TECHNICAL SPECIFICATIONS – CIVIL WORKS

TECHNICAL SPECIFICATION - CIVIL WORKS

SECTION PARTICULARS
Section - 1 GENERAL AND MATERIAL

Section - 2 SURVEY & GEOTECHNICAL INVESTIGATION FOR DESIGN

Section - 3 CONCRETE

Section – 4 BUILDING DETAILS

Section – 5 STRUCTURE STEEL WORKS

Section - 6 WATER SUPPLY AND SANITARY WORKS

Section – 7 EARTHWORK

Section – 8 INTAKE STRUCTURE

SPECIFICATIONS

SECTION: 1

GENERAL AND MATERIAL

 SECTION: 1
GENERAL AND MATERIAL
GENERAL

1.0 Employer’s Drawings:

1.1. The drawings listed in the Tender document are the Employer’s conceptual drawings
and are to be got approved prior to start of the works with actual site conditions &
level in consultation with EIC.

2.0 Drawing Sheet Format:

2.1. All drawings provided by the Contractor shall be on standard size sheets, prepared on
computer with AutoCAD and shall show the following particulars in a title block
located in the lower right-hand corner, in addition to the name of Contractor and
equipment manufacturer, date, scale, drawing number, revision number (R0 for
drawings submitted initially, R1, R2, etc. for drawings submitted subsequently) and
title.
Project name: - Nagarpalika Water Supply Scheme,

A blank space of 90 mm x 100 mm shall be provided for the Engineer’s approval stamp
and provision shall be made for details of revisions to be recorded.

2.2. All drawings submitted by the Tenderer/Contractor shall use the English language and
SI units. All drawings shall be clearly and fully cross-referenced to the other drawings
as relevant.

3.0 Tender / Contract Drawings:

3.1. Drawings submitted by the Tenderer shall show all the essential items of the Plant
offered together with sufficient details to enable the general arrangement of the
Plant to be determined.

3.2. The drawings and documents to be provided by the Tenderer / Contractor shall be as
per the schedules of price but shall not be limited to those listed:

4.0 Submissions and Approval of Drawings:

4.1. The following shall be the procedure for submission and approval of drawings:

4.1.1. The Contractor shall submit 4 copies of the drawings to the Employer. All the drawings
are to be signed by the Contractor or his authorized representatives

4.1.2. The Engineer’s Representative will review the drawings and, if found fit for approval,
the Employer will return 2 copies to the Contractor duly approved.
4.1.3. In case the drawings/documents are not fit for approval but worth for review, the
Engineer’s Representative will mark the comments on the drawings and return 2
copies to the Contractor. In such case, the Contractor shall resubmit the revised
drawings within two weeks as per sub-clause 4.1.1 above and the same shall be
repeated till the drawings are finally approved as per sub-clause 4.1.2 above.
4.1.4. If the submitted drawings/documents are not worth for review, the Contractor will be
informed accordingly.

4.1.5. On receipt of the approved drawings as per sub-clause 4.1.2 above, the Contractor
shall submit CD or Pen drive and documents to the employer.

4.1.6. After tests on completion, the Contractor shall submit, within 15 days of the
conclusion of the tests, floppies of the “As Built Drawings” to the Employer.

4.1.7 When the drawings are received by the Engineer’s Representative after revision by the
Contractor, he will only review the revision made and hence the Contractor shall
carefully identify all the revised details / dimensions and also describe the revisions in
the revision block.

4.1.8 No drawings, with corrections made after taking the prints, will be accepted.

4.1.9 Approval of drawings by the Engineer shall not relieve the Contractor of his
responsibility in terms of the Contract.

5.0 Delivery, Unloading and Storing at Site:

5.1. The Contractor shall be responsible for checking all materials delivered to Site and
shall keep the Engineer’s Representative fully informed of the state of deliveries. The
Contractor shall carry out, at his cost, all instructions of Engineer or his
Representative for proper unloading, preservation, maintenance, storage and security
of materials delivered to Site until he fulfills all his obligations under the Contract.

5.2. The Contractor shall erect and maintain on the Site any temporary storage facility as
required and approved by the Engineer.

5.3. Multiple handling and movement of materials during storage and retrieval shall be
avoided.

6.0 Spare Parts:

6.1. Spare Parts required after the taking over the Plant shall be filled up by the bidder in
the price schedule.

6.2. Spares during pre-commissioning trials, commissioning tests/maintenance, guarantee

etc. shall be provided by the Contractor. The necessary spares shall be brought by the
Contractor prior to the pre-commissioning test so as to avoid the downtime of
equipment due to non-availability of them. All these spares have to be provided as
required, by Contractor free of cost.

6.3. All spare parts shall be new, unused and strictly interchangeable with the parts for
which they are intended to be replacements and shall be treated and packed for long
storage under the climatic conditions prevailing at the Site. Each spare part shall be
clearly marked or labeled on the outside of its packing with its description, number
 and purpose. When more than one spare is packed in a single case or other container,
a general description of its contents shall be shown on the outside of such case or
container and a detailed list enclosed. All cases, containers and other packages shall
be marked and numbered in an approved manner for the purpose of identification.
Spares shall be delivered to Site after the completion of erection but before start of
commissioning of Plant along with technical leaflets and details. Spare parts shall be
indicated in the assembly drawing showing clearly the part numbers.

6.4. All cases, containers or other packages are liable to be opened for such examination as
the Engineer’s Representative may require and packing shall be designed to facilitate
opening and thereafter re-packing. In the event of some specific spares offered in the
Contract being withdrawn from manufacture owing to changes in design of equipment
or similar reasons viz., model being obsolete etc., the Contractor shall inform the
Employer before such withdrawal so that the Employer can take timely alternative
steps.

7.0 Tools:
7.1. Tools shall be delivered to site just prior to Tests on Completion.
7.2. The specified tools shall not be used for the erection of the Plant being supplied and
except that the Engineer may call upon the Contractor to demonstrate their use or
effectiveness, they must be handed over to the Employer in a completely new and
unused condition. Should the Contractor require any such tools at site for erection, he
shall provide his own.

The test equipment shall include special purpose items essential to the testing or re-
calibration of related items of Facilities.

MATERIALS AND WORKMANSHIP:

1.0 Introduction:
1.1 This part of the Specification sets out the general standards of materials to be
supplied and the workmanship required to be ensured by the Contractor. All
component parts of the Works shall, unless otherwise specified, comply with the
provisions of employer’s requirement or be subject to the approval of the Employer.
Particular attention shall be paid to a neat, orderly and well-arranged installation
carried out in a methodical competent manner.

2.0 Reference Specifications and Standards:

2.1 Where reference is made in the Specification to a British Standard Specification
(hereinafter abbreviated to `B.S’) issued by the British Standards Institution of 2, Park
street, London W.I., or to an Indian Standard Specification (I.S.) issued by the Bureau
of Indian Standards, (earlier known as Indian Standard Institution), ManakBhavan, 9
Bahadur shah Zafar Marg, New Delhi 110 002, or American Society for Testing and
materials (ASTM) issued by ASTM 1916 Race Street, Philadelphia, P.A., 19103, U.S.A.
or American national Standards Institute (ANSI) issued by ANSI 1430, Broadway, New
York, N.Y., 10018, U.S.A. or Japanese Industrial Standards (JIS) issued by Japanese
Standards Association, 4-1-24, Alaska, Minato-Ku, Tokyo 107, Japan or to any other
equivalent Standard it shall be to the latest revision of that Standard on the Tender
opening date.
2.2 The Contractor may propose at no extra cost to the Employer, the use of any relevant
authoritative internationally recognized Reference Standard.
2.3 All details, materials and utensils supplied and workmanship performed shall comply
with the specified Standards. If Tenderer offers equipment to other Standards, the
equipment/material should be equal or superior to those specified and full details of
the difference shall be supplied.
2.4 In the event of conflict between this Specification and the Codes for equipment,
provisions of this Specification shall govern. Certain specifications issued by national
or other widely recognized bodies are referred to in this Specification. In referring to
the Standard Specifications the following abbreviations are used:
IS : Indian Standard
ANSI : American National Standards Institute
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
ASTM : American Society of Testing and Materials
AWS : American Welding Society
AWWA : American Water Works Association
ISO : International Organization for Standardization
DIN : Deutsches Institute fur Normung
BS : British Standard
IEC : International Electro technical Commission
IEE : Institution of Electrical Engineers
IEEE : Institute of Electrical and Electronic Engineers
NEMA : National Electrical Manufacturers Association
AGMA : American Gear Manufacturer’s Association

3.0 Materials – General:

3.1 All materials incorporated in the Works shall be the most suitable for the duty
concerned and shall be new and of reputed make/approved quality, free from
imperfections and selected for long life and minimum maintenance. Non-destructive
tests, if called for in the Specification, shall be carried out. All submerged moving
parts of the Plant, or shafts and spindles or faces etc. in contact with them shall be of
corrosion resistant materials. All parts in direct contact with various chemicals, shall
be completely resistant to corrosion, or abrasion by these chemicals, and shall
maintain their properties without aging due to the passages of time, exposure to light
or any other cause.

4.0 Workmanship – General:

4.1 Workmanship and general finish shall be of first-class quality and in accordance with
best workshop practice.
4.2 All similar items of the Plant and their component parts shall be completely
interchangeable. Spare parts shall be manufactured from the same materials as the
originals and shall fit all similar items.
4.3 All parts, which can be worn or damaged by dust, shall be totally enclosed in dust
proof housings. All materials incorporated in the Works shall be the most suitable for
the duty concerned, free from imperfections and selected for long life and minimum
maintenance. All necessary accessories required for satisfactory and safe operation of
 the Plant shall be supplied by the Contractor unless it is specifically excluded from his
scope. Suitable provision by means of eyebolts or other means are to be provided to
facilitate handling of all items that are too heavy or bulky for lifting and carrying by
two men.

5.0 Welding:
5.1 Welding shall comply with the latest revision of the BS 5135 Code.
5.2 Welders shall be qualified in accordance with the requirement of the appropriate
section of BS 4871. The Engineer shall have the right to call for further qualification
from time to time from any welder who in the opinion of the Engineer does not
produce weld in accordance with the qualification. Each welder shall be assigned a
number and letter. Each welding elements shall clearly be identified as to its welder
marking the welder’s Code adjacent to the welds. A record chart shall be maintained
for each welder showing the procedures, for which he has qualified, the date of such
qualification, the type of defects produced and their frequency. The Engineer shall
disqualify the welder whose Work requires a disproportionate amount of repairs. All
procedures where required shall be qualified as per BS EN 283-3.

5.3 Inspection and quality of surveillance shall not be limited to the examination of
finished welds. The techniques employed shall be based on methods which are known
to produce good results and which have been verified at Site by actual demonstration.

5.4 Haphazard striking of the electrodes for establishing an arc shall not be permitted.
The arc shall be struck either on the joint or on a starting tag. The starting tag shall
be of the same material or a material compatible with the base metal being welded.
In case of any inadvertent strike on place other than the welding, the area affected
shall be ground flushed and examined by liquid penetration method.

5.5 Generally, a stringer bead technique shall be used with a slight oscillation of necessary
to avoid slag and to minimize the number of beads needed to fill exceed 3 times the
wire diameter. Vertical welds shall be made in upward direction. For all pipes above
300 mm dia., welding shall be done whenever possible, by 2 welders working
simultaneously along both sides of the pipe.

5.6 The root pass shall have less than 1.5 mm internal reinforcement. Defects like icicles,
burn through and excessive “such back”, etc. shall be cause for rejection of welds.

5.7 Final welds shall be suitable for appropriate fabrication of the non-destructive
examination of the weld. If grinding is necessary, the weld shall be blended into the
parent metal without gouging or thinning of the parent metal in any way. Uneven and
excessive grinding may be a cause for rejection. Fillet weld shall preferably be convex
and free from undercutting and overlap at the toe of weld. Convexity and concavity
shall not exceed 1.5 mm. The leg lengths shall not exceed the specified size by more
than 1.5 mm.

5.8 All attachments such as lugs, brackets and other non-pressure parts shall also be done
by qualified welders in accordance with the design details and materials
 specifications. Temporary attachments shall be removed in a manner that will not
damage the parent metal. Areas of temporary attachments shall be dressed smooth
and examined by ultrasonic or liquid penetration methods.

5.9 All tack welds shall be made using qualified procedure and welders, the number of
sizes of tack welds shall be kept as small as to consist of adequate strength and joint
alignments. All tack welds shall be examined visually for defects and if found
defective shall be completely removed. As welding proceeds, tack welds shall be
either removed completely or shall be properly prepared by grinding or filling their
starting ends so that they may be satisfactorily incorporated in the welds.
Unacceptable defects shall be removed by grinding machine or chipping or gouge.
Flame gouging may be permitted provided gouged surfaces are ground at least by 1.0
mm below the deepest indentation.

5.10 All weld repairs shall be carried out using the approved welding procedures and
welders. Re-welded areas shall be re-examined by the methods specified for the
original welds and the Engineer’s Representative shall duly qualify repair procedures.

6.0 Pre-heating and Post-heating Treatment:

6.1 Pre-heating and post heating treatment shall confirm to the relevant application
Codes. Pre-heating not exceeding 121 deg. C for all carbon steel construction above 25
mm thickness would be mandatory. Such pre-heating would be maintained during
flame cutting, flame or arc gouging, welding and repairs and may be done by gas
heating by gas torches/gas rings with neutral flame. The temperature shall be checked
by temperature indicating crayons. However, such pre-heating will not be necessary
for welds less than 6 mm size. In large diameter pipe fabricated out of plate
materials, production control test plates in accordance with the BS 4870-part 1 Table
6 to represent 30% of the long seams and each welder’s performance would be
mandatory.

7.0 Electrodes:
7.1 All electrodes shall be stored in their original sealed containers under dry conditions.
Electrodes shall remain identified until consumed. All electrodes shall be dried before
use. Drying ovens shall be provided in Work areas for drying purposes. Electrodes
withdrawn from oven shall be promptly used and excess unused electrodes shall be
promptly returned to oven.

8.0 Examination/NDT/Radiography
8.1 The various stages of examination and types shall be as stipulated in the respective
fabrication Codes. Radiographic examination shall be carried out as per provisions of
BS 2600 or BS 2910; Ultrasonic tests were called for shall be carried out as per
provisions of BS 3926; magnetic particle tests shall be carried out as per BS 6072.
Liquid penetration tests shall be carried out as per BS 6443.

9.0 Stainless Steel Welding:

9.1 All welding consumable such as electrodes, filler weirs, argon gas for shielding and
purging shall be of high quality and the proposed brand shall be furnished for approval
 of the Engineer. Weld deposits shall have similar or higher physical properties and
similar chemical composition to the members joined.

9.2 All electrodes shall be purchased in sealed containers only and stored in their packing
intact. The packets opened shall be consumed as early as possible. The electrodes
removed from the containers shall be kept in holding ovens at temperatures
recommended by electrode manufacturer. Special care shall be taken in avoiding
mixing of electrodes in the oven. The electrodes and filling wires shall be free from
rust, oil, grease, earth and other foreign matter.

9.3 Argon gas with purity 99.5% shall be used for shielding and purging. The purity of gas
shall be certified by the gas manufacturers.

9.4 Non-destructive examination of the welds shall be carried out to ensure quality of
weld.

9.5 The electric current for welding shall be direct current, straight polarity (electrode
negative). The welding current shall be kept minimum possible to ensure minimum
heat affected zone in the parent material. Other side of the weld joint shall be
periodically flushed with argon gas.

10.0 Castings:
10.1 Cast iron shall be of standard grey close-grained quality. The structure of the castings
shall be homogeneous and free from non-metallic inclusions and other injurious
defects. All surfaces of castings, which are not machined, shall be smooth and shall be
carefully fettled to remove all foundry irregularities.

10.2 Minor defects in depth not exceeding 12.5 percent of total metal thickness and which
will not ultimately affect the strength and serviceability of the casting may be
repaired by approved welding techniques. The Engineer shall be notified of large
defects and no repair welding of such defects shall be carried out without prior
approval of the Engineer. If the removal of metal for repair should reduce the stress
resisting cross section of the casting by more than 25 percent, or to such an extent
that the computed stress in the remaining metal exceeds the allowable stress by more
than 25 percent, then casting shall be rejected. Test coupons cast simultaneously with
the main castings shall be identified to check physical, chemical analysis of casting.
Major defects on casting are not acceptable. Castings repaired by welding for minor
defects shall be stress-relieved after such welding. Non-destructive tests as directed
by the Engineer will be required for any casting containing defects whose extent
cannot otherwise be judged, or to determine where repair welds have been properly
made.

11.0 Forging:
11.1 All major stress-bearing forging shall be made to a Standard Specification. Forging
shall be subjected to magnetic particle testing or dye penetration test at the areas of
fillets and change in section. The testing shall be conducted after rough machining (10
microns). Any defect, which will not machine out during the final machining, will be
 gouged out fully, inspected by dye penetration or magnetic particle inspection to
ensure that the defect is fully removed and repaired using an approved repair
procedure. Any indication, which proves to penetrate deeper than 2.5% of the finished
thickness of the component, shall be reported to the Engineer giving the details like
location, length, width and depth. For the magnetic particle inspection the choice of
wet or dry particles shall be at the Contractor’s discretion.

11.2 All forging shall be demagnetized after test and shall be heat-treated for the relief of
residual stresses.

12.0 Design Life:

12.1 The Works as a whole shall be new, of sound workmanship, robustly designed for a
long reliable operating life and shall be capable of 24 hours per day continuous
operation for prolonged period in the climatic and working conditions prevailing at the
Site, and with the minimum of maintenance. Particular attention shall be given to
temperature changes, the stability of paint finish for high temperatures, the rating of
engines, electrical machinery, thermal overload services, cooling systems and the
choice of lubricants for possible high and prolonged operating temperatures. The
Contractor shall be called upon to demonstrate this for any component part either by
service records, or evidence of similar equipment already installed elsewhere or
relevant type tests. Routine maintenance and repair shall as far as possible not
requires the services of highly skilled personnel.

12.2 The Plant shall be designed to provide easy access to and replacement of component
parts, which are subject to wear, without the need to replace whole units. No parts in
contact with water shall have a life from new to replacement or repair of less than
five years.

12.3 Design features shall include the protection of Plant against damage caused by vermin,
dirt, dust and dampness and to reduce risk of fire. Plant shall operate without undue
vibration, and parts shall be designed to withstand the maximum stresses under the
most severe condition of normal service. Materials shall have a high resistance to
change in their properties due to the passage of time, exposure to light, temperature
and any other cause, which may have a detrimental effect upon the performance or
life of the Works.
12.4 Plant located outside lockable areas/building shall have additional features to prevent
un-authorized operation.

13.0 Name Plate:

13.1 Each item of the Plant shall have permanently attached to it in a conspicuous position,
a nameplate and rating plate. Upon these shall be engraved or stamped, the
manufacturer’s name, type and serial number of Plant, details of the loading and duty
at which the item of Plant has been designed to operate, and such diagrams as may be
required by the Engineer. All indicating and operating devices shall have securely
attached to them or marked upon them designations as to their function and proper
manner of use.

13.2 Nameplates, rating plates and labels shall be of a non-flame propagating material,
 either non-hygroscopic or transparent plastic with engraved lettering of a contrasting
colour. Fixing shall be by means of non-corrosive screws; drive rivets or adhesives
shall not be used.

13.3 Warning labels shall be provided where necessary to warn of dangerous circumstances
or substances. Inscriptions or graphic symbols shall be black on a yellow background.

13.4 Instruction labels shall be provided where safety procedures such as wearing of
protective clothing are essential to protect personnel from hazardous or potentially
hazardous conditions. These labels shall have inscriptions or graphic symbols in white
on a blue background.

14.0 Nuts, Bolts, Studs and Washers:

14.1 Nuts, bolts, studs and washers for incorporation in the Plant shall conform to the
requirements of the appropriate standard. Nuts and bolts shall be of the best quality
of specified grade, machined on the shank and under the head and nut.

14.2 Fitted bolts shall be a light driving fit in the reamed holes they occupy, shall have the
screwed portion of such a diameter that it will not be damaged in driving and shall be
marked in a conspicuous position to ensure correct assembly at Site.

14.3 Washers, locking devices and anti-vibration arrangements shall be provided where
necessary Jointing hardware for the entire Plant shall be provided with sufficient
spares to cater for site losses.

14.4 Where bolts pass through structural members taper washers shall be fitted, where
necessary, to ensure that no bending stress is caused in the bolt. Where there is a risk
of corrosion, bolts, nuts and studs shall be designed so that the maximum stress does
not exceed half the yield stress of the material under any conditions. All bolts, nuts
and washers that are subject to frequent adjustment or removal in the course of
maintenance and repair shall be made of nickel-bearing stainless steel.

14.5 The Contractor shall supply all holding down, alignment and leveling bolts complete
with anchorages, nuts, washers and packing required to attach the Plant to its
foundations, and all bed plates, frames and other structural parts necessary to spread
the loads transmitted by the Plant to concrete foundations without exceeding the
design stresses.

15.0 Allowances for Wastage:

15.1 The Contractor shall supply reasonable excess quantities to cover wastage of those
consumable, which will be normally subject to waste during erection, commissioning
and setting to Work.

16.0 Painting – General:

16.1 The Contractor shall be responsible for the cleaning, preparation for painting, and
priming or otherwise protecting, as specified, all parts of the Plant at the place of
manufacture prior to packing.
16.2 Parts may be cleaned but surface defects may not be filled in before testing at the
manufacturer’s works. Parts subject to hydraulic test shall be tested before any
surface treatment. After test, all surfaces shall be thoroughly cleaned and dried out,
if necessary by washing with an approved de-watering fluid prior to surface treatment.
Except where the specification provides to the contrary all painting materials shall be
applied in strict accordance with the paint manufacturer’s instructions.

16.3 All protective coatings shall be suitable for use in warm humid climates. All primers,
under coats and finishes shall be applied by brush or airless spray, except where
otherwise specified. Consecutive coats shall be in distinct but appropriate shades. All
paints shall be supplied from the store to the painters, ready for application, and
addition of thinners or any other material shall be prohibited.

17.0 Painting at Place of Manufacture:

17.1 Steel and cast iron parts shall be sand blasted to near white cleaning before painting.
Edges, sharp covers etc. shall be ground to a curve before sand blasting. A primer
coat of a zinc rich epoxy resin based coating with at least 75 microns dry film
thickness is to be provided. In addition the parts are to be provided with adequate
number of coats of coal tar epoxy polyamine coating to a dry film thickness of 175
microns including primer coating.

18.0 Painting at Site:

18.1 Immediately on arrival at the site, all items of Plant shall be examined for damage to
the paint coat applied at the manufacturer’s works, and any damaged portions shall
be cleaned down to the bare metal, all rust removed, and the paint coat made good
with similar paint.

18.2 After erection, such items, which are not finish painted, shall be done so and, items
that have been finish painted at the manufacturer’s works shall be touched up for any
damaged paintwork. For finish painting, two coats of synthetic enamel conforming to
IS: 2932 shall be applied. Dry film thickness of each coat shall be at least 25 microns.

18.3 The dry paint film thickness shall be measured by Electrometer or other instruments
approved by the Employer. In order to obtain the dry film thickness specified the
Contractor should ensure that the coverage rate given by the paint manufacturer
would enable this thickness to be obtained. Strength of adhesion shall be measured
with an adhesion tester and this value shall not be less than 10 kg/cm2. Painted
fabricated steel work which is to be stored prior to erection shall be kept clear of the
ground and shall be laid out or stacked in an orderly manner that will ensure that no
water or dirt can accumulate on the surface. Suitable packing shall be laid between
the stacked materials. Where cover is provided, it shall be ventilated.

19.0 Galvanizing:
19.1 Wherever galvanizing has been specified the hot dip process shall be used. The
galvanized coating shall be of uniform thickness. Weight of zinc coatings for various
 applications shall not be less than those indicated below:

a) Fabricated steel
Thickness less than 2 mm but not less than 1.2 mm - 340 gms/sq.m
Thickness 2 mm and above - 460 gms/sq.m

b) Fasteners
Up to nominal size M10 - 270 gms/sq.m
Over M10 - 300 gms/sq.m

19.2 Galvanizing shall be carried out after all drilling; punching, cutting, bending and
welding operations have been carried out. Burrs shall be removed before galvanizing.
Any Site modification of galvanized parts should be covered well by zinc rich primer
and aluminum paint.

20.0 Support for Pipe work & Valves:

20.1. All necessary supports, saddles, sling, fixing bolts & foundation bolts shall be supplied
to support the pipe work. Valve and other facilities mounted in the pipe work shall be
supported independent of the pipes to which they connect.
 INSPECTION AND TESTING AT MANUFACTURER’S PREMISES

1.0 Inspection and Tests:

1.1 Valve:
1.1.1 During testing there shall be no visible evidence of structural damage to any of the
valve component.

1.1.2 Motorized valves shall be tested with their actuators, with a differential head
equivalent to their maximum working pressure, to prove that the actuators are
capable of opening and closing the valves under maximum unbalanced head condition
within the specified opening or closing period.

1.1.3 The following test shall be carried out for sluice valves:
a) Seat leakage test at rated pressure
b) Hydrostatic test at 1.5 times the rated pressure
c) Valve operation

1.1.4 The following test shall be carried out for non-return valves:
a) Seat leakage test at rated pressure
b) Body hydrostatic test at 1.5 times rated pressure
c) Operation

1.2 Pipe work:

1.2.1 Testing of pipes and fitting shall be carried out in accordance with relevant Indian
Standard and internationally approved standard. Pipes, fittings and expansion bellows
shall be hydrostatically tested for 1.5 times the rated pressure.
1.3. E.O.T. Crane:
1.3.1 The cranes shall be completely assembled in the Contractor’s or subcontractor’s Works
and shall be subjected to the tests as specified in IS- 807/IS-3177 or relevant
internationally approved standard. The Contractor shall provide the test weights.

1.4 Equipment for testing:

Equipment required for testing CC cubes and testing of steel bars are installed at main
H/W site.
 SPECIFICATIONS

SECTION:2

SURVEY & GEOTECHNICAL INVESTIGATION FOR DESIGN

Specifications for Minimum Investigations required for Project:

Survey and Soil Exploration:

To plan out and obtain pre-approval and subsequently carry out Topographic and level
Survey, preparing cross sections, Longitudinal sections, Soil exploration to obtain
foundation design data at various locations for all the components listed in preamble
on previous page, complete all as per general pre-approved plan and as per detailed
description and specifications and including submitting survey, soil exploration and
analysis reports in six copies along with two soft copies and getting the same approved
by the engineer in charge.

Work consists of providing all equipment, materials, labour etc. to carry out survey, to
provide permanent markers of various points for later use, to create permanent bench
mark of approved design and approved location on the site, to carry out soil
exploration to obtain information for foundation design as well as collecting data to
determine various design parameters, to collect all data, prepare interim and final
reports for submission and approval of the Engineer in-charge, all as per detailed
description, specifications and as directed by the Engineer in-charge. This may call for
revised hydraulic design, in case location of headwork/ sub headwork/ village level
sump etc. changes. However, minimum pipe size (as given in Schedules and drawings)
shall be adhered to. In certain cases, due to revised location of tail end point sump,
level may be higher or frictional losses may increase. This will demand pipe size of
higher diameter and contractor shall carry out hydraulic design to suit specific section
subject. In case level of such sump reduces or location reduces the length ultimately
resulting into permission of lower size, size given in schedule & drawing shall be
provided and on no account, it shall be reduced.

It must be clearly understood that the data furnished with the tender and suggested
procedure for survey and soil exploration are purely for general guidance of the
bidders for selecting the best design criteria. The contractor is expected to carry out
additional work if it becomes necessary in the process of selecting appropriate
criteria. In any case responsibility of assuring the guaranteed water supply will fully
rests with him.

Work Description:

Work under this item involves survey, soil exploration and investigation as described
below. Survey maps and all interim as well as final reports of soil investigation, other
tests as well as the reporting of final test shall be submitted in six paper copies as well
as two soft copies and these will form part of a permanent record of the project for
use during construction, operation, and maintenance stages as well as for future use.
All below mentioned work shall be all inclusive and will be carried out as per detailed
specifications and as directed by the Engineer in-charge.

Survey and soil investigation shall be completed within one & half month. In case after
delay of 15 calendar days the department will get completed the work from
departmental agency at the risk and cost of the contractor which shall be binding to
the contractor.

Survey work shall consist of the following:

A. To carry out Block level survey based on GTS benchmark, prepare longitudinal section
along alignment of all types of pipelines and prepare contour survey of the allotted
plot of land and the river bed of the width of 100m – 50m on either side - of the
suggested center line of the alignment, and prepare contour maps to a scale of 1:500
or larger. Survey in the river may be carried out with help of sounding technique or
long metallic rod inserted in water from the boat. All the levels/ distance may be
measured with help of total station or DGPS.

B. Selecting most appropriate location (on the basis of survey) to determine various
geotechnical parameters for carrying out design of various components shall be
responsibility of the contractors and it shall be carried out by laboratory approved by
GOG acceptable to GUDM.

C. Above survey shall be carried out in stages as and when required, using the latest
equipment like TOTAL STATION or DGPS with high accuracy. In case dumpy level/ auto
level is used, then fly back as well as closing error must be performed without which
survey will be considered as NOT completed. All levels will be based on GTS, and the
work shall include transferring level from a reliable established GTS benchmark in the
vicinity of the site of work and establishing a permanent bench mark on site at a
suitable location as per approved design and location. Above survey will be carried out
jointly with the representative of the owner, as per his convenience during day time.

D. Detailed Longitudinal Section for each pipe shall be prepared and HGL marked on it
for approval of GUDM. After marking of such data only, execution of pipeline shall be
permitted.

E. Detailed contour plan of the headwork/ sub headwork etc. prepared with interval of
0.2 m so as to determine position of various units.

