to sound base. Base of excavation shall then be
filled up to the required level with lean concrete. (Grade M-15 or as specified by Consultant)
Removal of buried piping, cables or any other underground services shall not be done
without prior permission of Site Engineer and all measures shall be taken to protect such
lines till their removal.

Adequate precautions as per Consultant’s advice shall be taken to ensure that the excavation
operations do not damage the adjoining structures or dislocate underground services.
Any trees coming in the alignment of the excavation shall be cut after obtaining prior
approval of concerned authorities and any specific requirement laid out by them shall be
complied with. Cut trees shall then be removed from site as per instruction of Site Engineer.
Roots of trees not coming in the portion of excavation pits but whose removal is essential
shall be removed and hollows shall be filled up during backfilling.

Suitable drainage arrangements shall be provided to prevent surface water entering excavated
pits. Water within the pits shall be bailed out or dewatering shall be carried out using pumps
of adequate capacity to keep excavations free of water. Water removed shall be disposed of,
away from the excavated area.

Excavation in rock shall be carried out either by chiseling with pneumatic drills or by
blasting. Chiseling shall be carried out to obtain correct slopes, shape and pattern of
excavation pits as per drawings.

Materials:
Murrum:
For backfilling soil shall be freshly excavated, free from
vegetation, boulders, silt and clay. Murrum can be either
hard or soft.
Sand: For backfilling Sand shall be of medium size,
hard, free from organic and other deleterious materials,
silt and clay.
Rubble: For soling shall be hard, tough, and durable. It shall be regular in shape and of size
of about 200 to 230 mm.
Notes:
All backfill material other than rubble shall be free from roots, grass and rubbish. It shall be
reasonably well graded and of maximum size 80 mm. All lumps and clods of size larger than
80 mm shall be broken down using wooden mallet.
Material brought from outside sources shall be approved by Quality Engineer at the place of
source and shall be visually checked each time during its delivery and unloading at site
throughout the period of backfilling work.
Backfill material (Murrum and rubble) shall be tested in laboratory at time of approval from
source. Change in source of materials shall be avoided. If unavoidable, the new sample and
the source shall be again approved by Quality Engineer before actual commencement of
supply of materials at site from fresh sources.
All backfill material shall be tested in laboratory once at the time of approval from source.
Water:
Water should be clean and free from dirt and organic matter. Treated water from STP can be
considered suitable for compaction of backfill material considering after satisfactory results.
Anti-termite solution:
Chlorpyrifos 20 EC conforming to IS 8944 or Imidacloprid 30.5 C conforming to IS 16131
shall be used for anti-termite treatment. Solution shall be from reputed manufacturer, well
packed and shall bear manufacturing date as well as expiry date. Manufacturer’s literature
indicating correct use of chemical with proper proportions of additives, if any, as also, degree
to which dilution is required shall be made available on site. Literature shall also include safety
precautions to be taken by users.
Blasting operation consumables:
Blasting operation consumables shall be purchased from a licensed supplier.
Manufacturer’s literature indicating complete procedure of carrying out
blasting operation shall be kept on site for ready reference.
Necessary permissions must be obtained for purchase and storage of blasting material/explosives.
Guidelines for Inspection of Backfill Material:
Testing shall be done in laboratory only once at the time of approval of source)

Excavated materials which in the opinion of Site Engineer are useful shall be stacked in
regular heaps, bunds with regular slopes. Such stacking shall be done within the lead (50 m
or as specified). Stacks of soil shall be properly leveled for providing natural drainage.

All softer material shall be laid along the center of heaps. The harder and more weather-
resisting materials shall be stacked to form the casing on the sides and the top of heaps of
softer material. Soft and hard rock shall be stacked separately.
Murrum, Sand and Rubble brought from outside shall be stacked separately in regular heaps
of height not more than 1.5m. Stacking shall be done as near to the place of filling as
possible to avoid excess lead.
Toe boards shall be provided to prevent stacked material from falling back into the excavated
pits.
Procedure for backfill:
Setting Out
After the site has been cleared, the limits of area should be set out true to lines, curves,
slopes, grades and sections as shown on the drawings. The limits of the area should be
marked by fixing batter pegs on both sides at regular intervals as guide before commencing
the construction. The area should be built sufficiently wider than the design dimensions so
that surplus material may be trimmed, ensuring that the remaining material is of the desired
density and in position specified, and conforms to the specified slopes. Benchmarks and other
stakes should be maintained as long as in the opinion of the engineer, they are required for
the work.

Compacting the Ground Supporting Area

Where necessary, the original ground should be leveled, scarified, mixed with water and then
compacted by rolling so as to achieve minimum 97 percent of MDD determined as per
IS:2720 (Part 8) for the foundation soil.
Where so directed by the Engineer, any unsuitable material occurring in the area foundation
shall be removed and replaced by approved materials laid in layers, to the required degree of
compaction.

Spreading and Compaction

The side soil cover of required width shall be provided along with the core and mechanically
compacted as the area progresses upwards. The addition of side cover subsequent to the
construction of the core is prohibited. The fill material should be spread by mechanical
means, finished by motor grader. The motor grader blade shall have hydraulic control so as
to achieve the specified grade.

The most efficient lift thickness is a function of roller weight and vibratory energy. Medium
weight vibratory rollers with dead weights in the range 60- 1 00 kN, provide satisfactory
compaction for loose layer thickness of about 200 mm. When vibratory roller of dead weight
100-120 kN are used, loose layer thickness up to 250 mm can be adopted if satisfactory
compaction achieved. The cover soil should be laid simultaneously before compaction, to
ensure confinement. Clods or hard lumps in cover soil shall be broken to have a maximum
size of 50 mm.
Moisture content of the fill material shall be checked at the site of placement prior to
commencement of compaction. Moisture content of soil laid for compaction shall normally
vary from OMC (determined as per IS: 2720 (Part 8): 1983 to OMC ± 2 per cent. The
moisture content limits can be varied depending on the weather conditions provided specified
compaction is achieved as revealed through actual site trials and there is no dust problem. It
may be noted that grain shape and particle size of soil make the upper layers difficult to
compact. At moisture contents higher than the appropriate range, soil may liquefy and would
be difficult to handle and compact. Moisture content of cover soil shall be maintained at its
OMC. Where water is required to be added to the fill material, it shall be sprinkled from a
water tanker fitted with a sprinkler capable of applying water uniformly without any
flooding. The water shall be mixed thoroughly by blading, harrowing or by suitable means
until uniform moisture content is obtained throughout the depth of the layer. If the material
delivered to the construction site is too wet, it shall be dried by aeration and exposure to sun,
till the moisture content is acceptable for compaction.

Soil can be compacted using vibratory only. Towed or self-propelled vibratory rollers are
recommended. Regardless of the equipment used, Soil must be compacted as early as
possible after spreading. The contractor shall demonstrate the efficacy of the equipment he
intends to use by carrying out compaction trials. The procedure to be adopted for these site
trials shall be first submitted to the Engineer for approval. Typically, several test areas are
developed where a series of compaction trials can be conducted. In such trials, usually one
parameter (such as, lift thickness, moisture content, etc.) is varied at a time while the others
remain constant.

Each layer of Soil shall be thoroughly compacted to the specified density. When vibratory
roller is adopted for compaction, two passes without vibration followed by 5 to 8 passes with
vibration would be sufficient to compact individual layers. Mass per meter width of roller is
recommended to be 2300-2900 kg/m and frequency range 1800-2200 rpm.

Each compacted layer shall be finished parallel to the final cross-section of the area to be
backfilled. The required moisture contents and compaction requirements shall be same, as for
the rest of the area; however, compacted layer thickness should not exceed 100 mm in such
cases.
Subsequent layers shall be placed only after the finished layer has been tested for its
density requirements. The contractor shall maintain record of all such tests. When density
measurements reveal any soft areas in the backfilled earth, further compaction shall be
carried out as directed by the client. In spite of that if specified degree of compaction is not
achieved, the material in the soft areas shall be removed and replaced by approved material,
and moisture content brought to permissible limits and recomputed to the required density.

Quality control
Quality of compacted material shall be controlled through periodic checks on the compaction
process or the product, singly or in combination as directed. The product must conform to the
specifications.

Control Test on Borrow Material (Murrum)

If soil from more than one source is being used at the project site, monitoring must be done to
identify the ash type being placed. The frequency of testing indicated refers to the minimum
number of tests to be conducted. The rate of testing must be stepped up as found necessary,
depending on the compaction methods employed at the project.

Anti-termite Solution:
Anti-termite solution shall be stored in a separate room with strict precautionary measures as
suggested by the manufacturer. Storage room shall be provided with adequate ventilation.

Equipment and Tools:

Excavation and backfilling Equipment’s: Excavators.
Jack hammers. Dumpers.
Surface compactor.
Vibratory roller (Both Mini (2 MT) & capacity above 10 MT). Dewatering pumps of suitable
capacity.
Pressure pump for spraying anti-termite treatment solution. Screeder.

Surveying Equipment’s:
Total Station.
Theodolite.
Whole station equipment.
Auto level.
Leveling staff.
Tools.
Crowbars. Pickaxes. Spades.
Wedges. Hammer.
Line thread (50m).
Measuring tape (50m).
Temporary Facilities: Platforms.
Walkways.
Shoring and strutting material. Night lamps.
 03. PILING

The method of installing the piles, including details of the equipment shall be submitted by the
Contractor and got approved from the Engineer before commencement of work.

In this procedure, construction of Bored and Cast-in-situ piles were briefed. The work shall be
done as per IS 2911 Part 1 Section 2 for Bored Cast in-situ works and in accordance with the
details shown on the drawings.

Cast-in-situ concrete piles may be either installed by making a bore into the ground by removal
of material or by driving a metal casing with a shoe at the tip and displacing the material
laterally. The two types of piles are termed as “bored piles” and “driven piles” respectively.
Cast-in-situ concrete piles may be cast in metal shells which may remain permanently in place.
However, other types of reinforced concrete cast-in-situ piles cased or uncased according to the
design.

Wherever, the metal casing suggested, it shall be of sufficient thickness (permanent steel liner
min thickness shall be 6mm) and strength to hold its original form and show no harmful
distortion after it and adjacent casings have been driven and the driving core, if any, has been
withdrawn.

Where bored cast-in-situ piles are used in soils liable to flow, the bottom of the casing shall be
kept enough in advance of the boring tool to prevent the entry of soil into the casing, thus
preventing the formation of cavities and settlements in the adjoining ground. The water level in
the casing should generally be maintained at the natural ground water level for the same reasons.
The joints of the casing shall be made as tight as possible to minimize inflow of water or leakage
of slurry during concreting.
Boring shall be carried out using rotary or percussion type equipment. Unless otherwise
approved by the Engineer, the diameter of the bore-holes shall be not more than the inside
diameter of the liner.
Prior to the lowering of the reinforcement cage into the pile shaft, the shaft shall be cleaned of
all loose materials. Cover to reinforcing steel shall be maintained by suitable spacers.

The diameter of the finished pile shall not be less than that specified, and a continuous record
shall be kept by the Engineer as to the volume of concrete placed in relation to the pile length
cast.

Concreting shall be done by tremie method. In tremie method, the following requirements are
particularly applicable:

When concreting is carried out for a pile, a temporary casing should be installed to sufficient
depth, so that fragments of ground cannot drop from the sides of the hole into the concrete as it
is placed. The temporary casing is not required except near the top when concreting under
drilling mud. The hopper and tremie should be a leak proof system.

Tremie diameter of minimum 200 mm shall be used with 20 mm diameter down aggregate. The
first charge of concrete should be placed with a sliding plug pushed down the tube ahead of it or
with a steel plate of adequate charge to prevent mixing of concrete and water. However, the plug
should not be left in the concrete as a lump.

The tremie pipe should always penetrate well into the concrete with an adequate margin of
safety against accidental withdrawal of the pipe. The tremie should be always full of concrete.
The pile should be concreted wholly by tremie and the method of deposition should not be
changed part way up the pile, to prevent the laitance from being entrapped within the pile.

All tremie tubes should be scrupulously cleaned after use. Normally, concreting of the piles
should be uninterrupted. In the exceptional case of interruption of concreting, but which can be
resumed within 1 or 2 hours, the tremie shall not be taken out of the concrete. Instead, it shall be
raised and lowered slowly, from time to time to prevent the
concrete from setting.
Concreting should be resumed by introducing a little richer concrete with a slump of about 20
mm for easy displacement of the partly set concrete.

In case of withdrawal of tremie out of the concrete, either accidentally or to remove a choke in
the tremie, the tremie may be reintroduced in the following manner to prevent impregnation of
laitance or scum lying on the top of the concrete already deposited in the bore.

The tremie shall be gently lowered on to the old concrete with very little penetration initially.
Fresh concrete slump between 150 mm to 180 mm should be filled in the tremie which will push
the plug forward and will emerge out of the tremie displacing the laitance/scum. The tremie will
be pushed further in steps making fresh concrete sweep away laitance/scum in its way. When
tremie is buried by about 60 to 100 cm, concreting may be resumed.

Removal of concrete above cut-off level

It is desirable that the concrete above cut off level is removed before the concrete is set. The
concrete may be removed manually or by specially made bailer or another device. Such removal
of concrete helps in preventing the damages of the good concrete below the cut off level which
results from chipping by percussion method.

The removal of concrete may be within the ± 25 mm from the specified cut off level preferably
on the (-) side. On removal of such concrete, the concrete shall be compacted with rammer with
spikes or it shall be vibrated.

In case the concrete is not removed before setting, a groove shall be made on outer perimeter by
rotary equipment before chipping by percussion method. The minimum embedment of cast-in-
situ concrete piles into pile cap shall be 150 mm. Any defective concrete at the head of the
completed pile shall be cut away and made good with new concrete.

The clear cover between the bottom reinforcement in pile cap from the tip of the pile shall be not
less than 25 mm. The clear cover for main reinforcement in the cap slap shall not be less than
60 mm. The reinforcement in the pile shall be exposed for full anchorage
length to permit it to be adequately bonded into the pile cap. Exposing such length shall be done
carefully to avoid damaging the rest of the pile.

In cases where the pile cap is to be laid on ground, a leveling course of M 15 nominal mix
concrete 75 mm thick shall be provided. In case of defective piles shall be removed or left in
place as instructed by Client without affecting the performance of adjacent piles or pile cap.
Additional piles shall be provided to replace the defective piles.
 04. Reinforced Cement Concrete Works

Form work
Formwork is temporary support given to concrete until it gains strength to withstand its self-
weight. Formwork shall be so designed to support safely the worst combined effects of all loads
within acceptable dimensional tolerance and without causing bulging or deflection.

Formwork should be:

Strong enough to bear the self-weight of formwork, wet concrete, reinforcement, and
dynamic effects of placing and compacting,
construction traffic and wind load.
Watertight to avoid grout loss.

Easily removable without any damage and should be

re-usable. It should be dimensionally accurate and
give the desired finish to the contact surface. Check
the shuttering work for vertical and horizontal
alignment, level, surface cleanliness, water tightness,
and ability to withstand loads without distortion.

Scaffolding
At the ground level, walk round the perimeter of the scaffold and check for Subsidence of the
ground. Cavities underneath sole plate’s. Dislocation of base plates. Rectify
with adjustable base plates or fill with concrete. Do not use poles/ Bamboo as struts or
supports.

Guardrails and toe boards

Both guardrails and toe boards should be fixed to the inside of the outer standards and remain in
position before decking is removed. Guardrails should be fitted at not less than 0.9m and not
more than 1.15m above the decking. Toe boards should be at least 150mm
high above the decking and the clear spacing between the guardrails and the boards should not
exceed 0.75m.

Shutter release agent/Mold release agent

The formwork oil basically serves the purpose of a separation medium. It acts as an
intermediary that avoids any damage to the concrete. It also helps keep the formwork clean and
ensures easy maintenance. This application of oil should be done with the help of foam or a
similar soft medium and should be applied within 48 hours prior to concreting.

Machine oil or used oil is totally unsuitable and is unacceptable at any cost due to the chemical
reaction this type of oil has on concrete. The quality of finished concrete is dependent on the
quality of formwork.

Tools to be used by tradesmen

Required tools must be available at site to ensure correct work. Basic tools of the shuttering
gang are Shuttering material - Props, Cup locks, C-clamps, Base plates, U- heads, Tie rods,
Acro-spans, Runners, Jacks and Column boxes, Hammer, Line tread, Hand saw, Spirit levels,
Tube levels, Plumb bobs, Measurement Tape, Aluminum straight edge, Right angle, Chipping
Tools, Crowbar.

Inspection methodology for Quality Assurance

Check the shuttering work as per drawing, surface cleanliness, water tightness, and ability to
withstand (loads without distortion. Stability, safety, dimensional correctness, levels and
alignment are the key factors.

Check for plumb and parallelism using 1m / 2m spirit level to the formwork at various points.
All formwork in the periphery of the building to be plumb.
For all required cut outs and shaft openings are as per drawings.
Inner right angles at all 4 corners checked using right angle template. iii.Check of
diagonals using a measuring tape.

Tools to be used for quality inspection

Measuring tape. Spirit
levels 2 -3m.
 Aluminum straight edge 2 -3m.
Right angle template.
Auto level.
Total station.
Installation works of Rebar, M&E, and Plumbing
The support works such as rebar, Mechanical & Electrical (M&E) and plumbing are to
commence immediately once the setup is done. The same is to be ensured before installing the
Aluminum formwork or any other system form work.
The support works for the slab section commence after the slab formwork panels are assembled.
Cover Blocks should be fixed on both sides of the rebar section for positioning and eliminate the
rebar from resting on the surface of the formwork panels.

Positioning of outlets for electrical switch boxes to its correct alignment can be done by riveting
the appropriate fit size mould to the formwork panels.
The electrical switch boxes are then securely cap to the fit size mould and fasten by way of
wiring to the formwork panels. Ensure that it is
properly secured to prevent grouting from building up
in the switchboxes.

Reinforcement
General Instructions
Start reinforcement works with proper "Good for Construction" drawings and general
specifications as issued by the consultant.

Earmark the reinforcement work yard and stack yard. Care should be taken to ensure
accessibility for trailers and availability of sufficient working space.
In case of extreme site constraints, the cutting and bending can be done elsewhere and
transported to site.
Materials
1. Mild steel bar should comply with IS 432.
2. TMT steel bars should comply with GFC drawing and relevant section of IS 1786.
3. Stack steel 300 mm clearance from ground on rigid platform.
4. Stack steel - Grade wise, consignment wise, diameter wise and length wise.
5. Protect stored steel from rusting, oil, grease and distortion.
6. Ensure Mill Certificate (MTC) is delivered with each load.
7. Binding wire shall be 18 - gauge soft annealed steel wire or as specified by Company.
8. Collect the rings used for bundling rods in bags and store them.
9. Cut pieces/ scrap should be stored separately in an enclosed area.
10. If steel is going to be exposed to weather for a long time, give cement wash to protect it from
corrosion.
11. Surface rusting is good as it ensures proper bonding and should not be a cause of worry.
12. Steel is tested for its chemical and physical properties. Chemical tests check for the Carbon,
Sulphur and Phosphorous content, while the physical tests check the Unit weight, Ultimate
tensile strength, Elongation, Bend and Re-bend test.
13. Test frequency should be as per approved ITP.

Cutting Bending and Placing Reinforcement

Cut the rods economically to reduce wastage as per the BBS. Start laying rods only after
shuttering is totally cleaned and oiled and checked for levels etc.
Pitted, deformed, defective, corroded, cracks; splits on bend bars should not be used and rejected,
and to be removed from site.
Neither the size nor length of the bars should vary with respect to drawings.
Tolerance for cutting of reinforcement = +50 or -25mm
Bending Tolerance = +0 or -10mm
Bar spacing « + or - 10mm
Take extreme care while bending steel already cast partially in concrete so as not to damage
the concrete around the bars.
All laps should be 50d or as specified in GFC drawing.
Laps are staggered and not more than 33% of bars shall be lapped in a section. Mechanical
splicing and welding of rods should be done only after proper details and instructions are
available from the structural consultant.
At time of concreting, reinforcement shall be free from mud, oil, grease, mortar dropping, mill
scale or other foreign matter.
Cover blocks shall be as per the grade of concrete and cured for at least 28 days immersed in
water. Cover block as per GFC drawing & specification. Generally, 15mm for slab, 25mm for
beam and 40mm for the footing is provided. It depends on the maximum size of aggregate, the
reinforcement size and the element concreted.

Chairs should be placed as last operation before concreting to avoid distortion of top rod due to
traffic. Check if dowels for columns, beams and slabs are given correctly and is of
required minimum length.

For slab reinforcement, the PMC should check and certify each work before concreting.
Highlight areas of reinforcement congestion and get the bar arrangement revised to facilitate
easy flow of concrete all around. Spacer bars shall maintain vertical distance between successive
layers of bars.

Binding wire ends after tying should be turned inside and should not stick out to the surface.
Work should be neat, correct as per drawing and specification. Engineer deployed at site shall
have prior experience of supervision in reinforcement works.

Tools to be used by tradesmen

Required tools must be available at site to ensure correct work. Basic tools of the
reinforcement gang are
Cutting Machine. Bending Machine. Twisters and tongs.
Long handle Steel cutters. Crowbar.
Measurement Tape. Levers
of varying sizes.
Marking stick and chalk. Chipping tools.
Hammer.

Inspection methodology for quality assurance

Steel Mill Certificate is delivered with each load. Adherence to reinforcement detail as per
drawings. Cover blocks for the above. Check overlapping wherever possible.
Check Binding wires - whether joints are properly bound.
Check for chairs and their disturbance due to movement of labor.
Columns to be checked for plumb. Check for plumb by holding the spirit level to the
formwork at various points.
Supports need to be checked. Dowels to be checked for adequate number and strength.
Tools to be used for quality inspection
Plumb bob.
Spirit levels - 1.0m – 1.5m length. Measuring tape.
Screw gauge.
Related "Good for Construction" drawings.
Concrete
All concrete ingredients shall conform to IS 456 relevant clauses and shall be tested before
commencement of work as per approved ITP.
Mixing of Concrete shall be done with Batching Plant only. Site mixer not permitted for
concrete production. Preference for ready-mix concrete from reputed companies possessing
automated batching plant, of at least 30 cum per hour capacity supported by adequate number of
transit mixers.
The logistics should be worked out to have consistent concrete supply.
Concrete should be received with a delivery note and Batch slip showing grade, quantity, water
cement ratio, slump, cement content, time of manufacturing, dosage of additive added, weight of
various ingredients of concrete. Go through the cycle data before accepting the concrete. Batch
slips shall be retained for a minimum period of 03 months.

Concrete shall be placed and compacted before its initial setting time but not later than 3 hours
of mixing. Do not add additive, water, or cement in concrete.
Slump to be measured and monitored as per site specifications/ GFC drawing. Recommended
for concrete mix is 125mm. FM 2 flooring slump of concrete shall be 150mm.

Place the concrete pump on horizontal, hard even surface and keep the approach area free of
materials to facilitate easy maneuverability of transit mixers. The approach should not slope
towards the concrete pump. The pipeline should be independently supported on vertical segment
and not on the shuttering. The vibrations due to pumping should not affect or displace shuttering
works.
Rich slurry with one bag of cement to be pumped, before pumping concrete to prime the inner
surface of the pipes. This slurry mixed with initial lot of concrete shall be collected separately to
remove from the site.

Be excessively careful while passing the ball while clearing the concrete in the pipeline after the
day's work is over. Due to negligence somebody could get hurt.
Employ professionals for connecting pipeline. Leave the pipeline, under the pump and adjacent
areas clean of concrete dumping after the work is completed.

Placing and Compaction

Do not use chutes longer than 4.5m or inclined at more than 45° to horizontal to pour concrete.
Place cements concrete to the required depth and vibrate it until entrapped air inside concrete is
released.

Pour concrete first into beams and then over the slab portion. Bond new concrete to previously
poured concrete. If the previous pour was less than 4 hours prior, the laitance film and porous
layer shall be removed from the surface of previous pour.
If the previous pour was more than 4 hours prior but less than 30 days old observe the above
process and expose aggregate with wire mesh, wash with clean water and use bonding agent.

Columns, beam, slab level of concrete top should be pre-marked before start of concreting
works. Check the slab level during concreting with line dory method and the leveling
instrument.
Use appropriate needles for vibration depending on the aggregate size, reinforcement spacing
and element to concrete. For big footings use 60mm needle, for slabs use 40mm needle, and for
starters and precast lintels use 25mm needle. Ensure that just adequate vibration is only done,
over vibration results segregation.

Use wooden runner to ram to form slurry on top of the concrete surface. Clean the shuttering
works of all spilled concrete immediately after concreting.
Leave vertical construction joints after consultation with the structural engineer.
Match the vibrators, masons to the rate of concreting. All surfaces of shuttering shall be
moistened before placing of concrete to reduce water loss due to absorption.
Slab should be sprayed with water after covering with hessian cloth 3 hours after concreting, i.e.
initial settings are over and ensure that hessian cloth will remain wet till ponding of water. Pond
water to a depth of 25mm using bunds the next day and keep water standing for 7 days at a
stretch.
In case ponding is not possible, cover it with hessian cloth and keep it moist throughout. Do not
ignore curing of slab to facilitate marking of columns for the upper slab. The beam bottoms
should be cleaned using high-pressure cleaners.
Columns, Walls and Starter
Remove the shuttering on the next day and wrap with moist hessian cloth after spraying water on
the column.
The concrete must be cured for a minimum of 7 days in case OPC and 10days for PPC or
Flyash based concrete.

Testing of Concrete - Slump Test, Temperature.

For every 25 cu.m of concrete Slump test to be carried out and any load under suspect can be
checked for slump by PMC/ Client representative.

Testing of Concrete - Cube Test

The sample shall be made at point of discharge of mixture.
Though Concrete is produced
from Ready-mixed Concrete Plant, Cube
sampling shall be as per IS 456 clause no.
15.2.2

For each Sample, take 3 specimen for 7 days curing

period and 3 specimen for 28 days curing period. In
case of any deviation, prior approval shall be
obtained from Corporate QHSE.
For concrete manufactured at site, there must be representative samples for the day's work and
for different elements like footing, slab, column and wall. Test results should be discussed with
the Project Manager even if the results are satisfactory.
In case of cube failure, the element to be identified and destructive/ non-destructive tests as
recommended by PMC/ Client to be conducted by the contractor at his risk and cost.

Tools to be used by Tradesmen

Required tools must be available at site to ensure correct work. Basic tools of the
concreting gang are:
Trowels. Shovels.
Gum boots. Vibrator.
Dumpy levels.
Spirit levels l-3m. Measuring tape. Masons trowels. Floating trowels.
Screed finishing derby. Steel trash tracks.
Hammer.
Leveling trowels. Wheelbarrow.
Long handle Aluminum leveler. Masons brushes and buckets. High pressure water cleaners.
Critical Checks for Concreting:
Before Concreting
Ensure base plates have been cleaned and sealed with sealing tape so that there is no leakage of
slurry. All reinforcements are in place especially chairs.
All cover blocks damaged during reinforcement laying are replaced. All sunken areas (sunken
beams, toilets and cut-out areas) have been properly cleaned of dust and oily substances using
high-pressure water cleaners.

During concreting
Ensure proper grade of concrete as per drawing and approved mix to be used. Check slab
and beam for parallelism using spirit levels before and after concreting. Check the top
surface of fresh concrete for evenness.
Ensure sufficient compaction using correct needle size of vibrator.

After concreting
Curing carried out as per guidelines.
Columns are covered with a damp hessian / jute cloth for 7 days, Slabs - water level is
maintained during ponding.
If pinholes or minor defects seen after de-shuttering, immediate touch up without delay. In case
of Major defects, get the designer consultant approval before repairing.
Ensure the cube test results are available at the end of the term indicated

Tools to be used for quality

Inspection Dumpy levels to check finished
slab level. Spirit levels l-3m.
Measuring tape.
Plumb bob.
All related "Good for Construction" drawings.
 05. Waffle walls – Casting & Erection

Cleaning the platform and surrounding area before starting the work. Temporary green
net barricading/screens shall be provided to control the dust.
Temporary shed shall be provided for proper protection of waffle casting during rainy season.

Base mould shall be placed on leveled concrete flooring. Mould shall be clean without
damaging and scratching the mould surface. All loose concrete and stains shall be removed.

Bolts at the corners of mould shall be tighten properly and sealed the corners with PU sealant.
Mould shall be leveled and packing shall be given if required. Check the dimensions and
diagonal of molds. Oil based mould releasing agent shall be applied evenly on surface of
moulds.

Reinforcement steel of grade either Fe 500D or shall be placed as per GFC drawing.
Reinforcement shall be clean properly, laid in true line and binding the same at each
intersection. Binding wire edges/ends shall not be touch in any surface of mould or not
projected in top surface.

Clear cover to rebar at web bottom 20 mm, at slab bottom 12mm/ 15mm shall be maintained as
per sketch using precast cover blocks and clear cover of 25 mm for sides shall be maintain by
laying and fixing rebar properly. Insert plates, lifting pins, panel joint pins with recess former
shall be placed and fixed properly. Same shall be checked visually for Quality.

Mould shall be covered using tarpaulin sheet after final pre-pour preparation till start the
pouring. Before starting the concrete, surrounding area shall be sprinkle with water.
Before starting the concrete of waffle, all finishing tools shall be checked for availability and for
its working.

Only weigh batching plant concrete of approved design mix of grade M35 shall be used with
slump between 70-90mm for precast panel. Same source of cement & fly ash shall be
maintained to achieve the uniform shade of concrete as far as possible.
Batch print shall be checked at the arrival of concrete transit mixer. Sampling of concrete shall
be carried out before placing for workability & cube testing.

One sample of concrete cubes shall be taken for each day. Minimum 3 concrete cubes shall
place near precast panel to check the next day strength for panel de-molding.
Concrete shall be placed using transit mixer chute smoothly without segregation. Spread the
concrete using concrete leveler. Initial concrete which is drop from mixer shall be taken aside to
avoid the honeycomb in waffle if required. Initial concreting to be started on flat surface of
panel.

Concrete shall be compacted adequately using screed vibrator. Two pass of surface vibrator
recommended to compact the concrete. Excess concrete shall be removed before final leveling.
Initial leveling & top compaction shall be done
using Aluminum straight edge.
Initial finishing of concrete shall be carried using
rough bull float and final finishing shall be carried
using fine bull float.
Groove shall be provided at the edge of panel
using edger during final finishing. Final finishing shall carry out using hand trowel wherever
required without impression.

Precast mould with concrete shall be covered with curing blanket of sandwiched tarpaulin with
bubble sheet immediate after final finishing of concrete till de-molding of panel.
Stoppers shall be used in mould with its fixing attachments as per requirement of panel size.
Pre-cast panel shall be lifted from the casting bed only after attending 16Mpa characteristic
strength. Strength shall be checked by testing of concrete cubes.

De-moulding and lifting of panel shall be carried out by third generation Pick-n-carry crane
with de-molding assembly under the guidance of safety officer. Before lifting the concrete
panel, corner bolts shall be loosened.
Precast waffle shall be stacked on wooden runner of same thickness. Precast shall not stacked
more than 6 panels one over other. Wooden runners shall be placed between two panels in same
vertical plane.

Curing shall be done for minimum 7 days using wet hessian cloth and water sprinkling.
Compressive strength test shall be carried on concrete cubes at the age of de-molding stage & at
the 07 days age for shifting. 28 days cube testing shall be done to ascertain the strength of
concrete.

Erection methodology:
Relevant latest GFC drawing shall be checked for availability and proper layout. Plinth
beam shall be check for erection of panel.
Mark the outer panel line on plinth beam using thread and color. Same line to be transferred in
Channel / Z purlin on the top. Outside MS cleat to be welded in same line to maintain the
verticality and alignment of panel.

Panels to be shifted from stack yard shall be check for any damage / crack in panel. In- ward and
out-ward register / record shall be maintained for requisition, checking and releasing of required
precast panel. Care shall be taken during shifting & handling of panel. In case of minor chipped
panel, repairing and cosmetic work shall be done before installation.
All required tools & machinery shall be check for working condition. Panel shall be aligned as
per drawing from outer face of the building. Verticality, level of panel shall be checked as per
drawing.

Panel shall be fixed with plinth beam by making the holes and bolts to be
tightened for fixing two panels. Minimum 10mm gap required between two waffle panels for
sealing purpose and minimum 25mm gap required between beam top and waffle bottom for
grouting purpose.

Welder shall be qualified before starting the welding work and approved through client.

Angle of (75x75x6) mm shall be welded with inserts of panel and structural channel section for
the fixing of panel. Welding shall be checked visually for its quality with angle & insert plate.
Level of angle shall be checked and there shall be no sagging in channel after welding. Painting shall
be carried out by properly cleaning the angle (Unless otherwise mentioned in BoQ, One coat primer
& 02 coats of paints –RAL 7001).
GP-2 shall be grout after panel fixing between plinth beam top & bottom of panel. GP-2
chamfer shall be done from both sides to avoid water entry through waffle bottom.
Curing of grouting work shall be carried out for 7 days.

Gaps between two waffle panels shall be filled with backer rod and sealant (Sikaflex Construction
(AP) or BASF PU Sealant Master Seal NP 472 Concrete grey colour).
Minimum 10mm thickness of sealant shall be maintained.
 06. Masonry (Brick/ Block)

Checks prior to start of Work

Follow the latest "Good for Construction" drawings duly signed by the architect.
Check for any variations/deviations from the approved architectural and services drawings. All
concrete surfaces of beams and columns meeting block work is to be hacked.
Use cement mortar of 1:2 on the hacked surface to create a roughened surface for proper
bonding, 3 days prior to start of block work. Cure the roughened surface for these 3 days, by
spraying water. Aluminum templates should be available at site to ensure correct door / window
openings.
For non-load bearing walls use solid / hollow 4 N/mm2 compressive strength blocks or as
specified by structural consultant.

Use (silt less than 8% by volume) medium grained

clean sand for mortar.
Approved brand & grade cement not older than 60
days should be used. The week of manufacture to be
verified on the bag.
Ensure that all required tools, accessories and
materials are available at the place of work.
Finished floor level should be button marked on structural slab. Lintels, chajjas and sills to be
cast with respect to finished floor level.

For bonding of block work to columns, wall ties shall be cast into columns at a vertical spacing
not greater than 500mm and should be aligned with the horizontal mortar band.

Checks during block work

Place the base course of block (1st course) after checking the vertical & horizontal
alignment. Get it checked thoroughly as per drawing.
If hollow blocks are used fill the lowest (1st course) with concrete 1:3:6 using 12mm
aggregate to give a firm base.

Mix mortar in proportion of 1:5 on plain MS sheet, using measuring box for measuring sand
and a measuring can to standardize quantum of water to get a consistent mix. Mix
well for uniformity. Mix mortar in small manageable quantities and use it within half an hour.
Mortar joints should not be more than 10 mm for both vertical and horizontal joints. The joints
should be neatly pointed using an Aluminum Straight edge. Do not construct more than 1.2-
meter height in a day. Give concrete band of 1:2:4 with 8 mm steel (2 Nos.) in a 100 mm thick
wall at every 1-meter height. Do not place the topmost block under the beam until the
immediate upper floor block work is raised up to the beam bottom, less one course.

Electrical conduit chasing shall be carried out along with the block work. Dowel blocks to be
left for further extension of block masonry. Continuous horizontal chasing should be avoided.
Chase block work using chasing machines.
Start chasing after 21 days of block work construction for tiled surfaces it is a better option to
chase after rough plaster is done and cured for 21 days. All nibs adjacent to columns and less
than 200mm should be cast in RCC at site using
M20 grade of concrete and curing for 7 days by
covering with hessian clothes.
For mortar joints more than 10mm, packing of chasing
for pipes; junction box etc. should be done in P.C.C.
1:2:4 using 12mm jelly and cured for minimum 3 days.
Write the date of work in paint on the block work and
monitor the curing accordingly.
Cure the block work by spraying water on the mortar joints only for at least 7 days.
Cast the cut lintel, sill, and chajja by giving a minimum bearing of 200mm with the bed block.
In the case of lintel, sills, and chajja over large openings, place them as end-to-end beam type. If
bearing cannot be given as required, use lockset (Fosroc) or equivalent to fix the reinforcement
of lintel into the column for a depth recommended by the manufacturer.
Check chajjas and sills for toppling effect. If suspect, build counterweight courses for lintel, sill,
and chajjas. Continuous vertical mortar joints should be staggered and vertical movement joints
to be given every 12 meters.
Care after block work
Do not entertain excessive chasing as it disturbs the mortar joints causing hairline cracks and
weakening the work.
Do not soak the blocks with water while curing. The moisture absorbed by the blocks will be
released subsequently causing volumetric variations and shrinkage cracks.
The interface between block and concrete is the most critical zone and needs special care. This
is due to incompatibility between two heterogeneous materials.
Before plastering, these zones should be given special treatment. (Discussed separately under
plastering)
After 7 days curing of mortar joints drive a nail into the joint to test the strength of joints at
random. Also look for colour variation in the mortar joints to identify problem areas.
Tools to be used by tradesmen
Required tools must be available at site to ensure correct work. Basic tools of the masons are:
Trowels, Line tread, Sand Sieve, Tube levels, Plumb bobs, Measurement Tape, Spirit levels l-
2m, Aluminum straight edge ix, Right angle, Chipping Tools, Masons trowels, Masons hammer,
Leveling threads, Masons brushes and buckets xv, Mortar boxes. Water Barrel.
Inspection methodology for quality assurance
Stage checks must be performed i.e. layout as base course, sill level, lintel level and completion
work. Any defective work must be removed on the day itself.

The first course in block work is the most important one. Check the layout, doors and opening
etc. Using the spirit levels, check if the erected wall is perfect - the surface should be free of
undulations, and cracks. The block work should be neat and clean visually.
Using the tape measure, ensure the diagonals are equal.
Using the 1-meter Spirit levels and aluminum flats check if the erected surface is parallel. Check
plumb at door and window openings.
Measure openings at various points for uniformity. If in doubt, crosscheck with diagonals.
Check if the corners are at right angles using the right-angle template.
Tools to be used for quality inspection
Measuring tape. Spirit levels - 1m.
Right angle template.
Related "Good for Construction" drawings.
 07. FM2 flooring

General
The Slab thickness shall be 170 mm minimum or as per good for construction drawing. The sub-
base shall consist of 250mm of well graded, well compacted material. Material must be non-
degradable and must not contain any soft materials such as chalk or sandstone. The
sub-base shall be capable of carrying construction traffic without
significant deformation or rutting.

The sub-base shall be placed and compacted in layers no thicker than 150mm.The level
tolerance of the sub-base shall be +0/-10mm. A paced 3m grid level survey shall be undertaken
by the contractor for record.

Slip Membrane
The slab is to be constructed on a 300µm (1200 gauge) polythene slip membrane lapped a
minimum 150mm and taped with 100mm wide jointing tape. The slip membrane shall have no
ripples or folds once laid. Where creases are present these should be positioned such that the
point faces downwards. The slip membrane shall be taken up the face of walls and isolation
details and taped to assure no bonding between the slab and other construction. Under formed
joints in the slab, laps in the slip membrane should be taken past a minimum of 300mm.

Welded Wire Mesh (Steel Reinforcement)

Reinforcement for the Main Slab shall be by one layer of steel mesh fabric Type A142 (6mm
diameter bars @ 200mm center each way) in accordance with BS 4483. The fabric will be in the
bottom of the slab with 50 mm cover.
Steel mesh fabric will be laid in accordance with the drawings. Steel mesh fabric shall be tied
where lapped. Laps in the reinforcement should not fall under the line of any proposed sawn
joints.

Sufficient spacers shall be provided so that the fabric does not touch the sub base when
deflected by personnel laying concrete and returns to required level when unloaded. The
maximum distance between spacers shall not exceed 800mm.
Steel mesh fabric shall terminate no more than 50mm from the edge of the slab and at formed
joints.
All re-entrant corners at columns, loading docks and floor penetrations to have 3No 12mm
diameter deformed high tensile bars, 1000mm long, fixed on spacers with 50mm top cover.
These bars shall be placed at 45 degrees at a maximum of 100mm center and a maximum of
100mm away from any isolation material. Alternatively, a 1x1m section of the reinforcement
used throughout the slab at 50mm top cover is permitted.

Concrete
The concrete shall be Grade M 35, in accordance with IS 456. Cement can be OPC 43/53. The
concrete will have minimum total cement content of 380 kg/m3 and a maximum total cement
content of 450 kg/m3. Based on Satisfactory site trails Client/ PMC to give approval.
The target spot slump shall be in the range of 110 mm to 140 mm. Slump tests shall be
undertaken in accordance with IS 456. Slump test shall be carried out for all loads and if any
trucks where the slump is outside of the specified acceptable variability shall be rejected.