Soil exploration work for A. intake, RCC and framed structures, underground
sumps, Pump Houses (positive/ negative suction), B. alignment of pipeline shall
consist of the following:

A. 150 mm bores or more diameters (Minimum one no per unit/ structure) will be made
to collect information for the foundation design of the intake well, approach bridge
supports, underground sump, Pump House, other structures. Minimum depth of bores
from the existing level at the location of various structures shall be governed by IS
stipulations or more as per requirement of specific structural design. Disturbed and
undisturbed soil samples will be collected, and grain size analysis by dry sieving/Wet
analysis, determination of liquid/plastic limit and other necessary tests like C value, N
value, Ø value and important parameters to carry out structural design and facilitate
execution of structures shall be carried out. All levels including ground level of the
bore point, levels of various strata and water levels etc. will be noted in reference to
GTS.
B. Trial pit and bore for laying of pipeline underground or saddle support/ pedestal/
bridge/ existing structure etc. shall be carried out in accordance with relevant IS
stipulation to facilitate strata identification and payment towards excavation and
other allied works. this shall also include collection of data necessary for structural
design of thrust block and other ancillary crossing works.

(A) Specification for drilling, investigation, furnishing details of bore logs, laboratory
testing and reporting:

1. The investigation bores shall be made by percussion method and not by rotary method.
No bentonite slurry or drilling mud shall be used. The bores shall be cased when it is
to be done in sandy and silty strata.
2. The quantity of boring mentioned in work description is approximate and likely to vary
materially if investigating alternative location of Infiltration Well becomes necessary.
Any change in the quantity of boring work shall not entitle the contractor for any
claim or compensation. His rates shall be deemed to cover such an eventuality.
3. The disturbed samples shall be collected at every 1.5 Mt. Depth or at the points where
the strata change whichever is less.
4. The samples so collected shall be preserved in systematic manner in core boxes, when
the bore is in progress. After the bore is completed, each of the samples shall be
packed in two separate poly thin bags with contents of approx. 0.5 Kg and properly
numbered giving other details so as to identify the position to which the samples
represent. All other details such as the bores Sr. Nos., the depth from which the
samples are taken etc. should be clearly given with the samples.
5. Out of the two sets of samples collected for every bore one set of samples with all
requisite details shall be sent to the laboratory for testing and the second set of
samples together with requisite details shall be supplied to the clients in their office
for record. The casing pipes shall be removed after above compliance and with the
approval of the Engineer in-charge. The recovered samples shall be tested in the
laboratory for grain size analysis and Atterbergs limits to identify the samples in
accordance with the provision in IS.1498, 1971. The testing of samples shall have to be
done at the recognized laboratory approved by the engineer-in charge.
6. The drilling shall be terminated at approx. 2.0 Mts. below the impervious (e.g. clay)
strata, when bores are being made primarily to find the level of impervious strata.
And if the samples collected indicate the soil being predominantly clayey further
drilling shall be discontinued. In sandy strata including sand with gravels and small size
boulders, Bores shall be extended at least up to 15 Mts. below bed level or low water
level whichever is lower, however if required by Client /Consultants, The bores may
have to be carried further.
7. Where bores are required to be done in water channel in river/ nallah bed, necessary
island/islands shall be prepared in sand or sand filled gunny bags. The cost of which
shall be covered within the rates quoted.
8. The rates quoted shall be inclusive for drilling in all kinds of strata including boulders,
soft or hard rock.
9. For every bore water level encountered shall be recorded together with variation in
water level if during the period of boring.
10. All levels shall be with reference to the GTS Bench Hark. For this purpose, a pucca
GTS Bench mark shall be established in the region of proposed survey and investigation
area.
11. The readings are to be recorded and observations are to be submitted with the reports
in the format as per Proforma 1 and 2 shown below. The Contractor shall prepare bore
charts for each and every bore in the approved manner and Proforma as required by
Client.
12. The disturbed samples are to be analyzed as per relevant clause of I.S. 2720 Part I to
IV.
13. The water samples of water pumped out during pump test shall be collected and
analyzed covering requirements of I.S. 10500 to establish its portability and the results
of the chemical and other tests submitted in the format shown in Proforma 3.
14. A Technical report covering the observations and tests is to be submitted to the client
with the contractor’s recommendations for selecting the most suitable site for the
Radial well which could give the desired yield. The site for location of the pumping
test shall be finalized in consultation with the clients before the work of pumping test
including necessary boring work for the same is taken up.
(B) Specification for preparing and submitting the full technical report:

1. The survey work shall be carried out with proper accuracy and permanent Bench Mark
shall be established at points which are approved by the Engineer in-charge. Also,
sufficient number of permanent identification marks shall be established on the bank
to enable establishment of base lines and the survey map to be included in the report
shall contain sufficient details with respect to these permanent marks to enable the
contractor to relocate the soil investigation bores as well as pump well and
piezometric bores positions.

2. Based on the soil investigation carried out, a contour map of the area investigated
showing the soil strata shall be prepared and included in the technical report.

3. The soil investigation work shall be carried out as per specifications and information
will be recorded in the format given in attached Proforma 1 and 2.

4. The short chemical analysis of water samples shall be carried out as per I.S. 10500 and
results reported in format given in attached Proforma 3.

5. The Proforma included in the tender are only for guidance and by no means are they
to be considered as the only ones required for reporting the investigation. Additional
information which is considered necessary shall be collected and recorded
systematically in proper format to arrive at the relevant conclusions.

6. Using these parameters discharge shall be calculated for different water levels of the
river, and the report shall make definite recommendations as regards to the number
of radials, their levels, and their lengths required to obtain the desired yield.

PROFORMA 1
Bore hole no. Date of start Date of comp. GTS value Revision no.

Penetration test
Th. Of layer in

soil
Bore dia in cm

Core recovery

N-Value
Undisturbed
description
Depth in m

Disturbed

Remarks
Method

sample

sample
Casing

Visual
Soil
m
 PROFORMA 2
Bore Date of Date of Termination depth Revision no.
hole no. start comp.
Depth of Grain size analysis
sample
% Gravel % sand Hydrometer LL% PL% PI%
% Silt % Clay

PROFORMA 3: CHEMICAL ANALYSIS OF WATER

Date of Source
collection
Date of arrival Location Village :
at lab
Lab ref. no.

Sr. Characteristics Permissible value as per IS 10500

no.
Desirable Relaxable in absence Analytical value
of alternate source
1 Color
2 Odor
3 Turbidity
4 Dissolved solids
5 pH
6 Total hardness as CaCO3
7 Calcium
8 Magnesium
9 Chloride
10 Sulphate
11 Nitrate
12 Fluoride
13 Manganese
Signature:

Date:
SPECIFICATIONS

SECTION:3

CONCRETE
 SECTION -3:

CONCRETE
2.0 Applicable Codes with latest revisions.

2.0.1 Materials
1) IS.269 Specification for 33 grade ordinary Portland cement.
2) IS.455 Specification for Portland slag cement.
3) IS.1489 Specification for Portland- Pozzolana cement (Part 1&2).
4) IS:8112 Specification for 43 grade ordinary Portland cement.
5) IS:12269 Specification for 53 grade ordinary Portland cement.
6) IS:12330 Specification for sulphate resisting Portland cement.
7) IS:383 Specification for coarse and fine aggregates from natural sources
For concrete.
8) IS:432 Specification for mild steel and medium (tensile steel bars and
hard-drawn steel) wires for concrete reinforcement. (Part 1 and 2)
9) IS:1786 Specification for high strength deformed steel bars and wires for
Concrete reinforcement.
10) IS:1566 Specification for hard-drawn steel wire fabric for concrete
Reinforcement.
11) IS:9103 Specification for admixtures for concrete.
12) IS:2645 Specification for integral cement water- proofing compounds.

13) IS:4990 Specification for plywood for concrete shuttering work.

2.0.2 Material Testing:

1) IS.4031 Methods of physical tests for hydraulic cement (Parts 1 to 15)

2) IS:4032 Method chemical analysis of hydraulic cement.
3) IS:650 Specification for standard sand for testing of cement.
4) IS:2430 Methods for sampling of aggregates for concrete.
5) IS: 2386 Methods of test for aggregates for concrete (Parts 1 to 8)
6) IS:3025 Methods of sampling and test (physical and chemical) for water
used in industry.
7) IS:6925 Methods of test for determination of water soluble chlorides in
Concrete admixtures.

2.0.3 Material Storage:

1) IS:4082 Recommendations on stacking and storing of construction
Materials at site.
 2.1.4 Concrete Mix Design:
1) IS:10262 recommended guidelines for concrete mix design.
2) SP:23 (S&T) Handbook on Concrete Mixes

2.1.5 Concrete Testing:

1) IS.1199 Method of sampling and analysis of concrete.

2) IS:516 Method of test for strength of concrete.
3) IS:9013 Method of making, curing and determining compressive strength
Of accelerated cured concrete test specimens.
4) IS:8142 Method of test for determining setting time of concrete by
Penetration resistance.
5) IS:9284 Method of test for abrasion resistance of concrete.
6) IS:2770 Methods of testing bond in reinforced concrete.

2.1.6 Equipment:

1) IS:1791 Specification for batch type concrete mixers.

2) IS:2438 Specification for roller pan mixer.
3) IS:4925 Specification for concrete batching and mixing plant.
4) IS:5892 Specification for concrete transit mixer and agitator.
5) IS:7242 Specification for concrete spreaders.
6) IS:2505 General Requirements for concrete vibrators: Immersion type.
7) IS:2506 General Requirements for screed board concrete vibrators.
8) IS:2514 Specification for concrete vibrating tables.
9) IS:3366 Specification for pan vibrators.
10) IS:4656 Specification for form vibrators for concrete.
11) IS:11993 Code of practice for use of screed board concrete vibrators.
12) IS:7251 Specification for concrete finishers.
13) IS:2722 Specification for portable swing weigh batchers for concrete
(Single and double bucket type).

14) IS:2750 Specification for steel scaffoldings.

2.1.7 Codes of Practice:

1) IS:456 Code of practice for plain and reinforced concrete.
2) IS:457 Code of practice for general construction of plain and reinforced
Concrete for dams and other massive structures.
3) 3) IS:3370 Code of practice for concrete structure for storage of liquids (Part1to4)
4) IS:3935 Code of practice for composite construction.
5) IS:2204 Code of practice for construction of reinforced concrete shell roof
6) IS:2210 Criteria for the design of reinforced concrete shell structures and
 Folded Plates.
7) IS:2502 Code of practice for bending and fixing of bars for concrete
Reinforcement.
8) IS:5525 Recommendation for detailing of reinforcement in reinforced
Concrete works.
9) IS:2751 Code of practice for welding of mild steel plain and deformed
bars used for reinforced concrete construction.
10) IS:9417 Specification for welding cold worked bars for reinforced
concrete construction.
11) IS:3558 Code of practice for use of immersion vibrators for consolidating
concrete.
12) IS:3414 Code of practice for design and installation of joints in buildings.
13) IS:4326 Code of practice for earthquake resistant design and construction
Of building.
14) IS:4014 Code of practice for steel tubular scaffolding (Parts 1 & 2)
15) IS:2571 Code of practice for laying in situ cement concrete flooring.
16) IS:7861 Code of practice for extreme weather concreting: Part 1
Recommended practice for hot weather concreting.

2.1.8 Construction Safety:

1) IS: 3696 Safety code for scaffolds and ladders. (Parts 1 &

2) IS:7969 Safety code for handling and storage of building materials.

3) IS:8989 Safety code for erection of concrete framed structures.

2.2 General:

The Engineer in charge shall have the right at all times to inspect all operations
including the sources of materials, procurement, layout and storage of materials, the
concrete batching and mixing equipment and the quality control system. Such an
inspection shall be arranged and the Engineer in charge’s approval obtained, prior to
starting of concrete work. This shall however, not relieve the Contractor from any of
his responsibilities. All materials which do not conform to the Specifications shall be
rejected.
Materials should be selected so that they can satisfy the design requirements of
strength, serviceability, safety, durability and finish with due regards to the functional
requirements and the environmental conditions to which the structure will be
subjected. Materials complying with codes/standards shall generally be used. Other
materials may be used after approval of the Engineer in charge and after establishing
their performance suitability based on previous data, experience or tests.
2.3 Materials:

2.3.1 Cement:
 Unless otherwise called for by the Engineer in charge, cement shall be ordinary
Portland cement conforming to IS: 269, IS: 8112 or IS: 12269. However, in any case,
cement grade shall not be lower than 43 grades.
Where Portland Pozzolana or slag cements are used, it shall be ensured that
consistency of quality is maintained, there will be no adverse interactions between
the materials and the finish specified is not marred.
Only one type of cement shall be used in a particular unit. The source of supply, type
or brand of cement within the same structure or portion thereof shall not be changed
without approval from the Engineer in charge.
Cement which is not used within 90 days from its date of manufacture shall be tested
at a laboratory approved by the Engineer in charge and until the results of such tests
are found satisfactory, it shall not be used in any work.
2.3.2 Aggregates (General):

Aggregates shall consist of naturally occurring stones (crushed or uncrushed), gravel

and sand. They shall be chemically inert, strong, hard, clean, durable against
weathering, of limited porosity, free from dust/silt/ organic impurities/deleterious
materials and conform to IS:383. Aggregates such as slag, crushed over burnt bricks,
bloated clay ash, sintered fly ash and tiles shall not be used.

Aggregates shall be washed and screened before use where necessary or if directed by
the Engineer in charge.

Aggregates containing reactive materials shall be used only after tests conclusively
prove that there will be no adverse effect on strength, durability and finish, including
long term effects, on the concrete.

The fineness modulus of sand shall neither be less than 2.2 nor more than 3.2.

The maximum size of coarse aggregate shall be as stated on the drawings but in no
case greater than 1/4 of the minimum thickness of the member.

Plums 160 mm and above of a reasonable size may be used in mass concrete where
directed. Plums shall not constitute more than 20% by volume of the concrete.

2.3.3 Water:

Water to be used for both mixing and curing shall conform to IS: 456. Potable water is
generally satisfactory. Water containing any excess of acid, alkali, sugar or salt shall
not be used.
2.3.4 Reinforcement:
All reinforcement steel shall be TMT tore steel conforming to relevant I.S. for all RCC
structure with CRS - Fe-415 conforming to IS-1786.

All reinforcement shall be clean, free from pitting, oil, grease, paint, loose mill
scales, rust, dirt, dust, or any other substance that will destroy or reduce bond.

2.3.5 Admixtures:
 Accelerating, retarding, water-reducing and air entraining admixtures shall conform to
IS: 9103 and integral water proofing admixtures to IS: 2645.

Admixtures may be used in concrete as per manufacturer's instructions only with the
approval of the Engineer in charge. An admixture's suitability and effectiveness shall
be verified by trial mixes with the other materials used in the works. If two or more
admixtures are to be used simultaneously in the same concrete mix, their interaction
shall be checked and trial mixes done to ensure their compatibility. There should also
be no increase in risk of corrosion of the reinforcement or other embedment.

Calcium chloride shall not be used for accelerating set of the cement for any concrete
containing reinforcement or embedded steel parts.

Wastage:

Wastage allowance for cement and steel shall be considered in the item rate and no
extra payment shall be paid to the Contractor on any account.

2.4 Samples and Tests:

All materials used for the works shall be tested before use.

Manufacturer's test certificate shall be furnished for each batch of cement/steel and
when directed by the Engineer in charge samples shall also be got tested by the
Contractor in a laboratory approved by the Engineer in charge at no extra cost.
Engineer in charge may appoint separate third party inspection for the material
testing to ensure the quality of the work. The Contractor shall replace the defective
material as an outcome of these tests.

Sampling and testing shall be as per IS: 2386 under the supervision of the Engineer in
charge.

Water to be used shall be tested to comply with requirements of IS: 456.

The Contractor shall furnish manufacturer's test certificates and technical literature
for the admixture proposed to be used. If directed, the admixture shall be got tested
at an approved laboratory at no extra cost.
2.5 Storing of Materials:

All materials shall be stored in a manner so as to prevent its deterioration and

contamination which would preclude its use in the works. Requirements of IS: 4082
shall be complied with.

The Contractor will have to make his own arrangements for the storage of adequate
quantity of cement. If such cement is not stored properly and has deteriorated, the
material shall be rejected. Cement bags shall be stored in dry weatherproof shed with
a raised floor, well away from the outer walls and insulated from the floor to avoid
moisture from ground. Not more than 15 bags shall be stacked in any tier. Storage
arrangement shall be approved by the Engineer in charge. Storage under tarpaulins
shall not be permitted. Each consignment of cement shall be stored separately and
consumed in its order of receipt.
 Each size of coarse and fine aggregates shall be stacked separately and shall be
protected from leaves and contamination with foreign material. The stacks shall be on
hard, clean, free draining bases, draining away from the concrete mixing area.

The Contractor shall make his own arrangements for storing water at site in tanks to
prevent contamination.

The reinforcement shall be stacked on top of timber sleepers to avoid contact with
ground/water. Each type and size shall be stacked separately.

2.6 Concrete:
2.6.1 General:

Concrete grade shall be as designated on drawings. In concrete grade M15, M20 etc.
the number represents the specified characteristic compressive strength of
150X150X150 mm cube at 28 days, expressed in N/mm2 as per IS:456. Concrete in the
works shall be "DESIGN MIX CONCRETE" or "NOMINAL MIX CONCRETE". All concrete
works of grade M5, M7.5 and M10 shall be NOMINAL MIX CONCRETE whereas all other
grades, M15 and above, shall be DESIGN MIX CONCRETE. Concrete grade shall not be
lower than M-20 for building and M-25 for water retaining structures (all units of STP
including distribution chambers, sludge chambers, inlet/ outlet chambers adjacent to
PST/ AT/ SST).

2.6.2 Design Mix Concrete:

(a) Mix Design & Testing:

For Design Mix Concrete, the mix shall be designed according to IS: 10262 and SP:23 to
provide the grade of concrete having the required workability and characteristic
strength not less than appropriate values given in IS:456. The design mix shall be
cohesive and does not segregate and should result in a dense and durable concrete and
also capable of giving the finish as specified. For liquid retaining structures, the mix
shall also result in water tight concrete. The Contractor shall exercise great care while
designing the concrete mix and executing the works to achieve the desired result.

The minimum cement content for Design Mix Concrete shall be as per Appendix-A of
IS:456 or as given below, whichever is higher.
Minimum Cement Content in Kg/m3 of
Grade of Concrete
Concrete
M15 260
M20 315
M25 360
M30 380
M 35 400

The minimum cement content stipulated above shall be adopted irrespective of

whether the Contractor achieves the desired strength with less quantity of cement.
The CONTRACTOR's quoted rates for concrete shall provide for the above eventuality
and nothing extra shall be paid to the CONTRACTOR on this account. Even in the case
where the quantity of cement required is higher than that specified above to achieve
 desired strength based on an approved mix design, nothing extra shall become payable
to the CONTACTOR.

It shall be the Contractor's sole responsibility to carry out the mix designs at his own
cost. He shall furnish to the EMPLOYER at least 30 days before concreting operations,
a statement of proportions proposed to be used for the various concrete mixes and the
strength results obtained. The strength requirements of the concrete mixes
ascertained on 150 mm cubes as per IS: 516 shall comply with the requirements of
IS:456.

Grade of Minimum Compressive Specified Characteristic Compressive

Concrete Strength N/sq.mm at 7 days Strength N/sq.mm at 28 days

M 15 10.0 15.0

M 20 13.5 20.0

M 25 17.0 25.0

M 30 20.0 30.0

M 35 23.5 35.0

M 40 27.0 40.0

A range of slumps which shall generally be used for various types of construction
unless otherwise instructed by the Engineer in charge is given below:

Structure/Member
Slump in millimeters
Maximum Minimum

Reinforced foundation walls and footings 75 25

Plain footings, caissons and substructure walls 100 25

Slabs, Beams and reinforced walls 75 25

Pump & miscellaneous Equipment Foundations 100 25

Building columns 50 25

Pavements 50 25

Heavy mass construction 50 25

(b) Batching & Mixing of Concrete:

Proportions of aggregates and cement, as decided by the concrete mix design, shall be
by weight. These proportions shall be maintained during subsequent concrete batching
by means of weigh batchers capable of controlling the weights within one percent of
the desired value.
 Amount of water added shall be such as to produce dense concrete of required
consistency, specified strength and satisfactory workability and shall be so adjusted to
account for moisture content in the aggregates. Water- cement ratio specified for use
by the Engineer in charge shall be maintained. Each time when the work stops, the
mixer shall be cleaned out, and while recommencing, the first batch shall have 10%
additional cement to allow for sticking in the drum.

Arrangement should be made by the Contractor to have the cubes tested in an

approved laboratory or in field with prior consent of the Engineer in charge. Sampling
and testing of strength and workability of concrete shall be as per IS:1199, IS:516 and
IS:456, IS 3370.

2.6.3 Nominal Mix Concrete;

(a) Mix Design & Testing:

Mix design and preliminary tests are not necessary for Nominal Mix Concrete.

However, works tests shall be carried out as per IS: 456. Proportions for Nominal Mix
Concrete and Water Cement Ratio may be adopted as per Table-3 of IS: 456. However,
it will be the Contractor's sole responsibility to adopt appropriate nominal mix
proportions to yield the specified strength.

(b) Batching & Mixing of Concrete:

Based on the adopted nominal mixes, aggregates shall be measured by volume.

However, cement shall be by weight only.

2.7 Formwork:
Formwork shall be all inclusive and shall consist of shoring, bracings, sides of footings,
walls, beams and columns, bottom of slabs etc. including ties, anchors, hangers,
inserts, false work, wedges etc.

The design and engineering of the formwork as well as its construction shall be the
responsibility of the Contractor. However, if so desired by the Engineer in charge, the
drawings and calculations for the design of the formwork shall be submitted to the
Engineer in charge for approval.

Formwork shall be designed to fulfill the following requirements:

(a) Sufficiently rigid and tight to prevent loss of grout/ slurry or mortar from the concrete
at all stages and appropriate to the methods of placing and compacting.

(b) Made of suitable materials.

(c) Capable of providing concrete of the correct shape and surface finish within the
specified tolerance limits.

(d) Capable of withstanding without deflection the worst combination of self-weight,

reinforcement and concrete weight, all loads and dynamic effects arising from
construction and compacting activities, earthquake, wind and weather forces.

(e) Capable of easy striking out without shock, disturbance or damage to the concrete.

(f) Soffit forms capable of imparting a camber if required.

(g) Soffit forms and supports capable of being left in position if required.

(h) Capable of being cleaned and/or coated, if necessary, immediately prior to casting
the concrete; design temporary openings where necessary for these purposes and to
facilitate the preparation of construction joints.

The formwork may be of timber, plywood, steel, plastic or concrete depending upon
the type of finish specified. Sliding forms and slip form may be used with the approval
of the Engineer in charge. Timber for formwork shall be well seasoned, free from sap,
shakes, loose knots, worm holes, warps and other surface defects. Joints between
formwork and between formwork and structures shall be sufficiently tight to prevent
loss of slurry from concrete, using seals if necessary.

The faces of formwork coming in contact with concrete shall be cleaned and two coats
of approved mold oil applied before fixing reinforcement. All rubbish, particularly
chippings, shavings, sawdust, wire pieces dust etc. shall be removed from the interior
of the forms before the concrete is placed. Where directed, cleaning of forms shall be
done by blasting with a jet of compressed air at no extra cost.

Forms intended for reuse shall be treated with care. Forms that have deteriorated
shall not be used. Before reuse, all forms shall be thoroughly scraped, cleaned, nails
removed, holes suitably plugged, joints repaired and warped lumber replaced to the
satisfaction of the Engineer in charge. The Contractor shall equip himself with enough
shuttering to allow for wastage so as to complete the job in time.

Permanent formwork shall be checked for its durability and compatibility with
adjoining concrete before it is used in the structure. It shall be properly anchored to
the concrete.

Wire ties passing through beams, columns and walls shall not be allowed. In their
place bolts passing through sleeves shall be used. Formwork spacers left in situ shall
not impair the desired appearance or durability of the structure by causing spilling,
rust staining or allowing the passage of moisture.

For liquid retaining structures, sleeves shall not be provided for through bolts nor shall
through bolts be removed if provided. The bolts, in the latter case, shall be cut at 25
mm depth from the surface and the hole made good by cement mortar of the same
proportion as the concrete just after striking the formwork.

Where specified all corners and angles exposed in the finished structure shall have
chamfers or fillets of 20 mm x 20 mm size.

Forms for substructure may be omitted when, in the opinion of the Engineer in charge,
the open excavation is firm enough (in hard non-porous soils) to act as a form. Such
excavations shall be larger, as approved by the Engineer in charge, than that required
as per drawing to compensate for irregularities in excavation.

The Contractor shall provide adequate props carried down to a firm bearing without
overloading any of the structures.

The shuttering for beams and slabs shall be so erected that the side shuttering of
beams can be removed without disturbing the bottom shuttering. If the shuttering for
a column is erected for the full height of the column, one side shall be built up in
 sections as placing of concrete proceeds or windows left for placing concrete from the
side to limit the drop of concrete to 1.0m or as approved by the Engineer in charge.
The Contractor shall temporarily and securely fix items to be casted (embedment /
inserts) in a manner that will not hinder the striking of forms or permit loss of grout.

Formwork showing excessive distortion, during any stage of construction, shall be

repositioned and strengthened. Placed concrete affected by faulty formwork, shall be
entirely removed and formwork corrected prior to placement of new concrete at
Contractor's cost.

The striking time for formwork shall be determined based on the following
requirements:

(a) Development of adequate concrete strength;

(b) Permissible deflection at time of striking form work;

(c) Curing procedure employed - its efficiency and effectiveness;

(d) Subsequent surface treatment to be done;

(e) Prevention of thermal cracking at re-entrant angles;

(f) Ambient temperatures; and

(g) Aggressiveness of the environment (unless immediate adequate steps are taken to
prevent damage to the concrete).

Under normal circumstances (generally where temperatures are above 20oC) forms
may be struck after expiry of the time period given in IS: 456 unless approved
otherwise by the Engineer in charge. For Portland Pozzolana/slag cement the stripping
time shall be suitably modified as approved by the Engineer in charge. It is the
Contractor's responsibility to ensure that forms are not struck until the concrete has
developed sufficient strength to support itself, does not undergo excessive
deformation and resist surface damage and any stresses arising during the construction
period.

2.8 Reinforcement Workmanship;

Reinforcing bars supplied bent or in coils shall be straightened cold without damage.
No bending shall be done when ambient temperature is below 5°C. Local warming may
be permitted if steel is kept below 10° C.

All bars shall be accurately cut and bent gradually and according to the sizes and
shapes shown on the drawings/ schedules or as directed by Engineer in charge. Re-
bending or straightening incorrectly bent bars shall not be done without the approval
of the Engineer in charge.

Reinforcement shall be accurately fixed and maintained firmly in the correct position
by the use of blocks, spacers, chairs, binding wire etc. to prevent displacement during
placing and compaction of concrete. The tied in place reinforcement shall be
approved by the Engineer in charge prior to concrete placement. Spacers shall be of
 such materials and designs as will be durable, not lead to corrosion of the
reinforcement and not cause spilling of the concrete cover.

Binding wire shall be 16-gauge soft annealed wires. Ends of the binding wire shall be
bent away from the concrete surface and in no case encroach into the concrete cover.

Substitution of reinforcement, laps/splices not shown on drawing shall be subject to

Engineer in charge’s approval.

2.9 Tolerances:
Tolerance for formwork and concrete dimensions shall be as per IS:456 unless
specified otherwise.

Tolerances specified for horizontal or vertical building lines or footings shall not be
construed to permit encroachment beyond the legal boundaries.

The formwork shall be designed and constructed to the shapes, lines and dimensions
shown on the drawings within the tolerances given below:

(a) Deviation from specified dimensions - 6 mm+ 12 mm

of cross section of columns and beams

(b) Deviations from dimensions of footings

(Tolerances apply to concrete
dimensions only, not to positioning of
vertical reinforcing steel or dowels

1) Dimension in plan - 12 mm+ 50 mm

2) Eccentricity 0.02 times the width of the

footing in the direction of
deviation but not more than 50
mm.

3) Thickness ± 0.05 times the specified

thickness

2.10 Preparation Prior to Concrete Placement:

Before concrete is actually placed in position, the inside of the formwork shall be
cleaned and mold oil applied, inserts and reinforcement shall be correctly positioned
and securely held, necessary openings, pockets, etc. provided.

All arrangements-formwork, equipment and proposed procedure, shall be approved by

the Engineer in charge. Contractor shall maintain separate Pour Card for each pour as
per the format enclosed.

2.11 Transporting, Placing and Compacting Concrete:

 Concrete shall be transported from the mixing plant to the formwork with minimum
time lapse by methods that shall maintain the required workability and will prevent
segregation, loss of any ingredients or ingress of foreign matter or water.

In all cases concrete shall be deposited as nearly as practicable directly in its final
position. To avoid segregation, concrete shall not be rehandled or caused to flow. For
locations where direct placement is not possible and in narrow forms the Contractor
shall provide suitable drops and "Elephant Trunks". Concrete shall not be dropped from
a height of more than 1.0m.

Concrete shall not be placed in flowing water. Under water, concrete shall be placed
in position by tremie or by pipeline from the mixer and shall never be allowed to fall
freely through the water.

While placing concrete the Contractor shall proceed as specified below and also
ensure the following:

(a) Continuously between construction joints and pre-determined abutments.

(b) Without disturbance to forms or reinforcement.

(c) Without disturbance to pipes, ducts, fixings and the like to be cast in; ensure that
such items are securely fixed. Ensure that concrete cannot enter open ends of pipes
and conduits etc.

(d) Without dropping in a manner that could cause segregation or shock.

(e) In deep pours only when the concrete and formwork designed for this purpose and by
using suitable chutes or pipes.

(f) Do not place if the workability is such that full compaction cannot be achieved.

(g) Without disturbing the unsupported sides of excavations; prevent contamination of

concrete with earth. Provide sheeting if necessary. In supported excavations,
withdraw the linings progressively as concrete is placed.

(h) If placed directly onto hardcore or any other porous material, dampen the surface to
reduce loss of water from the concrete.