Concrete temperature at delivery should not exceed 30°C (+2oC).

Water / Cement ratio: To minimize shrinkage, the W/C ratio shall be no more than 0.45.
Admixtures may be used to achieve the required slump. However, water should/be kept to the
minimum (160 Lit max) consistent with retaining sufficient free / bleed water for finishing.
Proposed admixtures are to be discussed with Client and approved prior to construction. All
admixtures are to be applied at the same time as water and in strict accordance with the
manufacturer’s instructions.
Aggregates shall conform to IS 383.
Concrete shall be obtained from a batching plant, which operates under a quality surveillance
system (certified concrete). This plant shall be approved by Client or its representative.

The Contractor shall submit a mix design for approval Client or its representative. Only potable
water is to be used for the concrete mix. Recycled water shall not be used. Concrete strength shall
be determined by crushing tests. Strength requirements shall be based on 28 days compressive
strength.
For each quantity of concrete poured in one day or for each 50 cubic meters, 6No test samples
shall be made. Of the 6No samples per test, 3No shall be tested at 7 days, 3No at 28 days.
Additional 3Nos can be casted to test at 56 days, should the test results at 28 days prove
unsatisfactory.

All test samples shall be stored by the Contractor in a place as per IS 516 and IS 1199. The tests
shall conform to the IS 456. Unsatisfactory test results needs further investigation NDT/
Destructive tests as per the PM/ QHSE instruction. If found test results of NDT/ Destructive test
results are not meeting the requirements may lead to disapproval of the sections of the Works.

Joints
All Joint types and locations to be approved by Client/it’s consultant.
The slab is to be isolated from the column bases with 20mm wide isolation material that is
compressible such as ‘Miothene’ or similar approved. It is essential that the isolation material is
a close fit to sub base to ensure complete isolation of the slab. All joints in the Miothene to be
fully taped. All slab penetrations to be isolated with 20mm wide isolation material that is
compressible such as ‘Miothene’. Where door jambs create re-entrant corners in the slab, the
reveals shall be isolated with a strip of Miothene, to the full width of jamb and to the full depth
of slab. The slip membrane should be fully lapped and taped up the outer face of the Miothene
and the trimmer bars installed to the re-entrant corner. Isolation to the perimeter walls and edge
beams can be achieved by continuing the slip membrane from under the slab up the face of the
wall or edge beam. The membrane is then to be neatly trimmed off at finished floor level after
construction of the floor.

The floor shall to be totally isolated from the building structure.

Trafficked Formed Free Movement Joints shall be provided with an Isedio Armour Joint
(www.isedio.com) or similar approved jointing system, fixed in strict accordance with the
manufacturer’s instructions.
Non-trafficked Formed Free Movement joints shall be provided with 150x100x8mm plate
dowels at 450mm center, steel strength to be 355N/mm2, as per the detail drawings.

All formed free movement Joints shall be leveled into a tolerance of +/- 1mm and rechecked and
adjusted during concrete placement.
Door thresholds, both internal and external, where butting up to a concrete slab or beam must
have a load transfer detail incorporated. Load transfer must be achieved using an Isedio Armour
Joint or similar approved detail.

All joint details and sections are shown on GFC drawings. Any deviation from the submitted
design to be pre-approved by Client design team.
Sawn restrained movement joints shall be provided as required. Saw cuts shall be 1/4 the depth
of the slab and a maximum of 4mm wide unless otherwise stated on the drawings. These shall
be provided at a nominal spacing of 6m and create a maximum aspect ratio of 1:1.5.Sawn Joints
are to be cut within 24 hours of concrete placement.

The outermost saw cuts should be done first, followed by cuts in an inwardly spiraling pattern
towards the center of the panel. Formwork shall be removed carefully to avoid damage to the
arris. All formwork, permanent or removable, shall be fully cleaned prior to each pour.

Construction Environment
Roof and walls shall be fully installed before the execution of the floor start. The slabs shall be
protected against the elements.
Doorways, windows and skylights shall be closed/sealed where practically possible. Rainwater
pipes shall be fitted to the roof to ensure that any rainwater is directed away from the floor area.

Construction Protection
Walls and columns of the building shall be protected from concrete splashes with 1m high
plastic sheeting taped to walls.
Finished floor shall be covered by 1000-gauge Plastic sheet.

Construction Methodology
The Contractor shall submit a pouring plan for every pour in which he describes all
activities during the construction process.
The floor will be poured in bays. The proposed pouring schedules shall be submitted to
Consultants for approval prior to any concrete being laid.
The casting of adjacent bays within 24 hours shall be avoided.
Concrete shall be compacted throughout the full depth of the slab. This shall be undertaken
either using mechanical screeds (Somero Laser Screed) or via the use of immersion vibrators,
depending on the slab construction method.
Areas around joints and edges of the slab shall be compacted via the use of immersion vibrators
even when mechanical screeds have been used to ensure full compaction is achieved.

Finishing
The Flooring Contractor shall be sufficiently experienced to know when finishing operations are
to begin.
The floor shall be finished using power floats and power trowels to a dense, closed polished
finished without burning/darkening the surface. If the flooring Contractor is uncertain of his
capabilities, then plastic finishing blades shall be used on final stages.

Trowels shall be taken to the edge of the formwork to ensure the edge of the slab receives the
same treatment as the interior of the slab.

Curing
Immediately after the final power troweling operation, the floor is to be sprayed with an acrylic
based, curing, sealing and hardening membrane – SIKA Proseal or BASF Masterkure 181 or
similar approved, in strict accordance with the manufacturer’s application instructions. The
following morning the floor is to be first covered in water and 1 layer of 250µm (1000 gauge)
plastic sheeting applied to further enhance the curing regime. The plastic sheeting is to remain
in place for at least 7 days. The surface of the floor is to be continually wetted for a minimum of
7 days.
After pouring remove cement spills from adjacent panels. Newly poured panels are to be fenced
off with barrier to avoid trespassing for a minimum of 7 days. The floor shall not be trafficked
for a minimum of seven days following the sealing operation.
Any alternative must be approved in advance by Design consultant/ Client Design team.

Surface Regularity
The ground floor slab will be constructed so that the surface regularity (flatness and levelness) is
within the tolerances as defined in The UK Concrete Society’s Technical Report 34 (TR34), 4th
edition. The floor should conform to the following classifications.
Free Movement – FM2 to TR34 4th Edition.
The floor will be independently tested by Client appointed flooring specialist within 7 days of
construction.

After Care
The floor can be used 7 days after completion by light traffic. The loads shall not exceed 30% of
the design capacity. The floor shall not be loaded to its design capacity until after 28 days.

All joints are to be sealed prior to practical completion with sealing compounds having a Shore
A hardness of 40. These joints are to be inspected at 3-monthly intervals during the defects
liability period and checked for arris damage.

Any significant arris damage must be repaired with a

suitable resin mortar placed in accordance with the
manufacturer’s recommendations. At the end of the
defect’s liability period, the joints in the aisles or free
movement areas of the floor slab are to be resealed
using a sealant with a minimum Shore A hardness of
80.

All efforts should be made in the construction and

detailing of the floor to reduce the possibility of
random cracking. If cracks do occur, they are to
be grouted with a low viscosity resin if they are wider than 0.5mm.
08. Plumbing
Internal works - water lines
Internal pipe work in Toilets and Kitchen to be concealed and carried out as per working
drawings. As per the heights mentioned in plumbing drawings, mark the line on walls by chalk
in proper alignment and plumb.

Start chasing of line using a chasing machine or chisel and hammer. The chasing should be done
keeping the following points in mind. Depth should not be more than pipe size. Width Sufficient
to accommodate the pipeline. Alignment Straightness should be considered. Height For all fittings
height as given in Drawing.
Check Class / Specifications of Materials. In absence of specification following may be used.
High Pressure threaded Blue UPVC Pipes of Schedule 80 to be used for cold water pipes made
of ASTM IS-17S5 and threaded as per IS 1239 (Part I) Class 1 Copper pipes as per BS 2871
Part 1 and fittings as BS 864 Part II should be used for Hot Water.
G.I. Fittings should be used for cold water - pipe work as per IS 1239 (Part II)
Prepare pipe-skeleton and check all joints for proper tightness. Only approved make pipes, pipe
fittings and accessories including jointing materials should be used.
Groove chasing should not exceed 30 mm after rough plaster for cold water supply line and cold
feed line and 50 mm for hot water supply lines.

While threading GI pipe at site, ensure square cut of pipe ends, chamfer the ends with a file,
insert proper size wooden plug in the pipe end and then carryout threading. The sharp edges of
gripping vice and other handling tools should be muffed with a suitable packing to prevent
damage of pipe surface.

The joints should be made with hand tightening of the fitting over pipe and covered with proper
layer of Teflon tape. To make the joint permanent, one to two turns over the hand tightened
joint is sufficient. Avoid over tightening as this may damage both the pipe and fittings

Special care should be taken while connecting UPVC pipe with G.I Fittings. High quality
shellac should be used for jointing.
Water tightness of line to be checked using pressure testing equipment. All other openings
should be plugged except end portions to which pressure gauge machine is connected.
The pressure reading should be above 7 kg/2cm (80 PSI); and there should not be even a single
drop of water coming out of the joints during testing. The duration of the test is 24 hours.

Cover the skeleton including fittings with good quality Hessian cloth and tie it properly for cold
water pipe work. Fix the skeleton in wall using 40 mm plumbing nails at 230 mm on alternate
side. Do the pressure testing once more after fixing in position and ensure no leakage.
Keep a gap of 10 mm between all pipes and fittings to accommodate thermal expansion and
contraction of pipes for longer life of the system. Horizontal lines within bathrooms should be
cement encased and tested before compacting of sunken floor to avoid any accidental damages.
Curing should be done over the plaster for at least 7 days.

Internal Works - UPVC Traps Installation

Determine correct location of P/Q/S Traps and set it on a firm base located relative to the floor
finish by pouring concrete on a slab.
Bedding can be carried out by pouring concrete around P/Q/S Traps, ensuring that outlet of Trap
is left clear on concrete.
Apply rubber lubricant on W.C. connector ring as well as on outer side of WC pan.
The outlet can be inserted in the socket end of pipe or fittings (as the case may be) and joint can
be solvent cemented to make a leak proof joint.

Jointing Instructions
Make sure the spigot end and inside of the socket is clean and the sealing ring is placed evenly
in the socket. When cutting pipes, make sure they are cut square. Chamfer the end cut to an
angle of 150 with a medium file. Cutting of pipes should be straight, as diagonal cutting leads to
leakages.

A correct depth of entry of the spigot into the socket is required to allow thermal movement. To
achieve this, push spigot fully into the socket (remove sealing ring at this time) and make a
mark on the spigot. Withdraw the spigot by 10 mm & mark the spigot with the bold line. This
bold mark indicates the correct depth of entry to allow the
necessary expansion gap.
Smear rubber lubricant evenly on the chamfered spigot and the sealing ring. Then insert the
spigot into socket with light twisting motion. Pull out the pipe to allow 10 mm expansion gap.

Maximum Support Distance in Meter

Size in mm 40 50 75 110 160
Horizontal 0.4 0.5 0.75 1.1 1.6
Vertical 1.2 1.5 2 2 2

External Pipe Work

Spacing of inspection chambers and manholes should be such that cleaning of sewer lines can
be done easily. Inlets and outlets of chambers and manholes are to be plugged during progress
of the work. It should remain plugged till completion of the sewer lines up to disposal so as to
avoid blockage / choke-up of sewer pipeline.

Ensure gully's/channels of inspection chambers/manholes are given a smooth curve if sewer

lines are intersecting at right angles. Bottom of gully's/channels should be laid in slope at inlet
to outlet of chambers and should be finished smooth.

All sewer pipes, traps and other fittings should be free from cracks, holes and burrs etc., and to
be checked before being put into use. Outflow of chamber should have 25 mm drop than inflow
of chamber.

Joints of sewer pipes to be plugged with cotton yarn (packing jute) before applying cement
slurry over joints. Heavy-duty chamber covers are to be used in parking and on road whereas
light duty covers may be used for other places. The covers used in manholes in sewer lines shall
invariably bear the word; 'SEWER' on the top and those used for storm water drains shall bear
the word 'STORM'.

Soil Waste & Rainwater (S.W.R) Drainage System Joining Instructions

Use only rubber lubricant for joining SWR pipes & fittings, where rubber ring is used.
Avoid misalignment of vertical SWR pipe stacks and incorrect spacing of pipe clips.
All entry to main stacks should be protected with water seal trap, wherever there is mixing of
soil & waste lines.
Keep a gap of 10 mm between all UV stabilized SWR pipes and fittings to accommodate
thermal expansion and-contraction of pipes for longer life of the system.
Smoke test should be avoided, and test plug / socket plug should be used for testing the lines.
Horizontal lines within bathrooms should be cement encased and tested before compacting of
sunken floors to avoid any accidental damages. When cutting pipes make sure they are cut
square.
Chamfer the end cut to an angle of 15° with a medium file.
A correct depth of entry of the spigot into the socket is required to allow the thermal movement.
To achieve this, push spigot fully into the socket (remove sealing ring currently) and make a
mark on the spigot. Withdraw the spigot by 10 mm & mark the spigot with a bold line. This
bold mark indicates the correct depth of entry to allow the necessary expansion gap.
Smear rubber lubricant evenly on the chamfered spigot and the sealing ring. Then insert the
spigot into socket with light twisting motion. Pull out the pipe to allow 10 mm expansion gap.
Tubes installed underground, lay on floors or in other inaccessible places must be able to
withstand twice the maximum working pressure.
While laying big pipelines, provision should be made for expansion joints, air vents and proper
anchorage. In case of longer runs, provide air valves at all higher points of ground. For large
diameter and higher-class pipes (6 kg / cm2 and above) always use heavy- duty solvent cement.
Within 24 hours, the rigid PVC pipes are ready for use.

Testing non-pressure installation above ground

The SWR drainage system can be use immediately after installation, as no waiting time is
required for joints to be set and dried. However, for testing, seal hermetically all openings
below the top of the section to be tested. The water level shall then be raised to a height of not
less than 3 meters above the highest point of the section being tested. Every joint shall be
carefully examined for leaks.
Duct & high-level pipe work
Pipe work in ducts and voids shall be supported from specially designed mild steel brackets and
cantilevers with swinging hangers. Roller type supports and *U' bolt clips shall be used.
The brackets shall be provided and fixed to the sidewalls, beams and ceilings, where a bracket
or support carries more than one pipe of different sizes, the spacing of the brackets or supports
shall be that specified for the smallest size of pipe. All pipes must be kept at least 150 mm from
lighting and power cables or conduits.
Pipes shall be spaced in ducts and below floors in a manner, which will permit subsequent
access to any pipe for maintenance or removal without disturbance to the remaining pipes.
All piping shall be grouped wherever practical and shall be erected to present a neat appearance.
Pipes shall be parallel to each other and fixed at right angles to structural members and shall
give maximum possible headroom. All pipe drops shall be truly vertical. All pipes must be
supported in such a manner to allow free movement for expansion and contraction and graded
to the required levels for air elimination and drainage.

Tools to be used by tradesmen

Required tools must be available at site to ensure correct work. Basic tools of the plumbing
gang are
1. Chisel 10. Mini Angle Grinding M/C
2. Chain Wrench 11. Drills
3. Pipe Wrench 12. Chasing Machines

13. Spirit Level

4. Sledgehammer
5. Screwdriver 14. Hammer Drill Bit
6. Bench Vice 15. Grinding Wheel
7. Pipe Vice 16. File
8. Die Set 17. Measuring Tape
9. Hammer Drilling M/C 18. Pressure Testing Machine

Inspection methodology for quality assurance

Check the direction of flow vis-a-vis the installation of pipes. The water must flow into the
sleeve. Check for leakage and subsequently establish whether due to faculty sealing [Insufficient
application of adhesive].
Check for slopes installed using spirit levels.
Ensure all joints are waterproofed to ensure leak proof pipes
Tools to be used for quality inspection
Spirit levels.
Plumb bob.
Measuring tape and related "Good for Construction" service drawings.
 09. Plastering

Checks prior to start of work

Ensure all the checks after block work is complied with .
The block work should have been cured for 7 days and dry before plastering is started. Button
marks the surface to be plastered keeping the bull minimum. 12mm plaster is the desired
thickness. Distance of button marks should be within an aluminum straight edge length.

Plastering mesh (Chicken mesh) should be 8" wide and fixed rigidly before plastering on the
junction between concrete and masonry surface with steel nails / wooden plug and nails. This
strip must be plastered and cured for minimum of 3 days before the entire wall is plastered.

Get the plastering specifications like lime finish, trowel finish, sponge finish, rough plaster and
zone of application clarified from architects. In case of external plaster grooves, it can be
incorporated to break the day's work without creating an uneven joint. The proposal should be
cleared for aesthetics from architect.

Do not plaster for a thickness of more than 15mm. In case it is required, the plastering should be
done in 2 coats. The first layer applied should be cured for a day before applying the subsequent
coats.
Cement of 43 grade OPC within 90 days old, Sand - FM 2 to 2.2, clean, fine silt content low
(<5%) and potable water should be used for mixing mortar.
All surfaces in concrete should be hacked (80 hacks per sq. ft) before plastering.

Checks during Plastering

All surfaces to be plastered must be wet to prevent absorption of water from plaster. Mix shall
be generally CM 1:4 for ceiling and 1:6 for wall plastering.

Mix mortar on MS sheet using measuring box for volumetric batching and measure mortar to
mix for consistency. Mix thoroughly for uniform mix and the CM should be used within 1h of
the mix.
After plastering check the surface for undulations using halogen lamps. Yellow light thrown on
the plastered wall from one-side shows undulations, if any, rectify immediately while the plaster
is still fresh. All cut- outs such as fan, junction box, electrical box and skirting line should be
finished to perfection.
Grooves and mortar bands should be given while plaster is wet.

Care to be taken after plastering

Cure the works for a minimum of 10 days. Write the date of plastering on the wall / ceiling with
permanent marker. All mortar spillage stuck to walls, floor and MS works shall be cleared after
the day's work.

Tools to be used by tradesmen

Required tools must be available at site to ensure correct work. Basic tools of the
plastering gang are
Trowels, Line thread, Sand Sieve Tube levels, Plumb
bobs, Measurement Tape, Spirit levels l-2m, Aluminum
straight edge, Right angle, Chipping Tools Masons
trowels, Floating trowel, Masons hammer,
Leveling threads, Masons brushes and buckets,
Mortar boxes, Water Barrel and
measuring can Halogen lamps, MS sheets,
Measuring box.
Inspection Methodology for Quality Assurance Internal plaster
Check for smooth finish using spirit levels for undulations, cracks and evenness / straightness in
vertical and horizontal directions. Ensure plastered surface is cured for entire recommended
period.
Ensure the 1-meter level markings are made along all walls. Measure the ceiling from this level -
it should be even at all points. [Check for ceiling plaster].
Ensure plastering is even at all points during plastering. Ensure the bull marking tiles are
removed.

External Plaster
Employment of specialized trowels to obtain different structural finishes for the external
plastering. No undulations and unevenness by using spirit levels.
Ensure all plastered surfaces are cured for entire recommended period.
Tools to be used for Quality Inspection
Spirit levels l-2m.
Measuring tape.
Related "Good for Construction" drawings.
 10. Gypsum works

Handling & Storage

Manual off-loading is only advisable on small sites. One man may carry small boards, but
generally two men will be required, and this will reduce the risk of damage to the boards. When
off-loading manually boards must always be carried on edge.

The boards should always be stored in a dry & covered place, sheltered from rain. They should
be supported on wooden battens, to avoid dampness from floors. These battens should not be
more than 45 cm apart on a flat surface. Gypboard should never be stacked on edge for long
periods as this can cause deformation.

Cutting
Gypboard can easily be cut either longitudinally or transversely. A cut should be made in the
face side of the board by means of a retractable knife. A line may be ruled prior to cutting, or
with practice. The rule may be drawn down the board at the required distance from the edge
whilst the board is scored with a knife at the end of the rule. Board should then be pressed with
both hands and the gypsum core will break in line with the cut in the side face. The board
should then be turned over and the other side paper be cut with the knife.