(i) Ensure that there is no damage or displacement to sheet membranes.

(j) Record the time and location of placing structural concrete.

Concrete shall normally be compacted in its final position within thirty minutes of
leaving the mixer. Concrete shall be compacted during placing with approved vibrating
equipment without causing segregation until it forms a solid mass free from voids
thoroughly worked around reinforcement and embedded fixtures and into all corners
of the formwork. Immersion vibrators shall be inserted vertically at points not more
than 450 mm apart and withdrawn slowly till air bubbles cease to come to the surface,
leaving no voids. When placing concrete in layers advancing horizontally, care shall be
taken to ensure adequate vibration, blending and melding of the concrete between
successive layers. Vibrators shall not be allowed to come in contact with
reinforcement, formwork and finished surfaces after start of initial set. Over-vibration
shall be avoided.
 Concrete may be conveyed and placed by mechanically operated equipment after
getting the complete procedure approved by the Engineer in charge. The slump shall
be held to the minimum necessary for conveying concrete by this method. When
concrete is to be pumped, the concrete mix shall be specially designed to suit
pumping. Care shall be taken to avoid stoppages in work once pumping has started.
Except when placing with slip forms, each placement of concrete in multiple lift work
shall be allowed to set for at least 24 hours after the final set of concrete before the
start of subsequent placement. Placing shall stop when concrete reaches the top of
the opening in walls or bottom surface of slab, in slab and beam construction, and it
shall be resumed before concrete takes initial set but not until it has had time to
settle as approved by the Engineer in charge. Concrete shall be protected against
damage until final acceptance.

2.12 Mass Concrete Works:

Sequence of pouring for mass concrete works shall be as approved by the Engineer in
charge. The Contractor shall exercise great care to prevent shrinkage cracks and shall
monitor the temperature of the placed concrete if directed.

2.13 Curing:
Curing and protection shall start immediately after the compaction of the concrete to
protect it from:

(a) Premature drying out, particularly by solar radiation and wind;

(b) Leaching out by rain and flowing water;

(c) Rapid cooling during the first few days after placing;

(d) High internal thermal gradients;

(e) Low temperature or frost;

(f) Vibration and impact which may disrupt the concrete and interfere with its bond to
the reinforcement.

All concrete, unless approved otherwise by the Engineer in charge, shall be cured by
use of continuous sprays or ponded water or continuously saturated coverings of
sacking, canvas or other absorbent material for the period of complete hydration with
a minimum of 7 days. The quality of curing water shall be the same as that used for
mixing.

Where a curing membrane is approved to be used by the Engineer in charge, the same
shall be of a non-wax base and shall not impair the concrete finish in any manner. The
curing compound to be used shall be approved by the EMPLOYER before use and shall
be applied with spraying equipment capable of a smooth, even textured coat.

Curing may also be done by covering the surface with an impermeable material such as
polyethylene, which shall be well sealed and fastened.

2.14 Construction Joints and Keys:

Construction joints will be as shown in the drawing or as approved by the EMPLOYER.
Concrete shall be placed without interruption until completion of work between
construction joints. If stopping of concreting becomes unavoidable anywhere, a
 properly formed construction joint shall be made with the approval of the Engineer in
charge.

Dowels for concrete work, not likely to be taken up in the near future, shall be coated
with cement slurry and encased in lean concrete as indicated on the drawings or as
approved by the Engineer in charge.

Before resuming concreting on a surface which has hardened all laitance and loose
stone shall be thoroughly removed by wire brushing/hacking and surface washed with
high pressure water jet and treated with thin layer of cement slurry for vertical joints
and horizontal layers.

When concreting is to be resumed on a surface which has not fully hardened, all
laitance shall be removed by wire brushing, the surface wetted, free water removed
and a coat of cement slurry applied. On this, a layer of concrete not exceeding 150
mm thickness shall be placed and well rammed against the old work. Thereafter work
shall proceed in the normal way.

2.15 Foundation Bedding:

All earth surfaces upon which or against which concrete is to be placed, shall be well
compacted and free from standing water, mud or debris. Soft or spongy areas shall be
cleaned out and back filled with either soil-cement mixture, lean concrete or clean
sand compacted as approved by the Engineer in charge. The surfaces of absorptive
soils shall be moistened.

Concrete shall not be deposited on large sloping rock surfaces. The rock shall be cut to
form rough steps or benches by picking, barring or wedging. The rock surface shall be
kept wet for 2 to 4 hours before concreting.

2.16 Finishes:
2.16.1 General:

The formwork for concrete works shall be such as to give the finish as specified. The
Contractor shall make good any unavoidable defects as approved consistent with the
type of concrete and finish as specified. Defects due to bad workmanship (e.g.
damaged or misaligned forms, defective or poorly compacted concrete) will not be
accepted. The Contractor shall construct the formwork using the correct materials and
to meet the requirements of the design and to produce finished concrete to required
dimensions, plumbs, planes and finishes.

Surface Finish Type F1:

The main requirement is that of dense, well-compacted concrete. No treatment is

required except repair of defective areas, filling all form tie holes and cleaning up of
loose or adhering debris. For surfaces below grade, which will receive waterproofing
treatment, the concrete shall be free of surface irregularities, which would interfere
with proper and effective application of waterproofing material specified for use.
Surface Finish Type F2:
The appearance shall be that of a smooth dense, well-compacted concrete showing
the slight marks of well fitted shuttering joints. The Contractor shall make good any
blemishes.
 Surface Finish Type F3:

This finish shall give an appearance of smooth, dense, well-compacted concrete with
no shutter marks, stain free and with no discoloration, blemishes, arises, air holes etc.
Only lined or coated plywood with very tight joints shall be used to achieve this finish.
The panel size shall be uniform and as large as practicable. Any minor blemishes that
might occur shall be made good by the Contractor.
Integral Cement Finish on Concrete Floor:

In all cases where integral cement finish on a concrete floor has been specified, the
top layer of concrete shall be screened off to proper level and tamped with tamper
having conical projections so that the aggregate shall be forced below the surface.
The surface shall be finished with a wooden float and a trowel with pressure. The
finish shall be continued till the concrete reaches its initial set. No cement or cement
mortar finish shall be provided on the surface. Where specified, a floor hardener as
approved by the Engineer-In-Charge shall be supplied and used as recommended by
the manufacturer.

The formwork for concrete works shall be such as to give the finish as specified. The
Contractor shall make good any unavoidable defects as approved consistent with the
type of concrete and finish specified; defects due to bad workmanship (e.g. damaged
or misaligned forms, defective or poorly compacted concrete) will not be accepted.
The Contractor shall construct the formwork using the correct materials and to meet
the requirements of the design and to produce finished concrete to required
dimensions, plumbs, planes and finishes.

2.17 Repair and Replacement of Unsatisfactory Concrete:

Immediately after the shuttering is removed, all the defective areas such as honey-
combed surfaces, rough patches, holes left by form bolts etc. shall be inspected by
the Engineer in charge who may permit patching of the defective areas or reject the
concrete work.

All through holes for shuttering shall be filled for full depth and neatly plugged flush
with surface.
Rejected concrete shall be removed and replaced by the Contractor at no additional
cost to the Employer.
For patching of defective areas all loose materials shall be removed and the surface
shall be prepared as approved by the Engineer in charge.

Bonding between hardened and fresh concrete shall be done either by placing cement
mortar or by applying epoxy. The decision of the Engineer in charge as to the method
of repairs to be adopted shall be final and binding on the Contractor. The surface shall
be saturated with water for 24 hours before patching is done with 1:5 cement sand
mortar. The use of epoxy for bonding fresh concrete shall be carried out as approved
by the Engineer in charge.

2.18 Vacuum Dewatering of Slabs:

Where specified floor slabs, either grade or suspended, shall be finished by vacuum
dewatering including all operations such as poker vibration, surface vibration, vacuum
processing, floating and toweling as per equipment manufacturers recommendation.
The equipment to be used shall be subject to the Engineer in charge's approval.
2.19 Hot Weather Requirements:

Concreting during hot weather shall be carried out as per IS: 7861 (Part I).

Adequate provisions shall be made to lower concrete temperatures which shall not
exceed 40º C at the time of placement of fresh concrete.

Where directed by the Engineer in charge, the Contractor shall spray non-wax based
curing compound on unformed concrete surfaces at no extra costs.

Cold Weather Requirements.

Concreting during cold weather shall be carried out as per IS: 7861 (Part II).

The ambient temperature during placement and up to final set shall not fall below 5º
C. Approved antifreeze/accelerating additives shall be used where directed.
For major and large scale concreting works the temperature of concrete at times of
mixing and placing, the thermal conductivity of the formwork and its insulation and
stripping period shall be closely monitored.

2.20 Liquid Retaining Structures:

The Contractor shall take special care for concrete for liquid retaining structures,
underground structures and those others specifically called for to guarantee the finish
and water tightness.

The minimum level of surface finish for liquid retaining structures shall be as defined
elsewhere. All such structures shall be hydro-tested.

The Contractor shall make all arrangements for hydro-testing of structure, all
arrangements for testing such as temporary bulk heads, pressure gauges, pumps, pipe
lines etc.

The Contractor shall also make all temporary arrangements that may have to be made
to ensure stability of the structures during construction.

Any leakage that may occur during the hydro-test or subsequently during the defects
liability period or the period for which the structure is guaranteed shall be effectively
stopped either by cement/epoxy pressure grouting, guniting or such other methods as
may be approved by the Engineer in charge. All such rectification shall be done by the
Contractor to the entire satisfaction of the Engineer in charge at no extra cost.

2.21 Testing Concrete Structures for Leakage:

Hydro-static test for water tightness shall be done at full storage level or soffit of
cover slab, as may be directed by the Engineer in charge, as described below:

In case of structures whose external faces are exposed, such as elevated tanks, the
requirements of the test shall be deemed to be satisfied if the external faces show no
sign of leakage or sweating and remain completely dry during the period of
observation of seven days after allowing a seven-day period for absorption after filling
with water.

In the case of structures whose external faces are buried and are not accessible for
inspection, such as underground tanks, the structures shall be filled with water and
after the expiry of seven days after the filling; the level of the surface of the water
 shall be recorded. The level of water shall be recorded again at subsequent intervals
of 24 hrs. Over a period of seven days. Backfilling shall be withheld till the tanks are
tested. The total drop in surface level over a period for seven days shall be taken as
an indication of the watertightness of the structure. The Engineer in charge shall
decide on the actual permissible nature of this drop in the surface level, taking into
account whether the structures are open or closed and the corresponding effect it has
on evaporation losses. Unless specified otherwise, a structure whose top is covered
shall be deemed to be water tight if the total drop in the surface level over a period
of seven days does not exceed 40 mm.

Each compartment/segment of the structure shall be tested individually and then all
together.

For structures such as pipes, tunnels etc. the hydrostatic test shall be carried out by
filling with water, after curing as specified, and subjecting to the specified test
pressure for specified period. If during this period the loss of water does not exceed
the equivalent of the specified rate, the structure shall be considered to have
successfully passed the test.

2.22 Optional Tests:

If the Employer feels that the materials i.e. cement, sand, coarse aggregates,
reinforcement and water are not in accordance with the Specifications or if specified
concrete strengths are not obtained, he may order tests to be carried out on these
materials in laboratory, to be approved by the Engineer in charge, as per relevant IS
Codes. Contractor shall have to pay for these tests.

In the event of any work being suspected of faulty material or workmanship requiring
its removal or if the works cubes do not give the stipulated strengths, the Engineer in
charge reserves the right to order the Contractor to take out cores and conduct tests
on them or do ultrasonic testing or load testing of structure, etc. The Engineer in
charge also reserves the right to ask the Contractor to dismantle and re-do such
unacceptable work, at no cost to the Engineer in charge. Alternately Engineer in
charge also reserves the right to ask the CONTRACTOR to dismantle and re-do such
unacceptable work at the cost of CONTRACTOR.

2.23 Grouting:

2.23.1 Standard Grout:

Grout shall be provided as specified on the drawings.

The proportion of Standard Grout shall be such as to produce a flow able mixture
consistent with minimum water content and shrinkage. Surfaces to be grouted shall
be thoroughly roughened and cleaned. All structural steel elements to be grouted
shall be cleaned of oil, grease, dirt etc. The use of hot, strong caustic solution for this
purpose will be permitted. Prior to grouting, the hardened concrete shall be
saturated with water and just before grouting, water in all pockets shall be removed.
Grouting once started shall be done quickly and continuously. Variation in grout mixes
and procedures shall be permitted if approved by the Engineer in charge. The grout
proportions shall be limited as follows:

Use Grout Thickness Mix Proportions Water

 Cement Ratio
(max)
One part Portland Cement
a) Fluid mix Under 25mm 0.44
to one part sand

25mm and over but One part Portland Cement

b) General mix 0.53
less than 50mm to 2 parts of sand

One part Portland Cement

c) Stiff mix 50mm and over 0.53
to 3 parts of sand

2.23.2 Non-Shrink Grout:

Non-shrink grout where required shall be provided in strict accordance with the
manufacturer's instructions / specifications on the drawing.

Inspection:
All materials, workmanship and finished construction shall be subject to continuous
inspection and approval of Engineer in charge. Materials rejected by Engineer in
charge shall be expressly removed from site and shall be replaced by Contractor
immediately.
Clean-Up:
Upon the completion of concrete work, all forms, equipment, construction tools,
protective coverings and any debris, scraps of wood, etc. resulting from the work shall
be removed and the premises left clean.

Acceptance Criteria:
Any concrete work shall satisfy the requirements given below individually and
collectively for it to be acceptable.

a) Properties of constituent materials;

b) Characteristic compressive strength;

c) Specified mix proportions;

d) Minimum cement content;

e) Maximum free-water/cement ratio;

f) Workability;

g) Temperature of fresh concrete;

h) Density of fully compacted concrete;

i) Cover to embedded steel;

j) Curing;

k) Tolerances in dimensions;

l) Tolerances in levels;

m) Durability;
n) Surface finishes;

o) Special requirements such as;

i) Water tightness

ii) Resistance to aggressive chemicals

iii) Resistance to freezing and thawing

iv) Very high strength

v) Improved fire resistance

vi) Wear resistance

vii) Resistance to early thermal cracking

The Engineer in charge's decision as to the acceptability or otherwise of any concrete
work shall be final and binding on the Contractor.

For work not accepted, the Engineer in charge may review and decide whether
remedial measures are feasible so as to render the work acceptable. The Engineer in
charge shall in that case direct the Contractor to undertake and execute the remedial
measures. These shall be expeditiously and effectively implemented by the
Contractor. Nothing extra shall become payable to the Contractor by the Employer for
executing the remedial measures.

2.24 Water stops:

2.24.1 Material:

The material for the PVC water stops shall be a plastic compound with the basic resin
of polyvinyl chloride and additional resins, plasticizers, inhibitors, which satisfies the
performance characteristics specified below as per IS:12200. Testing shall be in
accordance with IS: 8543.

a) Tensile strength : 3.6 N/mm2 minimum

b) Ultimate elongation : 300% minimum

c) Tear resistance : 4.9 N/mm2 minimum

d) Stiffness in flexure : 2.46 N/mm2 minimum

e) Accelerated extraction

i) Tensile strength : 10.50 N/mm2 minimum

ii) Ultimate elongation : 250% minimum

(f) Effect of Alkali : 7 days

i) Weight increase : 0.10% maximum

ii) Weight decrease : 0.10% maximum

iii) Hardness change : ± 5 points

 (g) Effect of Alkali : 28 days
i) Weight increase : 0.40% maximum

ii) Weight decrease : 0.30% maximum

iii) Dimension change : ±1%

PVC water stops shall be either of the bar type, serrated with center bulb and end
grips for use within the concrete elements or of the surface (kicker) type for external
use.

PVC water stops shall be of approved manufacture. Samples and the test certificate
shall be got approved by the Engineer in charge before procurement for incorporation
in the works. Alternatively, G.I. sheet of 18 gage (1.3mm) thick and 200mm wide can
be used by the contractor as construction joints.

Alternatively, contractors can use G.I sheet 200mm wide and 18 gauge thick as
constructions joints.

2.24.2 Workmanship:

Water stops shall be cleaned before placing them in position. Oil or grease shall be
removed thoroughly using water and suitable detergents.

Water stops shall be procured in long lengths as manufactured to avoid joints as far as
possible. Standard L or T type of intersection pieces shall be procured for use
depending on their requirement. Any non-standard junctions shall be made by cutting
the pieces to profile for jointing. Lapping of water stops shall not be permitted. All
jointing shall be of fusion welded type as per manufacturer's instructions.

Water stops shall be placed at the correct location/level and suitably supported at
intervals with the reinforcement to ensure that it does not deviate from its intended
position during concreting and vibrating. Care shall also be taken to ensure that no
honey-combing occurs because of the serrations/end grips, by placing concrete with
smaller size aggregates in this region. Projecting portions of the water stops
embedded in concrete shall be thoroughly cleaned of all mortar/ concrete coating
before resuming further concreting operations. The projecting water stop shall also be
suitably supported at intervals with the reinforcement to maintain its intended
position during concreting so as to ensure that it does not bend leading to formation of
pockets. In addition, smaller size aggregates shall be used for concreting in this region
also.
2.25 Preformed Fillers and Joint Sealing Compound:
2.25.1 Materials:
Preformed filler for expansion/isolation joints shall be non-extruding and resilient
type of bitumen impregnated fibers conforming to IS:1838 (Part I).
 Bitumen coat to concrete/masonry surfaces for fixing the preformed bitumen filler
strip shall conform to IS:702. Bitumen primer shall conform to IS:3384.

Sealing compound for filling the joints above the preformed bitumen filler shall
conform to Grade 'A' as per IS:1834.

2.25.2 Workmanship:

The thickness of the preformed bitumen filler shall be 25mm for expansion joints and
50mm for isolation joints around foundation supporting rotatory equipment's.
Contractor shall procure the strips of the desired thickness and width in lengths as
manufactured. Assembly of small pieces/thicknesses of strips to make up the specified
size shall not be permitted.
The concrete/masonry surface shall be cleaned free from dust and any loose particles.
When the surface is dry, one coat of industrial blown type bitumen of grade 85/25
conforming to IS: 702 shall be applied hot by brushing at the rate of 1.20 kg/m2. When
the bitumen is still hot the preformed bitumen filler shall be pressed and held in
position till it completely adheres. The surface of the filler against which further
concreting/masonry work is to be done shall similarly be applied with one coat of hot
bitumen at the rate of 1.20 kg/m2.
Sealing compound shall be heated to a pouring consistency for enabling it to run
molten in a uniform manner into the joint. Before pouring the sealing compound, the
vertical faces of the concrete joint shall be applied hot with a coat of bitumen primer
conforming to IS: 3384 in order to improve the adhesive quality of the sealing
compound.
Expansion joints between beams/slabs shall be provided with 100mm wide x 4mm
thick mild steel plate at the soffit of RCC beams/slabs to support and prevent the
preformed joint filler from dislodging. This plate shall be welded to an edge angle of
ISA 50 x 50 x 6mm provided at the bottom corner, adjacent to the expansion joint of
one of the beams/slabs, by intermittent fillet welding. Steel surfaces shall be provided
with 2 coats of red oxide zinc chrome primer and 3 coats of synthetic enamel paint
finish.
CONCRETE POUR CARD
POUR NO.: DATE:
DRG. NO.: STRUCTURE:
CONCRETE GRADE/QUANTITY/: MAX. AGGREGATE SIZE /
SLUMP: START / COMPLETION TIME:
SL. ITEM Remarks If
NO Any
1. BEFORE CENTRELINES CHECKED YES/NO
CONCRETING
2. FORMWORK AND STAGING CHECKED YES/NO
FOR ACCURACY, STRENGTH & FINISH
3 REINFORCEMENT CHECKED YES/NO
4 COVER TO REINFORCEMENT YES/NO
CHECKED
5 VERIFIEDTEST CERTIFICATE FOR YES/NO
CEMENT/STEEL
6 ADEQUACY OF MATERIALS / YES/NO
EQUIPMENT FOR POUR
7 EMBEDDED PARTS CIVIL YES/NO
(LOCATION & MECH. YES/NO
PLUMB) CHECKED
ELEC. YES/NO
8 SOFFIT(S) & POUR TOP(T) LEVELS CHECKED BEFORE S(B)
(B) & AFTER (A) FORM REMOVAL T(B)
S(A)
T(A)
9 CONSTRUCTION JOINTS LOCATION & TYPE
EXPANSION JOINTS – LOCATION AND TYPE
10 CEMENT CONSUMPTION IN KGS.
10A REINFORCEMENT CONSUMPTION DIAWISE IN KGS
11 NUMBER OF CUBES AND IDENTIFICATION MARKS
12 TEST CUBE RESULTS (7 DAYS / 28 DAYS)
13 CONCRETE CONDITION ON FORM REMOVAL V.GOOD/
GOOD/FAIR/POOR

Contractor's Representative Engineer- in-charge's

Representative

NOTES:
1. EACH POUR TO HAVE SEPARATE CARDS, IN TRIPLICATE ONE EACH FOR CLIENT, CONTRACTOR &
SITE OFFICE.
a) UNDER REMARKS, INDICATE DEVIATIONS FROM DWGS. & SPECIFICATIONS, CONGESTION IN
REINFORCEMENT IF ANY, UNUSUAL OCCURRENCES SUCH AS FAILURE OF EQUIPMENTS, SINKING
OF SUPPORTS / PROPS. HEAVY RAINS AFFECTING CONCRETING, POOR COMPACTION, IMPROPER
CURING, OTHER DEFICIENCIES, OBSERVATIONS ETC.
SPECIFICATIONS

: SECTION -4:
: BUILDING ITEMS:
 SECTION - 4:
BUILDING ITEMS.
Applicable Codes and Specifications
The following codes and standards are included in this section, as part of these
specifications. However, respective IS codes for the works not mentioned here shall
also be applicable for those particular items of work.

IS: 110 - Ready mixed paint, brushing, gray filler, for Enamels for use over primers
IS: 269 - Specification for 33 grade ordinary Portland cement
IS: 280 - Specification for mild steel wire for general
Engineering purposes
IS: 287 - Recommendations for maximum permissible Moisture content of timber
used for different purposes
IS: 383 - Specif. for coarse &fine aggregates from natural sources for concrete
IS: 412 - Expanded metal steel sheets for general purposes
IS: 419 - Specification for putty for use on window frames
IS: 428 - Distemper, oil emulsion, color as required
IS: 459 - Specification for unreinforced corrugated and semi-corrugated asbestos
cement sheets

IS: 702 - Specification for industrial bitumen

IS: 710 - Specification for marine plywood
IS: 712 - Specification for building limes
IS: 730 - Specification for hook bolts for corrugated sheet Roofing
IS: 733 - Wrought aluminum and aluminum alloys, bars, Rods and sections for
general engineering purposes
IS: 777 - Specification for glazed earthenware tiles
IS: 1003 - Specification for timber paneled and glazed shutters (Parts 1 & 2)
IS: 1038 - Specification for steel doors, windows and ventilators
IS: 1077 - Specification for common burnt clay building bricks
IS: 1081 - Code of practice for fixing and glazing of metal (steel &aluminum) doors,
windows and ventilators.
IS: 1124 - Method of test for determination of water absorption, apparent specific
gravity and porosity of natural building stones
IS: 1237 - Specification for cement concrete flooring tiles
IS: 1322 - Bitumen felts for water proofing and damp proofing
IS: 1346 - Code of practice for water proofing of roofs with bitumen felts
IS:1361 - Specification for steel windows for industrial buildings
IS: 1443 - Code of practice for laying and finishing of cement concrete flooring tiles
IS: 1477 - Code of practice for painting of ferrous metals in buildings (Parts 1 & 2)
IS: 1542 - Specification for sand for plaster
IS: 1580 - Specification for bituminous compounds for water-proofing and caulking
purposes
IS: 1597 - Code of practice for construction of stone masonry: Part 1 Rubble stone
masonry
IS: 1661 - Code of practice for application of cement and cement-lime plaster
finishes
IS: 1834 - Specification for hot applied sealing compound for joint in concrete
IS: 1838 - Specification for preformed fillers for expansion joint in concrete
Pavements and structures (none extruding and resilient type): Part 1
Bitumen impregnated fiber.
IS: 1948 - Specification for aluminum doors, windows and ventilators
IS: 1949 - Specification for aluminum windows for industrial buildings
IS: 2074 - Ready mixed paint, air drying, red oxide- zinc chrome, priming
IS: 2114 - Code of practice for laying in-situ terrazzo floor finish
IS: 2116 - Specification for sand for masonry mortars
IS: 2185 - Specification for concrete masonry units (Parts 1,2& 3)
IS: 2202 - Specification for wooden flush door shutters (Solid core type): Parts 1&2
IS: 2212 - Code of practice for brickwork
IS: 2250 - Code of practice for preparation and use of masonry mortars
IS: 2338 - Code of practice for finishing of wood and wood based materials (Parts 1
& 2)
IS: 2395 - Code of practice for painting concrete, masonry and plaster surfaces (Parts
1 & 2)
IS: 2402 - Code of practice for external rendered finishes
IS: 2571 - Code of practice for laying in-situ cement concrete flooring
IS: 2572 - Code of practice for construction of hollow concrete block masonry
IS: 2645 - Specification of integral cement waterproofing compounds
IS: 2690 - Specification for burnt clay flat terracing tiles: Part 1 Machine made
IS: 2691 - Specification for burnt clay facing bricks
IS: 2750 - Specification for steel scaffoldings
IS: 2835 - Flat transparent sheet glass
IS: 2932 - Specification for enamel, synthetic, exterior type (a) undercoating,
(b) finishing
IS: 3007 - Code of practice for laying of asbestos cement sheets - corrugated and
(Part 1 & 2) semi-corrugated sheets
IS: 3067 - Code of practice of general design details and preparatory work for
Damp-proofing and water- proofing of buildings
IS: 3068- Specification for broken brick (burnt clay) coarse aggregates for use in
Lime concrete.
IS: 3384 - Specification for bitumen primer for use in water-proofing and damp-
proofing
IS: 3462 - Specification for unbaked flexible PVC flooring
IS: 3495 - Method of test for burnt clay building bricks: Part 1 to 4
IS: 3536 - Specification for ready mixed paint, brushing, and wood primer, pink
IS: 3696 - Safety code of scaffolds and ladders (Parts 1 & 2)
IS: 4020 - Methods of test for wooden flush door: Type test
IS: 4021 - Specification for timber door, window and ventilator frames
IS: 4351 - Specification for steel door frames
IS: 4443 - Code of practice for use of resin type chemical resistant mortars
IS: 4457 - Specification for ceramic unglazed vitreous acid resisting tile
IS: 4631 - Code of practice for laying epoxy resin floor toppings
IS: 4832 - Specification for chemical resistant mortars (Part II)
IS: 4860 - Specification for acid resistant bricks
IS: 4948 - Specification for welded steel wire fabric for general use
IS: 5318 - Code of practice for laying of flexible PVC sheet and tile flooring
IS: 5410 - Cement paint, colour as required
IS: 5411 - Specification for plastic emulsion paint (Parts 1 & 2)
IS: 5437 - Wired and figured glass
IS: 5491 - Code of practice for laying of in-situ granolithic concrete floor topping
IS: 6042 - Code of practice for construction of light weight concrete block masonry
IS: 6248 - Specification for metal rolling shutters and rolling grilles
IS: 7193 - Specification for glass fiber base coal tar pitch and bitumen felts
IS: 7452 - Specification for hot rolled steel sections for doors, windows and
ventilators
IS: 8042 - Specification for white Portland cement
IS: 9197 - Specification for epoxy resin, hardeners and epoxy resin composites for
floor topping
IS: 9862 - Specification for ready mixed paint, brushing, bituminous, black, lead-free,
acid, alkali, water and chlorine resisting
IS: 12200 - Code of practice for provision of water stops at transverse contraction
joints in masonry and concrete dams
Brickwork:

Materials:
Bricks used in the works shall conform to the requirements laid down in IS: 1077. The
class of the bricks shall be as specifically indicated in the respective items of work.

The nominal size of the modular brick shall be 200 mm x 100 mm x 100 mm with the
permissible tolerances over the actual size of 190mm x90 mm x 90 mm as per IS: 1077.
The nominal thickness of one brick and half brick walls using modular bricks shall be
considered as 200 mm and 100 mm respectively. In the event of use of traditional
bricks of nominal size 230 mmx115mmx75mm with tolerance upto 3 mm in each
dimension, one brick and half brick walls shall be considered as 230 mm and 115 mm
respectively.
Bricks shall be sound, hard, and homogenous in texture, well burnt in kiln without
being vitrified, hand/machine mounded, deep red, cherry or copper colored, of
regular shape and size & shall have sharp and square edges with smooth rectangular
faces. The bricks shall be free from pores, cracks, flaws and nodules of free lime.
Hand Moulded bricks shall be Moulded with a frog and those made by extrusion process
may not be provided with a frog. Bricks shall give a clear ringing sound when struck
and shall have a minimum crushing strength of 3N/sq.mm unless otherwise specified in
the Items of work prepared by the Contractor.

The average water absorption shall not be more than 20 percent by weight up to class
12.5 and 15 percent by weight for higher classes. Bricks which do not conform to this
requirement shall be rejected. Over or under burnt bricks are not acceptable for use
in the works. Sample bricks shall be submitted to the GUDM for approval and bricks
supplied shall conform to approved samples. If demanded by GUDM, brick samples
shall be got tested as per IS: 3495 by Contractor. Bricks rejected by GUDM shall be
removed from the site of works within 24 hours.

Mortar for brick masonry shall consist of cement and sand and shall be prepared as per
IS: 2250. Mix shall be in the proportion of 1:5 for brickwork of thickness one brick or
above and 1:4 for brickwork of thickness half brick or below, unless otherwise
specified in the respective items of work prepared by the Contractor. Sand for
masonry mortar shall conform to IS:218. The sand shall be free from clay, shale, loam,
alkali and organic matter and shall be of sound, hard, clean and durable particles.
Sand shall be approved by GUDM. If so directed by the GUDM, sand shall be screened
and washed till it satisfies the limits of deleterious materials.
For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry
condition. Water shall then be added and mixing continued to give a uniform mix of
required consistency. Mixing shall be done thoroughly in a mechanical mixer, unless
hand mixing is specifically permitted by the GUDM. The mortar thus mixed shall be
used as soon as possible, preferably within 30 minutes from the time water is added to
cement. In case, the mortar has stiffened due to evaporation of water, this may be re-
tempered by adding water as required to restore consistency, but this will be
permitted only up to 30 minutes from the time of initial mixing of water to cement.
Any mortar which is partially set shall be rejected and shall be removed from the site.
Droppings of mortar shall not be re-used under any circumstances. The Contractor
shall arrange for test on mortar samples if so directed by the GUDM.

Workmanship:
Workmanship of brick work shall conform to IS: 2212. All bricks shall be thoroughly
soaked in clean water for at least one hour immediately before being laid. The cement
mortar for brick masonry work shall be as specified in the respective item of work
prepared by the Contractor. Brick work 200mm/230mm thick and over shall be laid in
English Bond unless otherwise specified. 100mm/115mm thick brickwork shall be laid
with stretchers. For laying bricks, a layer of mortar shall be spread over the full width
of suitable length of the lower course. Each brick shall be slightly pressed into the
mortar and shoved into final position so as to embed the brick fully in mortar. Only
full size bricks shall be used for the works and cut bricks utilized only as closers to
make up required wall length or for bonding. Bricks shall be laid with frogs on top.

All brickwork shall be plumb, square and true to dimensions shown. Vertical joints in
alternate courses shall come directly one over the other and be in line. Horizontal
courses shall be leveled. The thickness of brick courses shall be kept uniform. In case
of one brick thick or half brick thick wall, at least one face should be kept smooth and
plane, even if the other is slightly rough due to variation in size of bricks. For walls of
thickness greater than one brick both faces shall be kept smooth and plane. All
interconnected brickwork shall be carried out at nearly one level so that there is
uniform distribution of pressure on the supporting structure and no portion of the work
shall be left more than one course lower than the adjacent work. Where this is not
possible, the work shall be raked back according to bond (and not saw toothed) at an
angle not exceeding 45 deg. But in no case the level difference between adjoining
walls shall exceed one meter. Brickwork shall not be raised more than one meter per
day.

Bricks shall be so laid that all joints are well filled with mortar. The thickness of joints
shall not be less than 6 mm and not more than 10 mm. The face joints shall be raked
to a minimum depth of 10mm/15mm by raking tools during the progress of work when
the mortar is still green, so as to provide a proper key for the plastering/ pointing
respectively to be done later. When plastering or pointing is not required to be done,
the joints shall be uniform in thickness and be struck flush and finished at the time of
laying. The face of brickwork shall be cleaned daily and all mortar droppings removed.
The surface of each course shall be thoroughly cleaned of all dirt before another
course is laid on top. During inclement weather conditions, newly built brick masonry
works shall be protected by tarpaulin or other suitable covering to prevent mortar
being washed away by rain.

Brickwork shall be kept constantly moist on all the faces for at least seven days after
24 hrs of laying. The arrangement for curing shall be got approved from the E.I.C.

Double scaffolding having two sets of vertical supports shall be provided to facilitate
execution of the masonry works. The scaffolding shall be designed adequately
considering all the dead, live and possible impact loads to ensure safety of the
workmen, in accordance with the requirements stipulated in IS:2750 and IS:3696 (Part
I). Scaffolding shall be properly maintained during the entire period of construction.
Single scaffolding shall not be used on important works and will be permitted only in
certain cases as decided by the GUDM. Where single scaffolding is adopted, only
minimum number of holes, by omitting a header shall be left in the masonry for
supporting horizontal scaffolding poles. All holes in the masonry shall be carefully
made good before plastering/pointing.

In the event of usage of traditional bricks of size 230 mm x115mm x75mm, the courses
at the top of the plinth and sills as well as at the top of the wall just below the
roof/floor slabs and at the top of the parapet shall be laid with bricks on edge. All
brickwork shall be built tightly against columns, floor slabs or other structural
members.

To overcome the possibility of development of cracks in the brick masonry following

measures shall be adopted. For resting RCC slabs, the bearing surface of masonry wall
shall be finished on top with 12 mm thick cement mortar 1:3 and provided with 2
layers of Kraft paper Grade 1 as per IS:1397 or 2 layers of 50 micron thick polyethylene
sheets.
RCC/ steel beams resting on masonry wall shall be provided with reinforced concrete
bed blocks of 50 mm thickness, projecting 50mm on either sides of the beam, duly
finished on top with 2 layers of Kraft paper Grade 1 as per IS:1397 or 2 layers of 50
micron thick polyethylene sheets.

Steel wire fabric shall be provided at the junction of brick masonry and concrete
before taking up plastering work. Bricks for partition walls shall be stacked adjacent
to the structural member to pre-deflect the structural member before the wall is
taken up for execution. Further, the top most course of half or full brick walls
abutting against either a de-shuttered slab or beam shall be built only after any
proposed masonry wall above the structural member is executed to cater for the
deflection of the structural element.

Reinforced cement concrete transoms and mullions of dimensions as indicated in the

construction Drawings to be prepared by the Contractor are generally required to be
provided in the half brick partition walls.

Where the drawings prepared by the Contractor indicate that structural steel sections
are to be encased in brickwork, the brickwork masonry shall be built closely against
the steel section, ensuring a minimum of 20mm thick cement-sand mortar 1:4 over all
the steel surfaces. Steel sections partly embedded in brickwork shall be provided with
bituminous protective coating to the surfaces at the point of entry into the brick
masonry.

Facing bricks of the type specified conforming to IS: 2691 shall be laid in the positions
indicated on the Drawings prepared by the Contractor and all facing brickwork shall be
well bonded to the backing bricks/RCC surfaces. The level of execution of the facing
brickwork shall at any time be lower by at least 600 mm below the level of the
backing brickwork. Facing bricks shall be laid over 10 mm thick backing of cement
mortar. The mortar mix, thickness of joint and the type of pointing to be carried out
shall be as specified in the item of works prepared by the Contractor. The pattern of
laying the bricks shall be as specifically indicated in the Drawings prepared by the
Contractor. For facing brickwork, double scaffolding shall be used. Faced works shall
be kept clean and free from damage, discoloration etc., at all times.

Uncoursed Random Rubble Masonry, in Foundation, Plinth and Superstructure.

Materials:
Stones for the works shall be of the specified variety, which are hard, durable, fine
grained and uniform in colour (for superstructure work) free from veins, flaws and
other defects. Quality and work shall conform to the requirements specified in IS:
1597 (Part-I). The percentage of water absorption shall not exceed 5 percent as per
test conducted in accordance with IS: 1124. The Contractor shall supply sample stones
to the GUDM for approval. Stones shall be laid with its grains horizontal so that the
load transmitted is always perpendicular to the natural bed.

Cement-sand mortar for stone masonry works shall be in the proportion of 1:6.
Materials and preparation of mortar shall be as specified in clause 7.2.1.

Workmanship:
For All Works below ground level the masonry shall be random rubble uncoursed with
ordinary quarry dressed stones for the hearting and selected quarry dressed stones for
the facing.
For all works above ground level and in superstructure the masonry shall be random
rubble uncoursed, well bonded, faced with hammer dressed stones with squared
quoins at corners. The bushings on the face shall not be more than 40 mm on an
exposed face and on the face to be plastered it shall not project by more than 12 mm
nor shall it have depressions more than 10 mm from the average wall surface.

Face stones shall extend back sufficiently and bond well with the masonry. The depth
of stone from the face of the wall inwards shall not be less than the height or breadth
at the face. The length of the stone shall not exceed three times the height and the
breadth on base shall not be greater than three-fourths the thickness of wall nor less
than 150 mm. The height of stone may be up to a maximum of 300 mm. Face stones or
hearting stones shall not be less than 150 mm in any direction. Chips and spalls shall
be used wherever necessary to avoid thick mortar joints and to ensure that no hollow
spaces are left in the masonry. The use of chips and spalls in the hearting shall not
exceed 20 percent of the quantity of stone masonry. Spalls and chips shall not be used
on the face of the wall and below hearting stones to bring them to the level of face
stones.

The maximum thickness of joints shall not exceed 20 mm. All joints shall be
completely filled with mortar. When plastering or pointing is not required to be done,
the joints shall be struck flush and finished as the work proceeds. Otherwise, the
joints shall be raked to a minimum depth of 20 mm by a raking tool during the
progress of the work while the mortar is still green.

Through or bond stones shall be provided in walls up to 600 mm thick and in case of
walls above 600 mm thickness, a set of two or more bond stones overlapping each
other by at least 150 mm shall be provided in a line from face to back. In case of
highly absorbent types of stones (porous lime stone and sand stone, etc.) the bond
stone shall extend about two-thirds into the wall and a set of two or more bond stones
overlapping each other by at least 150 mm shall be provided. Each bond stone or a set
of bond stones shall be provided for every 0.5 sq.m of wall surface.

All stones shall be sufficiently wetted before laying to prevent absorption of water
from the mortar. All connected walls in a structure shall be normally raised uniformly
and regularly. However, if any part of the masonry is required to be left behind, the
wall shall be raked back (and not saw toothed) at an angle not exceeding 45deg.
Masonry work shall not be raised by more than one meter per day. Green work shall be
protected from rain by suitable covering. Masonry work shall be kept constantly moist
on all the faces for a minimum period of seven days for proper curing of the joints.

Type of scaffolding to be used shall be as specified in clause 7.2.2.

Coursed Rubble Masonry (First Sort) for Superstructure:

Materials:
The Material specification for the work shall be as per clause 7.3.1.

Workmanship:
All Courses shall be laid truly horizontal and shall be of the same height in any course.
The height of course shall not be less than 150 mm and not more than 300 mm. The
width of stone shall not be less than its height.

Face stones shall tail into the work for not less than their height and at least 1/3rd the
number of stones shall tail into the work for a length not less than twice their height
but not more than three-fourths the thickness of the wall whichever is smaller. These
should be laid as headers and stretchers alternately to break joints by at least 75 mm.
The face stones shall be squared on all joints and beds; the bed joints being hammer
or chisel dressed true and square for at least 80 mm back from the face and the side
joints for at least 40 mm. The face of the stone shall be hammer dressed so that the
bushing shall not be more than 40 mm on an exposed face and 10 mm on a face to be
plastered. No portion of the dressed surface shall show a depth of gap more than 6
mm from a straight edge placed on it. The remaining unexposed portion of the stone
shall not project beyond the surface of bed and side joints.

No spalls or pinning shall be allowed on the face. All bed joints shall be horizontal and
side joints shall be vertical and no joints shall be more than 10 mm in thickness. When
plastering or pointing is not required to be done, the joints shall be struck flush and
finished as the work proceeds. Otherwise, the joints shall be raked to a minimum
depth of 20 mm by a raking tool, during the progress of the work while the mortar is
still green.

Hearting shall consist of flat bedded stones carefully laid on their proper beds and
solidly bedded in mortar. The use of chips shall be restricted to the filling of
interstices between the adjacent stones in hearting and these shall not exceed 10
percent of the quantity of the stone masonry. Care shall be taken so that no hollow
spaces are left anywhere in the masonry.

The requirement regarding through or bond stones shall be as specified in clause 7.3.2
with the further stipulation that these shall be provided at 1.5 m to 1.8m apart clear
in every course but staggered at alternate courses.

The quoins which shall be of the same height as the course, in which they occur, shall
not be less than 450 mm in any direction. Quoin stones shall be laid as stretchers and
headers alternately. They shall be laid square on their beds, which shall be rough
chisel dressed to a depth of at least 100 mm from the face. These stones shall have a
minimum uniform chisel draft of 25mm width at four edges, all the edges being in the
same plane.

Type of scaffolding to be used shall be as per Clause 7.2.2. Requirements of execution

of the work and curing shall be as stipulated in clause 7.3.2.

Concrete Block Masonry:

Materials
Masonry units of hollow and solid concrete blocks shall conform to the requirements of
IS: 2185 (Part I).

Masonry units of hollow and solid light-weight concrete blocks shall conform to the
requirements of IS: 2185 (Part 3).

Masonry units of autoclaved cellular concrete blocks shall conform to the requirements
of IS: 2185 (Part 3).

The height of the concrete masonry units shall not exceed either its length or six times
its width.

The nominal dimensions of concrete block shall be as under.

Length 400, 500 or 600 mm
Height 100 or 200 mm
Width 100 to 300 mm in 50 mm increments
Half blocks shall be in lengths of 200, 250 or 300mm to correspond to the full-length
blocks.
Actual dimensions shall be 10mm short of the nominal dimensions.

The maximum variation in the length of the units shall not be more than ±5 mm and
maximum variation in height or width of the units shall not be more than ± 3mm.

Concrete blocks shall be either hollow blocks with open or closed cavities or solid
blocks. Concrete blocks shall be sound, free of cracks, chipping or other defects which
impair the strength or performance of the construction. Surface texture shall as
specify. The faces of the units shall be flat and rectangular, opposite faces shall be
parallel and all arises shall be square.

The bedding surfaces shall be at right angles to the faces of the block.

The concrete mix for the hollow and solid concrete blocks/light weight concrete
blocks shall not be richer than one part of cement to six parts of combined aggregates
by volume. Concrete blocks shall be of approved manufacture, which satisfy the
limitations in the values of water absorption, drying shrinkage and moisture
movement, as specified for the type of block as per relevant IS code. Contractor shall
furnish the test certificates and also supply the samples for the approval of GUDM.

Workmanship:

The type of the concrete block, thickness and grade based on the compressive
strength for use in load bearing and/or non-load bearing walls shall be as specified.
The minimum nominal thickness of non-load bearing internal walls shall be 100mm.
The minimum nominal thickness of external panel walls in framed construction shall
be 200 mm.
The workmanship shall generally conform to the requirements of IS: 2572 for concrete
block masonry, IS: 6042 for light weight concrete block masonry and IS:6041 for
autoclaved cellular concrete block masonry works.

From considerations of durability, generally concrete block masonry shall be used in

superstructure works above the damp-proof course level.

Concrete blocks shall be embedded with a mortar which is relatively weaker than the
mix of the blocks in order to avoid the formation of cracks. Cement mortar of
proportion 1:6 shall be used for the works. Preparation of mortar shall be as specified
in clause 7.2.1.

The thickness of both horizontal and vertical joints shall be 10mm. The first course
shall be laid with greater care, ensuring that it is properly aligned, leveled and plumb
since this will facilitate in laying succeeding courses to obtain a straight and truly
vertical wall. For the horizontal (bedding) joint, mortar shall be spread over the entire
top surface of the block including front and rear shells as well as the webs to a
uniform layer of 10mm. For vertical joints, the mortar shall be applied on the vertical
edges of the front and rear shells of the blocks. The mortar may be applied either to
the unit already placed on the wall or on the edges of the succeeding unit when it is
standing vertically and then placing it horizontally, well pressed against the previously
laid unit to produce a compacted vertical joint. In case of two cell blocks with slight
depression on the vertical sides these shall also be filled up with mortar to secure
greater lateral rigidity. To assure satisfactory bond, mortar shall not be spread too far
ahead of actual laying of the block as the mortar will stiffen and lose its plasticity
Mortar while hardening shrinks slightly and thus pulls away from the edges of the
block. The mortar shall be pressed against the units with a jointing tool after it has
stiffened to effect intimate contact between the mortar and the unit to obtain a
weather tight joint. The mortar shall be raked to a depth of 10mm as each course is
laid to ensure good bond for the plaster.

Dimensional stability of hollow concrete blocks is greatly affected by variations of

moisture content in the units. Only well dried blocks should be used for the
construction. Blocks with moisture content more than 25% of maximum water
absorption permissible shall not be used. The blocks should not be wetted before or
during laying in the walls. Blocks should be laid dry except slightly moistening their
surfaces on which mortar is to be applied to obviate absorption of water from the
mortar.

As per the design requirements and to effectively control cracks in the masonry, RCC
bound beams/studs, joint reinforcement shall be provided at suitable locations. Joint
reinforcement shall be fabricated either from mild steel wires conforming to IS: 280 or
welded wire fabric/high strength deformed basis.

For jambs of doors, windows and openings, should concrete blocks shall be provided. If
hollow units are used, the hollows shall be filled with concrete of mix 1:3:6. Hold fasts
of doors/windows should be arranged so that they occur at block course level.

At intersection of walls, the courses shall be laid up at the same time with a true
masonry bond between at least 50% of the concrete blocks. The sequence for
construction of partition walls and treatment at the top of load bearing walls for the
RCC slab shall be as detailed under clause 7.2 for the brick work. Curing of the mortar
joints shall be carried out for at least 7 days. The walls should only be lightly
moistened and shall not be allowed to become excessively wet. Double scaffolding as
per clause 7.2.2 shall be adopted for execution of block masonry work. Cutting of the
units shall be restricted to a minimum. All horizontal and vertical dimensions shall be
in respectively, adopting modular co-ordination for walls, opening locations for doors,
windows etc.

Concrete blocks shall be stored at site suitably to avoid any contact with moisture
from the ground and covered to protect against wetting.

Damp - Proof Course:

Materials and Workmanship:
Where Specified, all the walls in a building shall be provided with damp-proof course
cover at plinth to prevent water from rising up the wall. The damp-proof course shall
run without a break throughout the length of the wall, even under the door or other
openings. Damp-proof course shall consist of 50 mm thick cement concrete of 1:2:4
nominal mix with approved water-proofing compound admixture conforming to IS:
2645 in proportion as directed by the manufacturer. Concrete shall be with 10 mm
downgraded coarse aggregates.

The surface of brick work/stone masonry work shall be leveled and prepared before
laying the cement concrete. Side shuttering shall be properly fixed to ensure that
slurry does not leak through and is also not disturbed during compaction. The upper
and side surface shall be made rough to afford key to the masonry above and to the
plaster.

Damp-proof course shall be cured properly for at least seven days after which it shall
be allowed to dry for taking up further work.

Miscellaneous Inserts, Bolts etc.

All the miscellaneous inserts such as bolts, pipes, plate embedment etc., shall be
accurately installed in the building works at the correct location and levels, all as
detailed in the construction Drawings to be prepared by the Contractor. Contractor
shall prepare and use templates for this purpose, if so directed by the GUDM. In the
event, of any of the inserts are improperly installed, Contractor shall make necessary
arrangements to remove and reinstall at the correct locations/levels, all as directed
by the GUDM.

Wood Work for Doors, Windows, Ventilators & Partitions

Materials
Timber to be used shall be first class Teak wood as per IS: 4021. Timber shall be of the
best quality and well-seasoned by a suitable process before being planned to the
required sizes. The maximum permissible moisture content shall be from 10 to 16
percent for timber 50mm and above in thickness and 8 to 14 percent of timber less
than 50mm in thickness for different regions of the country as stipulated in IS:287.
Timber shall be close grained, of uniform colour and free from decay, fungal growth,
boxed heart, pitch pockets or streaks on the exposed edges, borer holes, splits and
cracks.

Flush door shutters of the solid core type with plywood face panels shall conform to IS:
2202 (Part 1) and with particle board/hard board face panels shall conform to IS:
2202 (Part 2).

Transparent sheet glass shall conform to the requirements of IS: 2835. Wired and
figured glass shall be as per IS: 5437.
Builder’s hardware for fittings and fixtures shall be of the best quality from approved
manufacturers.

Workmanship:

The workmanship and finish of wood work in doors, windows, ventilators and partitions
shall be of a very high order. Contractor shall ensure that work is executed in a
professional manner by skilled carpenters for good appearance, efficient and smooth
operation of the shutters.

All works shall be executed as per the detailed Drawings prepared by the Contractor
and/or as directed by the GUDM.

All members of the door, window, and ventilator shall be straight without any warp or
bow and shall have smooth well-planned faces. The right angle shall be checked from
the inside surfaces of the respective members of the frame. Frames shall have mortise
and tenon joints which shall be treated with an approved adhesive and provided with
metal or wood pins. The vertical members of the door frame shall project 50 mm
below the finished floor level. The finished dimension of frames shall be rebated on
the solid for keying with the plaster and for receiving the shutters. The depth of
rebate for housing the shutter shall be 15 mm. The size of the frames shall be as
specified in the respective items of work prepared by the Contractor. The
workmanship shall generally conform to the requirements specified in IS:4021.

The face of the frames abutting the masonry or concrete shall be provided with a coat
of coal tar.
Three hold fasts using 25 mm x 6 mm mild steel flats 225 mm long with split ends shall
be fixed on each side of door and window frames, one at the center and the other two
at 300 mm from the top and bottom of the frame. For window and ventilator frames
less than 1 m in height, two hold fasts on each side shall be fixed at quarter points.

Timber paneled shutters for doors, windows and ventilators shall be constructed in the
form of framework of stiles and rails with panel insertion. The panels shall be fixed by
either providing grooves in the stiles and rails or by beading. Glazing bars shall be as
detailed in the Drawings prepared by the Contractor. The stiles and rails shall be
joined by mortise and tenon joints at right angles. All members of the shutter shall be
straight without any warp or bow and shall have smooth, well-planned faces at right
angles to each other. The right angle for the shutter shall be checked by measuring
the diagonals and the difference shall not be more than  3 mm. Timber panels made
from more than one piece shall be jointed with a continuous tongued and grooved
joint, glued together and reinforced with metal dowels. The workmanship shall
generally conform to the requirements specified in IS: 1003 (Parts 1 & 2). The
thickness of the shutter, width/thickness of the stiles/rails/panel type shall be as
specified. Marine plywood panels conforming to IS:710 shall be used for doors where
specified.

Details of the wooden flush door shutters, solid core type with specific requirement of
the thickness, core, face panels, viewing glazed panel, Venetian louver opening, teak
wood lapping etc. shall be as specified. Panels of shutter shall be of marine plywood
conforming to IS:710. Flush door shutters shall be from reputed manufacturers and
Contractor shall submit test results as per IS:4020, if so desired by the GUDM.

Glazing of door, window, ventilator and partitions shall be with either flat transparent
sheet glass, wired or figured glass. Transparent sheet glass shall be of 'B' quality as per
IS:2835. The thickness and type of glazing to be provided shall be as specified.

The material of the fittings and fixtures either of chromium plated steel, cast brass,
copper oxidized or anodized aluminum shall be as specified. The number, size and
type of the fittings and fixtures shall be as specified.

Woodwork shall not be provided with the finishes of painting/varnishing etc. unless it
has been approved by the GUDM. The type of finish and the number of coats shall be
as stipulated in the respective items of work prepared by the Contractor. Preparation
of the wood surfaces and application of the finishes shall be in accordance with clause
7.32.

Wooden hand railing and architraves shall be of the size and shape with the fixing
arrangement as indicated in the Drawings prepared by the Contractor.

The framework of the partitions with mullions and transoms shall be with the sections
of dimensions as specified. Panels of double/single glazing/plywood shall be fixed as
per details specified. Partitions shall be fixed rigidly between the floor and structural
columns/beams including provision of necessary shims for wedging etc. Finished work
shall be of rigid construction, erected truly plumb to the lines and levels, at locations
as per the construction Drawings prepared by the Contractor.

Any carpentry work which shows defects due to inadequate seasoning of the timber or
bad workmanship shall be removed and replaced by Contractor with work as per
Specifications.

Steel Doors, Windows and Ventilators:

Materials:
Hot rolled steel sections for the fabrication of steel doors, windows and ventilators
shall conform to IS: 7452, which are suitable for, single glazing.

Pressed steel door frames for steel flush doors shall be out of 1.25mm thick mild steel
sheets of profiles as per IS: 4351.
Transparent sheet glass shall conform to the requirements of IS: 2835. Wired and
figured glass shall be as per IS: 5437.

Builder’s hardware of fittings and fixtures shall be of the best quality from the
approved manufacturers.

Workmanship:
All steel doors, windows and ventilators shall be of the type as specified in the
respective items of work prepared by the Contractor and of sizes as indicated in the
Drawings prepared by the Contractor prepared by the Contractor. Steel doors,
windows and ventilators shall conform to the requirements as stipulated in IS: 1038.
Steel windows shall conform to IS: 1361, if so specified.

Doors, windows and ventilators shall be of an approved manufacture. Fabrication of

the unit shall be with rolled section, cut to correct lengths and metered. Corners
shall be welded to form a solid fused welded joint conforming to the requirements of
IS: 1038. Tolerance in overall dimensions shall be within ±1.5mm. The frames and
shutters shall be free from wrap or buckle and shall be square and truly plain. All
welds shall be dressed flush on exposed and contact surfaces. Punching of holes, slots
and other provisions to install fittings and fixtures later shall be made at the correct
locations as per the requirements. Samples of the units shall be got approved by the
GUDM before further manufacture/purchase by the Contractor.

Type and details of shutters, hinges, glazing bar requirement, couplings, locking
arrangement, fittings and fixtures shall be as described in the respective items of work
and / or as shown in the Drawings prepared by the Contractor for single or composite
units.

For windows with fly proof mesh as per the item of work prepared by the Contractor,
rotor operator arrangement, for the operation of the glazed shutters from the inside
shall be provided.

Pressed steel door frames shall be provided with fixing lugs at each jamb, hinges,
lock-strike plate, mortar guards, angle threshold, shock-absorbers of rubber or similar
material as per the requirements of IS: 4351. Pressed steel doorframes shall be fixed
as `built-in’ as the masonry work proceeds. After placing it plumb at the specified
location, masonry walls shall be built up solid on either side or each course grouted
with mortar to ensure solid contact with the doorframe, without leaving any voids.
Temporary struts across the width shall be fixed, during erection to prevent bow/sag
of the frame. Door shutters of flush welded construction shall be 45 mm thick,
fabricated with two outer skills of 1.25mm thick steel sheets, 1mm thick steel sheet
stiffeners and steel channels on all four edges. Double shutters shall have meeting
stile edge beveled or rebated. Provision of glazed viewing panel, louvers shall be
made as per the items of works and/or Drawings prepared by the Contractor. Shutters
shall be suitably reinforced for lock and other surface hardware and to prevent
sagging/twisting. Single sheet steel door shutters shall be fabricated out of 1.25mm
thick steel sheets, mild steel angles and stiffeners as per the Drawings prepared by the
Contractor.

Doors, windows and ventilators shall be fixed into the prepared openings. They shall
not be ‘built-in’ as the masonry work proceeds, to avoid distortion and damage of the
units. The dimensions of the masonry opening shall have 10mm clearance around the
overall dimensions of the frame for this purpose. Any support of scaffolding members
on the frames/glazing bars is prohibited.
 Glazing of the units shall be either with flat transparent glass or wired / figured glass
of the thickness as specified in the items of works prepared by the Contractor. All
glass panels shall have properly squared corner and straight edges. Glazing shall be
provided on the outside of the frames.

Fixing of the glazing shall be either with spring glazing clips and putty conforming to
IS:419 or with metal beads. Pre-formed PVC or rubber gaskets shall be provided for
fixing the beads with the concealed screws. The type of fixing the glazing shall be as
indicated in the items of work and/or in Drawings prepared by the Contractor.

Steel doors, windows and ventilators shall be provided with finish of either painting as
specified or shall be hot dip galvanized with thickness of the zinc coating as stipulated
all as described in the respective items of works prepared by the Contractor.

The material of the Builders hardware of fittings and fixtures of chromium plated
steel, cast brass, brass copper oxidized or anodized aluminum shall be as specified in
the items of works prepared by the Contractor. The number, size and type of fittings
and fixtures shall be as in the Drawings /items of works prepared by the Contractor.

Installation of the units with fixing lugs, screws, mastic caulking compound at the
specified locations shall generally conform to the requirements of IS:1081. Necessary
holes etc required for fixing shall be made by the Contractor and made good after
installation. Workmanship expected is of a high order for efficient and smooth
operation of the units.

Aluminum Doors, Windows, Ventilators & Partitions:

Materials:
Aluminum alloy used in the manufacture of extruded sections for the fabrication of
doors, windows, ventilators shall conform to designation HE9-WP of IS: 733.

Transparent sheet glass shall conform to the requirements of IS: 2835. Wired and
figured glass shall be as per IS: 5437.

Builder's hardware of fittings & fixtures shall be of the best quality from approved
manufacturers.

Workmanship:
All aluminum doors, windows, ventilators and partitions shall be of the type and size
as specified. The doors, windows, ventilators shall conform to the requirements of IS:
1948. Aluminum windows shall conform to IS: 1949, if so specified.

All aluminum units shall be supplied with anodized finish. The minimum anodic film
thickness shall be 0.015 mm. Doors, windows and ventilators shall be of an approved
manufacture. Fabrication of the units shall be with the extruded sections, cut to
correct lengths, mitered and welded at the corners to a true right angle conforming to
the requirements of IS: 1948. Tolerance in overall dimensions shall be within ± 1.5mm.
The frames and shutters shall be free from warp or buckle and shall be square and
truly plane. Punching of holes, slots and other provisions to install fittings or fixtures
later shall be made at the correct locations, as per the requirements. Aluminum swing
type doors, aluminum sliding windows, partitions shall be as specified.

IS:1948 and IS:1949 referred to incorporates the sizes, shapes, thicknesses and weight
per running meter of extruded sections for the various components of the units.
However, new sizes, shapes, thicknesses with modifications to suit snap-fit glazing
clips etc. are being continuously being added by various leading manufacturers of
extruded sections, which are available in the market. As such, the sections of the
various components of the unit proposed by the Contractor will be reviewed by the
GUDM and will be accepted only if they are equal to or marginally more than that
given in the codes/as specified.

The framework of the partitions with mullions and transom shall be with anodized
aluminum box sections. Anodized aluminum box sections shall be in-filled with timber
of class 3 (silver oak or any other equivalent) as per IS: 4021. Panels of double/single
glazing/plywood shall be fixed as per details indicated in the Drawings to be prepared
by the Contractor. Partitions shall be fixed rigidly between the floor and the structural
columns/beams including provision of necessary shims for wedging etc. Finished work
shall be of rigid construction, erected truly plumb to the lines and levels, at locations
as per the construction Drawings to be prepared by the Contractor.