Sawing
Gypboard may be cut using a normal saw. A fret saw, or an electric tool may also be used for
cutting of curves. When large quantities of board are to be cut, the use of a circular handsaw is
advisable.

Making holes/ cut-outs

Electrical or manual carpenters' tools may be used for making cut-outs. Drills should be used
when making holes for electrical installations. For holes of diameter less than 50mm a high-
speed still drill gives a better result.

Planning
The edges of the board can be pared off using a plane. A file may also be used to level off any
irregularities, which may remain after cutting. The edges of both paper faces may be trimmed
up if necessary, using fine sandpaper.
Bending
Gypboard may also be used to line curved areas. The curvature radius will be 60cms for 9.5mm
Gypboard. Both sides of the Gypboard should be sprayed with water until they are damp. The
board should then be bent very slowly and carefully and fixed into position. Before joining, the
boards should be completely dry.

Jointing and Finishing

Gypboard is available with two different types of edge finish. The longitudinal edge may be
tapered of square, depending on the type of application and the convenience of using one or
another finish. Tapered edge board gives an invisible joint, the gap between each board being
filled and finished in such a way that the lining or partitions present a continuous, smooth and
seamless surface. Square edge board can be used when visible joint system is required
incorporating a surface joint strip, or where the board is required to be incorporated into a metal
grid suspended ceiling system.

Process of Jointing & Finishing

1st application - Embedding of paper tape into joints by using taping knife.
2nd application - After first application is dried. Second finishing coat is applied. 3rd
application - Final finishing coat application followed with topcoat.

Illustrative construction procedure

i. Ceiling. Suspended
Ceiling. Grid
Ceiling.
ii. Walls.
Half Partition walls.
Full-length partition walls.
Wall Lining.
iii. Joining and Finishing.

Tools to be used by tradesmen

The Gypboard range of accessories is designed to facilitate ease of handling. Ordinary tools can
be used to cut and work with this versatile material. However, to ensure more efficient handling
and a better finish, an extensive range of accessories are available.
Taping Knife
100 mm wide taping knife, flexible steel bladed knife for embedding joint tape.
Applicator
200 mm wide rigid Bakelite blade with plastic grip for applying Gypboard jointing compound.
Foot Lifter
For holding Gypsum board in position tight against ceiling leaving hands free for
fixing.
Electric drill with clutch attachments
Converts standard electric drill to a power screwdriver suitable for fixing Gypboard to metal
frame system.
Stud interlocking tools
Simple action punches through stud to lock two lengths together when using boxed or extended
studs.
Crimping tool
Punches and locks together 0.55 mm sections. Used for crimping at the base and head of the
partition or separating wall. Also used in Gypboard steel beam and column encasement system.

Inspection methodology for quality assurance

Check for line level plumb using the same tools used for block masonry.
Ensure the joints are recessed to 4 mm to 5 mm at the joints to the width of the fiber mesh.
Ensure fiber-mesh / paper tape is fixed for all joints and horizontal corners.
Ensure gypsum corner beads are fixed at all vertical joints. Gap between two boards should not
exceed more than 5 mm. Ensure two joints of Gypsum board are treated with only jointing
compound of Indian Gypsum Limited and not Plaster of Paris (POP).
Ensure horizontal bracings are provided for GI frame in partitions of more than 3m high. Ensure
horizontal bracings are provided for GI frame in slender partitions or places where switch plates,
wall mounted fixtures, etc. are fixed.

Avoid gypsum walls and partitions in water prone areas like toilets, pantry kitchen etc. The dust
from sanding at the joints should be removed either using soft cloth or soft broom before
start of painting works.
Ensure fisher plug with 35mm long GI screws are used for perimeter channel fixing and black star
screws of 25mm are used for fixing boards.
For prevention of cracks at joints ensure that: Paper tape is used and pressed properly at the
joints. 'V' grove is cut & filled properly at square edge joint. Drywall screws are properly driven
with clutch attachment, arresting movement between board & frame. Vibrations of A.C. duct/
generators are not passing onto the ceiling / partitions.

Tools to be used for quality Inspection

Plumb bob, Spirit levels 3m, Right angle, Measuring tape, Related "Good for Construction"
drawings.
 11. Waterproofing

Flat Roofs and Sloped Roofs

The surface to be waterproofed should be prepared thoroughly by chipping all cement mortar
deposits/ loose material, dust etc. using a chisel, wire and coir brush.
The surface, which is to be waterproofed, should be ponded with water and any dampness /
leakage should be marked in the ceiling below the terrace. Wherever leakage persists, 12mm
diameter GI nipples should be fixed depending on the depth of dampness, on such weak
locations in the ceiling, and is pressure grouted with neat cement slurry admixed with expansive
grouting. V grooves should be cut along the concrete / brickwork junctions on joints. Surface
cracks if any should be filled with polymer modified diluted solution and in cut-outs, around the
sleeves, drainpipe joints and filled with sealant.
Every upturn and pipe outlet should be reinforced with fiber mat between the two coats.

Two coats of Acrylic polymer based waterproofing system or equivalent should be applied on
terrace and parapet walls. One coat of neat cement mixed with polymer additive should be
applied as bonding coat.
A protective screed of 20-25mm thick should be provided with proper slopes. The treated area
should be plastered to required slope as per drawing and cured for a minimum of 3-4 days. To
ensure water tightness, the treated area shall be filled with water and tested.

Over the treated surface, weathering course tiles should be laid on the terrace maintaining a
proper slope.

Sunken Areas/ Slabs

The surface, which is to be waterproofed, should be cleaned thoroughly from all loose material,
and dust, using wire and coir brush.

The surface, which is to be waterproofed, should be ponded with water and any dampness/
leakage should be marked in the ceiling below the terrace.
Whenever leakage persists, 12mm diameter GI nipples should be fixed depending on the depth
of dampness, on such weak locations in the ceiling and it is pressure grouted with neat cement
slurry admixed with expansive grouting.
V grooves should be cut along the concrete / brickwork junctions on joints. Surface cracks if any
should be filled with polymer modified diluted solution and also in cut-outs, around the sleeves,
drainpipe joints and should be filled with sealant.

Two coats of Acrylic polymer based waterproofing system should be applied as a bonding coat
on the treated surface. All joints between the beam and block work should be covered with the
fiber mat.
Plaster the treated area with neat cement and high-grade waterproofing additive to the required
slope as per drawing to protect the coating from wear and tear.

The treated area should be subjected for testing by ponding water at least for a depth of 150mm
for 24hrs. The chasing for concealed plumbing and electrical works should be completed before
the start of waterproofing and the chasing must be treated with mechanical tools.

Over the treated area, stone dust should be filled and roughly finished with 75mm thick screed
concrete 1:2:4 to facilitate laying of tiles. The screed concrete floor level should be 20mm
below the main floor, to facilitate a level difference between main area and toilet after tiling and
to prevent toilet water entering the main area.

Methodology of Waterproofing in toilet and wash areas using chemical

compound Ensure the cement plastering for all toilet and shower areas are plumb, and at right
angles to the facing walls, ceiling and floor levels. Further the plaster should have an even
surface and a slightly rough texture. The flooring during the finishing stage must be adjusted to
the slope of screed level set towards water-outlets.

After sufficient time for setting of plaster, clean the plastered surface using a mason's brush of
all dirt and dust particles. Before each application, the base must be dry and free of all dust-
particles and foreign materials.
Mark out the areas to be waterproofed, with the help of a pencil, measuring tape and spirit
levels. Separate this area from the rest using masking tape.
Apply the base coat Latex Polymer based as the first coat. This coat is done uniformly using the
Masons brush over the entire area. Allow this coat to dry for about 20 minutes.
Let the drying process be natural and do not subject the area to any wind-draft.
During the drying period of the basecoat, the two-component sealing material (Polymer based),
made up of the powder component and the liquid component should be mixed slowly and evenly
in the ratio of 2:1, using the mechanical stirrer (imported from Germany for the purpose). For
example, for every 2 Kg of Powder component mix with 1 Liter of the liquid compound. Stir
this mixture slowly and uniformly into a homogenous mass free of any knots or nodules
(Mixing time- 3 minutes).

Now the well-mixed sealing medium maybe applied uniformly using the 6mm area teethed
trowels first vertically in all the corners, in the spray areas of the shower up to a height of 2
meters and in the rest of the toilet area to a height of 0.30 meters. Subsequently the Polymer
based sealing strip (caulking strip) will be placed along the corners
and fixed uniformly using the right edged trowel and pressed firmly along the corners.
Now please ensure that the sealing strip also called the
caulking strip, is fixed firmly in the corner ensuring
there is no air gap.

Subsequently the sealing compound is applied

uniformly using the 6 mm-teethed trowels ensuring
the thickness of the applied layer is maintained evenly
at 1 mm. In the region where
the pipe connections project from the plastered area, overlap such areas with the strips and apply
the compound to fix them.
After sufficient time for drying (About 24 hours), the second layer of 1 mm layer is to be
applied thus bringing the total thickness of the application to 2 mm. Now remove the masking
tape.
After allowing about 24 hours for drying, the walls are tiled, using "MURE IN-Flexi-mortar"
adhesive using the 6 mm teeth trowels.
After the walls are completely tiled, the flooring tiling is also taken up in a similar fashion. This
means repetition of the procedures 1 to 8 before the floor tiles are brought on, so that the
flooring is also well waterproofed and sealed.

Tools to be used by tradesmen

Required tools must be available at site to ensure correct work. Basic tools of the
waterproofing gang are

Dumpy levels, Line dory, Spirit level, Tube level, Plumb bob, Aluminum straight edge,
Trowels, Mason's brush, Mechanical Stirrer (German), 6mm teethed trowel, right edged trowel,
Finishing boards and sponge, Chipping tools, Hammer, Water barrel, Bitumen roller.

Inspection Methodology for Quality Assurance

Check whether method of waterproofing is as recommended by consultant and proper
application methods. Check whether all the drawings with relevant details for water proofing
treatment are available with the site staff.
The waterproofing supervision job card should be attached.

Tools to be used for Quality Inspection

Dumpy levels.
Spirit levels 3m.
Measuring tape.
Calculators.
12. Painting
Storage of Paint
All containers of paint, thinners and allied materials shall be stored preferably in a separate
room. The room shall be well ventilated and free from excessive heat, sparking and direct rays
of the sun. The lids of containers shall not be opened except when using the paint. The paint
shall be used before the expiry of its shelf life marked on the containers.

Checks prior to start of work

The approved and duly certified shade and type of paint shall be made available at site in
sufficient quantity. Ensure that the wall and ceiling surfaces are completely dry prior to the
application of paint. Ensure that all furniture and the flooring is protected before starting the
painting works. Proper scaffolding arrangement with safety measures to be taken. All loose
particles, dirt and dust must be thoroughly scrubbed from the surface using sandpaper. All
painting accessories
like brush, roller, mixing tray etc. to be
thoroughly cleaned and washed outside the
working premises before starting the works.

Primer application with brush dilution ratio not

to exceed 1:1 with water as thinner solvent.
A drying period of 24 hours is required before
the putty application.
Application of 2 putty coats, ensure the first coat is thoroughly dried before applying the final coat.
Putty to be applied uniformly to cover all undulations.
Proper sanding of surfaces to render a smooth surface prior to the application of paints. Ensure
that the dust on the surface is thoroughly wiped off after sanding the puttied surface.
 Guidelines to observe while painting
First coat paint to be applied with brush and finished with roller preferably with single mix and
dilution ratios not to exceed the below said criteria, i.e., 2 parts of paint to 1 part of water.
Ensure a drying period of 4 to 6 hours before application of the final coat of paint. All external
walls and semi-exposed areas such as balconies and utility walls, to be given a textured finish.
 13. Tiling

Storage of tiles
The tiles shall be stacked on edges on regular platforms in proper layers and tiers. Height of
stack shall not be more than 1 meter. During unloading, care shall be exercised to avoid
breakage. Tiles of different quality, size and thickness shall be stacked separately. Special care
should be taken to ensure different batch materials do not get mixed up.

Tiles supplied in crates shall be stored as such. The crates shall be opened one at a time as and
when required for use. Tiles supplied in cartons shall be handled with care. Within the site, the
tiles shall be transported on platform trolleys.
Manufacturer's test certificate to establish conformity with relevant IS Codes shall be furnished
by supplier.

Wall tiling
All chasing for the concealed piping and electrical conducing etc. shall be carried out before
commencement of work. In order to obtain uniform tonality, it is recommended to mix tiles
from different boxes for lying to great, harmonious tonality.
Backing plaster shall be initially carried out on the brick / block walls so as to achieve a
background that is fairly to plumb and at right angles in all corners.
This plaster shall be furnished rough to provide key while fixing of the ceramic tiles.
The backing plaster shall be carried out not earlier than 28 days after the masonry has been
constructed. So also, the ceramic tiling shall be fixed only after allowing a period of 28 days
after the plastering, to allow for shrinkage of the plaster.

Cutting of tiles should be kept to the minimum. Cut tiles shall finish into internal corners and
floor, wherever possible.
Make sure the distance from the skirting board or worktop to the top of the batten is no more
than on whole tile allowing the grouting gap. The main body of whole tiles – known as the 'field'
– is fixed first and the adhesive can dry – Then the border or edge tiles are fitted.
Tiles shall be soaked in water for at least two hours prior to use. Neat cement paste shall be
battered on the back of the tile pressed on to the background surface and tapped gently with a
wooden / rubber mallet.
Any gap between the tile and the background shall be filled with cement paste to avoid
hollowness behind tiles.
Wall tiles shall be fixed with a joint of 2.5mm between tiles. Proprietary spacers shall be used
for achieving a uniform joint width in all directions.
Great care shall be exercised to keep all courses perfectly horizontal and perfectly vertical.
From time to time, hold a spirit level or straight edge across the tile surface to ensure
straightness. All corners shall be provided with proprietary PVC corner strips and tiling started
beyond the strip. The joints shall be filled with a proprietary non-shrink waterproof filler
material of matching colour after a minimum gap of 24 hours and finished slightly recessed.

Tile Flooring
The concrete base to receive flooring shall be cleared off mortar dropping etc. and cleaned
thoroughly.
Cement mortar (1:3) screed shall be spread evenly in the room based on the "level dots" made
already and tamped. The recommended thickness of mortar should be in the range of 20-25 mm.
In order to obtain uniform tonality, it is recommended to mix tiles from different boxes for lying
to great, harmonious tonality.
Cement slurry of 'Honey' like consistency (1 bag to 60 liters of water) shall be prepared and
spread on the mortar bed to an extent that can be covered with the tiles within half an hour. The
tiles shall be placed on the slurry coat matching all four corners and fixed in place with the help
of a wooden / rubber mallet.

Alternatively, tiles can be laid on a bed of adhesive using plastic spacers, to create a gap
between tiles, which can be grouted later. Lay around one sq. meter of adhesive at a time and
press the tiles into place, with correct gap provided by spacers, available in different thickness.
Proper slopes shall be given in flooring of toilets and balconies to ensure quick drainage of
water on the surface.

Floor tiles shall be laid with minimum joint width, which shall be grouted with a proprietary
non-shrink, waterproof filler material.
After the tiles have been laid, clean the joints thoroughly with a brush to remove loose mortar
before it dries up.
For the tiles to set properly it is essential to allow a 24-hour setting period before filling. Do
not allow anyone to walk on the freshly tiled surface.

Grouting
Grout shall be used approved type and brand only. The gaps between ceramic tiles need to be
filled with grout. Plain and coloured ready mixed grouts are also available. To spread the grout,
use a rubber squeeze making sure it is pushed (well into the gaps between the tiles.

Remove excess grout regularly as it is difficult to get off once it has been allowed to harden.
Wipe off the extra grouting (before it sets hard)with a damp sponge and polish with a dry cloth.
Filling of grout in the floor will be the last activity only to be done along snagging. All grouts to
be of lighter shade of the tile.
Chipped tiles should not be used. All ceramic and terracotta tile should be immersed in water 12
hrs. before laying. Stick the name of the
tile mason over the tiled area done by him.

For skirting using vitrified or ceramic tile the wall

level and tile level should be flush with 4 mm pre-
groove. However, avoid using cut tiles for skirting
unless skirting tiles are factory manufactured and
come with chamfered edges. Granite / marble skirting are preferred. Cure all tiling works and
joint filling works for 3 days.

Tools to be used by Tradesmen

Required tools must be available at site to ensure correct work. Basic tools of the tiling gang are
Trowels, Line thread, Tube levels, Plumb bobs, Measurement Tape, Spirit levels l-2m, Sand
sieve, Aluminum straight edge, Right angle, Chipping Tools, Masons hammer, Rubber
hammer, Leveling threads, Tile cutter, Masons brushes and buckets.
Mortar boxes.

Inspection methodology for Quality Assurance

Check for conformance of the tiled pattern, specifications and tile grout colour to the approved
drawings. Check for uniformity in line, level and grout thickness visually.
Check of straightness of tiled surface. The fresh tiled surface should be of proper level using a
spirit level / Aluminum straight edge or line thread.
Ensure the cement and the sand have been checked / tested prior to tiling. Ensure that no tile is
broken / cracked, and the joints are well filled.

Tap the tiled surface to check for hollowness. The tiled surface should be covered with POP /
tarpaulin sheets to prevent damage to the tiled surface.

Tools to be used for Quality Inspection

Plumb bobs.
Spirit levels l-2m.
Aluminum straight edge.
Measuring Tape.
Approved "Good for Construction" Drawings.
 14. Structural Steel Works

Refer latest duly approved "Good for Construction" drawings only. If the fabrication works
are done at site, ensure proper electrical connections and proper working platform.
All the joints should be properly welded from either side. Excess weld should be grinded off
but ensure too much of grinding should be avoided on welded joints as it may tend to weaken
the joints. After grinding the edges and all corners should be finished off with metal paste.

Allow the metal paste to completely dry and sand the parts to perfection. Avoid
chamfered or filleted edges; ensure joints to be in perfect plane and perpendiculars. Apply one
coat of metal primer with brush before fixing. Ensure rosettes are placed in position before
fixing the grills or railings.
Painting 2 coats enamel for railings after the completion of external painting works. Anchor bolts
to be used instead of coach screw, for fixing railing to concrete block work.
Rosette detail to be given for all holdfasts going into wall/ floor.
Rosette should be painted keeping it away from the wall and after drying pushed to fix in
place using spot adhesive. All mortar spillage stuck to MS works shall be cleared after the
day's work. It is good practice to cover the grill with a plastic cover while the plastering is in
progress.

Tools to be used by Tradesmen

Required tools must be available at site to ensure correct work
Trowels, Line dory, Sand Sieve, Tube levels, Plumb bobs, Measurement Tape, Spirit levels l-
2m, Right angle, Chipping Tools, Masons trowels, Floating trowel, Masons hammer, Leveling
threads.

Inspection methodology for Quality Assurance Ensure plastering is cured for entire
recommended period.

Tools to be used for Quality Inspection

Spirit levels l-2m, Measuring tape, Related "Good for Construction" drawing.
 15. Doors
Doors
Door fixing involves fixing of three components - Door Frames, Architraves and Shutters. Door
fixing should be done in such a way that the frame binds well with the wall.
The door frame must be plumb to ensure shutters close without nudging.
The colour of the shutter, architrave and door frame should match to give a uniform look.

The door frame is fixed only after all civil works for that area are completed. The first coat of
Painting and the flooring should be complete.
While unloading, shifting, handling and stacking, care shall be taken to avoid dragging one unit
over the other as it may cause damage particularly to decorative surfaces. The material should be
lifted and carried preferably flat to avoid damage to corners/sides. If the materials are received
in crates, they shall be stacked as such and removed from the crate as and when required for the
work.

The Site Opening sizes to be perfect and in conformance to actual doorframe size. Aluminum
templates / sub-frames must be adopted on-site for all door and window openings. Calibrated
Aluminum templates should be used for finishing openings like doors, window ventilators,
exhaust fan opening, AC openings etc. Sufficient gap should exist between the finished wall
surface and frame for the Worth Glue. (10 mm recommended). All dimensions i.e. height, width
and the wall thickness should be properly checked.

Place the inner frame in position. Check the plumb and tighten the doorframe on the inner frame
with wooden wedges. Once the frame is assured to be in plumb fill the gaps with polyurethane
foam (Worth Glue). Leave the frame for 2 hours to set.
Worth glue should be pumped in adequate quantity to avoid any shaking of the door frame.
Clean up the surface of the frame after the glue has dried and place the architrave on the frame
and check for any gaps and sand accordingly to attain a final smooth surface. Fix the architraves
with lamellose and Lacquer Glue.