Specific provisions as stipulated for steel doors, windows, ventilators under clause
7.9.2 shall also be applicable for this item work. Glazing beads shall be of the snap-fit
type suitable for the thickness of glazing proposed as indicated in the items of works
prepared by the Contractor. A layer of clear transparent lacquer shall be applied on
aluminum sections to protect them from damage during installation. This lacquer
coating shall be removed after the installation is completed.

Steel Rolling Shutters:

Materials and Workmanship:
Rolling shutters shall be of an approved manufacture, conforming to the requirements
specified in IS: 6248.

The type of rolling shutter shall be self-coiling type (manual) for clear areas upto12
m2, gear operated type (mechanical) for clear areas up to 35 m2 and electrically
operated type for areas up to 50 sq.m. Mechanical type of rolling shutters shall be
suitable for operation from both inside and outside with the crank handle or chain
gear operating mechanism duly considering the size of wall/column. Electrical type of
rolling shutter shall also be provided with a facility for emergency mechanical
operation.

Rolling shutters shall be supplied duly considering the type, specified clear
width/height of the opening and the location of fixing as indicated in the Drawings
prepared by the Contractor. Shutters shall be built up of interlocking laths 75 mm
width between rolling centers formed from cold rolled steel strips. The thickness of
the steel strip shall not be less than 0.90 mm for shutters up to 3.50m width and not
less than 1.20 mm for shutters above 3.50 m width. Each lath section shall be
continuous single piece without any welded joint. The guide channels out of mild steel
sheets of thickness not less than 3.15 mm shall be of either rolled, pressed or built-up
construction. The channel shall be of size as stipulated in IS:6248 for various clear
widths of the shutters.

Hood covers shall be of mild steel sheets not less than 0.90 mm thick and of approved
shape. Rolling shutters shall be provided with a central hasp and staple safety device
in addition to one pair of lever locks and sliding locks at the ends.

All component parts of the steel rolling shutter (excepting springs and insides of guide
channels) shall be provided with one coat of zinc chrome primer conformity to IS:2074
at the shop before supply. These surfaces shall be given an additional coat of primer
after erection at the site along with the number of coats and type of finish paint as
specified in the respective items of works prepared by the Contractor. Painting shall
be carried out as per clause 7.33.
In case of galvanized rolling shutter, the lath sections, guides, lock plate, bracket
plates, suspension shaft and the hood cover shall be hot dip galvanized with a zinc
coating containing not less than 97.5 percent pure zinc. The weight of the zinc coating
shall be at least 610gms/m2.

Guide channels shall be installed truly plumb at the specified location. Bracket plate
shall be rigidly fixed with necessary bolts and holdfasts. Workmanship of erection shall
ensure strength and rigidity of rolling shutter for trouble free and smooth operation.

Rubble Sub-Base:
Materials:
Stones used for rubble packing under floors on grade, foundations etc., shall be clean,
hard, durable rock free from veins, flaws, laminations, weathering and other defects.
Stones shall generally conform to the requirements stipulated in IS: 1597 (Part I).

Stones shall be as regular as can be obtained from quarries. Stones shall be of height
equal to the thickness of the packing proposed with a tolerance of  10 mm. Stones
shall not have a base area less than 250 sq cm nor more than 500 sq.cm, and the
smallest dimension of any stone shall not be less than half the largest dimension. The
quality and size of stones shall be subject to the approval of the GUDM.

Workmanship:
Stones shall be hand packed carefully and laid with their largest base downwards
resting flat on the prepared sub-grade and with their height equal to the thickness of
the packing. Stones shall be laid breaking joints and in close contact with each other.
All interstices between the stones shall be wedged-in by small stones of suitable size,
well driven in by crow bars and hammers to ensure tight packing and complete filling-
in of the interstices. The wedging shall be carried out simultaneously with the placing
in position of rubble packing and shall not lag behind. After this, any interstices
between the smaller wedged stones shall be unfilled with clean hard sand by brooming
so as to fill the joints completely.

The laid rubble packing shall be sprinkled with water and compacted by using suitable
rammers.

Base Concrete:
The thickness and grade of concrete and reinforcement shall be as specified in items
of works prepared by the contractor.

Before placing the blinding concrete, the sub-base of rubble packing shall be properly
wetted and rammed. Concrete for the base shall then be deposited between the
forms, thoroughly tamped and the surface finished level with the top edges of the
forms. Two or three hours after the concrete has been laid in position, the surface
shall be roughened using steel wire brush to remove any scum or laitance and swept
clean so that the coarse aggregates are exposed. The surface of the base concrete
shall be left rough to provide adequate bond for the floor finish to be provided later.

Terrazzo and Plain Cement Tiling Work:

Materials:
Terrazzo tiles and cement tiles shall generally conform in all respects to standards
stipulated in IS:1237. Tiles shall be of the best quality manufactured adopting
hydraulic pressure of not less than 14N/mm2.
The type, quality, size, thickness colour etc, of the tiles for flooring/dado/skirting
shall be as specified.

The aggregates for terrazzo topping shall consist of marble chips which are hard,
sound and dense. Cement to be used shall be either ordinary Portland cement or white
cement with or without coloring pigment. The binder mix shall be with 3 parts of
cement to 1 part of marble powder by weight. The proportion of cement shall be
inclusive of any pigments. For every one part of cement-marble powder binder mix,
the proportion of aggregates shall be 1.75 parts by volume, if the chips are between
1mm to 6mm and 1.50 parts by volume if the chips are between 6mm to 25mm.

The minimum thickness of wearing layer of terrazzo tiles shall be 5mm for tiles with
chips of size varying from 1mm up to 6mm or from 1mm up to 12mm. This shall be
6mm for tiles with chips varying from 1mm up to 25mm. The minimum thickness of
wearing layer of cement/colored cement tiles shall be 5mm. This shall be 6mm for
heavy duty tiles. Pigment used in the wearing layer shall not exceed 10 percent of the
weight of cement used in the mix.

Workmanship
Laying and finishing of tiles shall conform to the requirements of workmanship
stipulated in IS: 1443.

Tiling work shall be commenced only after the door and window frames are fixed and
plastering of the walls/ ceiling is completed. Wall plastering shall not be carried out
upto about 50 mm above the level of proposed skirting/dado.

The base concrete shall be finished to a reasonably plane surface about 40 to 45mm
below the level of finished floor. Before the tiling work is taken up, the base concrete
or structural slab shall be cleaned of all loose materials, mortar droppings, dirt,
laitance etc. using steel wire brush and well wetted without allowing any water pools
on the surface. A layer of 25mm average thickness of cement mortar consisting of one
part of cement to 6 parts of sand shall be provided as bedding for the tiles over the
base concrete. The thickness of bedding mortar shall not be less than 10mm at any
place. The quantity of water to be added for the mortar shall be just adequate to
obtain the workability for laying. Sand for the mortar shall conform to IS:2116 and
shall have minimum fineness modulus of 1.5. The surface shall be left rough to provide
a good bond for the tiles. The bedding shall be allowed to harden for a day before
laying of the tiles. Neat cement slurry using 4.4 kg of cement per m2of floor area shall
be spread over the hardened mortar bedding over such an area at a time as would
accommodate about 20 tiles. Tiles shall be fixed in this slurry one after the other,
each tile being gently tapped with a wooden mallet till it is properly bedded and in
level with the adjoining tiles. The joints shall be in straight lines and shall normally be
1.5mm wide. On completion of laying of the tiles in a room, all the joints shall be
cleaned and washed fairly deep with a stiff broom/wire brush to a minimum depth of
5mm. The day after the tiles have been laid, the joints shall be filled with cement
grout of the same shade as the colour of the matrix of the tile. For this purpose, white
cement or grey cement with or without pigments shall be used. The flooring should be
kept moist and left undisturbed for 7 days for the bedding/joints to set properly.
Heavy traffic shall not be allowed on the floor for at least 14 days after fixing of the
tiles.

About a week after laying the tiles, each and every tile shall be lightly tapped with a
small wooden mallet to find out if it gives a hollow sound; if it does, such tiles along
with any other cracked or broken tiles shall be removed and replaced with new tiles to
proper line and level. The same procedure shall be followed again after grinding the
tiles and all damaged tiles replaced, properly jointed and finished to match. For the
purpose of ensuring that such replaced tiles match with those laid earlier, it is
necessary that the Contractor shall procure sufficient quantity of extra tiles to meet
this contingency.

Wherever a full tile cannot be provided, tiles shall be cut to size and fixed. Floor tiles
adjoining the wall shall go about 10mm under the plaster, skirting or dado.

Tile skirting and dado work shall be executed only after laying tiles on the floor. For
dado and skirting work, the vertical wall surface shall be thoroughly cleaned and
wetted. Thereafter it shall be evenly and uniformly covered with 10mm thick backing
of 1:4 cement sand mortar. For this work the tiles as obtained from the factory shall
be of the size required and practically full polished. The back of each tile to be fixed
shall be covered with a thin layer of neat cement paste and the tile shall then be
gently tapped against the wall with a wooden mallet. Fixing shall be done from the
bottom of the wall upwards. The joints shall be in straight lines and shall normally be
1.5mm wide. Any difference in the thickness of the tiles shall be evened out in the
backing mortar or cement paste so that the tile faces are in conformity & truly plumb.
Tiles for use at the corners shall be suitably cut with beveled edges to obtain a neat
and true joint. After the work has set, hand polishing with carborundum stones shall
be done so that the surface matches with the floor finish.

Wall plastering of the strip left out above the level of skirting/dado shall be taken up
after the tiles are fixed.

Chequered terrazzo tiles for flooring and for stair treads shall be delivered to site
after the first machine grinding.

Machine grinding and polishing shall be commenced only after a lapse of 14 days of
laying. The sequence and three numbers of machine grinding operations, usage of the
type of carborundum stones, filling up of pin holes, watering etc. shall be carried out
all as specified in IS:1443.

Tiles shall be laid to the levels specified. Where large areas are to be tiled the level of
the central portion shall be kept 10mm higher than that at the walls to overcome
optical illusion of a depression in the central portion. Localized deviation of ±3mm in
any 3m length is acceptable in a nominally flat floor.

In-Situ Terrazzo Work:

Materials:
The requirements of marble aggregates for terrazzo topping shall be as per clause
7.14.1.

Cement shall first be mixed with the marble powder in dry state. The mix thus
obtained shall be mixed with the aggregates in the specified proportions. Care shall be
taken not to get the materials into a heap which results in the coarsest chips falling to
the edges and cement working to the center at the bottom. Materials shall be kept, as
far as possible, in an even layer during mixing. After the materials have been
thoroughly mixed in the dry state, water shall be added, just adequate to obtain
plastic consistency for the desired workability for laying. The mix shall be used in the
works within 30 minutes of the addition of water to the cement.
Workmanship:
The thickness, type, quality, size and colour of chips etc. for the in-situ terrazzo finish
for flooring/dado/ skirting shall be as specified in the respective items of works
prepared by the Contractor. Laying and finishing of in-situ work shall conform to the
requirements of workmanship stipulated in IS: 2114.

In-situ terrazzo finish shall be laid over hardened concrete base. The finish layer
consists of an under layer and terrazzo topping. The under layer shall be of cement
concrete of mix 1:2:4 using 10mm downgraded coarse aggregates. The combined
thickness of under layer and topping shall not be less than 30 mm for flooring and
20mm for dado/skirting work.

The minimum thickness of topping shall be 6mm if chips used are between 1mm to
4mm, 9mm if chips are between 4mm to 7mm and 12mm if chips are between 7mm to
10mm. If chips larger than 10mm size are used, the minimum thickness shall be one
and one third the maximum size of chips.

Both the under layer and later the topping shall be divided into panels not exceeding 2
m2for laying so as to reduce the possibility of development of cracks. The longer
dimension of any panel shall not exceed 2m. Dividing strips shall be used to separate
the panels. When the dividing strips are not provided, the bays shall be laid
alternately, allowing an interval of at least 24 hours between laying adjacent bays.

Dividing strips shall be either of aluminum, brass or other material as indicated in the
items of works prepared by the Contractor. Aluminum strips should have a protective
coating of bitumen. The thickness of the strips shall not be less than 1.5mm and width
not less than 25mm for flooring work.

Concrete base shall be finished to a reasonably plane surface to a level below the
finished floor elevation equal to the specified thickness of terrazzo finish. Before
spreading the underlayer, the base concrete surface shall be cleaned of all loose
materials, mortar droppings, dirt, laitance etc. and well wetted without allowing any
water pools on the surface. Dividing strips or screed strips, if dividing strips are not
provided shall be fixed on the base and leveled to the correct height to suit the
thickness of the finish. Just before spreading the under layer the surface shall be
smeared with cement slurry at 2.75 Kg/m2. Over this slurry, the under layer shall be
spread and leveled with a screening board. The top surface shall be left rough to
provide a good bond for the terrazzo topping.

Terrazzo topping shall be laid while the under layer is still plastic and normally
between 18 to 24 hours after the under layer is laid. Cement slurry of the same colour
as the topping shall be brushed on the surface immediately before laying is
commenced. The terrazzo mix shall be laid to a uniform thickness and compacted
thoroughly by tamping and with a minimum of toweling. Straight edge and steel floats
shall be used to bring the surface true to the required level in such a manner that the
maximum amount of marble chips come up and spread uniformly all over the surface.

The surface shall be left dry for air-curing for a period of 12 to 18 hours. Thereafter it
shall be cured by allowing water to stand in pools for a period of not less than 4 days.

Machine grinding and polishing shall be commenced only after a lapse of 7 days from
the time of completion of laying. The sequence and four numbers of machine grinding
operations, usage of the type of carborundum stones, filling up of pinholes, wet
curing, watering etc shall be carried out all as specified in IS: 2114.
 Shahabad / Tandur/ Kota Stone Slab work:
Materials:
The slabs shall be of approved selected quality, hard, sound, dense and homogenous in
texture, free from cracks, decay, weathering and flaws. The percentage of water
absorption shall not exceed 5 percent as per test conducted in accordance with IS:
1124.

The slabs shall be hand or machine cut to the required thickness. Tolerance in
thickness for dimensions of tile more than 100mm shall be ±5mm. This shall be ±2mm
on dimensions less than 100mm. Slabs shall be supplied to the specified size with
machine cut edges or fine chisel dressed to the full depth. All angles and edges of the
slabs shall be true and square, free from any chipping giving a plane surface. Slabs
shall have the top surface machine polished (first grinding) before being brought to
site. The slabs shall be washed clean before laying.

Workmanship:
The type, size, thickness and colour/shade etc. of the slabs for flooring/ dado/
skirting shall be as specified in the respective items of works prepared by the
Contractor.

Preparation of the concrete base, laying and curing shall be as per clause 7.14.2.

Dado / skirting work shall be as per clause 7.14.2. The thickness of the slabs for
dado/skirting work shall not be more than 25mm. Slabs shall be so placed that the
back surface is at a distance of 12mm. If necessary, slabs shall be held in position
temporarily by suitable method. After checking for verticality, the gap shall be filled
and packed with cement sand mortar of proportion 1:3. After the mortar has acquired
sufficient strength, the temporary arrangement holding the slab shall be removed.

Grinding and polishing shall be as per clause 7.14.2 except that first grinding with
coarse grade carborundum shall not be done and cement slurry with or without
pigment shall not applied before polishing.

Carborundum Tile Finish:

Materials:
Carborundum tiles shall generally conform in all respects to the standards stipulated in
IS: 1237 for heavy duty tiles. Tiles shall be of the best quality manufactured adopting
hydraulic pressure of not less than 14 N/mm2.

The topping shall be uniform and of thickness not less than 6mm. The quantity of
Carborundum grit shall be not less than 1.35 kg/sq.m used with cement with or
without pigment. The Carborundum grit shall pass through 1.18mm mesh and shall be
retained on 0.60 mm mesh.

Workmanship:
Requirements as detailed for terrazzo/cement tile finish under clause 7.14.2 shall be
applicable for Carborundum tile flooring.

Glazed Tile Finish:

Materials:
 Glazed earthenware tiles shall conform to the requirements of IS: 777. Tiles shall be of
the best quality from an approved manufacturer. The tiles shall be flat, true to shape
and free from flaws such as crazing, blisters, pinholes, specks or welts. Edges and
underside of the tiles shall be free from glaze and shall have ribs or indentations for a
better anchorage with the bedding mortar. Dimensional tolerances shall be as
specified in IS: 777.

Workmanship:

The total thickness of glazed tile finish including the bedding mortar shall be 20 mm in
flooring/dado/skirting. The minimum thickness of bedding mortar shall be 12mm for
flooring and 10mm for dado/skirting work.
The bedding mortar shall consist of 1 part of cement to 3 parts of sand mixed with just
sufficient water to obtain proper consistency for laying. Sand for the mortar shall
conform to IS: 2116 and shall have minimum fineness modulus of 1.5.

Tiles shall be soaked in water for about 10 minutes just before laying. Where full size
tiles cannot be fixed, tiles shall be cut to the required size using special cutting device
and the edges rubbed smooth to ensure straight and true joints.

Colored tiles with or without designs shall be uniform and shall be preferably procured
from the same batch of manufacture to avoid any differences in the shade.

Tiles for the flooring shall be laid over hardened concrete base. The surface of the
concrete base shall be cleaned of all loose materials, mortar droppings etc well
wetted without allowing any water pools on the surface. The bedding mortar shall
then be laid evenly over the surface, tamped to the desired level and allowed to
harden for a day. The top surface shall be left rough to provide a good bond for the
tiles. For skirting and dado work, the backing mortar shall be roughened using a wire
brush.
Neat cement slurry using 3.3 kg cement per m2of floor area shall be spread over the
hardened mortar bed over such an area as would accommodate about 20 tiles. Tiles
shall be fixed in this slurry one after the other, each tile being gently tapped with a
wooden mallet till it is properly bedded and in level with the adjoining tiles. For
skirting and dado work, the back of the tiles shall be smeared with cement slurry for
setting on the backing mortar. Fixing of tiles shall be done from the bottom of the
wall upwards. The joints shall be in perfect straight lines and as thin as possible but
shall not be more than 1mm wide. The surface shall be checked frequently to ensure
correct level/required slope. Floor tiles near the walls shall enter skirting/dado to a
minimum depth of 10mm. Tiles shall not sound hollow when tapped. All the joints
shall be cleaned of grey cement with wire brush to a depth of at least 3mm and all
dust, loose mortar etc. shall be removed. White cement with or without pigment shall
then be used for flush pointing the joints. Curing shall then be carried out for a
minimum period of 7 days for the bedding and joints to set properly. The surface shall
then be cleaned using a suitable detergent, fully washed and wiped dry.
Specials consisting of coves, internal and external angles, cornices, beads and their
corner pieces shall be of thickness not less than the tiles with which they are used.

In-Situ Cement Concrete Floor Topping:

Materials:
The mix proportion for the in-situ concrete floor topping shall be 1:2.5:3.5 (one part
cement: two and half parts sand: three and half parts coarse aggregates) by volume
unless otherwise specified.

The aggregates shall conform for the requirements of IS: 383.

Coarse aggregates shall have high hardness surface texture and shall consist of crushed
rock of granite, basalt, trap or quartzite. The aggregate crushing valve shall not
exceed 30 percent. The grading of the aggregates of size 12.5mm and below shall be
as per IS: 2571.

Grading of the sand shall be within the limits indicated in IS: 2571.

Workmanship:
The thickness of the floor topping shall be as specified in the items of work prepared
by the Contractor. The minimum thickness of the floor topping shall be 25mm.

Preparation of base concrete/structural slab before laying the topping shall be as per
clause 7.13. The surface shall be rough to provide adequate bond for the topping.

Mixing of concrete shall be done thoroughly in a mechanical mixer unless hand mixing
is specifically permitted by the GUDM. The concrete shall be as stiff as possible and
the amount of water added shall be the minimum necessary to give just sufficient
plasticity for laying and compacting. The mix shall be used in the work within 30
minutes of the addition of water for its preparation.

Floor finish shall be laid in suitable panels to reduce the risk of cracking. No dimension
of a panel shall exceed 2 meters and the length of a panel shall not exceed one and a
half times its breadth. Topping shall be laid in alternate panels; the intermediate
panels being cast after a gap of at least one day. Construction joints shall be plain
vertical butt joints.

Screed strips shall be fixed dividing the area into suitable panels. Immediately before
depositing the concrete topping, neat cement slurry at 2.75 kg/m2of area shall be
thoroughly brushed into the prepared surface. Topping shall then be laid, very
thoroughly tamped, struck off level and floated with wooden float. The surface shall
then be tested with a straight edge and mason's spirit level to detect any inequalities
and these shall be made good immediately.

Finishing of the surface by Trowelling shall be spread over a period of one to six hours
depending upon the temperature and atmospheric conditions. The surface shall be
trowelled 3 times at intervals so as to produce a smooth uniform and hard surface.
Immediately after laying, the first Trowelling just sufficient to give a level surface
shall be carried out avoiding excessive Trowelling at this stage. The surface shall be
re- trowelled after sometime to close any pores and to scrap off excess water or
laitance, which shall not be trowelled back into the topping. Final Trowelling shall be
done well before the concrete has become too hard but at a time when considerable
pressure is required to make any impression on the surface. Sprinkling of dry cement
or cement-sand mixture for absorbing moisture shall not be permitted.
Immediately after the surface is finished, it shall be protected suitably from rapid
drying due to wind/ sunlight. After the surface has hardened sufficiently to prevent
any damage to it, the topping shall be kept continuously moist for a minimum period
of 10 days.

It is preferable to lay the topping on hardened base concrete, as against being laid
monolithically with a lesser thickness, since proper levels and slopes with close
surface tolerances is achievable in practice, owing to its greater thickness. Further, as
this would be laid after all other building operations are over, there will be no risk of
any damages or discolorations to the floor finish which are difficult to repair
satisfactorily.

In-Situ Granolithic Concrete Floor Topping:

Materials and Workmanship:
The Requirements of materials and workmanship shall be all as per clause 7.19 for in-
situ cement concrete floor topping except that the mix proportion of the concrete
shall be 1:1:2 (cement: sand: coarse aggregates) by volume.

The minimum thickness of granolithic floor topping on hardened concrete base shall be
40mm.

Floor Hardener Topping:

Materials & Workmanship:
Floor Hardener topping shall be provided either as integrally finished over the
structural slab/grade slab or lay monolithically with the concrete/granolithic floor
finish on top of hardened concrete base.

Floor hardener of the metallic or non-metallic type suitable for the performance of
normal / medium/ heavy duty function of the floor, the quantum of ingredients and
the thickness of topping shall be as specified in the respective items of work prepared
by the Contractor. For monolithic application with the floor finish/slab the thickness
of the layer shall be 15mm. The topping shall be laid within 2 to 3 hours after
concrete is laid when it is still plastic but stiffened enough for the workmen to tread
over it by placing planks. The surface of the concrete layer shall be kept rough for
providing adequate bond for the topping. Laitance shall be removed before placing
the topping. The topping shall be screened and thoroughly compacted to the finished
level. Trowelling to a smooth finish shall be carried out as per clause 7.19.2. After the
surface has hardened sufficiently, it shall be kept continuously moist for at least 10
days. The procedure for mixing the floor hardener topping shall be as per
manufacturer's instructions.

Surface shall be prevented from any damages due to subsequent building operations
by covering with 75 mm thick layer of sand.

PVC Sheet/Tile Flooring:

Materials:
PVC floor covering shall be of either unbaked homogeneous flexible type in the form
of sheets/tiles conforming to IS: 3462 or homogeneous PVC asbestos tiles conforming
to IS: 3461. Surface of the sheets/tiles shall be free from any physical defects such as
pores, blisters, cracks etc. which affects the appearance and serviceability. Tiles/
sheets shall meet with the tolerance limits in dimensions specified in the IS.
Contractor shall submit the test certificates, if so desired by the GUDM.

Each tile/sheet shall be legibly and indelibly marked with the name of the
manufacturer or his trade mark, IS certificate mark, and batch number.
The adhesive to be used for laying the PVC flooring shall be rubber based and of the
make as recommended and approved by the manufacturer of PVC sheets/tiles.
The type, size, colour, plain or mottled and the pattern shall be as specified in the
respective items of work prepared by the Contractor.

Workmanship:
PVC Floor covering shall be provided over an under bed of cement concrete floor finish
over the base concrete or structural slab. It is essential that the sub-floor and the
under bed are perfectly dry before laying the PVC flooring. This shall be ensured by
methods of testing as stipulated in Appendix-A of IS: 5318.

The surface of the under bed shall have trowelled finish without any irregularities,
which creates poor adhesion. Surface shall be free of oil or grease and thoroughly
cleaned of all dust, dirt and wiped with a dry cloth.

PVC sheets/tiles shall be brought to the temperature of the area in which they are to
be laid by stacking in a suitable manner within or near the laying area for a period of
about 24 hours. Where air-conditioning is installed, the flooring shall not be laid on
the under bed until the A/C units have been in operation for at least 7 days. During
this period, the temperature range shall be between 20deg.C and 30deg.C and this
shall be maintained during the laying operations and also for 48 hours thereafter.

Layout of the PVC flooring shall be marked with guidelines on the under bed and PVC
tiles/sheets shall be first laid for trial, without using the adhesive, according to the
layout.

The adhesive shall be applied by using a notched trowel to the surface of the under
bed and to the backside of PVC sheets/tiles. When the adhesive has set sufficiently for
laying, it will be tacky to the touch, which generally takes about 30 minutes. The time
period need be carefully monitored since a longer interval will affect the adhesive
properties. Adhesive shall be uniformly spread over only as much surface area at one
time which can be covered with PVC flooring within the stipulated time.

PVC sheet shall be carefully taken and placed in position from one end onwards slowly
so that the air will be completely squeezed out between the sheet and the background
surface and no air pockets are formed. It shall then be pressed with a suitable roller to
develop proper contact. The next sheet shall be laid edge to edge with the sheet
already laid, so that there is minimum gap between joints. The alignment shall be
checked after each row of sheet is completed and trimmed if considered necessary.

Tiles shall be laid in the same manner as sheets and preferably, commencing from the
center of the area. Tiles should be lowered in position and pressed firmly on to the
adhesive with minimum gap between the joints. Tiles shall not be slide on the surface.
Tiles shall be rolled with a light wooden roller of about 5kg to ensure full contact with
the underlay. Work should be constantly checked to ensure that all four edges of
adjacent tiles meet accurately.

Any excess adhesive which may squeeze up between sheets/tiles shall be wiped off
immediately with a wet cloth. Suitable solvents shall be used to remove hardened
adhesive.

A minimum period of 24 hours shall be given after laying for the development of
proper bond of the adhesive. When the flooring is thus completed, it shall be cleaned
with a wet cloth soaked in warm soap solution.

Metallic edge strips shall be used to protect the edges of PVC sheets/tiles which are
exposed as in doorways/ stair treads.
Hot sealing of joints between adjacent PVC sheet flooring to prevent creeping of
water through the joints shall be carried out, using special equipment as per
manufacturer's instructions.

Acid Resisting Brick/Tiling Work:

Materials:
The ceramic unglazed vitreous acid resisting tiles shall conform to the requirements of
IS: 4457. Acid resistant bricks shall conform to the requirements of IS: 4860.

The finished tile/brick when fractured shall appear fine grained in texture, dense and
homogeneous. Tile/brick shall be sound, true to shape, flat, free from flaws and any
manufacturing defects affecting their utility. Tolerance in dimensions shall be within
the limits specified in the respective IS.

The tiles/bricks shall be bedded and jointed using chemical resistant mortar of the
resin type conforming to IS: 4832 (Part II). Method of usage shall generally be as per
the requirements of IS: 4443.
Workmanship:
The resin shall have viscosity for readily mixing with the filler by manual methods. The
filler shall have graded particles which permit joint thickness of 1.5 mm.

The base concrete surface shall be free from dirt and thoroughly dried. The surface
shall be applied with a coat of bitumen primer conforming to IS: 3384. The primed
surface shall then be applied with a uniform coat of bitumen conforming to IS: 1580.
Tiles or bricks shall be laid directly without the application of bitumen, if epoxy or
polyester resin is used for the mortar. Just adequate quantity of mortar which can be
applied within the pot life as specified by the manufacturer shall be prepared at one
time for bedding and jointing. Rigid PVC/Stainless steel/chromium plated tools shall
be used for mixing and laying. For laying the floor 6 to 8 mm thick mortar shall be
spread on the back of the tile/brick. Two adjacent sides of the tile/brick shall be
smeared with 4 to 6 mm thick mortar. Tile/brick shall be pressed into the bed and
pushed against the floor and with the adjacent tile/ brick, until the joint in each case
is 2 to 3 mm thick. Excess mortar shall then be trimmed off and allowed to harden
fully. Similar procedure shall be adopted for the work on walls by pressing the
tile/brick against the prepared wall surfaces and only one course shall be laid at a
time until the initial setting period.

The mortar joints shall be cured for a minimum period of 72 hours with 20 to 25%
hydrochloric acid or 30 to 40% sulphuric acid. After acid curing, the joints shall be
washed with water and allowed too thoroughly dry. The joints shall then be filled with
mortar to make them smooth and plane. Acid curing is not required to be carried out
if epoxy or polyester resin is used for the mortar.

Resin mortars are normally self-curing. The area tiled shall not be put to use before 48
hours in case epoxy, polyester and furan type of resin is used for the mortar. If
phenolic or cashew nut shell liquid resin is used for the mortar, the area tiled shall not
be put to use for 7 to 28 days respectively, without heat treatment. This period shall
be 2 to 6 days respectively, if heat treatment is given with infrared lamp.

Epoxy Lining Work:

Materials:
The epoxy resin and hardener formulation for laying of joint less lining work in floors
and walls of concrete tanks/trenches etc. shall be as per the requirements of IS:9197.
The epoxy composition shall have the chemical resistance to withstand the following
conditions of exposure:
Hydrochloric acid up to 30% concentration
Sodium hydroxide up to 50% concentration
Liquid temperature up to 60deg.C
Ultraviolet radiation
Alternate wetting and drying
Sand shall conform to grading zone III or IV of IS: 383.