Allow the architraves to set for 2 hours. Tighten the surfaces with C- clamps. Hang the shutters
with hinges using screws; fix the Iron Mongeries and doorstopper.
Cover the door handle with foam. Cover the door shutter with green polythene sheets and
masking tape before the second coat of painting commences. The sealant is the last
activity before handing over to Client, done by specialized workers only.

Tools to be used by Tradesmen

Required tools must be available at site to ensure correct work.
Plumb bob.
Chisel.
Hammer.
Planer.
Worth Glue gun.
Drilling machine.
Worth Glue.
Lacquer Glue. Plywood
Inner Frame. Inner
frame/wedges. Clamps.

Inspection methodology for quality assurance

Check the Doorframe, Front Architrave, Back Architrave and shutters for Perpendicular, using
spirit levels and right angle. Colour homogeneity of the Doorframe, Front Architrave, Back
Architrave and door shutters must be ensured for uniformity.
Door shutters should close without nudging and a uniform gap should be visible between the
doorframe and shutter. The horizontal and vertical gap between the doorframe and plastered
wall should be filled with silicone sealant.

Tools to be used for quality inspection

Plumb bob. Spirit
levels l-2m. Right
angles.
Approved drawings and schedule of openings.
 16. Installation of UPVC window

Window installation involves the fixing of window frame at an earlier construction stage and
subsequent installation of the window sashes.

Installation of Sub-frame
The sub-frame system comprises a sub-frame which is either cast in or anchored to the wall. The
main frame is then installed onto the sub frame at a much later stage of the construction.

Proper alignment and settling out of the sub-frame are crucial in ensuring the ease of operation
of the window. Positioning of sub-frame using ride up blocks or aluminum shin plates. Checking
of plumb and alignment of sub-frame.

After confirming the setting out of the sub-frame, anchor the sub-frame to the wall. Sub- frame
should be temporarily stiffened with PVC packs near the point of anchoring/ bolting. Insertion of
stiffeners near the anchoring/bolting points.

Fixing of sub-frame to the wall. Anchor/bolt heads and joints between external wall and sub-
frame shall be sealed with sealant for effective water tightness. Sealing of anchor/bolt heads.
Sealing of joints between external wall and sub-frame.

Protective tapes should remain intact throughout the subsequent construction works. The
temporary stiffeners should also remain in place prior to installation of the inner frames.

Installation of Mainframe
After completion of all the wet trades (plastering/dado/cladding/etc.,) around the window
opening, the main frame is then fixed onto the sub-frame. Prior to fixing the main frame, the
sub-frame should be checked for any physical damages. Any damaged sub-frame should be
repaired or replaced. Setting out of the sub-frame should also be verified before the installation
of the main frame. The sub-frame should be cleaned and clear of the dust and debris. Dust and
debris accumulated in the sub-frame could affect the alignment and fixing of the main frame. It
may also cause blockage to the weep holes, resulting in overflow of incidental water into the
interior.
Verifying setting out of sub-frame. Clearing dust and debris from sub-frame. The installation of
main frame should be carried out only by trained and approved vendors.
Fitting the main frame onto sub-frame. Fitting of the finishing trim. Millet should be used to
knock the finishing trim in place.

Sealing of gap between wall and window frame

The gaps between the window frame and wall must be properly sealed to prevent water seepage
at these locations. Depending on the size of the gap, waterproof grouting or sealant can be used.

Application of sealant
Sealant could be used to seal the gap between wall and window frame if the gap size is between
7-10 mm. Before the application of sealant, clean the aluminum window frame with white spirit
using a clean rag. The frame and wall surfaces around the gap should be protected with masking
tape to prevent the sealant from staining these surfaces and to obtain a neat sealant joint.
The joint should have continuous caulking to ensure that all areas are filled.
Remove the excess sealant and tool the joint to achieve a smooth surface.

Installation of Window Glazing

It is recommended that glazing work for inner glass panels are carried out in the factory, where
higher work quality can be achieved. Where this is not possible, glazing work must be carried
out on site with proper handling and good workmanship. For fixed glass panels, glazing is
usually done on site.

The protective tapes should only be removed when glazing works is to be carried out. The
following verification works should be carried out prior to glazing work. Window frame:

Inner frame and associated hardware should be checked for defect. Damaged frames or
hardware should be replaced. Inner frame should be cleaned and free from dust and debris.
Weep hopes in the inner frames should be cleared of blockage to allow discharge of incidental
water.
Glass panel:
Compliance with physical specifications such as dimensions of panel. Labels on the glass panels
should be checked against the window schedule. For tempered/Laminated glass, check for the
associated log/ trademark labels. The orientation of the glass panels should be standardized such
that the positioning of these logos/trademarks is consistent.

Gasket:
Gasket should be checked for any physical damages. Defective gasket should not be used.
Gasket should be free from dust and dirt to ensure good grip onto the frame and beadings.
Profile of the gaskets should be compatible with that of the beads used to secure the glass
panels.

Installation of accessories:
Window installation is completed with the fixing of accessories, including handles, locking
devices, etc., Alignment of the accessories should be checked during and after installation.
Precaution should be taken to avoid damage to glass panel and window frame during fixing the
accessories.
The accessories should be protected until all construction activities are completed.

Water tightness test.

Field water tightness test should be carried out to verify the water tightness performance of the
installed windows.
 17. PEB Erection work

Column erection
As per erection sequence the primary erection will start from braced bay at Grids. Column is
made ready with all Fixtures, painting duly Completed. Wire Sling is fixed to the column at exact
lifting position. Guy Ropes are fixed to the column before lifting.
Lifting Equipment lifts the Structural Column Vertically and is positioned in the Pedestal. Anchor
Bolts Nuts are fixed and tightened. Guy Ropes are tied all four sides to provide adequate
supports.
Column plumb is checked, and Wire Sling is released using Boom lift.

Braced column erection

Same Procedure is followed for lifting the second column.
The Portal beam is the primary tying member between the two columns. It is lifted using Crane
and boom lift is used for bolting the portal
beam.

The Eave Strut is immediately erected after the

erection of second Column, if it is not a braced bay.

The Eave Strut being a cold form member can be lifted using crane.

Bracing Rods can be lifted using crane and fixed to the adjacent Columns. Hill Side washers are
used to tighten the brace rods. The same procedure is followed for erection of the columns on the
other side of the grid.

Assembly of rafter segment

The segments of Rafter are shifted from stacking yard to the required position of Erection.

With the help of Erection Part Mark Drawing the Rafter Segments are assembled in the ground.
The High tensile bolts are used for connecting the segments of the Rafter. The Erection Manager
at Site ensures that Specified Torque and its limits are used by the erection team as per approved
torque table issued by the Designer.
All fixtures such as purlin Clips Flange Braces are fixed to the Rafter at ground which helps in
easy alignment of the structural Member after erection. Guy Ropes are used as temporary
supports for the Rafter before fixing of its secondary members. These Steel Ropes are also fixed
to the Rafter before Erection of Rafter.

Erection of rafter
The Position of lift of Rafter is also designed by studying the Bending Moment Diagram of the
Assembled Rafter’s Lift. The Crane load Carrying Capacity during the lift of rafter is studied and
Higher Load Carrying Capacity Cranes are used for Erection of Rafter.

Essential Safety Devices of Lifting Equipment’s Such as Safe Working Load Display System.
Overload Indicator, Limit Switch must periodically Checked and Inspected in Internal Safety
Audits by Safety In charge.

Bolting of rafter with column

Once the Rafter is lifted to the required Position of Bolting, boom lifts are used to fix the Bolts at
the Connection of Column and Rafter.

The Alignment of Rafter can be adjusted using tested and certified Turn buckles which are fixed
in the Guy Ropes tied to the Heavy Kelly Blocks. After Stabilizing the Rafter with all its
Connections and Guy Ropes the Cranes can be released for the immediate lifting of next Rafter.

Lifting of second rafter

The same procedure is adopted for lifting of next rafter.
After lifting the second rafter the secondary members are lifted using cranes and fixed between
the two rafters. All the secondary members connecting the rafters are fixed with the help of Boom
Lifts.
The bracings between the rafters are also erected simultaneously immediately after the erection of
Roof Purlins.

Erection of remaining frames

After Erection of all the structural fixtures of Braced Bay, the Next Frame can be taken up for
Erection. The Same procedure should be followed for erection of the successive frames. All
secondary members should be erected before erection of successive Grid.
Plumb and Alignment of Structure should be checked before erection of next Frame. After
Completion of two Successive Braced Bays, Purlin Fixtures such as Sag Rods can be fixed. Guy
Ropes for the Braced Bay Should not be removed till the Completion of Sheeting Works.
METHOD STATEMENTS FOR FIRE PROTECTION SYSTEM
 Fire Protection System

Scope
This Method Statement refers to various work procedures contained within Client Project
Quality Assurance Plan & Contract Specification, which explains and covers the installation
of Fire Protection system. (Fire Hydrant System, Automatic Sprinkler System, Portable Fire
Extinguishers, Fire Pumps).

References
Client Project Quality Plan.
Client Health Safety & Environment Plan.
National Building Code (NBC).
Approved Technical Data Sheets.
Design Intend Drawings & Approved Shop Drawings.
Manufacturer's Catalogues & Recommendations.

Tools/ Equipment’s
Welding Machine.
Hand Drill machine / grinding machine. Pipe Cutting Machine.
Water Tank and Hose. Sprit level.
Plumb bob. Hammer.
Ladders & scaffolding. Cutting set.
Hand Grinder.
Hydrostatic Pressure testing pump with calibrated gauge. Paint Brushes. DFT
meter

Materials
The received Firefighting system's pipes shall (Mild Steel, Heavy grade-C Class, Plain End)
confirms to IS:1239 up to 150mm dia and IS:3589 for above 200mm dia, Fire Fighting
Pumps, Fire Hydrants, Fire Hose Box, Hose Reels, Landing Valves, Fire Extinguishers used
for Fire Protection system shall confirms to approved Technical Data Sheets.
Upon receipt of Firefighting system's pipes, Firefighting Pumps, Fire Hydrants, Fire Hose
Box, Hose Reels, Landing Valves, Fire Extinguishers, the materials shall be checked by
QA/QC Engineer / FPS Engineer-In charge thoroughly before offering to the Consultant for
Inspection / Approval.

Handling & Storage

The Fire Fighting pipes and fitting while unloading shall be slowly lowered not dropped to
the ground. Protection shall be provided if chains are used to tie down the piping load during
unloading / loading.
The storage area shall be kept in proper level, and the stacked pipes shall have uniform
supports (spacing not more than 4.0 meters) throughout their length. Material shall be kept
100mm above the ground level. Manufacturer’s instructions shall be followed for storage,
wherever applicable.

If mechanical lifting equipment is used, ensure no metallic slings, hooks or chains will be
used in direct contact with the pipe. Rope or nylon belt sling will be preferred which will not
damage the pipe surface. The pipes stacked in External storage area shall be properly
covered with tarpaulin sheet until taken out for installation.

All the pipe fittings shall be stored in the boxes /gunny bags as supplied by the fitting’s
manufacturer. Upon receipt of Fire hose Box, Hose Reels, Fire Hydrants, Landing Valves,
Fire Extinguishers used for Fire Fighting system, the materials shall be handled & stored in
covered storage area properly.

Upon arrival at site, the materials shall be off-loaded carefully using necessary manpower
and required equipment to ensure that no damage is caused to the materials.
All the received Fire Fighting pipes and its accessories shall be checked with respect to
approved Technical Data sheets then offered for Consultant Inspection / Approval.

Any discrepancies, damages etc. found during receipt shall be identified and handled
separately.
Fire Fighting Pumps and its accessories shall be off-loaded carefully using necessary
manpower and required equipment to ensure that no damage is caused to the Fire Fighting
Pumps and its accessories. Materials shall be stored with proper identification and
traceability.

All the received Fire Fighting Pumps and its accessories shall be checked with respect to
approved material submittals in terms of their make, model type, point of origin and capacity
etc. and then offered for Consultant Inspection / Approval.

Any discrepancies, damages etc. found shall be identified and handled separately.
 18. Installation procedures

To carry out installation activities for Fire Fighting System, below mentioned procedure shall be
followed step by step in sequential manner. Installation of Fire Fighting Pipe works - Main
Distribution Pipe works for automatic sprinkler, Fire Hydrant and Valves

Ensure only latest revision of Approved shop drawing and Coordination drawings are used for
installation. Shop drawings to be submitted to MEP design team for review and approval. Mark
the pipe routing on the soffit of slab, duly coordinated with other services and as per the
approved coordinated shop drawings / Reflected Ceiling Plan Drawings.

Two coat of approved Zinc rich primer shall be applied for Fire Fighting piping before
installation. Thickness of each coat shall not be less than 25 microns.
All pipes and valves shall be installed as per approved firefighting Construction drawings.

Install hangers and supports of approved material submittal and as per approved installation
details / Manufacturer recommendation. Supports distance shall not exceed Maximum 4 meters
in any case. Provide Additional Supports in Elbows and in Main branch take off. Structural
Steel supports with 'U' clamp shall be used for vertical riser pipes where pipes passing through
the shafts. All such supports shall be as per approved shop drawings.
The support spacing for the FPS pipes shall be in accordance with the approved shop drawings.

PIPE SIZES SUPPORT SPACING (MAXIMUM) IN MTRS

25 NB 2.0 MTRS
32 NB TO 50 NB 2.5 MTRS
65 NB TO 80 NB 3.0 MTRS
100 NB TO 150 NB 4.0 MTRS

The pipes shall be installed at designated levels as per approved coordination drawings. The
pipes shall be cut to required length. All sharp edges and burrs shall be removed by grinding the
surface.
The piping system should be straight as possible. Necessary changes of direction shall be made
with approved pipe fittings. Before joining, the pipes and fittings shall be checked for defects
and jointing surfaces has been cleaned thoroughly.
Pipes up to 50mm dia shall be joined by Socket welding, and pipes above 65mm dia shall be by
Butt welded or as per specification. Flanged joints shall be made with 3mm thick insertion
rubber gasket.

Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR) shall be
prepared for the process adopted for the wielding. The welder’s qualification and approval shall
be ensured before deployment of welding personnel. All welding works shall be carried out as
per WPS. Welding register shall be maintained for each of the joint with welder identification to
check the quality of weld at job site by respective welder. All safety procedure shall be followed
before commencing any welding works and while carrying out welding works. Where welding
works carried out near inflammable materials, precaution shall be taken to prevent any fire
hazards

All valves shall be installed as per approved shop

drawings and adequate space shall be available for
operation. Valves shall be installed with stem in the
upright or horizontal position.
The valve flanges shall be jointed with nut and bolts to the piping system. Approved air vents
shall be installed at the top of each riser as per the details given in the approved shop drawings.
Test and drain assembly shall be installed to test the water flow in the automatic sprinkler piping
network. Location of the assembly shall be as per approved shop drawings.

All installed Fire Protection system piping works shall be thoroughly checked and shall be
offered for Consultant Inspection & Approval.
After completion of installation in all respect Hydrostatic Pressure test shall be conducted as per
the procedure. (Refer test procedure)

All pipes above ground and in exposed locations shall be painted with two coats of synthetic
enamel paint of approved shade.
 19. Installation of underground Firefighting pipeline

Check the alignment, dimension, level of excavation before proceeding the pipeline lowering /
installation. Pipeline shall be laid to a minimum depth of 1meter (top of the pipe) from the
finished ground level. The pipe joints shall be properly welded, and hydro tested before
backfilling.

Pipes shall be ensured for proper cleaning. Ensure welding of pipes shall be done as per WPS.
Wrapping one layer of 4mm thick anticorrosive tape of 150/250mm width with overlapping of
15mm and shall be wound in a spiral fashion and bonded completely to pipe by thermo fusion
process. Pipes shall be lowered to the trench and alignment of piping shall be done. Any
welding on existing line / spot welding shall be done with proper working

space, shall be finished with touch up primer painting, wrapping and such a joint shall be
inspected during final pressure test. Testing of field weld joints shall be carried with DPT.

All the underground pipes shall be Holiday tested for damages of Anti corrosive treatment and
damages should be rectified before closing of trenches.
 20. Installation of Automatic Sprinkler Heads, External Fire Hydrants, Fire
Hose reels, Landing Valves and hose pipes, Fire Brigade inlet
connection

After the first fix installation (Main & Distribution Pipe works) work, sprinklers shall be
installed. Sprinklers above false ceiling shall be upright sprinkler and below false ceiling shall be
pendant type as per the approved material submittal.
Sprinklers shall be located as per approved reflected ceiling plan drawing showing coordinated
sprinkler head locations. The sprinkler heads shall be UL listed

with quartzite bulb, rated temperature -68deg.C. Sprinklers shall have ½ inch threaded ends.
Teflon tape shall be put over thread of the sprinkler and the sprinkler shall be tightening with
screwed fitting by using special sprinkler wrench.

Sprinklers for below false ceiling shall be dropped by using flexible pipes of approved make &
size and length. Sprinklers for below false ceiling shall be fixed with recessed (two piece) type
Rosette plate.
Location of the Fire hose reels shall be
installed as per the approved Shop
drawings.
The hose reels shall be installed on a
swinging arm within fire shaft all in
accordance with the manufacturer's instruction. Each hose reel shall be connected to supply and
stop valve, strapped and locked in the open position or of lock shield pattern.

Fire hose cabinet shall be installed as per coordinated and approved fire protection drawings. The
landing valves, External Fire Hydrants, Fire brigade inlet connection shall be installed as per
approved material submittal.

Fire hose cabinet / Fire shafts shall be marked noticeably "FIRE" 80mm size on both doors.
Ensure that the Fire hose cabinet contains fire hose with nozzle as per approved shop drawings.
All fire extinguishers shall be provided as per approved shop drawing. Location of fire
extinguishers shall be as per approved construction drawings.

All the installation works shall be inspected, and checklists shall be maintained.
 21. Installation procedures for firefighting pumps

To carry out installation activities for Fire Fighting Pumps and its accessories, below mentioned
procedure shall be followed step by step in sequential manner.

General instructions for installation of firefighting pumps:

All equipment (Electric driven pump sets, Diesel engine, jockey pump and controllers etc.) shall
be slowly lowered and kept on the place where they must be installed in the building. Protection
shall be provided if chains blocks are used to tie down the equipment are during installation
process.

While shifting of equipment’s, safety precaution must be taken to avoid any damage to equipment
or any causality.
It shall be ensured that proper clearance is available from civil works before commencement of
works.
It shall be ensured that the work area is clean and safe for carrying out the activities. Prior to
start of works, it shall be ensured that the relevant shop drawings and coordination drawings
are approved and issued for construction.
It shall be ensured that all electrical requirements such as cable trays, entry side lugs, glands etc.
are finalized and coordinated.

All equipment’s shall be properly covered / protected.

 22. Installation procedure for electric driven fire pump

Visually inspect the exterior casing of the Electric Driven Fire Pump and its accessories for any
damages during shifting and transferring of the units to the Fire pump room.

Electric Driven Fire Pump and its accessories shall be as per approved material submittal.
Ensure the area of installation and foundations for pump are good for operation and
maintenance.
Pump shall be installed on concrete foundation as per manufacturer’s recommendation and
approved material submittal.

Ensure the Manufacture’s guidelines are strictly followed for installation and preservation of
Manufacturer guidelines to handover to the consultant. Gate valve and Non-Return Valve shall
be installed as per the approved shop drawing for each pump as the procedure described above.

A threaded type coupling shall be fixed on the discharge manifold for pressure gauges. Pressure
gauges are screw type shall be installed on the discharge manifold by using Teflon tape. All
discharge piping shall be done as per the approved shop drawing.

The control panel shall be installed as per the approved material submittal / approved shop
drawing. Ensure the electric supply to the panel shall be done as per the approved electrical
Drawing and Method Statement.

Fabricated MS angle supports shall be painted with two coat Zink rich primer and two coat of
enamel paint (Black painted). It shall be installed to support the piping, all Valve etc. as per the
approved drawings. Alignment of Pumps shall be done before commissioning. Installed pump
shall be offered for Consultant’s Inspection.
 23. Installation procedure for diesel engine driven fire pump

Visually inspect the exterior casing of the Diesel Driven Fire Pump and its accessories for any
damages during shipping and transferring of the units.
Diesel Driven Fire Pump and its accessories shall be as per approved material submittal. Ensure
the area of installation and foundations for pump are good for operation and maintenance.

Pump shall be installed on concrete foundation as per manufacturer’s recommendation and

approved material submittal. Manufacture’s guidelines for installation shall be followed which
shall be supplied with the delivery of the pumps.
A discharge piping shall be done as per the approved shop drawing. Gate valve and Non- Return
Valve shall be installed as per the approved shop drawing for each pump.

Pressure gauges shall be installed on the discharge manifold. Diesel engine shall be installed as
per the approved drawings and material submittal. The control panel shall be installed as per the
approved Shop drawing / Layout.

Engine shall be installed on the concrete pedestal with base frame. Alignment of Pumps shall be
done before commissioning. Engine fuel tank shall be installed as per the approved shop
drawings. The fuel piping shall be done as per technical specification.

Fuel Tank shall be installed as per the approved shop drawing. Engine back up batteries shall be
installed as per the approved drawings. Wiring from batteries to engine shall be done as per the
requirements of the manufacture. The control panel shall be installed as per the approved Shop
drawing / Layout. Ensure the electric supply to the panel shall be done as per the approved
electrical Drawing and Method Statement.

Fabricated MS angle supports (Primer & Black painted) shall be installed to support the piping,
all Valve etc. as per the approved drawings. Installed pump shall be offered for Consultant’s
Inspection.

Exhaust piping shall be insulated with rock wool insulation and the external surface shall be
cladded with GI Sheet.
 24. Installation procedure for jockey pump

Visually inspect the exterior casing of the Jockey Fire Pump and its accessories for any damages
during shipping and transferring of the units. Jockey Fire Pump and its accessories shall be as
per approved material submittal.
Ensure the area of installation and foundations for pump are good for operation and
maintenance.
Jockey pump shall be installed on concrete foundation as per manufacturer’s recommendation
and approved material submittal.

Manufacture’s guidelines for installation shall be followed which shall be supplied with the
delivery of the pumps. Jockey pump discharge piping shall be connected to main header.
Gate valve and Non-Return Valve shall be installed as per the approved shop drawing for each
pump. The control panel shall be installed as per the approved material submittal
/ approved shop drawing.

Ensure the electric supply to the panel shall be done as per the approved electrical Drawing and
Method Statement. Fabricated MS angle supports (Primer and Black painted) shall be installed
to support the piping, all Valve etc. as per the approved drawings. Alignment of Pumps shall be
done before commissioning.

Installed pump shall be offered for Consultant’s Inspection.

 25. Painting of Pipes & Fittings - Methodology

Surface preparation: (Base preparation)

Contractor shall ensure prior to the commencement of painting job, all relevant inspection and
testing of pipes has been completed and all rectification has been completed.

External surface of pipe shall be cleaned before initial priming and the minimum surface finish
as specified in respective literature of paint system. Remove grease, oil and other contaminants
preferably by using mechanical tools (Power wire brushing) along with manual chipping and
wire brushing to remove loose rust.

Performance and longevity will depend on the degree of surface cleaning achieved. The applied
cleaning method shall not result thinning of the pipe wall beyond the limits of the pipe
specification. Cleaning shall be carried out immediately before application of the priming coat.
Piping shall not be carried out under damp or frosty condition unless approved means of
heating and drying of pipes are used. Base preparation shall be done by applying Phosphate
solution.

Procedure: (Prime coat + Final coat)

Prior to the commencement of paint work, ensure all manufacturer recommended tools are
available at site. Stir the components thoroughly and then mix base and catalyst in equal
proportions by volume to uniform consistency, avoid over agitation if mixing is done with
power mixer.
Add 10% thinner T4 immediately before application or as per manufacturer’s product
specification.
Application of first primer coat should preferably be done by brushing by using short bristle for
working the material into all irregularities. Primer coat paint and finish coat paint both shall be
of same manufacturer and must use only approved makes recommended by Client. To achieve
desired performance, it is essential that recommended film thickness is obtained (Min thickness
of paint 130 Microns).

Any pipe that has become wet after cleaning and priming shall be re-cleaned to the required
standard and re-primed. After drying of first coat application, after 5hrs -24 hrs. gap second and
final coats shall be applied.
 Painting Scheme (External):
Phosphating Solution
Prime coat - Epoxy paint, (1 or more coat min 60 Microns) (60 Microns) Final
coat - PU Paint (2 or more coat, min 35 Microns each) (70 Microns)
Recommended makes of Paints:
a. Asian Paints (I) Ltd.
b. Berger Paints (I) Ltd. c. AkzoNobel (I) Ltd.
c. Shalimar Paints
Note: Contractor shall strictly follow all safety precautions mentioned in the Manufacturer
Material Safety Data Sheet (MSDS).

Painting Scheme (Internal):

a. Phosphating Solution
b. Primer coat (2 or more coat, min 30 Microns each) (60 Microns)
c. Final coat - Synthetic Enamel (2 or more coat, min 35 Microns each) (70 Microns)
Recommended makes of Paints:
a. Asian Paints (I) Ltd.
b. Berger Paints (I) Ltd. c. AkzoNobel (I) Ltd.
c. Shalimar Paints
Note: Contractor shall strictly follow all safety precautions mentioned in the Manufacturer Material
Safety Data Sheet (MSDS).
 26. Testing

A. Hydrostatic Testing
Water leak test shall be conducted to ensure and prove the tightness of the joints and ensure that
there are no leaks in the piping.

The water pressure test shall be applied to the system in full or in sections. If the systems are tested
in sections, the connections to the previously tested section shall be included. The pipes shall be
jointed properly, plugged properly except for the point for air release.
A minimum of two numbers identical
calibrated pressure gauge shall be installed at extreme of the piping circuit being tested. Pipe shall
be filled with clean water by temporary water supply, leaving all high points open to vent all
entrapped air.

After all air from the system is released, the all air vent point shall be plugged. Piping shall be
pressurized gradually by using mechanical
pump.

The Fire protection piping systems shall be tested

hydrostatically for not less than 2 hours at 1.5times
of the system working pressure without leaks as
per the contract specification.

While the system is under pressure, a careful inspection shall be made for all pipes and joints and
if any leak in joints or evidence of defective pipe or fitting is found, the defective work shall be
corrected immediately by replacing defective parts with new joints and materials. After the
correction is made the pressure test shall be repeated for the piping network.

The testing will be witnessed by the consultant to their satisfaction and approval shall be obtained.
Only after approval of testing water pressure shall be released.

After testing all pipes shall be flushed with portable water to remove foreign materials.
B. Holiday Testing
Underground pipes after lowered to into trenches shall be Holiday Tested for damages of
Anticorrosion treatment and damages should be rectified and shall be informed to Project
Manager before closing the trenches.

C. Radiographic Testing (wherever applicable)

Underground pipes joints shall be tested for radiographic for 10% of the total underground
joints. Test results and films shall be submitted to consultant for approval, defects found shall be
rectified.
 27. Inspection

Inspection 1: Material Inspection of Firefighting system Pipes & Accessories.

Inspection 2: Material Inspection of Firefighting Pumps & Accessories.
Inspection 3: Mock-up Installation Approval.
Inspection 4: Installation of Firefighting system piping (A/G & U/G) and accessories.
Inspection 5: Pressure testing of Firefighting Piping work.
Inspection 6: Installation of Firefighting system Equipment’s and accessories.
Inspection 7: Installation of Automatic Sprinklers and accessories.
Inspection 8: Installation of Firefighting pumps and accessories.
METHOD STATEMENTS FOR ELECTRICAL WORKS
28. Method statement for conduit work
Work procedure
Receipt and storage of conduit:
Soon after receipt of conduit, inspection shall be carried out to confirm make,fire category,
quantity, and conduit diameter and conduit thickness as approved technical specifications.
Physical verification of conduit shall be done to check for any damages. Conduits shall be
properly stacked as per their sizes in stores. Conduit Identification tags shall be provided at every
stack.

Pre-installation
a. Shop drawings shall be prepared based on GFC
drawings and it shall be getting approved from MEP
consultant /MEP head or Project Head.
b. Before laying the conduit, approaches shall be
made available to reach to site and carry conduit to required place.
c. Before laying of conduits location of beams and wall shall be checked as per approved shop
drawing for point marking.

Installation
a) Marking of conduit layout as per the approved shop drawing shall be done.
b) After marking proper size of conduit shall be selected as per drawing and submittal. Conduit
shall be properly laid as per route. Coupler shall be provided at the joint of two conduits.
c) Bending of conduit shall be done with bending spring to the required angle.
d) All the junction boxes for fixture shall be fixed as per the drawing. All the vertical drops in
beam shall be put as per wall location. After laying, conduits and accessories shall be tied with
the help of approved clamp and fixing procedure.
e) Red oxide and paint shall be provided to the MS member, if any has been used as support.
Proper distance shall be maintained between Electrical & Communication conduit as per
specification.

f) All the required measurements shall be taken for preparation of “As Built drawings”. Fan &
Chandelier Hook Box shall be done as per approved shop drawing.

g) Minimum 25mm spacing shall be kept in-between conduits terminating at DB.

h) Necessary records in various stages of work shall be maintained at site.

 29. Method statement for Switch & socket

Receipt and storage of switch & sockets:

a. Soon after receipt of Switch & Sockets, inspection shall be carried out to co firm quality,
quantity and size of conduit.
b. Physical verification Switch & Sockets shall be done to check for any damages.
c. Switch & Sockets shall be properly stacked size wise in stores.
d. Identification tags shall be provided at every stack.

ii. Pre-installation
a. Shop drawings shall be prepared based on GFC drawings and it shall be getting
approved from MEP consultant / MEP head.
b. Before installation of Switch & Sockets approaches shall be made available to reach to site.
c. Ensure the completion G.I. / PVC back boxes
installation work is completed.

d. Before installation of Switch & Sockets location shall be

checked as per drawing.

iii. Installation
a. Marking of Switch & Sockets shall be as per the
approved shop drawing shall be done.
b. After marking proper size of Switch & Sockets shall be selected as per drawing.
c. Check that proper module, type & rating of switches are used.

iv. Testing and commissioning

a. Check all switches and sockets for damages or cracks.
b. Check for leakage current is there over switch or socket surface.
c. Check switch for fan, light etc. as per Box schedule shown in shop drawing.
d. Check for sparking in switch sockets during operation.
e. Check all sockets with test lamps for proper operation between phase to neutral and phase to
Earth connections.
f. Check for proper size (1 module or 2 module) and wattage (100 watt or 200 watt) fan
Regulator is used as per shop drawings.
g. Check for TV, TEL and DATA sockets operation.
h. Check for abnormal sound during switching of switches.
i. Check spring tension of all switches.

Necessary quality check records in various stages of work shall be maintained at site.
30. Method statement for point wiring
Work procedure
i. Receipt and storage of wires:
a. Soon after receipt of wires inspection shall be carried out to conform make, quality,
quantity and size of wire.
b. Physical verification wires shall be done to check for any external damages.
c. Wires shall be properly stacked size wise/ colour wise in stores. Identification tags shall
be provided at every stack.
ii. Pre-installation
Shop drawings shall be prepared based on GFC drawings and it shall be got approved from MEP
consultant / MEP head.
Conduit shall be made free from any blockages by pulling cord. If blockages found, then
water pressure treatment shall be done.

Installation
a. Wire shall be pulled with help of G.I. wire / nylon thread. Enough quantity of wire shall
be kept at both ends for termination.
b. Wire shall be terminated at DB end with proper size of lugs. Ferruling shall be done to
Identify the circuit.

Testing and commissioning

a. Check each circuit for continuity test and insulation resistance test.
b. Check earthing for each light and socket point with 100W, 230 Volts test lamp and
multimeter.
c. Check operation of each light and socket point with 100W, 230 Volts test lamp and
multimeter.

d. Check earthing for each ceiling and exhaust fan point with 100W, 230 Volts test lamp
and multimeter.
e. Check operation of each ceiling and exhaust fan point with 100W, 230 Volts test lamp
and multimeter.

f. Ensure proper size of wire is used as given in the DB schematic.

g. Check tightness of wire in each switch, socket, connector, DB, ceiling rose and
Holders.
h. Check voltage (P-P, P-N, and N-E) with voltmeter at incoming cable inside DB, care
to be taken during measurement of phase to phase voltage.
i. Check voltage (P-P, P-N, and N-E) with voltmeter at each socket point, light point, fan
point keep records for same.
j. Check tripping of RCCB with test push button provided on RCCB.
k. Check tagging of wire in all boards and DB.
l. Check operation of each bell switch with test bell buzzer.

m. Necessary records in various stages of work shall be maintained at site.

31. Method statement for light fixture
Work procedure:
i. Receipt and storage of lighting fixture
a. After receipt of lighting fixture, inspection shall be carried out on random samples to check
make, model, quantity & quality and for any damages to fixture body.
b. Fixture shall be stacked in an enclosed structure.
c. The Packing of Light Fixture shall not be removed till actual installation.

ii. Pre-installation
a. The location of Light Fixture shall be marked on site as per approved shop drawing & further
to be approved by site MEP Team.
b. Before installation clearance shall be taken from MEP Manager.
c. Wiring installation & testing work for shall be completed before installation of fixture.

iii. Installation
a. Fixture shall be fixed at marking as per approved shop drawing & manufacture’s
recommendation with required accessories.
b. Termination of wires shall be done with required ferrules & lugs.
c. Earthing wire shall be properly terminated to earth terminal given on fixture.
d. Check cover of all light fixtures is properly tight to avoid fall.

iv. Testing and commissioning

a. Wiring of fixture shall be properly checked for its tightness, there should not be any
leakage current flowing over light fixture body. Check this with multi meter and test lamp.
b. Colour temperature of lamp should be verified.
c. The fixtures shall be tested with suitable type of 230 Volt rated lamps.
d. Check voltage at fixture connectors before charging, it should be between 220 Volts – 240
Volts only.

Necessary records in various stages of work shall be maintained at site.

32. Method statement for distribution board
Work procedure
i. Receipt and storage of DBs

a. All the DBs and its accessories as per approved SLD is delivered at site shall be
inspected by quality & site engineer as per Approved material submittal.

b. DB shall be stored as per manufacturer’s recommendations in a covered & dry space.

c. Site manager and vendor shall take care of DB

accessories till installation.

d. Site team shall ensure delivery of DB as per

project schedule.
Pre-installation of DBs

a. Shop drawings shall be prepared based on GFC drawings and it shall be getting approved
from MEP consultant / Regional MEP head or CO-MEP Team.

b. Work shall be carried out by the contractor under supervision of the site MEP
Manager/supervisor.

c. MEP engineer will check all the installations as per the Installation check list. Location of
the DB to be marked on the wall as per the setting-out given in approved shop drawing.

d. Check the provision for incoming, outgoing cable / wires entry shall be as per approved
shop drawing.
Installation of DBs

a. Site Engineer must ensure that the DB to be used at site is of correct type and free from
any damage or deformation or scratches.

b. All internal components shall be verified against the approved material submittals and
approved layout.

c. The DB internal earth bus bar shall be earthed with earthing wires.

d. Termination of cables / wires shall be done using approved cable glands, lugs, ferrules.

e. As built Circuit Wiring Diagram shall be placed inside DB door.

f. All the circuit wiring shall be identified with ferrules as per circuit reference given in shop
drawing.
Testing commissioning

a. Check DB switch gear rating as per SLD.

b. Check Switchgear category (should be C category). Check leakage rating of RCCB (Should
be 30 mA).

c. Check Neutral, phase and earth bus bar are separate and insulated with PVC Sleeve.

d. Check Only copper cable link is used for internal connections.

e. Check Insulation resistance value of DB (P-P, P-N and N-E) with 1000Volt megger.

f. Check Voltages (P-P, P-N, and N-E) with 500 Volt AC voltmeter. Check tightness of wire
in each MCB and RCCB.

g. Check circuit tagging is done with PVC ferrules. Check SLD inside DB door cover.

h. Necessary records in various stages of work shall be maintained at site.

 33. Method statement for lightning protection system

Work procedure
i. Receipt and storage
a. Material shall be stored in a covered / dry space at all the time to avoid being damaged.
b. All materials received at site shall be inspected and ensured that the materials are as per
approved material submittal.

Pre-installation

a. Shop drawings shall be prepared based on GFC drawings and it shall be getting approved
from MEP consultant / MEP head.

b. Earthing strip form the air-terminal to mesh on the uppermost part of the building structure
i.e. roof. Complete strip network shall be bonded to all down conductors round the
periphery and a branch conductor to be taken horizontally and all these down conductors to
be bonded by using approved clamps.

c. Work shall be carried out by the contractor under supervision of the site MEP Manager
/supervisor.

d. Number & sizes of Air Terminals, roof earthing strip & down conductors shall be based on
the approved shop drawings and specifications. When different metal to be connected a
bimetallic clamp shall be used.

Installation

a. Any roof (e.g. staircase, Lift Machine Room, Over Head Tank, etc.) on top of the main roof
shall have air termination network and it shall be connected to lower roof network.

b. The DC earth strip clamp shall be fixed on the route as shown in the approved shop
drawings and the straightness shall be checked along with building finish, on the top roof
high level.

c. If applicable, a minimum of two MS bars shall be used as down conductors in each column.

d. If applicable, the minimum overlap dimension to connect two MS bars shall be at least 20
times the diameter of the re-bar.
e. Alternatively, suitable clamps should be used at distance of each 10cm till the above
dimension is achieved.

f. If applicable, MS bars in the designated columns should be used as down conductors, with
a suitable junction box to be recessed at approx. 1000 mm above the finished paving level
for the test link.

g. If applicable, the electrical continuity of the MS bars shall be determined by electrical

testing at the uppermost part and the ground level.

h. The overall electrical resistance should not be greater than 10 Ω, measured using test
equipment suitable for this purpose. If this value is not achieved, or it is not practical to
conduct such testing, the MS bar shall not be used as a natural down conductor.

i. Bond each down conductor throughout its length to the building MS bar with spacing not
more than 1.5 meter. All bonding to MS bar shall be by using manufacturer’s standard
materials and tools for the same.

j. Thermo weld all connections between cables, aerial terminals and ground rods.
Compression type connectors may be used where approved by the consultant.

k. The earthing shall be done as per local authorities’ requirements.

l. Earthing electrode shall be provided with each down conductor separately and the number
of earth rods in each earth pit shall be decided based upon the calculations.

m. Measure the resistance & continuity of the complete installation and submit for review to
MEP consultant.

n. Test clamps shall be provided in each inspection pit to allow for testing and commissioning.

o. Earthing pits with cover in concrete shall be installed flush with finished floor level and be
fully accessible.

p. All metallic parts protruding outside the extended air termination network (e.g. balcony
handrails etc.) shall be connected to the air termination using suitable clamps.
iv. Testing commissioning

a. Check earth resistance at minimum of 3 places (near earth pit, in the vertical run and at
Terrance level near device) with clamp on type earth tester. This value should be less
than 10 ohms.

b. Necessary records in various stages of work shall be

maintained at site.
 34. Method statement for earthing

Work procedure
i. Receipt and storage

a. Material shall be stored in a covered / dry space at all the time to avoid being damaged.

b. All materials received at site shall be inspected and ensured that the materials are as per approved
material submittal.

Pre-installation

a. The numbers & locations of earthing pits shall be as per approved shop drawing.

b. The earthing strip sizes & number shall be as per approved earthing schematic.

Installation

a. All earthing strip shall be readily available with all necessary provisions for connections at the earth
pit.

b. The earthing connection must be mechanically and electrically

sound protected against damage, corrosion, and vibration.

c. Zinc chromate and aluminum paint shall be applied for all G.I.
earthing strip joints.

d. All Copper strip joints shall be done with brazing along holding
clamps.

e. All electrical equipment shall be earthed by two separate and distinct connections with earth.

f. As far as possible, all earth connections shall be visible for inspection.

g. All metal conduits, trunking, cable sheaths, switchgear, distribution fuse boards, lighting fittings and
all other parts made of metal shall be connected by means of two separate and distinct.

h. Conductors to an efficient earth electrode.