The hardener shall be of the liquid type such as Aliphatic Amine or an

Aliphatic/Aromatic Amine Adduct for the epoxy resin. The hardener shall react with
epoxy resin at normal ambient temperature.

Contractor shall furnish test certificates for satisfying the requirements of the epoxy
formulation if so directed by the GUDM.

Workmanship:
The minimum thickness of epoxy lining shall be 4 mm. It is essential that the concrete
elements are adequately designed to ensure that water is excluded to permeate to the
surface, over which the epoxy lining is proposed. The epoxy lining shall be of the
trowel type to facilitate execution of the required thickness for satisfactory
performance.

The concrete surfaces over which epoxy lining is to be provided shall be thoroughly
cleaned of oil or grease by suitable solvents, wire brushed to remove any dirt/dust and
laitance. The surfaces shall then be washed with dilute hydrochloric acid and rinsed
thoroughly with plenty of water or dilute ammonia solution. The surfaces shall then be
allowed to dry. It is essential to ensure that the surfaces are perfectly dry before the
commencement of epoxy application. Just adequate quantity of epoxy resin which can
be applied within the pot life as specified by the manufacturer shall be prepared at
one time for laying and jointing. Rigid PVC/stainless steel/chromium plated tools shall
be used for laying. Trowelling shall be carried out to obtain uniformly the specified
thickness of lining.

Lining shall be allowed to set without disturbance for a minimum period of 24 hours.
The facility shall be put to use only after a minimum period of 7 days of laying of the
lining.

Water-Proofing:
General:
The work shall include waterproofing for the building roofs, terraces, toilets, floor
slabs, walls, planters, chhajjas, sills and any other areas and at any other locations
and situations as directed by the Employers Representative.

The waterproofing treatment shall be carried out on top of lime concrete (brick bat
coba) laid to slope on roof surfaces. The brick bat-coba shall be covered as specified
below.

The work shall be carried out by an experienced specialist Sub-Contractor who shall be
appointed only after prior approval of the GUDM.

Modified Bituminous Membrane:

Modified Bituminous Membrane shall be “SUPER THERMOLAY” 4 mm thick weighing 4
Kg/sq.m, manufactured using APP Polymer modified bitumen with a central core of
non-woven polyester reinforcement (200 gms/sqm) and with top and bottom layers of
thermo fusible film (top layer could also be sand finished) made by STP Limited in
collaboration with Bitumen Company Limited. “PLYFLEX” of Bitumen Company
Limited, Saudi Arabia supplied by STP Limited shall also be acceptable or other
equivalent specification.

Waterproofing of Roofs with Lime Concrete:

Materials:
Broken brick coarse aggregates prepared from well/over burnt bricks shall be well
graded having a maximum size of 25mm and shall generally conform to IS:3068.
Lime shall be class C lime (fat lime) or factory made hydrated lime conforming to
IS:712.

Workmanship:
Lime concrete shall be prepared by thoroughly mixing the brick aggregates inclusive of
brick dust obtained during breaking with the slaked lime in the proportions of 2 1/2
(two and a half) parts of brick aggregates to 1 part of slaked lime by volume. Water
shall be added just adequate to obtain the desired workability for laying. Washing
soap and alum shall be dissolved in the water to be used. The quantity of these
materials required per cum of lime concrete shall be 12kg of washing soap and 4kg of
alum. Brick aggregates shall be soaked thoroughly in water for a period of not less
than six hours before use in the concrete mix. Lime concrete shall be used in the
works within 24 hours after mixing.

The roof surface over which the water-proof treatment is to be carried out shall be
cleaned of all foreign matter by wire brushing, dusting and made thoroughly dry.
Preparation of surfaces shall be as stipulated in IS: 3067.

The slope of the finished waterproofing treatment shall be not less than 1 in 60 for
efficient drainage. This shall be achieved either wholly in the lime concrete layer.

The average thickness of lime concrete, slope and the finish on top of machine-made
burnt clay flat terracing tiles conforming to IS:2690 (part I) shall be as specified in the
items of work to be prepared by the Contractor. Cement concrete flooring tiles in lieu
of clay terracing tiles shall be provided if so specified in the items of work prepared by
the Contractor, duly considering the traffic the terrace will be subjected to.

The minimum compacted thickness of lime concrete layer shall be 75mm and average
thickness shall not be less than 100mm. In case, the thickness is more than 100mm, it
shall be laid in layers not exceeding 100mm to 125mm. Laying of lime concrete shall
be commenced from a corner of the roof and proceeded diagonally towards center and
other sides duly considering the slopes specified for effectively draining the rain-water
towards the down take points. Lime concrete fillet for a minimum height of 150mm
shall be provided all along the junction of the roof surface with the brick masonry
wall/parapet/column projections. These shall then be finished on top with provision of
clay terracing tiles/cement concrete tiles.

After the lime concrete is laid it shall be initially rammed with a rammer weighing not
more than 2 Kg and the finish brought to the required evenness and slope.
Alternatively, bamboo strips may be used for the initial ramming. Further
consolidation shall be done using wooden THAPIES with rounded edges. The beating
will normally have to be carried on for at least seven days until the THAPI makes no
impression on the surface and rebounds readily from it when struck. Special care shall
be taken to properly compact the lime concrete at its junction with parapet walls or
column projections. During compaction by hand-beating, the surface shall be sprinkled
liberally with lime water (1 part of lime putty and 3 to 4 parts of water) and a small
proportion of sugar solution for obtaining improved water-proofing quality of the lime
 concrete. On completion of beating, the mortar that comes on the top shall be
smoothened with a trowel or float, if necessary, with the addition of sugar solution
and lime putty. The sugar solution may be prepared in any one of the following ways
as directed by the GUDM.

a) By mixing about 3 Kg of Jaggery and 1.5 Kg of BAEL fruit to 100 liters of water.

b) By mixing about 600 gm of KADUKAI (the dry nuts shall be broken to small pieces
and allowed to soak in water), 200 gm of jaggery and 40 liters of water for 10 sq.m of
work. This solution shall be brewed for about 12 to 24 hours and the resulting liquor
decanted and used for the work.

The lime concrete after compaction shall be cured for a minimum period of seven days
or until it hardens by covering with a thin layer of straw or hessian which shall be kept
wet continuously. Machine made flat terracing tiles shall be of the size and thickness
as specified. Tiles shall be soaked in water for at least one hour before laying.
Bedding for the tiles shall be 12mm thick in cement mortar 1:3. Tiles shall be laid,
open jointed with 4 to 6 mm wide joints, flat on the mortar and lightly pressed and set
to plane surface true to slope, using a trowel and wooden straight edge. They shall be
laid with their longitudinal lines of joints truly parallel and generally at right angles to
the direction of run-off gradient. Transverse joints in alternate rows shall come
directly in line with each other. Transverse joints in adjacent courses shall break
joints by at least 50 mm. The joints shall be completely filled and flush pointed with
cement mortar 1:2 mixed with water proofing compound as per manufacturer's
instructions. Curing shall be carried out for a minimum period of seven days. Finishing
on top with cement concrete tiles or in-situ cement concrete floor topping shall be
carried out in similar fashion as described for clay tiles in above paragraph. Tiles to
be used shall be supplied after the first machine grinding of the surface.

Waterproofing of Roofs/Terraces etc.:

(A) Water proofing of Horizontal Surfaces:
The waterproofing shall be applied as follows:
A coat of Blown Bitumen 85/25 shall be applied at the rate of 1.45 kg/sq.km

A roll of Modified Bituminous Membrane shall be unrolled over the primed surface and
completely bonded to the substrate by pressing down evenly for the full width of the
roll using a wooden roller. Torching shall be done, where recommended by the
manufacturer and were directed by the GUDM, as the unrolling progresses.

The side overlaps shall be minimum 100 mm whereas the end overlaps shall be
minimum 150 mm; both shall be bonded and sealed by flame torching. Care shall be
taken that the membrane is lapped with the treatment along the vertical surface and
roof gutter treatment for at least 500 mm. The membrane shall be properly
overlapped/terminated at all openings, rainwater down takes etc. to ensure that such
junctions do not become sources of leakage.

Top of membrane finally shall be painted with anti glouse reflective paint.

(B) Waterproofing of Vertical Surfaces at Roof Level and Gutters:

The Water proofing shall be applied as described in (a) above.

Modified Bituminous membrane shall be unrolled and bonded to the substrate after
applying a coat of bitumen and by pressing down evenly for the full width of the roll.
Light torching shall be done to ensure complete bonding.
The membrane shall be overlapped with treatment for the horizontal surface by at
least 500 mm.

The membrane shall be taken up to a pre-cut chase anchored and sealed.

Khurras and Rainwater down Pipes:

Down pipes shall be isolated from RCC work with 6 mm polyethylene foam fixed with
adhesive (Araldite) and sealed with silicone sealant prior to laying membrane. A water
proofing flashing composed of one layer of Hessian based self-finished felt Type 3
Grade 1 and two layers of aluminum foil of 0.075 mm thickness shall be provided. This
flashing shall be carried into the down take pipes for at least 150 mm and sealed with
hot bitumen. The Contractor shall closely coordinate the work with the agency
providing and fixing the rainwater down take pipes.

Testing:
The treated area (flat and horizontal only) shall be tested by allowed water to stand
on the treated areas to a depth of 150 mm for a minimum period of 72 hours.

The treated area (flat and horizontal) shall have continuous slope towards the
rainwater outlets and no water shall pond anywhere on the surface.

Cement Plastering Work:

Materials:
The proportions of the cement mortar for plastering shall be 1:3 (one part of cement
to three parts of sand). Cement and sand shall be mixed thoroughly in dry condition
and then just enough water added to obtain a workable consistency. The quality of
water and cement shall be as per relevant IS standards. The quality and grading of
sand for plastering shall conform to IS: 1542. The mixing shall be done thoroughly in a
mechanical mixer unless hand mixing is specifically permitted by the GUDM. If so
desired by the GUDM sand shall be screened and washed to meet the Specifications.
The mortar thus mixed shall be used as soon as possible preferably within 30 minutes
from the time water is added to cement. In case the mortar has stiffened due to
evaporation of water this may be re-tempered by adding water as required to restore
consistency but this will be permitted only up to 30 minutes from the time of initial
mixing of water to cement. Any mortar which is partially set shall be rejected and
removed forthwith from the site. Droppings of plaster shall not be re-used under any
circumstances.

Workmanship:
Preparation of surfaces and application of plaster finishes shall generally conform to
the requirements specified in IS:1661 and IS:2402.

Plastering operations shall not be commenced until installation of all fittings and
fixtures such as door/window panels, pipes, conduits etc. are completed.

All joints in masonry shall be raked as the work proceeds to a depth of 10mm/20mm
for brick/stone masonry respectively with a tool made for the purpose when the
mortar is still green. The masonry surface to be rendered shall be washed with clean
water to remove all dirt, loose materials, etc., Concrete surfaces to be rendered shall
be roughened suitably by hacking or bush hammering for proper adhesion of plaster
and the surface shall be evenly wetted to provide the correct suction. The masonry
surfaces should not be too wet but only damp at the time of plastering. The dampness
shall be uniform to get uniform bond between the plaster and the masonry surface.
Interior plain faced plaster - This plaster shall be laid in a single coat of 13mm
thickness. The mortar shall be dashed against the prepared surface with a trowel. The
dashing of the coat shall be done using a strong whipping motion at right angles to the
face of the wall or it may be applied with a plaster machine. The coat shall be
trowelled hard and tight forcing it to surface depressions to obtain a permanent bond
and finished to smooth surface. Interior plaster shall be carried out on jambs, lintel
and sill faces etc. as shown in the drawing and as directed by the GUDM.

Plain Faced Ceiling plaster - This plaster shall be applied in a single coat of 6mm
thickness. Application of mortar shall be as stipulated in above paragraph.

Exterior plain faced plaster - This plaster shall be applied in 2 coats. The first coat or
the rendering coat shall be approximately 14mm thick. The rendering coat shall be
applied as stipulated above except finishing it to a true and even surface and then
lightly roughened by cross scratch lines to provide bond for the finishing coat. The
rendering coat shall be cured for at least two days and then allowed to dry. The
second coat or finishing coat shall be 6 mm thick. Before application of the second
coat, the rendering coat shall be evenly damped. The second coat shall be applied
from top to bottom in one operation without joints and shall be finished leaving an
even and uniform surface. The mortar proportions for the coats shall be as specified in
the respective item of work. The finished plastering work shall be cured for at least 7
days.

Interior plain faced plaster 20mm thick if specified for uneven faces of brick walls or
for random/coursed rubble masonry walls shall be executed in 2 coats similar to the
procedure stipulated in above paragraph.

Exterior Sand Faced Plaster- This plaster shall be applied in 2 coats. The first coat
shall be approximately 14mm thick and the second coat shall be 6mm thick. These
coats shall be applied as stipulated above. However, only approved quality white sand
shall be used for the second coat and for the finishing work. Sand for the finishing
work shall be coarse and of even size and shall be dashed against the surface and
sponged. The mortar proportions for the first and second coats shall be as specified in
the respective items of work.

Wherever more than 20mm thick plaster has been specified, which is intended for
purposes of providing beading, bands, etc. this work shall be carried out in two or
three coats as directed by the GUDM duly satisfying the requirements of curing each
coat (rendering/floating) for a minimum period of 2 days and curing the finished work
for at least 7 days.

In the case of pebble faced finish plaster, pebbles of approved size and quality shall
be dashed against the final coat while it is still green to obtain as far as possible a
uniform pattern all as directed by the GUDM.

Where specified in the Drawings to be prepared by the Contractor prepared by the

Contractor, rectangular grooves of the dimensions indicated shall be provided in
external plaster by means of timber battens when the plaster is still in green
condition. Battens shall be carefully removed after the initial set of plaster and the
broken edges and corners made good. All grooves shall be uniform in width and depth
and shall be true to the lines and levels as per the Drawings to be prepared by the
Contractor prepared by the Contractor.

Curing of plaster shall be started as soon as the applied plaster has hardened
sufficiently so as not to be damaged when watered. Curing shall be done by
continuously applying water in a fine spray and shall be carried out for at least 7 days.
For waterproofing plaster, the Contractor shall provide the water-proofing admixture
as specified in manufacturer’s instruction while preparing the cement mortar.

For external plaster, the plastering operations shall be commenced from the top floor
and carried downwards. For internal plaster, the plastering operations for the walls
shall commence at the top and carried downwards. Plastering shall be carried out to
the full length of the wall or to natural breaking points like doors/windows etc. Ceiling
plaster shall be completed first before commencing wall plastering.

Double scaffolding to be used shall be as specified in clause 7.2.2.

The finished plaster surface shall not show any deviation more than 4mm when
checked with a straight edge of 2m length placed against the surface.

To overcome the possibility of development of cracks in the plastering work following

measures shall be adopted.
Plastering work shall be deferred as much as possible so that fairly complete drying
shrinkage in concrete and masonry works takes place.
Steel wire fabric shall be provided at the junction of brick masonry and concrete to
overcome reasonably the differential drying shrinkage/thermal movement.
Ceiling plaster shall be done, with a trowel cut at its junction with wall plaster.
Similarly trowel cut shall be adopted between adjacent surfaces where discontinuity
of the background exists.

Cement Pointing:
Material:
The cement mortar for pointing shall be in the proportion of 1:3 (one part of cement
to three parts of fine sand). Sand shall conform to IS: 1542 and shall be free from clay,
shale, loam, alkali and organic matter and shall be of sound, hard, clean and durable
particles. Sand shall be approved by GUDM and if so, directed it shall be
washed/screened to meet specification requirements.

Workmanship:
Where pointing of joints in masonry work is specified, the joints shall be raked at least
15mm/20mm deep in brick/stone masonry respectively as the work proceeds when the
mortar is still green.

Any dust/dirt in the raked joints shall be brushed out clean and the joints shall be
washed with water. The joints shall be damp at the time of pointing. Mortar shall be
filled into joints and well pressed with special steel trowels. The joints shall not be
disturbed after it has once begun to set. The joints of the pointed work shall be neat.
The lines shall be regular and uniform in breadth and the joints shall be raised, flat,
sunk or 'V' as may be specified in the respective items of work. No false joints shall be
allowed.

The work shall be kept moist for at least 7 days after the pointing is completed.
Whenever colored pointing has to be done, the coloring pigment of the colour required
shall be added to cement in such proportions as recommended by the manufacturer
and as approved by the GUDM.

Water-Proofing Admixtures;
Water-proofing admixture shall conform to the requirements of IS: 2645 and shall be
of approved manufacture. The admixture shall not contain calcium chloride. The
quantity of the admixture to be used for the works and method of mixing etc. shall be
as per manufacturer's instructions and as directed by the GUDM.
Painting of Concrete, Masonry & Plastered Surfaces:
Materials:
Oil bound distemper shall conform to IS: 428. The primer shall be alkali resistant
primer of the same manufacture as that of the distemper.

Cement paint shall conform to IS: 5410. The primer shall be a thinned coat of cement
paint. Lead free acid, alkali and chlorine resisting paint shall conform to IS: 9862.

Colour wash shall be made by addition of a suitable quantity of mineral pigment, not
affected by lime, to the prepared white wash to obtain the shade/tint as approved by
the GUDM.

All the materials shall be of the best quality from an approved manufacturer.
Contractor shall obtain prior approval of the GUDM for the brand of manufacture and
the colour/shade. All materials shall be brought to the site of works in sealed
containers.

Workmanship:
Contractor shall obtain the approval of the GUDM regarding the readiness of the
surfaces to receive the specified finish, before commencing the work on painting.
Painting of new surfaces shall be deferred as much as possible to allow for thorough
drying of the sub- strata.

The surfaces to be treated shall be prepared by thoroughly brushing them free from
dirt, mortar droppings and any loose foreign materials. Surfaces shall be free from oil,
grease and efflorescence. Efflorescence shall be removed only by dry brushing of the
growth. Cracks shall be filled with Gypsum. Workmanship of painting shall generally
conform to IS: 2395. Surfaces of doors, windows etc. shall be protected suitably to
prevent paint finishes from splashing on them.

White Wash:
The prepared surfaces shall be wetted and the finish applied by brushing. The
operation for each coat shall consist of a stroke of the brush first given horizontally
from the right and the other from the left and similarly, the subsequent stroke from
bottom upwards and the other from top downwards, before the first coat dries. Each
coat shall be allowed to dry before the next coat is applied. Minimum of 2 coats shall
be applied unless otherwise specified. The dry surface shall present a uniform finish
without any brush marks.

Colour Wash:
Colour wash shall be applied in the same way as for white wash. A minimum of 2 coats
shall be applied unless otherwise specified. The surface shall present a smooth and
uniform finish without any streaks. The finished dry surface shall not show any signs of
peeling/powdery and come off readily on the hand when rubbed.
Cement Paint:
The prepared surfaces shall be wetted to control surface suction and to provide
moisture to aid in proper curing of the paint. Cement paint shall be applied with a
brush with stiff bristles. The primer coat shall be a thinned coat of cement paint. The
quantity of thinner shall be as per manufacturer's instructions. The coats shall be
vigorously scrubbed to work the paint into any voids for providing a continuous paint
film free from pinholes for effective water proofing in addition to decoration. Cement
paint shall be brushed in uniform thickness and the covering capacity for two coats on
plastered surfaces shall be 3 to 4 kg/m2. A minimum of 2 coats of the same colour
shall be applied. At least 24 hours shall be left after the first coat to become
sufficiently hard before the second coat is applied. The painted surfaces shall be
thoroughly cured by sprinkling with water using a fog spray at least 2 to 3 times a day.
 Curing shall commence after about 12 hours when the paint hardens. Curing shall be
continued for at least 2 days after the application of final coat. The operations for
brushing each coat shall be as detailed above.

Oil bound Distemper:

The prepared surfaces shall be dry and provided with one coat of alkali resistant
primer by brushing. The surface shall be finished uniformly without leaving any brush
marks and allowed to dry for at least 48 hours. A minimum of two coats of oil bound
distemper shall be applied, unless otherwise specified. The first coat shall be of a
lighter tint. At least 24 hours shall be left after the first coat to become completely
dry before the application of the second coat. Broad, stiff, double bristled distemper
brushes shall be used for the work. The operations for brushing each coat shall be as
detailed above.

Acid, Alkali Resisting Paint:

A minimum of 2 coats of acid/alkali resisting paint shall be applied over the prepared
dry surfaces by brushing. Primer coat shall be as per manufacturer's instructions.

Plastic Emulsion Paint:

The prepared surface shall be dry and provided with one coat of primer which shall be
a thinned coat of emulsion paint. The quantity of thinner shall be as per
manufacturer's instructions. The paint shall be laid on evenly and smoothly by means
of crossing and laying off. The crossing and laying off consists of covering the area
with paint, brushing the surface hard for the first time over and then brushing
alternately in opposite directions two or three times and then finally brushing lightly
in a direction at right angles. In this process, no brush marks shall be left after the
laying off is finished. The full process of crossing and laying off constitutes one coat.
The next coat shall be applied only after the first coat has dried and sufficiently
become hard which normally takes about 2 to 3 hours. A minimum of 2 finishing coats
of the same colour shall be applied unless otherwise specified. Paint may also be
applied using rollers. The surface on finishing shall present a flat velvety smooth finish
and uniform in shade without any patches.

Acrylic Emulsion Paint:

Acrylic emulsion paint shall be applied in the same way as for plastic emulsion paint. A
minimum of 2 finishing coats over one coat of primer shall be provided unless
otherwise specified.
Painting & Polishing of Wood Work:
Materials:
 Wood primer shall conform to IS: 3536.
 Filler shall conform to IS: 110.
 Varnish shall conform to IS: 337.
 French polish shall conform to IS: 348.
 Synthetic enamel paint shall conform to IS: 2932.

All the materials shall be of the best quality from an approved manufacturer.
Contractor shall obtain prior approval of the GUDM for the brand of manufacture and
the colour/shade. All materials shall be brought to the site of works in sealed
containers.
 Workmanship:
The type of finish to be provided for woodwork of painting or polishing, the number of
coats, etc. shall be as specified in the respective items of work to be prepared by the
Contractor. Primer and finish paint shall be compatible with each other to avoid
cracking and wrinkling. Primer and finish paint shall be from the same manufacturer.
Painting shall be either by brushing or spraying. Contractor shall procure the
appropriate quality of paint for this purpose as recommended by the manufacturer.
The workmanship shall generally conform to the requirements of IS:2338 (Part I). All
the wood surfaces to be painted shall be thoroughly dry and free from any foreign
matter. Surfaces shall be smoothened with abrasive paper using it across the grains
and dusted off. Wood primer coat shall then be applied uniformly by brushing. The
number of primer coats shall be as specified in the item of work to be prepared by the
Contractor. Any slight irregularities of the surface shall then be made- up by applying
an optimum coat of filler conforming to IS:110 and rubbed down with an abrasive
paper for obtaining a smooth surface for the undercoat of synthetic enamel paint
conforming to IS:2932. Paint shall be applied by brushing evenly and smoothly by
means of crossing and laying off in the direction of the grain of wood. After drying,
the coat shall be carefully rubbed down using very fine grade of sand paper and wiped
clean before the next coat is applied. At least 24 hours shall elapse between the
applications of successive coats. Each coat shall vary slightly in shade and this shall be
got approved by the GUDM. The number of coats of paint to be applied shall be as
specified in the item of work to be prepared by the Contractor. All the wood surfaces
to be provided with clear finishes shall be thoroughly dry and free from any foreign
matter. Surfaces shall be smoothened with abrasive paper using it in the direction of
the grains and dusted off. Any slight irregularities of the surface shall be made up by
applying an optimum coat of transparent liquid filler and rubbed down with an
abrasive paper for obtaining a smooth surface. All dust and dirt shall be thoroughly
removed. Over this prepared surface, varnish conforming to IS:337 shall be applied by
brushing. Varnish should not be retouched once it has begun to set. Staining if
required shall be provided as directed by the GUDM. When two coats of varnish is
specified, the first coat should be a hard-drying undercoat or flatting varnish which
shall be allowed to dry hard before applying the finishing coat. The number of coats to
be applied shall be as specified. For works where clear finish of French polish is
specified the prepared surfaces of wood shall be applied with the polish using a pad of
woolen cloth covered by a fine cloth. The pad shall be moistened with polish and
rubbed hard on the surface in a series of overlapping circles to give an even finish over
the entire area. The surface shall be allowed to dry before applying the next coat.
Finishing shall be carried out using a fresh clean cloth over the pad, slight dampening
with methylated spirit and rubbing lightly and quickly in circular motions. The finished
surface shall have a uniform texture and high gloss. The number of coats to be applied
shall be as specified.

Painting of Steel Work:

Materials:
 Red-oxide – zinc chrome primer shall conform to IS: 2074.
 Synthetic enamel paint shall conform to IS: 2932.
 Aluminum paint shall conform to IS: 2339.

All the materials shall be of the best quality from an approved manufacturer.
Contractor shall obtain prior approval of the GUDM for the brand of manufacture and
the colour/shade. All the materials shall be brought to the site in sealed containers.

Workmanship:
Painting work shall be carried out only on thoroughly dry surfaces. Painting shall be
applied either by brushing or by spraying. Contractor shall procure the appropriate
quality of paint for this purpose as recommended by the manufacturer. The
workmanship shall generally conform to the requirement of IS: 1477 (Part 2).
The type of paint, number of costs etc. shall be as specified in the respective items of
work. Primer and finish paint shall be compatible with each other to avoid cracking
and wrinkling. Primer and finish paint shall be from the same manufacturer. All the
surfaces shall be thoroughly cleaned of oil, grease, dirt, rust and scale. The methods
to be adopted using solvents, wire brushing, power tool cleaning etc., shall be as per
IS: 1477 (Part – I) and as indicated in the item of work. It is essential to ensure that
immediately after preparation of the surfaces; the first coat of red oxide-zinc chrome
primer shall be applied by brushing and working it well to ensure a continuous film
without holidays. After the first coat becomes hard dry, a second coat of primer shall
be applied by brushing to obtain a film free from `holidays. After the second coat of
primer is hard dry, the entire surface shall be wet rubbed cutting down to a smooth
uniform surface. When the surface becomes dry, the undercoat of synthetic enamel
paint of optimum thickness shall be applied by brushing with minimum of brush marks.
The coat shall be allowed too hard-dry. The under coat shall then be wet rubbed
cutting down to a smooth finish, taking adequate care to ensure that at no place the
undercoat is completely removed. The surface shall then be allowed to dry. The first
finishing coat of paint shall be applied by brushing and allowed too hard-dry. The gloss
from the entire surface shall then be gently removed and the surface dusted off. The
second finishing coat shall then be applied by brushing. At least 24 hours shall elapse
between the applications of successive coats. Each coat shall vary slightly in shade
and this shall be got approved by the GUDM.

Flashing:
Materials:
Anodized Aluminum sheets shall be 1.00mm thick with anodic film thickness of 0.025
mm.

Galvanized mild steel sheets shall be 1.00mm thick with zinc coating of 800 gms/sq.m.

Bitumen felt shall be either Hessian base self-finished bitumen felt Type-3 Grade I
conforming to IS:1322 or glass fiber base self-finished felt Type-2 Grade 1 conforming
to IS:7193.

Workmanship:
The type of the flashing and method of fixing shall be as specified.
Flashing shall be of the correct shape and size as indicated in the construction
Drawings to be prepared by the Contractor and they shall be properly fixed to ensure
their effectiveness.
Flashing shall be of long lengths so as to provide minimum number of joints. The
minimum overlap at joints shall be 100mm.
Fixing of the flashing shall be either by bolting with bitumen washers or by tucking
into the groove 75 mm wide x 65 mm deep in masonry/concrete along with cement
mortar 1:4 filleting as indicated in the Drawings to be prepared by the Contractor.
Curing of the mortar shall be carried out for a minimum period of 4 days.
Bitumen felt flashing of the type as specified shall be provided with 2 coats of
bituminous paint at the rate of 0.10 liter/m2after the installation.

Thermal Insulation for Ceiling

Thermal insulation shall be “Thermocole” TF type or similar approved or Resin bonded
fiber glass boards.
 Fixing:
“Thermocole” Boards:
Soffit of R.C. Slab shall be thoroughly cleaned with wire brush and 85/25 industrial
grade hot bitumen conforming to IS: 702 shall be applied uniformly over the surface at
the rate of 1.5 Kg/m2.

Thermocole boards (T.F. variety) of 50mm thickness shall be stuck by means of the
same grade of hot bitumen. The boards shall be further secured with screws, washers
and plugs. The joints of the boards shall be sealed with bitumen.

Fiber Glass Boards:

Timber pegs 50mm x 50mm x 50mm shall be fixed to the slab at 600mm centers with
6mm x 65mm long wood screws. 20-gauge G.I. lacing wire shall be tied to the pegs.

`Crown’ 200 fiberglass boards 50mm thick shall be stuck to the pegs with CPRX
compound or any other suitable adhesive and be held in position by the 20-gauge G.I.
lacing wires. The insulation boards shall be covered with 20mm – 24 gauge hexagonal
G.I. chicken wire mesh, nailed to the timber pegs and 30 gauge aluminum sheets shall
be fixed over the chicken wire mesh with 50mm overlap and secured to the timer pegs
by screws. If the insulation is specified to rest on top of the false ceiling, it shall be
properly installed and anchored to the framework. In case additional battens are
required for proper installation, Contractor shall include its cost in the rate for
insulation.

Plaster of Paris Board for False Ceiling:

Materials:
Plaster of Paris Boards:
 The plaster of Paris boards to be used in the false ceiling shall be of an approved
manufacture or manufactured at site by methods and materials approved by GUDM.
 The plaster of Paris shall be of the calcium-sulphate hemi-hydrate variety and shall
contain not less than 35 percent Sulphur trioxide and other requirements as per
IS:2547 (Part I) However, its fineness shall be such that the residue, after drying, and
sieving on I.S. sieve designation 3.35mm for 5 minutes shall not be more than 1
percent by weight. Initial setting time shall not be less than 13 minutes. The average
compressive strength of plaster determined by testing 5 cm cubes 24 hours after
removal from molds and drying in an oven at 40 Deg. C till the weight of the cubes is
constant, shall not be less than 84 Kg per sq.cm.
 The plaster of Paris boards reinforced with hessian cloth or coir shall be prepared in
suitable sizes as shown on the drawings or as directed by GUDM. Wooden forms of
height equal to the thickness of boards shall be placed on truly level and smooth
surface such as a glass sheet. The edges of the boards shall be truly square. The glass
sheet or surface on which form is kept and the form sides shall be given a thin coat of
non-staining oil to facilitate the easy removal of the board. Plaster of Paris shall be
evenly spread into the form up to about half the depth and hessian cloth or coir shall
be pressed over the plaster of Paris layer. The weight of hessian cloth or coir in the
board shall be 250gm per sq.m. The ends of the hessian/coir reinforcement shall be
turned over at all edges to form a double layer for a width of 50mm. The hessian
cloth shall be of an open web texture so as to allow the plaster below and above to
intermix with each other and form an integral board. The form shall then be filled
with plaster of Paris which shall be uniform pressed and then wire cut to an even and
smooth surface. The board shall then be allowed to set initially for an hour or so and
then removed from the form and allowed to dry and harden for about a week. The
board after drying and hardening shall give a ringing sound when struck. The boards
shall be true and exact to shape and size and the exposed face shall be truly plane and
smooth.
 The size of boards shall generally be 600mm x 600 mm x 12 mm thick. Boards shall be
kept dry in transit and stored flat in a clean dry place and shall not be exposed to
moisture. The boards shall always be carried on edges.

Timber Frame Work:

Timber for frame work of false ceiling grid and hangers shall be of good quality and
well-seasoned. It shall have uniform colour, reasonably straight and close grains and
shall be free from knots, cracks and sapwood. It shall be treated with approved anti-
termite preservative as directed by the GUDM. Extreme care shall be taken so that
the preservative treatment does not stain the ceiling boards. In case metal hangers
are used, these shall be M.S. flats or bars, having two coats of red oxide zinc chromate
paint primer, as shown on drawings or as approved by GUDM.

Metal Frame Work:

The metal frame work may be made of sections of light metal, such as anodized
aluminum, mild steel or as shown on the drawings. The shape of cross-section shall be
such as to facilitate proper suspension and proper fixing of the ceiling boards covering
them and shall be structurally sound and rigid.

Construction:
 Contractor shall ensure that the frame to support the ceiling is designed for structural
strength and the sizes, weight and strength of ceiling boards to be fixed and other
loads due to live load, air-conditioning ducts, grills, electrical wiring and lighting
fixtures, thermal insulation, etc. as shown on the drawings. Contractor shall also
submit a detailed drawing to show the grid work, sizes of grid members, method of
suspension, position of openings for air-conditioning and lighting, access doors, etc.
 Structural design of timber member for the frame shall be in accordance with IS: 883,
and metal sections shall be of appropriate size and thickness and shall be of approved
manufacture, all as approved by GUDM.
 The false ceiling grid work shall be carried out as per the approved drawings or as
directed by GUDM. In case of timber grid work, the grid work shall consist of teak
wood runners of minimum size 60mm deep x 40mm wide along one direction at 1.2m
center to center and secondary runners of size 50mm deep x 40 mm wide at 60mm
center to center perpendicular to the main runners.
 The timber grid work shall be suspended with the help of wooden hangers or metal
hangers at 1.2m center to center in both the directions. Wooden hangers shall be
adopted for flat R.C. roof slab structures whereas metal hangers for flat R.C. roof or
structural steel floors / tresses. Metal hangers shall be fabricated from mild steel /
galvanized flats of 35mm x 6mm size or bars of 10mm dia. Threaded at the lower end
and anchored securely in the roof concrete or welded to inserts provided on the
underside of slabs, beams etc. All M.S. hangers shall be given two coats of red oxide
zinc chromate paint primer. In case the roof work is of A.C. sheeting supported on
purlins and trusses; hangers shall be suspended from roof steel work. The
arrangement of metal hangers shall be such that the level of false ceiling can be
adjusted during fixing of the ceiling frame work. The ceiling frame work shall be
secured to hangers by means of washers and nuts. The ends of main runners shall
preferably be embedded into the masonry work.
 The metal frame work when it is anodized aluminum false ceiling grid system shall
consist of aluminum main member of special T-Profile of 38mm x 38mm x 1.5mm
thick, interlocking with each other to form frames of various sizes, 600mm x 600 mm
or as shown on the drawing. The main members shall be suspended from the roof
structures by means of steel hangers as described for timber frame work and
supported at the walls by means of anodized aluminum wall angles.
 In the case of timber frame work, all the edges of the plaster of Paris board shall be
fixed to frame members by means of counter sunk and rustles screws of 2.74 mm size,
40mm long at a spacing of 100mm to 150 mm c/c and 12mm from the edge of the
board. Holes for screws shall be drilled and screws slightly countersunk into the
 boards. The boards shall be fixed to wooden framework with a joint clearance of
about 3mm. The joints shall always be in perfect line and plane.
 In case of aluminum grid system, boards shall be just placed into the frames formed by
the main `T’ members and the cross members fitted with the clips for locking boards.
Contractor shall take utmost care so as not to force the boards in position and a slight
gap shall be provided so as not to make a tight joint. The boards shall be cut with a
saw, if required, to any shape and size.
 As the work of false ceiling may be inter-connected with the work of air-conditioning
ducts and lighting, Contractor shall fully co-operate with the other agencies entrusted
with the above work, who may be working simultaneously. Contractor shall provide
necessary openings in the false ceiling work for air-conditioning, lighting and other
fixtures. Additional framing, if required, for the above opening shall also be provided
at no extra cost to Employer. Removable or hinged type inspection or access trap
doors shall be provided at locations specified by GUDM.

Finishing:
It is essential that false ceiling work should be firm and in perfect line and level and
all boards free from distortion, bulge, and other defects. All defective boards and
other material shall be removed from site immediately and replaced, and ceiling
restored to original finish to the satisfaction of GUDM. The workmanship shall be of
highest order and all joinery work for timber work shall be in the best workmanship
manner. The joints for aluminum frame work shall be of inter-locking type so that
when the cross member is in place, it cannot be lifted out. The countersunk heads of
screws and all joints shall be filled with plaster of Paris and finished smooth. After
filling the joints, a thick skin of the finishing material shall be spread about 50mm
wide on either side of the joint and on to it shall be trowelled dry a reinforcing scrim
cloth about 10mm wide. If metal scrim is used, a stiffer plaster will be necessary to
enable the Trowelling of the scrim down to the board.

Fire Stopping:
In case of fire protective ceilings, fire resisting barriers at suitable intervals shall be
provided. These shall completely close the gap between the false ceiling and soffit of
the structural slab. The material of the barrier shall be as indicated by GUDM
(Reference may be made to the British Standards Institutions CP 290: Code of Practice
for suspended ceiling and lining of dry construction using metal fixing system, for
guidance).

False or Cavity Floor;

Frame Work:

The false floor shall consist of a framework of suitable structural member designed to
carry the loads specified. This frame work shall be supported on suitably designed
stools placed at 600mm center to center in both directions. The stools shall consist of
a mild steel base plate with a mild steel stud having adjustable lock nut and coupling
at the center and another mild steel plate at top serving as a prop head. The above
framework shall be suitably designed to accommodate 35mm thick, 600mm square
panels. The base plate shall be fixed to the reinforced concrete floor with an
approved adhesive compound or with 4 Nos. 6mm dia. Anchor fasteners. Bedding of
1:2 or richer cement sand mortar shall be provided locally under the base plates of
stools to provide a level surface.

The prop head shall be provided with mild steel lugs welded on top and each placed
perpendicular to the other for proper positioning and supporting the main and cross
members. The stools shall be capable of adjustment to accommodate concrete floor
level irregularities up to plus or minus 15mm. The framing members shall be
completely removable and shall remain in position without screwing or bolting to the
prop heads. All steel framework including steel stools shall be given a coat of zinc
chromate primer and two coats of enamel paint of approved colour and shade.
Floor Panels:
The floor panels shall be made of 600mm x 600mm x 35 mm thick medium density
unvineared/ non-prelaminated teak wood particle boards having a density of not more
than 800 kg/cu.m bonded with boiling water proof phenol formaldehyde synthetic
resin and shall be of fire resistant, termite resistant and moisture proof quality,
generally conforming to IS:3087-specification for wood particle boards (Medium
Density )for general purposes.

The thermal conductivity of the boards shall not exceed 0.12

kCal/hrs./sq.m/deg./C/m. The panel size given above may be suitably modified near
electrical panel/equipment and also to suit room dimensions with panel size not more
than 600mm under any circumstances. Exposed 2mm thick vinyl edging shall be
provided on all edges of individual panels. Each panel shall be given a coat or primer
and two coats of approved fire-resistant paint from underside. The particle boards
shall be faced with 600mm x 600 mm x 2mm thick approved make flooring tiles
conforming to IS:3462 – “Specification for unbaked flexible PVC flooring” and of
approved colour and shade. The completed panel shall be completely removable and
shall remain in position without screwing or bolting to the on the inner side with
stickers for easy identification and reassembly whenever required. Suitable backing
material shall be provided on the underside of the particle board to prevent warping
and / or to cater to specified loading. Suitable removable covers shall be provided to
serve as outlets for the cables.

Imposed Loading:

The finished floor shall be capable of supporting uniformly distributed loads of 500 to
1000 Kg. per m2of floor area as specified in data sheet. A point load of 450 Kg on 600
sq.mm on any part of the panel or a line load of 725 Kg on 100mm strip across the
panel length shall not result in a deflection greater than 2.5mm.

Finish:
The finished floor shall be true to lines and levels and present a neat flush surface.
Vendor Drawing:
Vendor shall prepare and submit a layout drawing for false floor giving all details
including supporting system for approval. If so called for, vendor shall also submit his
calculations for the supporting system with all relevant data assumed, to the GUDM for
his approval. Work shall be carried out on approved drawings only.

Fire Proof Doors:

Material and Workmanship:

The design of fire proof doors and the materials to be used in their fabrication have to
be such that they shall be capable of providing the effective barrier to the spread of
fire. The materials, fabrication and erection of fire proof doors shall confirm to
IS:3614 (Part–I). The fire proof doors shall be obtained from an approved
manufacturer. Specific approval for such purchase shall be obtained beforehand.
Sample approval shall also be obtained from testing authority as per the standard IS:
3614 (Part–2) for the specified degree of fire rating in hours. All fire proof doors shall
have specified sizes and confirm to the description in the respective items of work.

Fire proof door shutters shall be of zinc coated weldable steel (confirming to BS: 6687)
or stainless steel (conforming to IS: 304) sheet (18G minimum) fixed in a frame work of
rolled channel. The shutter shall consist of an insulating material like mineral wool in
required thickness to satisfy the specified fire rating. Normally the thickness of door
shutter shall not be less than 35mm for two hour fire rating and 46 mm for four hour
fire rating. The shutter with the required insulating material shall be mounted on
angle iron frame or the special made frame from zinc coated (16G minimum) weldable
steel sheet. The shutter shall be fixed to frame by means of suitable hinges and shall
have a three way latching system. All the doors shall be provided with a coat of
primer and one coat of synthetic enamel paint to attain the specified fire rating. All
other accessories like hinges, door lock, hold fasts, etc. shall be provided as approved
by TAC (Tariff Advisory Committee). All these accessories shall be compatible with
the material used for door and shutter.
 SPECIFICATIONS
: SECTION - 5:

: STRUCTURAL STEEL WORK:

 SECTION - 5 :
STRUCTURAL STEEL WORK

Applicable Codes and Specifications:

The supply, fabrication, erection and painting of structural steel works shall comply with the
following specifications, standards and codes unless otherwise specified herein. All
standards, specifications and codes of practices referred to herein shall be the latest editions
including all applicable official amendments and revisions.

IS : 808
Dimensions for Hot Rolled Steel sections
IS : 814 Covered Electrodes for Manual Metal Arc Welding of Carbon and Carbon
Manganese Steel
IS : 800
Code of Practice for General Construction in Steel
IS : 801 Code of Practice for Use of Cold Formed Light Gauge Steel Structural Members
in General Building Construction
IS : 806
Code of Practice for Use of Steel Tubes in General Building Construction
IS : 7205
Safety Code for Erection of Structural Steel Work
IS : 7215
Tolerances for Fabrication of Steel Structures
IS : 4000
High Strength Bolts in Steel Structure – Code of Practice
AISC
Specifications for Design, Fabrication and Erection of Buildings
IS : 1161
Steel Tubes for structural purposes
IS:10 Ready Mixed paint, Brushing, Red Lead, Non-setting, Priming.
IS:102
IS:110
Ready Mixed paint, brushing, grey filler for enamels for use over primers.
IS:117 Ready Mixed paint, Brushing, Finishing, and Exterior Semigloss for general
purposes, to Indian Standard colours.
IS:158 Ready Mixed paint, Brushing, Bituminous, Black, Lead free, Acid, Alkali and
heat resisting.
IS:159 Ready Mixed paint, Brushing, Acid resisting for protection against acid fumes,
colour as required.
IS:341
Black Japan, Types A, B and C
IS:2339
Aluminum paint for general purposes, in Dual container

IS:2932 Specification for enamel, synthetic, exterior, type 1,

(a) Undercoating, (b) finishing
IS:2933 Specification for enamel, exterior, type 2,
(a) Undercoating, (b) finishing.
IS:5905
Sprayed aluminum and zinc coatings on Iron and Steel.
IS:6005
Code of practice for phosphating of Iron and Steel.
IS:9862 Specification for ready mixed paint, brushing, bituminous, black, lead free,
acid, alkali, water & chlorine resisting.
IS:13183
Aluminum paint, Heat resistant.
SIS-05-5900
(Swedish Standard)
IS : 1239
Mild steel tubes, tubulars and other Wrought steel fittings

Part 1 – Mild steel tubes

Part 2 – Mild steel tubulars and other wrought steel pipe fittings
IS : 1363
Hexagon Head Bolts, Screws and Nuts of product Grade C (Size range M5 to
(Parts 1 to 3) M64)

IS : 1367
Technical Supply Conditions for Threaded Fasteners
(All parts)

IS : 1852
Rolling and Cutting Tolerances for Hot Rolled Steel Products
IS : 1977
Structural Steel (Ordinary Quality)
IS : 2062
Steel for General Structural Purposes
IS : 2074
Ready Mixed Paint, Air drying, Red Oxide Zinc Chrome and Priming
IS : 3502
Steel Chequered Plate
IS : 3757
High Strength Structural Bolts
IS : 5369
General Requirements for Plain Washers and Lock Washers
IS : 5372
Taper Washers for Channels
IS : 5374
Taper Washer for 1 Beams
IS : 6610
Heavy Washers for Steel Structures
IS : 8500
Structural Steel-micro alloyed (medium and high strength qualities)
IS : 803 Code of practice for design, fabrication and erection of vertical mild steel
cylindrical welded storage tanks
IS : 816 Code of Practice for use of Metal Arc Welding for General construction in Mild
Steel
IS : 822
Code of Procedure for Inspection of Welds
IS : 1182 Recommended Practice for Radiographic examination of Fusion – Welded Butt
Joints in Steel Plates
IS : 1200
Method of Measurement in Building Civil Works
IS : 1477
Code of Practice for Painting of (Parts 1&2) Ferrous Metals in Buildings
IS : 2595
Code of Practice for Radiographic Testing
IS : 3658
Code of Practice for Liquid Penetrate Flaw Detection
IS : 5334
Code of Practice for Magnetic Particle Flaw Detection of Welds
IS : 9595 Recommendations for Metal Arc Welding of Carbon and Carbon Manganese
Steel

Steel Materials:
Steel materials shall comply with the referred to in Sub-Clause 4.1.
All materials used shall be new, unused and free from defects.

Steel conforming to IS: 1977 shall be used only for the following:
Fe310-0 For general purposes such as door/window frames, grills, steel gates,
handrails, fence posts, tee bars and other non-structural use.
(St 32-0)

Fe410-0 For structures not subjected to dynamic loading other than wind loads such

(St 42-0) as: Platform roofs, foot over bridges, building, factory sheds etc.

Fe510-0 Grade steel shall not be used

(St 42-0)

a) If welding is to be employed for fabrication

b) If site is in severe earthquake zone
c) If plastic theory of design is used

Drawings prepared by the VENDOR/CONTRACTOR:

The VENDOR/CONTRACTOR shall prepare all fabrication and erection drawings for the entire
work. All the drawings for the entire work shall be prepared in metric units. The drawings
shall preferably be of one standard size and the details shown there in shall be clear and
legible.

All fabrication drawings shall be submitted to the Engineer-In-Charge for approval.

No fabrication drawings will be accepted for Engineer In charge’s approval unless checked and
approved by the VENDOR/Contractor’s qualified structural engineer and accompanied by an
erection plan showing the location of all pieces detailed. The VENDOR/CONTRACTOR shall
ensure that connections are detailed to obtain ease in erection of structures and in making
field connections.

Fabrication shall be started by the VENDOR/CONTRACTOR only after Engineer In charge’s

approval of fabrication drawings. Approval by the Engineer-In-Charge of any of the drawings
shall not relieve the VENDOR/CONTRACTOR from the responsibility for correctness of
engineering and design of connections, workmanship, fit of parts, details, material, errors or
omissions or any and all work shown thereon. The Engineer In charge’s approval shall
constitute approval of the size of members, dimensions and general arrangement but shall
not constitute approval of the connections between members and other details.

The drawings prepared by the VENDOR/CONTRACTOR and all subsequent revisions etc. shall
be at the cost of the VENDOR/CONTRACTOR for which no separate payment will be made.

Fabrication:
General:
All workmanship and finish shall be of the best quality and shall conform to the best-approved
method of fabrication. All materials shall be finished straight and shall be machined/ground
smooth true and square where so specified. All holes and edges shall be free of burrs.
Shearing and chipping shall be neatly and accurately done and all portions of work exposed to
view shall be neatly finished. Unless otherwise approved by the Engineer-In-Charge, reference
may be made to relevant IS codes for providing standard fabrication tolerance. Material at
the shops shall be kept clean and protected from weather.
Connections:
Shop/field connections shall be as per approved fabrication drawings. In case of bolted
connections, taper washers or flat washers or spring washers shall be used with bolts as
necessary. In case of high strength friction grip bolts, hardened washers to be used under the
nuts or the bolt heads whichever are turned to tighten the bolts. The length of the bolt shall
be such that at least one thread of the bolt projects beyond the nut, except in case of high
strength friction grip bolts where this projection shall be at least three times the pitch of the
thread.

In all cases where bearing is critical, the unthreaded portion of bolt shall bear on the
members assembled. A washer of adequate thickness may be provided to exclude the threads
from the bearing thickness, if a longer grip bolt has to be used for this purpose.

All connections and splices shall be designed for full strength of members or loads. Column
splices shall be designed for the full tensile strength of the minimum cross section at the
splice.

All bolts, nuts, washers, electrodes, screws etc., shall be supplied/brought to site 10% in
excess of the requirement in each category and size. Rates shall cover the cost of this extra
quantity.

All members likely to collect rainwater shall have drain holes provided.

Straightening:
All materials shall be straight and, if necessary, before being worked shall be straightened
and/or flattened by pressure and shall be free from twists. Heating or forging shall not be
resorted to without the prior approval of the Engineer-In-Charge in writing.

Rolling and Forming:

Plates, channels, R.S.J. etc., for circular bins, bunkers, hoppers, gantry girders, etc., shall be
accurately laid off and rolled or formed to required profile/shape as called for on the
drawings. Adjacent sections shall be match-marked to facilitate accurate assembly, welding
and erection in the field.

High Strength Friction Grip Bolting:

Inspection after tightening of bolts shall be carried out as stipulated in the appropriate
standards depending upon the method of tightening and the type of bolt used.
Welding:
Welding procedure shall be submitted to the Engineer-In-Charge for approval. Welding shall
be entrusted to qualified and experienced welders who shall be tested periodically and
graded as per IS 817, IS: 7310 (Part 1) and IS: 7318 (Part 1).

While fabricating plated beams and built up members, all shop splices in each component
part shall be made before such component part is welded to other parts of the members.
Wherever weld reinforcement interferes with proper fit-up between components to be
assembled off welding, these welds shall be ground flush prior to assembly.

Approval of the welding procedure by the Engineer-In-Charge shall not relieve the Contractor
of his responsibility for correct and sound welding without undue distortion in the finished
structure.
No welding shall be done when the surface of the members is wet nor during periods of high
wind.

Each layer of a multiple layer weld except root and surfaces runs may be moderately penned
with light blows from a blunt tool. Care shall be exercised to prevent scaling or flaking of
weld and base metal from overweening.

No welding shall be done on base metal at a temperature below –50 C. Base metal shall be
preheated to the temperature as per relevant IS codes.

Electrodes other than low-hydrogen electrodes shall not be permitted for thickness of 32 mm
and above.

All welds shall be inspected for flaws by any of the methods described under Sub-clause
4.6.3. The choice of the method adopted shall be agreed with the Engineer-In-Charge.

The correction of defective welds shall be carried out in a manner approved by the Engineer-
In-Charge without damaging the parent metal. When a crack in the weld is removed,
magnetic particle inspection or any other equally positive means approved by the Engineer-In-
Charge shall be used to ensure that the whole of the crack and material up to 25 mm beyond
each end of the crack has been removed. The cost of all such tests and operations incidental
to correction shall be borne by the Contractor.

Tolerances:
The dimensional and weight tolerances for rolled shapes shall be in accordance with ARE:
1852 for indigenous steel and equivalent applicable codes for imported steel. The tolerances
for fabrication of structural steel shall be as per ARE: 7215.

Cutting, punching, drilling, welding and fabrication tolerances shall be generally as per
relevant IS codes.

End Milling:
Where compression joints are specified to be designed for bearing, the bearing surfaces shall
be milled true and square to ensure proper bearing and alignment.

Inspection:
General:

The Contractor shall give due notice to the Engineer-In-Charge in advance of the works being
made ready for inspection. All rejected material shall be promptly removed from the shop
and replaced with new material for the Engineer In charge’s inspection. The fact that certain
material has been accepted at the Contractor’s shop shall not invalidate final rejection at site
by the Engineer-In-Charge if it fails to conform to the requirements of these specifications, to
be in proper condition or has fabrication inaccuracies which prevent proper assembly nor shall
it invalidate any claim which the Employer may make because of defective or unsatisfactory
materials and/or workmanship.

No materials shall be painted or dispatched to site without inspection and approval by the
ENGINEER INCHARGE unless such inspection is waived in writing by the ENGINEER-IN-CHARGE.

The Contractor shall provide all the testing and inspection services and facilities for shop
work except where otherwise specified.
For fabrication work carried out in the field the same standard of supervision and quality
control shall be maintained as in shop fabricated work. Inspection and testing shall be
conducted in a manner satisfactory to the Engineer-In-Charge.

Inspection and tests on structural steel members shall be as set forth below.

Material Testing:
If mill test reports are not available for any steel materials the same shall be tested by the
Contractor to the Employer’s Representative’s satisfaction to demonstrate conformity with
the relevant specification.

Tests on Welds:
(a) Magnetic Particle Test:
Where welds are examined by magnetic particle testing, such testing shall be carried out in
accordance with relevant IS codes. If heat treatment is performed, the completed weld shall
be examined after the heat treatment. All defects shall be repaired and retested. Magnetic
particle tests shall be carried out using alternating current. Direct current may be used with
the permission of the Engineer-In-Charge.

(b) Liquid Penetrate Inspection:

In the case of welds examined by Liquid Penetrate Inspection, such tests shall be carried out
in accordance with relevant IS Code. All defects shown shall be repaired and rechecked.

(c) Radiographic Inspection:

All full strength butt welds shall be radio graphed in accordance with the recommended
practice for radiographic testing as per relevant IS code.

Dimensions, Workmanship & Cleanliness:

Members shall be inspected at all stages of fabrication and assembly to verify that
dimensions, tolerances, alignment, surface finish and painting are in accordance with the
requirements shown in the Contractor’s approved fabrication drawings.

Test Failure:
In the event of failure of any member to satisfy inspection or test requirement, the
Contractor shall notify the Engineer-In-Charge. The Contractor must obtain permission from
the Engineer-In-Charge before any repair is undertaken. The quality control procedures to be
followed to ensure satisfactory repair shall be subject to approval by the Engineer-In-Charge.

The Engineer-In-Charge has the right to specify additional testing as he deems necessary, and
the additional cost of such testing shall be borne by the Employer, only in case of successful
testing.

The Contractor shall maintain records of all inspection and testing which shall be made
available to the Engineer-In-Charge.

Shop Matching:
For structures like bunkers, tanks, etc. Shop assembly is essential. For other steel work,
such as columns along with the tie beams/bracings may have to be shop assembled to ensure
satisfactory fabrication, obtaining of adequate bearing areas etc., if so desired by the
Engineer-In-Charge. All these shop assemblies shall be carried out by the Contractor.

Drilling Holes for other works:

As a part of this Contract, holes in members required for installing equipment or steel
furnished by other manufacturers or other contractors shall be drilled by the
VENDOR/CONTRACTOR at no extra cost of the EMPLOYER. The information for such extra
holes will be supplied by the EMPLOYER/ENGINEER-IN-CHARGE.

Marking of Members:
After checking and inspection, all members shall be marked for identification during erection.
This mark shall correspond to distinguishing marks on approved erection drawings and shall be
legibly painted and stamped on it. The erection mark shall be stamped with a metal dye with
figures at least 20 mm high and to such optimum depth as to be clearly visible.

All erection marks shall be on the outer surface of all sections and near one end, but clear of
bolt holes. The marking shall be so stamped that they are easily discernible when sorting out
members. The stamped marking shall be encircled boldly by a distinguishable paint to
facilitate easy location.

Erection marks on like pieces shall be in identical locations. Members having lengths of 7.0 m
or more shall have the erection mark at both ends.

Errors:
Any error in shop fabrication which prevents proper assembling and fitting up of parts in the
field by moderate use of drift pins or moderate amount of reaming will be classified by the
Engineer-In-Charge as defective workmanship. Where the Engineer-In-Chargerejects such
material or defective workmanship, the same shall be replaced by materials and workmanship
conforming to the Specifications by the Contractor, at no cost to the Employer.

Painting of Steel Work:

All fabricated steel material, except those galvanized shall receive protective paint coating
as specified in specification, which is described below.

Materials:

Red-oxide – zinc chrome primer shall conform to IS: 2074.

Synthetic enamel paint shall conform to IS: 2932.
Aluminum paint shall conform to IS: 2339.
All the materials shall be of the best quality from an approved manufacturer. Contractor
shall obtain prior approval of the Engineer-In-Charge for the brand of manufacture and the
colour/shade. All the materials shall be brought to the site in sealed containers.

Workmanship:

Painting work shall be carried out only on thoroughly dry surfaces. Painting shall be applied
either by brushing or by spraying. Contractor shall procure the appropriate quality of paint
for this purpose as recommended by the manufacturer. The workmanship shall generally
conform to the requirement of IS: 1477 (Part 2).

The type of paint, number of costs etc. shall be as specified in the respective items of work.
Primer and finish paint shall be compatible with each other to avoid cracking and wrinkling.
Primer and finish paint shall be from the same manufacturer. All the surfaces shall be
thoroughly cleaned of oil, grease, dirt, rust and scale. The methods to be adopted using
solvents, wire brushing, power tool cleaning etc., shall be as per IS: 1477 (Part – I) and as
indicated in the item of work. It is essential to ensure that immediately after preparation of
the surfaces; the first coat of red oxide-zinc chrome primer shall be applied by brushing and
working it well to ensure a continuous film without holidays. After the first coat becomes
hard dry, a second coat of primer shall be applied by brushing to obtain a film free from
`holidays’.
After the second coat of primer is hard dry, the entire surface shall be wet rubbed cutting
down to a smooth uniform surface. When the surface becomes dry, the undercoat of synthetic
enamel paint of optimum thickness shall be applied by brushing with minimum of brush
marks. The coat shall be allowed to hard dry. The under coat shall then be wet rubbed
cutting down to a smooth finish, taking adequate care to ensure that at no place the
undercoat is completely removed. The surface shall then be allowed to dry.

The first finishing coat of paint shall be applied by brushing and allowed to hard dry. The
gloss from the entire surface shall then be gently removed and the surface dusted off. The
second finishing coat shall then be applied by brushing.

At least 24 hours shall elapse between the applications of successive coats. Each coat shall
vary slightly in shade and this shall be got approved by the Engineer-In-Charge.

Acceptance of Steel, its Handling & Storage:

The Contractor shall carefully check the steel to be erected at the time of acceptance. Any
fabrication defects observed should be brought to the notice of the Engineer-In-Charge.

No dragging of steel shall be permitted. All steel shall be stored 300mm above ground on
suitable packing to avoid damage. It shall be stored in the order required for erection, with
erection marks visible. All storage areas shall be prepared and maintained by the Contractor.
Steel shall not be stored in the vicinity of areas where excavation or grading will be done and,
if so stored temporarily, this shall be removed by the Contractor well before such excavation
and/or grading commences to a safe distance to avoid burial under debris. Scratched or
abraded steel shall be given a coat of primer in accordance with the Specifications for
protection after unloading and handling prior to erection. All milled and machined surfaces
shall be properly protected from rust/corrosion by suit able coating and also from damage.

Anchor Bolts & Foundations:

The Contractor shall carefully check the location and layout of anchor bolts embedded in
foundations constructed, to ensure that the structures can be properly erected as shown on
the drawings. Any discrepancy in the anchor bolts/foundation shall be reported to the
Engineer-In-Charge.