Testing commissioning
Check earth resistance value by opening test link with earth tester, this should not be more than 5 Ohms.
Check earth resistance at each DB, panel, DG set and Transformers with clamp on type earth tester.
Necessary records in various stages of work shall be maintained at site.
 35. Method statement for panel

Work procedure
i. Receipt and storage

a. Material shall be stored in a covered / dry space at all the time to avoid being damaged.

b. All materials received at site shall be inspected and ensured that the materials are as per
approved material submittal.

ii. Pre-installation

a. The Panel received on site shall be cross verified with the approved GA & Schematic
drawing.

b. Before commencement of work make sure that all material delivered to site is inspected
properly by quality & site engineer and check if it is stored properly as per manufacturer’s
recommendations in a covered / dry space at all the time.

c. Site Engineer must ensure that the switchgear panels to be used at site are of free from any
damage or deformation.

d. The panels installed at open terrace last basement & external area shall have suitable
foundation for protection against water logging.

e. QA/QC engineer will check all the installations as/ per the Installation check list.

f. Ensure that the work area is ready and safe to start the installation of LV Panel.

iii. Installation

a. Ensure the installation of Panel are carried out in accordance with manufacturer’s
installation recommendations, requirement.

b. Ensure the floor surface is ready with base frames anchored on the open trenches inside
the room to install the Panel.

c. The loading - unloading of Panels at site shall be done as per standard procedure to avoid
damage.

d. When the panels have been moved its destination, it will be un-crated, unpacked and
removed from its timber base.
e. Minimum clearance shall be maintained at rear side of the panel so that easy access for
termination of cables and other maintenance works can be carried out.

f. All knockouts made on the panel covers shall be filed and provided with grommets to avoid
sharp edges and unused knockouts shall be covered.

g. The connection of bus bar trunking with panel shall be done rigidly with proper
supports.

h. All relay and other breaker current settings shall be done as per design & loading
requirement & conveyed to MEP consultant.

i. The functioning of all equipment & components (i.e. fuse switches, circuit breakers,
contactors, relays etc.) shall be checked manually.

j. All connections are checked for tightness/torque prior to energization in accordance with
the manufacturer’s recommendation.

k. All components/door interlocks should be adjusted correctly and must operate freely.

l. Identification labels of approved type shall be fixed on the panel.

m. Ensure that all cable entries and other openings of Electrical / HV Room, Wall / Floor are
carried out with proper approved sealant.

n. The manufacturer’s representative to verify the site installations and provide acceptance of
same prior to energization of Panel after obtaining clearance from site engineer.

o. After the above operations, all doors are closed and locked and keys should be maintained
by the supervisor until panel is ready to handover to the commissioning team.
iv. Testing commissioning

a. Check insulation resistance value of each MCCB with the help of 1000 Volt megger, this
value should be more than 10 Mega Ohm.

b. Check control circuit wiring with the help of continuity tester and multimeter for wiring
checks.

c. Check Insulation value of all incoming and outgoing bus bars and it Should be more than 10
Mega Ohm.

d. After successful testing of IR value, the panel can be charged. Check all VSS and ASS for
proper functioning.

e. Check all PT and CT connections.

f. Check voltage at each feeder section with the help of 500 Voltmeter in case of 440 Volt
rated panels.

g. For HT panel see voltmeter reading as shown in

the 11-22-33KV/110 rated voltmeter.

h. Check auto and manual operation of each switch

gear. Check protection device setting as per
requirement.

i. Check protection checks for each MCCB and

ACB for overload, short circuit and earth fault release checks and records should be
maintained.

j. Check each cable end termination for voltage check and measure voltages (P-P, P- N, N-E,
and P-E). Switch off switch and check there should not be any voltage in the outgoing cable,
Ideal readings should be 415 Volts,230 Volts,0

k. volts and 230 Volts respectively.

l. Necessary records in various stages of work shall be maintained at site.

36. Method statement for cables & cable tray
Work procedure
i. Receipt and storage

a. Material shall be stored in a covered / dry space at all the time to avoid being damaged.

b. All materials received at site shall be inspected and ensured that the materials are as per
approved material submittal.

Pre-installation

a. The cabling & cable tray work shall be done as per the approved shop drawing.

b. Ensure all related civil works are completed for the area of installation and clearance is
obtained from respective agencies to proceed further.

c. Check the coordination with other MEP services, ensure that there is no interference
between each service and ensure reasonable access is available to do installation, servicing
and maintenance works.

d. The trench, trunking & trays installation shall be ready before starting cabling work.

Installation

a. Cable trays formed from perforated metal will be installed and coordinated as indicated on
the approved shop drawings.

b. Cable trays will be independently supported from the main structure, wherever possible, at
intervals not exceeding 1.5m.

c. Cable trays will be cut along a plain line of metal and not through the perforations, all cut
edges shall be prepared and treated with galvanized paint and de-burred of any rough
remaining metalwork.

d. Cable trays will be connected between adjacent lengths tee or bend pieces by butt joints, and
securely fastened by mushroom head steel roofing bolts, connections shall be mechanically
strong so that no relative movement between the two length can occur and shall be
efficiently and adequately bonded.

e. Property expansion splice plate will be used to join adjacent lengths of tray. Trays will not
be joined when crossing a construction expansion joint. At these points the tray shall be
bridged with a flexible earth conductor.
f. Cable ladders will follow the same criteria as trays where applicable and shall be supported
at intervals of not more that 1500mm on steelworks of adequate strength and rungs shall be
slotted for cable clamping or tying.

g. Where cables turn down to panels or switch boards, drop out accessories will be used with
each ladder to support the cables as shown on the construction drawings.

h. Cable tray deflection shall not exceed 1/100 of a 1.2m span at the midpoint of the span after
cable installation. It will comply with the manufacturer recommendation.

i. Cable ladder deflection shall not exceed 1/100 of the span at the mid-point of the center
span of a 1.5 span continuous beam after cable installation. It will comply with the
manufacturer recommendation. The following will be adhered to:

Maximum allowable pulling tension shall not be exceeded.

Minimum bending radius shall be adhered to as per

specification/manufacturers recommendations.

Rollers will be used at intervals to prevent dragging the

cables during the cable installation on cable tray or ladder
rack. Curve rollers will be settled at the proper position to
keep the cable within suitable bending radius for pulling
cable around curves and bends.

j. The installation from cable drum onto cable tray or ladder

rack drum setting position will be determined in
consideration of the cable laying direction, so that the cable can be reeled out onto tray or
rack in a smooth curve.

k. Each cable will be fitted with a cable identification tag as per specifications. The tag will
indicate the cable number and destination.

l. Cables installed on cable ladder will be secured by approved cable fasteners. The cable
cleating will have adequate strength to support the cable during fault conditions.

m. Saddles and fixings for securing multi-core cables to the cable tray system will be of the
approved type, with the maximum spacing of 150mm. Single core cables installed on cable
trays will be secured by the approved cable fasteners.

n. Internal Bending Radii of Power Cables as per specifications/manufacturers

recommendations.
o. At each joint or termination, a non-ferrous label shall be fixed to the cable giving size and
identification of the cable.

p. Cable trays as per approved material and specification will be connected to the equipment
via appropriate wiring accessories.

q. Reduction in the number of strands of a cable core will not be allowed at a cable joint or
termination.

r. Where a compression joint is made, the appropriate tools specified by the manufacturer of
joint connectors will be used. The compression joints will be made by inserting the cores to
be jointed into the opposite end of a compression jointing coupling.

s. Cable support bracket will firmly clamp the incoming cable at a suitable distance from the
termination.

t. Cable terminations will be carried out in strict accordance with the termination
manufacturer’s instruction leaflets and great care shall be taken to ensure that terminations
and equipment remain clean and free from contamination during the terminating process.

u. Testing will normally consist of installation and continuity checks for phase and neutral.
v. Testing commissioning

w. Necessary records in various stages of work shall be maintained at site.

 37. Method statement for rising mains (bus bar)

Work procedure
i. Receipt and storage

a. Material shall be stored in a covered / dry space at all the time to avoid being damaged.

b. All materials received at site shall be inspected and ensured that the materials are as per
approved material submittal.

ii. Pre-installation

a. The Bus-bar work shall be done as per the approved shop drawing.

b. Ensure all related civil works are completed for the area of installation and clearance is
obtained from respective agencies to proceed further.

c. Check the coordination with other MEP services, ensure that there is no interference between
each service and ensure reasonable access is available to do installation, servicing and
maintenance works.

iii. Installation

a. The Work shall be carried out by the site staff under strict supervision and guidance of the
concerned engineer.

b. QA/QC engineer will check all the installations as per the Installation check list.

c. Handle the bus bars with due care and attention. Do not subject bus bars to torsions, dents,
violent impact, or sharp movements that may damage their internal components.

d. Do not lift the bus bars from their ends. This could not just damage the bus bar, but also
cause injury to the personnel carrying out the operation. When using a crane to install the
bus bar, use nylon slings to balance the weight.

e. Do not use belts or other systems to lift them to the junction windows, or the expansion cap.
This may damage the bus bars.

f. When not installing the bus bar immediately upon receipt, ensure appropriate storage for the
time required before installation, following the storage instructions. Do not drag the bus bar
along the floor. This could cause irreversible damage.
g. To correctly move bus bars, cranes may be used. These would enable to lift the bus bars
from the floor very easily.

h. Do not move already assembled bus bars, as this would cause stress at the point of the
electric joint.

i. Do not position the bus bars near water pipes.

j. Only use bracketing systems supplied by manufacturer.

k. Check that the operating voltage coincides with that indicated on the product plate.

l. Check that the system operating current does not exceed the product rated current.

m. For outdoor installations, protect the bus bar with a protection canopy. The IP55 protection
degree can be affected by unsuitably protected outdoor installation.

n. The securing of the mono block does not require a torque wrench, as correct torque is
ensured by a self-piercing nut, which will break when this is reached.

o. Secure both caps using the nuts supplied or using nuts with toothed washers. Check the
alignment of the line along the three main directions.

p. Check the distance between the two elements is as per manufacturer. This check can be
completed using the joint cap.

q. Complete visual inspections to ascertain the status of the plastics (no broken or damaged
plastics, and no foreign material), and the bus bars.

r. If opening the Monoblock after assembly, new self-piercing nuts when reassembling it are
preferable. If refitting the existing ones, use a calibrated torque wrench. The torque must be
as per manufacturer’s recommendation.

s. Check that all the joint caps have been fitted correctly. Complete the 1.1 kV megger test
shall be done.

t. It is reminded that a bus bar electric system must be regularly checked following the
requirements of the applicable regulation.

u. Fireproofing at all floor penetrations of bus bar to be carried out.

iv. Testing commissioning

a. Check Insulation resistance by disconnecting source and load ends.

b. With the help of 1000 Volt megger (IR value between P-P, P-N, P-E, N-E), these values
should be more than 10 Mega Ohms.
c. Carry High voltage test (2500 Volts) between (P-P, P-N, P-E, and N-E) by disconnecting
source and load ends, check leakage current developed. Leakage current should not be more
than 30 mA.

d. Necessary records in various stages of work shall be maintained.

 38. Method statement for diesel generator sets

Work procedure
i. Receipt and storage

a. Material shall be stored in a covered / dry space at all the time to avoid being
damaged.

b. All materials received at site shall be inspected and ensured that the materials are as per
approved material submittal.

Pre-installation

a. The location of DG shall be as per approved electrical shop drawing. The foundation of DG
shall be done as per DG vendor requirement.

b. For Multiple sets ensure minimum distance between DG sets as per manufacturer’s
guidelines.

c. Proper & sufficient openings in DG room for ventilation as per approved ventilation shop
drawing.

d. Heavy duty air cleaners for dusty environment should be made.

e. Correct size of exhaust piping as per model /KV Rating to ensure back pressure within
specs.

Installation

a. Insulation & lagging of exhaust pipes/ silencer inside DG Room (except elbow &
bellow).

b. Provide shortest exhaust pipe routing with minimum number of bends.

c. Provision for genset lifting is provided on base-rails. Unload the genset from base rail by
lifting with proper genset lifting tackle or nylon sling / steel rope of suitable capacity and
crane so as to ensure no damage to oil sump, air cleaner, radiator pipes etc. Spreader bar /
spacer plate of suitable size should be required to avoid damages to genset components.

d. Do not lift the genset from engine and alternator hooks.

e. Keep the genset covered with polyethylene or tarpaulin during installation to ensure that
water does not enter inside.

f. Enough opening / shutters should be provided to the D.G. room so that entry and placement
of D.G. set is possible easily. While making room layout provision should be made for
Cables, Fuel lines, Breather vent, Coolant / lube oil drain, Raw water lines, Oil / spares
storage.

g. Enough opening should be provided to the D.G. room so that entry and placement of D.G.
set is possible easily.

h. Exhaust flexible shall have its free length when it is installed.

i. However, if exhaust pipe length is more than 7 m then additional bellow / provision for
expansion should be provided.

j. It is recommended to use ‘Schedule B’ MS pipes with one coat of red oxide & 2 coat of
bituminous paint along with required insulation & aluminum cladding.

k. There should be rain trap to avoid rainwater entry. If rain cap is used the distance between
exhaust pipe and rain cap should be higher than diameter of pipe. It is also recommended
that horizontal run of exhaust piping should slope downwards away from engine to the
condensate trap. Silencer should be installed with drain plug at bottom. Height of exhaust
should be as per CPCB norms.

l. Typically fuel tank should be placed on the level as that of engine i.e. floor mounted. Locate
fuel tank such that fuel outlet point (at bottom of fuel tank) is maximum 1.8 m (6 feet)
below the fuel pump inlet or for top mounted fuel tank, top side of fuel tank is max 1.5 m (5
feet) above fuel return line. In case of Top Mounted tanks non-return valves are must in fuel
supply and return lines of specified value.

m. Batteries supplied with genset are generally dry and uncharged. First charging of uncharged
batteries is very important and should be done from authorized battery charging center. It
takes about 72-80 hours.

n. Batteries should be placed on stands and relatively at cool place.

o. For AMF applications, a static battery charger working on mains supply is always
recommended to keep the batteries charged.

p. Make sure that the polarity of the battery connections is correct before applying power to
the all-Electronic Controls. Do not test wire leads to see if they are ‘live’ by flashing them
on either engine body or the ECP mounting stand.
q. Disconnect all connections to the control system on engine / genset before doing any
welding work on set.

r. Turn off or remove AC power from the battery charger and then remove –ve battery cable
from the engine genset battery. This will avoid possible PCB damage and someone
else starting engine / Genset accidentally.

s. Make sure the battery area is well ventilated before servicing the battery. Arcing can cause
explosion due to hydrogen gas given off by batteries. Always refer to the wiring diagram
and product manual supplied with the engine / genset for details.

t. While terminating cables avoid any tension on the bolts /bus bars. While terminating
R.Y.B. phase notations should be maintained in the alternator and control panel for easy
maintenance. Crimped cables should be connected to alternator and control panel through
cable glands.

u. Overheating due to loosen thumbing / undersize cables causes most of electrical failures,
hence ensure that correct size of cables and thimbles is used. For AMF application, use
multi core 2.5 sq. mm armored copper cable for control application. Care to be taken, that
weights of cables should not fall on alternator / base rail. It is recommended to support
output cables on separate structure on ground.

v. External wirings, when provided for remote voltage /excitation monitoring / droop CT etc.
shall be screened sheathed type. Maximum length of such wiring shall not exceed 5 meters.

w. The generating set and all associated equipment control, and switch gear panels must be
earthed before the set is put into operation.

x. For genset with AVM’s between engine / alternator and base rail. The earthing MUST be
done at the engine alternator and NOT at base-rail.

y. Genset should be earthed at two distinct points through a conductor heavy enough to carry
the short circuit current without burning out.

z. The cable termination box of Alternator shall be as per the no & sizes of cables terminated
on it.
Testing commissioning

a. Before delivery of DG set to site, inspection and testing of DG set at factory is must.

b. Ensure the DG set is prime rated or standby type. Check IR value of DG, panel and DG
cables.

c. Check earthing value at DG panel, DG set, its value should not be more than 5 Ohms.

d. Witness the tests carried out by DG vendor at site, Site engineer should not carry any test on
DG set at his own before taking over.

e. Cross check the voltage, frequency of the generated voltage (It should be 415 Volts
between phase to phase, 230 Volts between phase to neutral and frequency should be 50
Hertz. Check the DG set on full load, these readings should not vary by 1%.

f. Check ON /OFF operations of DG set in auto and manual mode.

g. Check ON/OFF operations of all switch gears in Auto and manual mode. Check
emergency push switch on DG set and on panel is working or not.

h. Check protection settings of all switch gears before putting any load on DG set and its
panel.

i. Necessary records in various stages of work shall be maintained.

METHOD STATEMENT FOR INFRA WORKS (CONSTRUCTION OF
FLEXIBLE PAVEMENTS & SURFACE DRAIN)
 39. Sub grade construction

a. The sub-grade is top 300 mm compacted layer in embankment or cutting just beneath the
pavement crust.

b. The sub grade in embankment is compacted to a higher standard than the lower layers of
the Embankment.

c. In cutting, the cut formation, which serves as the sub grade, is treated similarly to
achieve.

d. The specified density to provide a suitable foundation for the pavement.

Methodology
Setting out, dewatering, stripping of topsoil etc. Ensure that the soil for sub grade meets the
specified requirements in terms of physical properties and the specified CBR value for
pavement design.
Compact each layer of the material in the sub grade at OMC (±) 2% to at least 95% of
Maximum Dry Density as per IS:2720 (Part 8). If the difference between the sub grade level
(top of the sub-grade on which the pavement rests) and ground level is less than 300 mm and the
ground does not have the needed 100% relative compaction with respect to IS: 2720 (Part-8),
loosen the ground up to a level 300 mm below the sub grade level, correct moisture content to
OMC (±) 2% and compact in layers to 95% of the maximum dry density as per IS: 2720 (Part
8).

If the sub grade soil does not possess the requisite engineering properties like highly plastic
black cotton soil and other weak soils yielding very low soaked CBR values, the same should be
improved in strength (CBR) and workability by treatment with additives like lime/cement etc.

In conditions where salt concentration is more than 0.2%, a capillary cut-off of coarse sand
should be provided below the sub grade as shown in the drawings to check the upward
movement of moisture from below.
For a road in cutting, prepare the sub grade in accordance with MORTH specification to receive a
sub-base course.

Ensure that the sub grade is compacted and finished

to the design strength consistent with other physical
requirements.

Maintain the surface of sub grade, always during construction, at such a cross fall as will shed.
Water and prevent ponding.
 40. Surface drains

Methodology

a. Ensure that the surface drains are provided strictly according to the Drainage Plan for the
road.

b. Excavate to the specified lines, grades, levels and dimensions.

c. Remove all excavated material from the area adjoining the drains. If the excavated material
is found suitable, utilize in embankment/sub-grade construction, otherwise dispose of the
material away from the road site.

d. Ensure that the excavated bed and sides of the drains are in conformity with the specified
dimensions, levels and slopes.

e. Protect the surface of drains with turf cover or other suitable lining as shown on the
drawings. Consult the local agricultural department for selecting the appropriate species of
grass/vegetation.

f. Provide proper gradients and fix the invert for quick disposal of
water to the outfall.

g. For any stretch of the road passing through a built-up area,

ensure that any water coming from the adjacent habitations
discharges only into the drain and is not allowed to flow over
the road surface.

h. Any sharp edges, where cut/fill surfaces meet the ground level, should be rounded off to
prevent erosion and promote turfing.

i. Provide safe outlets to natural or artificial water courses.

j. Provide catch water/intercepting drains on hill slopes to intercept water from upper reaches,
such drains to be provided over stable slopes only, outside any slide or unstable areas.
 41. Granular sub-base (GSB)

Methodology

a. Obtain materials from approved sources. The material should be natural sand, murrum,
gravel, crushed stone, crushed slag, brick metal, kankar or a combination thereof and it shall
conform to grading and physical requirements indicated in Table 401.1.

b. Remove all vegetation and other extraneous material etc. From the sub grade already
prepared, lightly sprinkle with water, if necessary, and roll with two passes of 80-100 kN
road roller or any other suitable vibratory roller.

c. The sub-base material should be spread in layers not exceeding 100 mm compacted
thicknesses. If suitable vibratory rollers are available, the compacted thickness of layer can
be up to a maximum of 225 mm. When the sub-base material consists of a combination of
materials, mixing shall be done mechanically by the mix- in-place method, except for
small sized
jobs.

d. Each layer shall be uniformly spread and

thoroughly compacted. Spreading and
compaction shall be carried out as per Clause
401.4.2 of the MORTH Specifications.

e. Compaction should be carried out at OMC, with a tolerance limit of (±) two percent. If the
loose material is dry, as compared to OMC, water should be added by sprinkling and
thoroughly mixed for uniform wetting. If it has more water than the optimum, it should be
left exposed to sun and aeration till the moisture content is acceptable for compaction. Each
layer should be compacted to 95 per cent maximum dry density as per Modified Proctor
Test-IS 2720 (Part 8).

f. Approval of the Engineer should be obtained for each layer. Such an approval would require
surface level and compaction control tests. The earthen shoulders should be constructed
simultaneously with the sub-base construction.
 42. Wet mix macadam base
Methodology

a. The surface to receive Wet Mix Macadam (WMM) shall be prepared as per MORTH specification.

b. WMM shall be prepared in an approved mixing plant with mixing arrangements like the pug
mill or pan type mixer of concrete batching plant. For small quantities of WMM, the Engineer may
permit the use of concrete mixers.

c. Optimum moisture for mixing shall be determined in accordance with IS: 2720 (Part 8) after
replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm
size. Lateral confinement for WMM should be provided by laying material in shoulder along with
the wet mix layer. Immediately upon mixing, the aggregates shall be spread uniformly and evenly
upon the prepared sub-base, in required quantities.

d. In no case should the material be dumped in heaps, directly on the area where it is to be laid. The
mix may be spread either by a paver-finisher or motor grader.

e. Thickness of a single compacted WMM layer shall not be less than 75 mm. When vibrating or other
approved types of compacting equipment are used, the compacted thickness of up to 200 mm may be
adopted.

f. The surface of aggregate shall be carefully checked with templates and all high or low spots should
be remedied by removing/ adding aggregate as required. The thickness of layer shall be tested with
depth blocks. No segregation of large and fine aggregates shall be allowed.

g. After the mix is laid to proper thickness, grade and cross fall/ camber, the same shall be uniformly
compacted with a suitable roller. Rolling shall be continued till the density achieved is at least 95%
of the maximum dry density as per IS: 2720 (Part 8).

h. If the surface irregularity of WMM course exceeds the permissible tolerances, the full thickness of
layer shall be scarified over the affected area, reshaped by adding premixed material or removed and
replaced with fresh premixed material as applicable and re- compacted. The area treated in this
manner shall not be less than 5 m long and 2 m wide. In no case shall depressions be filled up with
unmixed and un-graded materials or fines.

i. After final compaction of WMM, the road shall be allowed to dry for at least 24 hours.

j. Preferably no vehicular traffic should be allowed on the finished WMM surface till it has dried and
the wearing course has been laid.
 43. Water bound macadam sub-base/ base/surfacing
Methodology

a. The surface to receive the WBM course should be prepared to the lines, grade and cross fall.
It should be made free of dust and extraneous material. Large irregularities, where
predominant, should be made good by providing profile corrective course.

b. Where the WBM is laid over a fine-grained soil sub grade, it is advisable to lay a 100 mm
thick intervening layer of screenings or coarse sand.

c. Any existing bituminous surface over which WBM is to be laid shall be completely removed
before laying WBM layer.

d. The coarse aggregate should meet the physical and grading requirements laid down in Table
405.1 and Table 405.2. Coarse aggregate can be crushed or broken stone, crushed slag, over
burnt brick aggregate, kankar, laterite meeting the prescribed requirements.

e. The spreading of coarse aggregate shall be done from stockpiles along the side of the
roadway or directly from vehicles. In no case the aggregate shall be dumped in heaps
directly on the surface prepared to receive the aggregates nor shall hauling over
uncompacted or partially compacted base be permitted.

f. The coarse aggregate shall be spread uniformly on the prepared sub grade, sub-base or base
to proper profile (by using templates placed across at 6.0m intervals) in such quantities that
would give the required compacted thickness. The thickness of compacted layer should be
100 mm for Grading 1 and 75mm for Grading 2 and 3. The appropriate quantity of
aggregates is given in Table 405.4. The surface should be checked with templates and all
high or low spots remedied.

g. Roll the surface with suitable road rollers till aggregates are partially compacted with
sufficient void space left for application of screenings. However, where screenings are not to
be applied as in the case of soft aggregates, compaction shall be continued until the
aggregates are thoroughly keyed. Rolling shall proceed from inner edge to outer edge at the
super-elevated portions and from the edges towards the center in other portions. The edge
should be first compacted with roller running forward and backward.
i) Check the profile transversely and longitudinally with templates/ straight edge. Correct the
irregularities by loosening the surface, adding or removing the needed amount of
aggregates and re-rolling until the entire surface conforms to the specified camber/ cross
fall and grade.

j) Apply screenings to completely fill the interstices maintaining a slow and uniform rate, in
three or more applications. The screenings should not be damp at the time of application.

k) Do not apply screenings as fast and thick as to form cakes or ridges on the surface.
Continue dry rolling and brooming till no more screenings can be forced into the voids of
coarse aggregates.

l) Sprinkle water on the surface taking care that the underlying layer is not damaged.

m) Sprinkling, sweeping and rolling should continue till aggregates are thoroughly keyed, well
bonded and firmly set in its full depth and a grout has been formed of screenings.

n) In case the screenings are not of crushable type such as murrum or gravel, it is necessary to
add binding material (PI between 4 and 6) after application of screenings.

o) The binding material should be applied in two or more layers at a slow and uniform
generally, the quantity required for 10 m2 of 75 mm thickness of WBM is 0.06 to 0.09 m3
and for 100 mm thickness, the corresponding quantity would be 0.08 to 0.10 m3.

p) In case WBM surface is not to be covered with bituminous surfacing, PI of binding

material shall be between 4 and 10.

q) The process of water sprinkling, sweeping and rolling should continue till the resulting
slurry forms a wave ahead of roller.

r) The compacted WBM course should be allowed to completely dry and set before the next
pavement course is laid or traffic is allowed.

s) The earthen shoulders should be constructed simultaneously with the WBM construction in
accordance with Sub-Section 407.

t) The finished surface of WBM should conform to the prescribed tolerances given in Para B.
Where the surface irregularity exceeds the tolerances, the WBM layer should be scarified
to its full depth over the affected area and corrected by adding or removing and replacing
with fresh material.
 44. Preparation of surface

This Subsection deals with preparing an existing granular or black-topped surface prior to laying a
bituminous course.

Methodology
a. Preparing an existing granular surface

1. All loose and extraneous materials should be removed, and surface cleaned where a granular
profile corrective course is to be provided prior to laying a bituminous course; the existing
granular surface after cleaning should be slightly watered and the granular course laid.

2. The surface of all granular layers on which a bituminous course is to be laid should be cleaned
of all loose material and dust by air jet or wire brushes or other approved means and should be
correct to line, level and camber within the tolerances specified for base course.

3. Where a profile corrective course of bituminous material is to be laid, the granular surface
after removal of all loose material and dust should be primed with a suitable bituminous
primer as per ‘Sub-section’ 502.

b. Scarifying an existing bituminous surface

1. Where an existing bituminous layer is required to be removed, it should be done by hand

picking without causing undue disturbance to the underlying layers. Any underlying material
which may have been disturbed should be removed and fresh base material supplemented, if
necessary and compacted.

2. The compacted granular surface, finished to line, level and cross-slope should be primed as
per specified procedure.

c. Preparing an existing bituminous surface

1. The surface shall be cleaned, and any potholes and cracks repaired before laying bituminous
treatment.

a) Pothole and patch repairs

2. The existing bituminous surface should be inspected, and all pothole and patch areas made
free of any loose, defective material. The edges of all potholes shall be cut / trimmed with
hand tools vertically to form rectangular shape and shall be thoroughly cleaned with wire
brush, compressed air or other approved means. All dust and loose materials should be
removed from site. Layers below the level of bituminous construction should be replaced
using material of equivalent specification to the original construction and degree of
compaction. The area of bituminous construction should be primed and/or tacked with an
emulsion (meeting requirements of IS: 8887) depending on whether the lower area is granular
or bituminous in nature. The sides of the excavated position should be painted with tack coat
material using a hand brush/sprayer.

3. The bituminous patching material should be either a hot mix or a cold mix, adopting the
respective specification. The bituminous mixture prepared in a plant of suitable capacity
should be placed in layers of not more than 100mm (loose) and compacted in layers with
roller/plate compactor/hand roller/rammer to the desired compaction standard.

4. In the final layer, the mix should be spread slightly proud of the surface so that after rolling,
the surface shall be flush with the adjoining surface.

5. Where required, a Seal Coat should be applied as per the specified procedure. The surface
levels should be checked using a 3 m straight edge.

Crack sealing
a. The fine cracks (less than 3 mm in width) should be sealed by Fog Spray, which is a very
light application of low viscosity Slow Setting Emulsion. Prior to this treatment, it is
important that the surface is thoroughly cleaned, preferably with compressed air. The Fog
Spray should be applied at a rate of 0.5-1.0 liter/m2 of the specified emulsion, using 0.5-1.0
liter/m2 of the specified emulsion, using an approved hand-held ‘sprayer. For sites in sub-
zero temperatures, Medium Curing Cutback as per IS 217can be used.

b. The wide cracks (more than 3 mm in width) should be filled with crusher dust or other
approved fine material passing 4.75 mm sieve to a level about 5 mm below the road surface
level. After sweeping the surface clear of dust, Slow Setting emulsion should be poured into
the cracks, minimizing any spillage. If spillage does occur, crusher dust
 should be applied to blot up the spillage. Isolated areas, with wide cracks, shall be cut and
patched as per Section 501.

c. Profile corrective course, where specified, a profile corrective course should be provided.

d. After preparing the surface as explained above, the profile corrective course with the
specified material should be laid and compacted to the requirements of the specification.

e. A tack coat should be applied over a primed granular surface or an existing

f. bituminous surface prior to laying the bituminous profile corrective course.

g. Short sags or depressions in the surface should be corrected by laying profile corrective
course in the form of flat wedges (layers).

h. The thickness of layer at any point should not be more than 100 mm.

i. Where the profile corrective course is laid in more than one-layer, successive layers should
completely extend over and fully cover the underlying layer.
 45. Prime coat over granular base
Methodology

a. Bituminous primer should be slow setting bitumen emulsion, use of cutback being restricted
to areas having sub-zero temperature or for emergency operations.

b. The prime coat should be applied only on the topmost granular base layer, over which
bituminous treatment is to be applied. The granular base surface should be swept clean of
dust and loose particles and where required, lightly and uniformly sprinkled with water to
moist the surface.

c. The primer should be sprayed uniformly over the dry surface of absorbent granular base,
using suitable bitumen pressure distributor or sprayer capable of spraying primer at specified
rates and temperature to provide a uniformly unbroken spread of primer. Normal
temperature range of spraying emulsion should be 20°C to 60°C. The rate of application
depends upon the porosity characteristics of the surface to be primed.

d. Rate of application of Bituminous Emulsion for Prime Coat

S. No Porosity Type of Viscosity Rate of application per 10
surface Kinematic Say bolt sq. M (kg)
Viscosity Furol
(Centistokes) (Seconds)
1 Low WMM/WBM 30 – 60 14 – 28 6–9
2 Medium Cement 70 – 140 33 – 66 9 – 12
stabilized
soil base
3 High Gravel base 250 - 500 117 - 234

e. A very thin layer of coarse sand may be applied to the surface of the primer to prevent it
from getting picked up under the wheels of vehicles delivering materials for construction
of bituminous layer.

f. The surface should be allowed to cure preferably for 24 hours. Unabsorbed primer
should be blotted with sand using the minimum quantity possible.
 46. Tack coat
Methodology

a. Use a rapid setting bitumen emulsion for applying a tack coat, the use of cutback being
restricted to areas having sub-zero temperature or for emergency applications.

b. The surface on which tack coat is to be applied should be clean, free from dust, dirt and any
extraneous materials and dry.

c. The surface should be prepared as mentioned in the section of Preparation of surface.

d. The binder should be sprayed uniformly over the surface using suitable bitumen pressure
sprayer capable of spraying bitumen and emulsion at specified rates and temperature to
provide a uniformly unbroken spread of bitumen emulsion. For smaller jobs, a pressure hand
sprayer may be used. Normal range of spraying temperature should be 20°C-60°C in case of
emulsion and 50°C-80°C in case of cutback. The rate of application depends upon the type
of surface.

e. The surface should be allowed to cure until all the

volatiles have evaporated.
47. Bituminous macadam
Methodology

a. Prepare the base on which bituminous macadam course is to be laid and shape to the specified
lines, grade and cross-section.

b. Apply tack coat over the base preparatory to laying of the bituminous macadam.

c. Bituminous Macadam should be prepared in a Hot Mix Plant of adequate capacity. Ensure
manufacturing and rolling temperatures for Bituminous Macadam.

d. Manufacturing and Rolling Temperatures for Bituminous Macadam

Bitumen Bitumen Aggregate Mixed Laying (oc) Rolling (oc)

Penetration Mixing (oc) Mixing (oc) Material (oc)
35 160 – 170 160 – 170 Max. 170 Min. 140 Min. 100
65 150 – 165 150 – 170 Max .165 Min. 130 Min. 100
90 140 -160 140 -165 Max. 155 Min. 130 Min. 100
e. Transfer the mixed material quickly to site of work and lay by means of an approved self-
propelled mechanical paver.

f. Commence initial rolling with 80-100 kN rollers (three-wheel or tandem type), beginning from
the edge and progressing towards the center longitudinally. On super elevated portions, rolling
should progress from lower to upper edge parallel to center line of pavement. Thereafter, do
intermediate rolling with vibratory or pneumatic tyre road rollers. This should be followed by
final rolling while the material is still workable.

g. Any high spots or depressions noticed after the roller has passed over the whole area once should
be corrected by removing or adding premixed material. Rolling should recommence thereafter.
Each pass should have an overlap of at least one-third of the track made in the preceding pass.
Rolling should be continued till all roller marks have been eliminated.
For single lane roads no longitudinal joint is required, while for double-lane roads longitudinal
joints may be required depending on the paver width.

h. For making longitudinal or transverse joint, cut the edges of the bituminous layer laid earlier to
their full depth to expose fresh surface and apply a thin coat of binder. Lay adjacent new layer and
compact flush with the existing layer.

i. Cover the bituminous macadam with the wearing course within a period of 48 hours. If there is
any delay in providing wearing course the bituminous macadam surface should be covered with a
seal coat before opening to traffic.
48. Premix carpet (20 mm Thick) (Open graded Premix Surfacing using Bitumen)
Methodology

a. Prepare the base on which premix carpet is to be laid to the specified lines, grade and
cross-section.

b. Apply a prime coat followed by tack coat over a granular base preparatory to laying of the
carpet.

c. The quantities of material required for 20 mm thick premix carpet are as follows:

Aggregate Quantity
(a) Nominal size 13.2 mm (passing 22.4 mm sieve and retained on 11.2 mm 0.18 M3
sieve)
(b) Nominal size 11.2 mm (passing 13.2 sieve and retained on 5.6 mm sieve) 0.09 m3
Total 0.27 m3

Binder Quantity
For 0.18 m3 of 13.2 mm nominal size stone at 52 kg bitumen per m3 9.5 kg
For 0.09 m3 of 11.2 mm nominal size stone at 56 kg bitumen per m3 5.1 kg
Total 14.6 kg

d. Prepare the mix in a hot mix plant of suitable size with separate dryer arrangement for
aggregate.

e. Mixing should be thorough to ensure that a homogenous mixture is obtained. The

temperature of bitumen at the time of mixing should be in the range of 1500 C to 1630 C
and that of aggregates 1550C to 1630C, provided that the difference between the
temperature of aggregate and the binder should not exceed 140C. If modified bitumen is
used, temperature should be as recommended as per the requirements. The temperature at
the time of discharge of the mixture should be between l30°C and 160°C.

f. Locate hot mix plant near the work site. The mixed material should be transported quickly
to the site of work and laid uniformly by suitable means. The premixed material shall be
spread on the road surface with rakes.

g. Commence rolling with 80-100 kN rollers (three-wheel or tandem type), beginning

 from the edge and progressing towards the center longitudinally. (On super elevated
portions, rolling should progress from lower to upper edge parallel to center line of
pavement). Continue rolling operations till a smooth uniform surface is achieved and all
roller marks are eliminated. Each pass should have an overlap of at least one- third of the
track made in the preceding pass.

h. Correct any high spots or depressions noticed after the roller has passed over the whole area
once by removing or adding premixed material and recompacting.

i. Provide a seal coat to the surface immediately after laying the carpet as per details.

j. Ordinarily, the road may be opened to traffic after laying the seal coat with restrictions.

49. Premix carpet using bitumen emulsion

 Methodology

a. Prepare the base on which premix carpet is to be laid to the specified lines, grade and cross
section.

b. Apply a tack coat over an existing prepared black top surface.

c. The quantities of material required for 20 mm thick premix carpet should be as

indicated below.
i) Aggregate as per the mentioned requirements.
ii) Binder: Cationic bitumen emulsion.

For 0.18 m3 of 13.2 mm nominal size stone at 78 kg cationic bitumen emulsion

14.0 kg per m3
For 0.09 m3 of 11.2 mm nominal size stone at 84 kg cationic bitumen emulsion per m3
Total 7.5 kg

21.5 kg

d. Premix bitumen emulsion and aggregates in a suitable mixture such as cold mixing plant as
per IS:5435 (revised) or concrete mixture.

e. Spread the premix to the desired thickness, grade, cross fall within 10 minutes of applying
the tack coat and ensure that all leveling, raking is completed within 20 minutes of the
mixing.

f. The premixed material shall be spread on the road surface with rakes. Commence rolling
with 80-100 kn rollers (three-wheel or tandem type),

g. beginning from the edge and progressing towards the center longitudinally. (On super
elevated portions, rolling should progress from lower to upper edge parallel to center line of
pavement). Continue rolling operations till a smooth uniform surface is achieved and all
roller marks are eliminated. Each pass should have an overlap of at least one-third of the
track made in the preceding pass.

h. Provide a seal coat as specified in the contract within 4-6 hours after laying the premix
carpet. Follow Sub-section 510 for the work on seal coat.

i. Preferably, the road should be opened to traffic after 24 hours of laying the seal coat. In
single lane roads traffic may ordinarily be allowed after 6-8 hours with the care that the
speed is rigorously restricted to not more than 16 km/h.
 50. Seal coat
The seal coat shall be any of the three types mentioned below:
Type A: Liquid seal coat comprising of an application of layer of bituminous binder followed
by a cover of stone chips.
Type B: Premixed seal coat comprising of a thin application of fine aggregate premixed with
bituminous binder.
Type C: Premixed seal coat comprising of an application of 6.7 mm size stone chips premixed
with bituminous binder.

Methodology
Apply seal coat immediately after laying the bituminous course. The surface should be clean and
free of dust and extraneous material before application of the seal coat.

Type A Seal coat with bitumen:

a. Apply heated bitumen with a temperature between 1500C and 1630C uniformly with the
help of a bitumen sprayer.
b. Immediately thereafter, spread stone chips over the bitumen layer at a uniform rate,
preferably, with the help of a mechanical grit spreader to cover the surface completely.
c. Commence rolling with 80-100 kn rollers (3-wheel or tandem type), beginning from the
edge and progressing towards the center longitudinally. On super elevated portions, rolling
should progress from lower to upper edge parallel to center line of pavement. If required,
spread additional chips by hand to make up irregularities. Continue rolling operations until
all aggregate particles are firmly embedded and present a uniform closed surface.

Type A seal coat with emulsion.

a. Apply emulsion uniformly over the prepared surface by mechanical sprayers.

b. Immediately after application of emulsion, spread aggregate uniformly and evenly by

mechanical means.
c. Roll the surface following the procedure given in Para 1 (iii) above.
Type B seal coat with bitumen.

a. Follow the methodology described for preparing the premix.

b. Roll the surface with 80 to 100 kn roller.
c. Continue rolling of the mix until the voids in the bituminous surface are completely
sealed and a smooth and uniform surface is obtained.

d. Type B seal coat with emulsion.

e. Follow the methodology of premix carpet using bitumen emulsion.

f. Type C seal coat.

g. Premix carpet may be referred to for preparation of the mix, spreading and rolling the
same.

h. Traffic on Type B and Type C seal coat may be allowed after completion of rolling
operations and the surface is at ambient temperature. Traffic on Type A seal coat

i. may be allowed only on the following day. In exceptional circumstances the road with
Type A seal coat may be opened to traffic
immediately after rolling but the traffic speed
should be restricted to 16 km/h until the
following day.