Leveling of column bases to the required elevation may be done either by providing shims or
three nuts on the upper threaded portion of the anchor bolt. All shim stock required for
keeping the specified thickness of grout and in connection with erection of structures on
foundations, crane brackets or at any other locations shall be of good M.S. plates and shall be
supplied by the Contractor at his cost.

A certain amount of cleaning of foundations and preparing the area is considered normal and
shall be carried out by the Contractor at no extra cost. Here beams bear in pockets or on
walls; bearing plates shall be set and leveled as part of the work. All grouting under column
base plates or beam bearing plates will be carried out by the Contractor.

Assembly & connections:

Field connections may be effected by riveting, bolting, welding or by use of high strength
friction grip bolts as shown on the design and erection drawings.

All field connection work shall be carried as per the drawings. All bolts, nuts, washers, rivets,
electrodes required for field connections shall be supplied by the Contractor free of cost. All
assembling shall be carried on a level platform. Drifts shall be used only for drawing the work
to proper position and must not be used to such an extent as to damage the holes. Size of
drifts larger than the normal diameter of hole shall not be used. Any damaged holes or burrs
must be rectified to the satisfaction of the Engineer-In-Charge.

Corrections of minor misfits and reasonable amount of reaming and cutting of excess stock
from rivets shall be considered as a part of erection. Any error in the shop, which prevents
proper fit on a moderate amount of reaming and slight chipping or cutting, shall be
immediately reported to the Engineer-In-Charge.

Erection:
All structural steel shall be erected as shown on the drawings prepared by the Contractor.
Proper size steel cable slings, etc., shall be used for hoisting. Guys shall not be anchored to
existing structures, foundations, etc., unless so permitted by the Engineer-In-Charge in
writing. Care shall be taken to see that ropes in use are always in good condition.

Steel columns in the basement, if any, are to be lowered and erected carefully with the help
of a crane and/or derrick without damaging the basement walls or floor.

Structural steel frames shall be erected plumb and true. Frames shall be lifted at points such
that they are not liable to buckle and deform. Trusses shall be lifted only at node points. In
the case of trusses, roof girders, all of the purlins and wind bracing shall be placed
simultaneously and the columns shall be erected truly plumb on screed bars over the
pedestals. All steel columns and beams shall be checked for plumb and level individually
before and after connections are made. Temporary bracings shall be introduced wherever
necessary to take care of all loads to which the structure may be subjected, including
erection equipment and the operation thereof. Such bracings shall be left in place as long as
may be required for safety and stability.

Chequered plates shall be fixed to supporting members by tack welding or by countersunk

bolts as shown/specified in relevant drawings and/or as approved by the Engineer-In-Charge.
The edges shall be made smooth and no burrs or jagged ends shall be left. While splicing,
care should be taken so that there is continuity in pattern between the two portions. Care
should also be taken to avoid distortion of the plate while welding. The erection of
chequered plates shall include:
a) Welding of stiffening angles/vertical stiffening ribs
b) Cutting to size and making holes to required shape wherever necessary to allow service
piping and/or cables to pass through
c) Splicing as shown in relevant drawings
d) Smoothening of edges
e) Fixing of chequered plates by tack welding or by countersunk bolts
f) Providing lifting hooks for ease of lifting.

As erection progresses, the work shall be securely bolted to take care of all dead load, wind,
seismic and erection stresses. No riveting or welding or final bolting shall be done until the
structure has been properly aligned and approved by the Engineer-In-Charge. No cutting,
heating or enlarging of the holes shall be carried out without the prior written approval of the
Engineer-In-Charge. The Contractor shall furnish test certificates.
Inspection:
The Engineer-In-Charge shall have free access to all parts of the job during erection and all
erection shall be subjected to his approval. In case of faulty erection, all dismantling and re-
erecting required will be at the Contractor’s cost. No paint shall be applied to rivet heads or
field welds or bolts until these have been approved by the Engineer-In-Charge.
Tolerances:
General:
Tolerances mentioned below shall be achieved after the entire structure or part thereof is in
line, level and plumb.

Columns:
Deviation of column axes at foundation top level with respect to true axes:
(a) In longitudinal direction ±5 mm
(b) In lateral direction ±5 mm
Deviation in the level of bearing surface of columns at foundation top with respect to true
level±5mm.
Out of plumbness (verticality) of column axis from true vertical axis, as measured at column
top:
(a) For columns up to and including 15 meters ±1/1000 of column height in mm
or ±15 mm whichever is less
(b) For columns exceeding ±1/1000 of column height in mm
or ±20 mm whichever is less
Deviation in straightness in longitudinal transverse planes ±1/1000 of column height in mm
of column at any height or ±10 mm whichever is less
Point along the height
Difference in erected position of adjacent Pairs of ±10 mm
columns along length or across width of building prior to
connecting trusses/beams with respect to true distance
Width of building prior to connecting trusses/beams with ±10 mm
respect to true distance
Deviation in any bearing or seating level with respect to ±5 mm
true level
Deviation in differences in bearing level of a member on ±10 mm
adjacent pair of columns both across and along the
building
Trusses and Beams:
Shift at the center of span of top chord member with ±1/250 of height of truss in mm
respect to the vertical plane passing through the center of or ±15 mm whichever is less
bottom chord.
Lateral shift of top chord of truss at the center of span ±1/1500 of height of truss in mm
from the vertical plane passing through the center of or ±15 mm whichever is less
supports of the truss
Lateral shift in location of truss from its true vertical ±10 mm
position
Lateral shift in location of purlin true position ±5 mm
Deviation in difference of bearing levels of trusses or 1. ±20 mm for trusses
beams from 2. For beams : the true
difference
Depth < 1800mm : ±6mm
Depth > 1800mm : ±10mm
Deviation in sag in chords and diagonals of truss between 1/1500 of length in mm or 10mm
node points whichever is smaller
Deviation in sweep of trusses, beams etc. horizontal plan 1/1000 of span in mm subject to
a maximum of 10 mm
Crane Girders & Rails
Shift in the center line of crane rail respect to center line ±5 mm
of web of with crane girder
Shift in plan of alignment of crane rail with respect to ±1 mm
true axis of crane rail at any point
Difference in alignment of crane rail in plan measured ±1 mm
between any two points 2 meters apart
Deviation in crane track with respect to true gauge
For track gauges upto and Including 15 meters ±5 mm
For track gauges more than 15 meters ± [5 + 0.25 (S-15)] where S in
meters is true gauge
Deviation in the crane real level at any point from true ±1/1200 of the gauge distance
level or±10mm whichever is less
Difference in the crane rail actual levels between any two ±2 mm
points 2 meters apart along the rail length
Difference in levels between crane track Rails at
(a) Supports of crane girders ±15 mm
(b) Mid span of crane girders ± 20 mm
Relative shift of crane rail surfaces at a joint in plane and 2 mm
elevation surfaces for smooth transition
Relative shift in the location of crane stops (end buffers)1/1000 of track gauge subject to
along the crane tracks with track gauge S maximum of 20 mm S in

Painting:
After steel has been erected, all bare and abraded spots, rivet heads, field welds, bolt heads
and nuts shall be spot painted with primer. Before paint is applied, the surface shall be dry
and free from dust, dirt, scale and grease. All surfaces inaccessible after erection shall
receive two coats of the approved paint before erection.

Clean up of Work site:

During erection, the Contractor shall at all times keep the working and storage areas used by
him free from accumulation of waste materials or rubbish. Before completion of erection, he
shall remove or dispose of in a satisfactory manner all temporary structures, waste and debris
and leave the premises in a condition satisfactory to the Engineer-In-Charge.
 SPECIFICATIONS
SECTION -6:

WATER SUPPLY AND SANITARY WORKS

 SECTION -6 :

WATER SUPPLY AND SANITARY WORKS

Applicable Codes:
The following standards and codes are made a part of this Employer’s Requirement. All
standards, codes of practice referred to herein shall be the latest editions including all
official amendments and revisions.

IS: 210 : Specification for grey iron castings

IS: 269 : Specification for ordinary and low heat Portland cement

IS: 383 : Specification for coarse and fine aggregates from natural sources for concrete

IS: 432 : Specification for mild steel and medium tensile steel bars and hard drawn steel
wire for concrete reinforcement

IS: 456 : Code of Practice for plain and reinforced concrete

IS: 458 : Concrete Pipes (with and without reinforcement).

IS: 516 : Methods of tests for strength of concrete

IS: 554 : Dimensions for pipe threads where pressure tight joints are required on the
threads.

IS: 651 : Salt glazed stoneware pipes and fittings.

IS: 774 : Flushing Cisterns for water closets and urinals (valueless siphonic type)

IS: 775 : Cast iron brackets and supports for wash basins and sinks.

IS: 781 : Sand-cast brass screw-down bib taps and stop taps for water services.

IS: 783 : Code of practice for lying of concrete pipes.

IS: 1068 : Electroplated coatings of nickel and chromium of iron and steel.

IS: 1077 : Specification for common burnt clay building bricks

IS: 1786 : Specification for high strength deformed steel bars and wires for concrete
reinforcement

IS: 1239 : Mild steel tubes (Part I) and mild steel tubular and other wrought steel pipe
fittings (Part II)

IS : 1536 : Centrifugally cast (spun) iron pressure pipes for water, gas and sewage.

IS : 1626 : Asbestos cement building pipes, gutters and fittings (spigot and socket types).

IS : 1703 : Copper Alloy float valves (horizontal plunger type) for water supply purposes.

IS : 1726 : Cast iron manhole covers and frames.

IS : 1729 : Sand cast iron spigot and socket soil, waste and ventilating pipes, fittings and
 accessories.

IS : 1742 : Code of practice for buildings drainage

IS : 2116 : Specification for sand for masonry mortars

IS : 2212 : Code of practice for brickwork

IS : 2250 : Code of practice for preparation and use of masonry mortars

IS : 2326 : Automatic flushing cisterns for urinals

IS : 2470 : Code of practice for design and construction of septic tanks (Parts I & II)

IS : 2556 : Vitreous sanitary appliances (Part I to Part XV)

IS : 2963 : Specification for copper alloy waste fittings for wash basins and sinks

IS : 3006 : Specification for chemically resistant glazed stoneware pipes and fittings

IS : 3311 : Waste plug and its accessories for sinks and wash basins

IS : 5455 : Specification for cast iron steps for manholes

IS : 4127 : Code of Practice for laying of glazed stoneware pipes

IS : 3495 : Methods of tests of burnt clay building bricks

IS : 4111 : Code of practice for ancillary structures in sewerage system manholes

IS : 5382 : Specification for rubber sealing rings for gas mains, water mains and sewers

IS : 5329 : Code of practice for sanitary pipe work above ground for buildings

IS : 5434 : Non-ferrous alloy bottle traps for marine use

Sanitary Installation:
The work shall be carried out complying in all respects with any specific requirements of the
local body in whose jurisdiction the work is situated, and as approved by the Employer’s
Representative.

Any damage caused to the building, or to installations therein, either due to negligence on
the part of the Contractor, or due to actual requirements of the work, shall be made good
and the building or the installation shall be restored to its original condition by the
Contractor.

All sanitary and plumbing work shall be carried out by licensed plumbers.

All sanitary appliances including sanitary fittings, fixtures, and toilet requisites shall be of
size, and design as approved by the Employer’s Representative. All white glazed porcelain
fixtures, such as wash basin, sink drain board, water closet pan, urinal, `P' trap etc. shall
have hard durable white glazed finish. They shall be free from cracks and other glazing
defects. No chipped porcelain fixtures shall be used. Joints between iron and earthenware
pipes shall be made perfectly air and water tight by caulking with neat cement mortar.
A) Indian Type Water Closet:
This shall be the long pan pattern with separate footrests made of white glazed earthenware;
white glazed vitreous china or of white glazed fire clay. The general requirements shall
conform to IS: 2556 (Parts III and X). Each pan shall have an integral flushing rim of suitable
type. It shall also have an inlet or supply horn for connecting the flush type. The flushing rim
and inlet shall be of the self draining type. It shall have a weep hole at the flushing inlet to
the pan. The flushing inlet shall be in the front, unless otherwise approved by the Employer’s
Representative. The inside of the bottom of pan shall have sufficient slope from the front
towards the outlet and the surface shall be uniform and smooth enable easy and quick
disposal while flushing. The exterior surface shall be unglazed and sufficiently rough or
grooved at right angles to the axis of the outlet. Pans shall be provided with a trap `P' or `S'
type with a minimum 50 mm water seal and 50 mm dia. vent horn. Pan shall be laid at the
correct location and level over a bed of lime concrete using brick aggregates (1 part lime
mortar to 2 parts brick bats with lime mortar to 2 parts of sand) or cement-sand admixture as
specified in the drawings.

B) European Type Water Closet:

Water closets shall be either of white glazed earthenware, white grazed vitreous china or
white glazed fire clay as specified and shall be of "Symphonic Wash down type" conforming to
IS.2556 (Part VIII). The closets shall be of one piece construction with approved
plastic/Bakelite seat and cover. Each water closet shall have 4 fixing holes having a minimum
diameter of 6.5 mm for fixing to floor and shall have an integral flushing rim of suitable type.
It shall also have an inlet of supply horn for connecting the flush pipe. The flushing rim and
inlet shall be of the self-draining type. The water closet shall have a weep hole at the
flushing inlet. Each water closet shall have an integral trap with either "S" or "P" outlet with
at least 50 mm water seal. The water closets shall have an anti siphonage 50 mm dia. vent
horn on the outlet side of the trap. The inside of water closets and traps shall be uniform and
smooth in order to ensure in efficient flush. The serrated part of the outlet shall not be
glazed externally. The water closet when sealed at the bottom of the trap in line with the
back plate shall be capable of holding not less than 10 liters of water between the normal
water level and the highest possible water level of the water closet installed.
Urinals:
Urinals shall be of the bowl pattern, either flat back or angle back type lipped in front. They
shall be of white glazed earthenware, white glazed vitreous china or white glazed fire clay,
and of size as specified conforming to IS:2556 (Part VI). The urinals shall be of one piece
construction. Each urinal shall be provided with not less than two fixings holes of a minimum
dia. of 6.5 mm on each side. Each urinal shall have an integral flushing box rim of suitable
type and inlet or supply horn for connecting the flush pipe. The flushing rim and inlet shall be
of the self-draining type. It shall have a weep hole at the flushing inlet of the urinal. At the
bottom of the urinal, an outlet horn for connecting to an outlet pipe shall be provided. The
exterior of the outlet horn shall not be glazed and the surface shall be provided with grooves
at right angles to the axis of the outlet to facilitate fixing to the uniform and smooth
throughout to ensure efficient flushing. The bottom of pan shall have sufficient slope from
the front, towards the outlet such that there is efficient draining of the urinal. The waste
fittings shall be chromium plated.

Wash Basins:
Wash basins shall be of white glazed earthenware, white glazed vitreous china or white
glazed fire clay as approved by the Employer’s Representative and conforming to IS.2556
 Type Size
Flat Back 630 x 450 mm
Flat Back 550 x 400 mm

(a) Wash basins shall be of one piece construction, including a combined overflow. All
internal angles shall be designed so as to facilitate cleaning. Each shall have a rim
sloping inside towards the bowl on all sides except skirting at the back. Basins shall be
provided with single or double tap holes as approved. The tap holes shall be square. A
suitable tap hole button shall be supplied if one tap hole is not required in
installation. Each basin shall have a circular waste hole to which the interior of basin
shall drain. The waste hole shall be either rebated or beveled internally with diameter
of 65 mm at top and a depth of 10 mm to suit a waste plug having 64 mm diameter.
Each basin shall be provided with non-ferrous 32 mm waste fittings. Stud slots to
receive the brackets on the underside of the wash basins shall be suitable for a
bracket with stud not exceeding 13 mm diameter, 5 mm high and 305 mm from the
back of basin to the center of the stud. The stud slots shall be of depth sufficient to
take 5 mm stud. Every basin shall have an integral soap holder recess or recesses
which shall fully drain into the bowl. The position of the chain stay-hole shall not be
lower than the overflow slot. A slot type of overflow having an area of not less than 5
cm2. shall be provided and shall be so designed as to facilitate cleaning of the
overflow. The Employer’s Requirements for waste plug, chain and stay shall be the
same as given for sinks.
(b) All the waste fittings shall be chromium plated. Bottle trap shall conform to IS. 5434.
The chromium plating shall be of service grade No. 2 conforming to IS.1068.

Sinks:

(a) The sinks shall be of white glazed earthenware, white glazed vitreous china or white
glazed fire clay as approved by the Employer’s Representative conforming to IS.2556
(Part V) and shall be of the following sizes:
450 x 300 x 150 mm
600 x 450 x 200 mm

(b) They shall be of one piece construction, including a combined overflow. The floor of
the sink shall gently slope towards the outlet. The outlet shall in all cases be suitable
for waste fittings having flange of 64 mm diameter and the waste hole shall have a
minimum diameter of 65 mm at the bottom to suit the waste fittings. The waste hole
shall be either rebated or beveled having a depth of 10 mm. Each sink shall be
provided with a non-ferrous 40 mm dia. waste fitting. The sink shall have overflow of
the weir type and the inverts shall be 30 mm below the top edge. Each sink shall be
provided with a waste plug, of suitable dia. chain and stay. The plug shall be of rubber
or other equally suitable material and shall be water tight when fitted. Plug chains
shall be of brass wire chromium plated. It shall have an overall length from the collar
to the stay of not less than 300 mm. There shall be a triangular or D shackle at each
end, one of which shall be brazed to the plug and the other securely fixed to the stay.
The 150 mm long shank of the waste shall be threaded conforming to the requirements
of IS: 2556 for sinks only. The waste fittings and plug fittings shall be chromium
plated. The chromium plating shall be of service grade No.2 conforming to IS: 1068.

Flushing Cisterns:
The flushing cisterns shall be automatic or manually operated high level or low level,
as approved by the Employer’s Representative. For water closets and urinals high level
cistern is intended to operate with minimum height of 125 cm and a low level cistern a
maximum height of 30 cm between the top of the pan and the underside of the
cistern. They shall be of cast iron, glazed earthenware, or pressed steel complying
 iron, glazed requirement of IS: 774. Automatic flushing cistern for urinals shall
conform to IS: 2326.

Cast Iron Soil Waste and Vent Pipes and Fittings:

All cast iron pipes and fittings shall be of uniform thickness with strong and deep
sockets, free from flaws, air holes, cracks, sand holes and other defects and conform
to IS: 1536. The diameter approved shall be internal diameter of pipe. The pipes and
fittings shall be true to shape, smooth and cylindrical and shall ring clearly when
struck over with a light hand hammer. All pipes and fittings shall be properly cleaned
of all foreign material before being fixed.

All plug bends of drainage pipes shall be provided with inspection and cleaning caps,
covers, which shall be fixed with nuts and screws. Pipes shall be fixed to the wall by
W.I. or M.S. holder bat clamps, unless projecting ears with fixing holes are provided at
socket end of pipe. The pipes shall be installed, truly vertical or to the lines and
slopes as indicated. The clamps shall be fixed to the walls by embedding their hooks in
cement concrete blocks (1:2:4) 10 cm x 10 cm making necessary holes in the walls at
proper places. All holes and breakages shall be made good. The clamps shall be kept
25 mm clear of the finished face of the walls to facilitate cleaning and painting of
pipes.

The annular space between the socket and spigot shall be filled with a gasket of hemp
or spun yarn soaked in neat cement slurry. The joint shall then be filled with stiff
cement mortar 1:2 (1 cement: 2 fine sand) well pressed with caulking tool and finished
smooth on top at an angle of 45°. The joint shall be kept wet for not less than 7 days
by tying a piece of gunny bag kept moist. Joints shall be perfectly air tight as well as
water tight.

C.I. pipes and fittings which are exposed shall be first cleaned and then painted with a
coat of red lead primer. Two coats of zinc paint with white base and mixed with
pigment of required colour to get the approved shade shall be given over the base
primer coat.

The thickness of fittings and their socket and spigot dimensions shall conform to the
thickness and dimensions approved for the corresponding sizes of straight pipes.

The connection between the main pipe and branch pipes shall be made by using
branches and bends with access for cleaning. Floor traps shall be provided with 25 mm
dia. puff pipe where the length of the waste is more than 1800 mm or the floor trap is
connected to a waste stack through bends.
All cast iron pipes and fittings including joints shall be tested by a smoke test to the
satisfaction of the Employer’s Representative and left in working condition after
completion. The smoke test shall be carried out as stated under:

Smoke shall be pumped into the pipe at the lowest and from a smoke machine which
consists of a bellow and a burner. The material usually burnt is greasy cotton waste
which gives out a clear pungent smoke which is easily detectable by sight as well as by
smell if there is a leak at any point of the pipeline. Water test and air test shall be
conducted as stipulated in IS: 5329.

Galvanized Mild Steel (G.I) Pipe:

The pipes shall be galvanized mild steel welded pipes and seamless screwed and
sockets tubes conforming to the requirements of IS: 1239, for medium grade. They
shall be of the diameter (nominal bore) approved. The sockets shall be designated by
the respective nominal bores of the pipes for which they are intended. The pipes and
sockets shall be finished neatly, well galvanized on both inner and outer surfaces, and
shall be free from cracks, surface flaws, laminations and other defects. All screws,
threads shall be clean and well cut. The ends shall be cut cleanly and square with the
axis of the tube.

All screwed tubes and sockets shall have pipe threads conforming to the requirements
of IS.554. Screwed tubes shall have taper threads while the sockets shall have parallel
threads.

The fittings shall be of malleable cast iron or mild steel tubes complying with all the
appropriate requirements as approved for pipes. The fittings shall be designated by
the respective nominal bores of the pipes for which they are intended. The fittings
shall have screw threads at the ends conforming to the requirements of IS: 554.
Female threads on fittings shall be parallel and male threads (except on running
nipples and collars of unions) shall be tapered.

The pipes and fittings shall be inspected at site before use to ascertain that they
conform to the specification. The defective pipes shall be rejected. Where the pipes
have to be cut or rethreaded, the ends shall be carefully filled out so that no
obstruction to bore is offered. The ends of the pipes shall then be threaded
conforming to the requirements of IS.554 with pipe dies and taps carefully in such a
manner as will not result in slackness of joints when the two pieces are screwed
together. The taps and dies shall be used only for straightening bent and damaged
screw threads and shall not be used for turning of the threads so as the make them
slack, water tight joint. The screw- thread of pipes and fittings shall be protected
from damage until they are fitted. The pipes shall be cleaned and cleared of all
foreign matter before being laid. In jointing the pipes, the inside of the socket and the
screwed end of the pipes shall be oiled and rubbed over with white lead and a few
turns of spun yarn wrapped around the screwed end of the pipe. The end shall then be
screwed in the socket, tee, etc., with the pipe wrench. Care should be taken that all
pipes and fittings are properly jointed so as to make the joints completely water tight
and pipes are kept at all times free from dust and dirt during fixing. Burrs from the
joint shall be removed after screwing. After laying, the open ends of the pipes shall be
temporarily plugged to prevent access of soil or any other foreign matter. Any threads
exposed after jointing shall be painted or in the case of underground piping thickly
coated with approved anticorrosive paint to prevent corrosion.

For internal work the galvanized iron pipes and fittings shall run on the surface of the
walls or ceiling (not in chase) unless otherwise specified. The fixing shall be done by
means of standard pattern holder bat clamps, keeping the pipes about 1.5 cm clear of
the wall. Pipes and fittings shall be fixed truly vertical/horizontal. When it is found
necessary to conceal the pipes, chasing may be adopted or pipes fixed in the ducts of
recesses etc. provided there is sufficient space to work on the pipes with the usual
tools. The pipes shall not ordinarily be buried in walls or solid floors. Where
unavoidable, pipes may be buried for short distances provided adequate protection is
given against damage, but the joints in pipes shall not be buried. M.S. pipe sleeve
shall be fixed at a place where a pipe is passing through a wall or floor for reception
of the pipe and to allow freedom for expansion/contraction and other
movements/maintenance. In case the pipe is embedded in walls or floors it should be
painted with anti-corrosive bitumastic paint of approved quality. The pipe should not
come in contract with lime mortar or lime concrete as the pipe is affected by lime.
Under the floors the pipes shall be laid in layer of sand filling or as approved by the
Employer’s Representative.

G.I. pipes with socket and spigot ends shall be provided with lead caulked joints
wherever specified and the joints shall conform to the requirements of IS.3114.

The work of excavation and backfilling shall be done true to line and gradient in
accordance with General Employer’s Requirements for earthworks in trenches for
pipes laid underground.

The pipes shall be laid on a layer of 10.0 cm sand and filled upto 15 cm above the
pipes. A sand cushion of 15cm on either side of the pipe shall also be provided. The
remaining portion of the trench shall then be filled with excavated earth. The surplus
earth shall be got rid of as directed. When excavation is done in rock the bottom shall
be cut deep enough to permit the pipes to be laid on a cushion of sand 75 mm
minimum.
The pipes and fittings after they are laid and jointed shall be subjected to hydrostatic
pressure test as approved by the Employer’s Representative and shall satisfactorily
pass the test. Pipe line system shall be tested in sections as the work proceeds,
keeping the joints exposed for inspection. Pipes shall be slowly and carefully charged
with water allowing all air to escape. All draw off taps shall then be closed and water
pressure gradually raised to test pressure. Care shall be taken to ensure that pressure
gauge is accurate and preferably should have been recalibrated before the test. Pump
used having been stopped; the section of the pipeline shall maintain the test pressure
for at least half an hour. Any joints or pipes found leaking shall be removed and
replaced by the Contractor.

The G.I. pipe line shall be cut to the required length at the position where the meter
and stop cock are required to be fixed. The ends of the pipes shall be threaded. The
meter and stop cock shall be fixed in position by means of connecting pipe, G.I. nuts,
sockets, etc. The stop cock shall be fixed near the inlet of the water meter. The paper
disc inserted in the ripples of the meter shall be removed and meter installed exactly
horizontally or vertically and with the arrow cast on the body of the meter pointing in
the direction of flow. Care shall be taken that the factory seal of the meter is not
disturbed. Whenever the meter is to be fixed to a newly fitted pipe line, the pipe line
will have to be completely washed before fixing the meter. For this purpose, a
connecting piece of pipe equal to the length of the meter is to be fixed on the new
pipe line. The water shall be allowed to flow completely to wash the pipe line and
then the meter installed as described above by replacing the connecting piece.
Stoneware pipes and fittings:
All pipes with spigot and socket ends shall conform to IS: 651/3006 and shall be of
grade `A'. These shall be sound, free from visible defects such as fine cracks or hair
cracks. The glaze of the pipes shall be free from crazing. The pipes shall give a sharp
clear note when struck with a light hammer.

The following information shall be clearly marked on each pipe and fitting:
(a) Internal diameter;
(b) Grade;
(c) Date of manufacture;
(d) Name of manufacturer or his registered trade-mark or both.

All pipes and fittings shall have ISI mark.

Jointing of GSW pipes and fittings shall be done as per the requirements of the
following Employer’s Requirements and the relevant IS. After jointing, extraneous
material if any shall be removed from the inside of the pipes and fittings and the
newly made joints shall be thoroughly cured. In case, rubber sealing rings are used for
jointing, these shall conform to IS: 5382.

Spigot and Socket Joint (Cement Joint):

The spigot of each pipe shall be slipped home well into the socket of the pipe
previously laid and adjusted in the correct position. In each joint, spun yarn soaked in
neat cement slurry or tarred gasket shall be passed around the joint and inserted in it
by means of a caulking tool. More skeins of yarn or gasket shall be added if necessary
and shall be well caulked. Yarn or gasket so rammed shall not occupy more than one-
fourth of the depth or socket. Cement mortar (1:1) shall be slightly moistened and
carefully inserted by hand into the remaining space of the joint after caulking of yarn
or gasket. The mortar shall than be caulked into the joint with a caulking tool. More
cement mortar shall be added until the space of joint has been completely filled with
tightly caulked mortar. The joint shall then be finished of neatly outside the socket at
an angle of 45 degrees. The cement mortar joints shall be cured at least for seven
days before testing.

The approximate quantity of cement required for each joint for certain common sizes
of pipes are give below for guidance:

Nominal diameter of pipe (mm) Cement (kg)

150 1.5
200 2.0
250 2.5
300 3.25
350 4.5
400 5.5
450 6.5
Spigot and Socket Joint (Bituminous Joint):
The general requirements for this type of joint shall be as specified in 5.12.1 the
material for jointing shall consist of composition of asphalt and sand in the ratio of
1:7. Asphalt and sand shall be boiled together and filled into the socket in a molten
state with the aid of special moulds.

Spigot and Socket Joint (Rubber Ring Joint):

The pipe with the rubber ring accurately positioned on the spigot shall be pushed well
home into the socket of the previously laid pipe by means of uniformly applied
pressure with the aid of a jack or similar appliance. The rubber rings conforming to IS:
5382 shall be used, and the manufacturer's instructions shall be deemed to form a part
of this Employer’s Requirements. The rubber rings shall be lubricated before making
the joint and the lubricant shall be soft soap water or an approved lubricant supplied
by the manufacturer.

Cleaning of Pipes:
As soon as a stretch of GSW pipes has been laid complete from manhole to manhole or
for a length as approved by the Employer’s Representative, the Contractor shall run
through the pipes both backward and forward a double disc or solid or closed cylinder
50 mm less in diameter than the internal diameter of pipes. The open end of an
incomplete stretch of pipeline shall be securely closed as approved by the Employer’s
Representative to prevent entry of mud or silt etc. If as a result of the removal of any
obstruction the Employer’s Representative considers that damages may have been
caused to the pipe lines, he shall be entitled to order the length to be tested
immediately. Should such test prove unsatisfactory the Contractor shall repair the
pipeline and carry out such further tests as are required by the Employer’s
Representative.
It shall also be ascertained by the Contractor that each length from manhole to
manhole or the length as approved by the Employer’s Representative is absolutely
clear and without any obstruction by means of visual examination of the interior of the
pipeline suitably illuminated by projected sunlight or otherwise.
After laying and jointing of GSW pipes is completed the pipe line shall be tested as per
the following Employer’s Requirements and as approved by the Employer’s
Representative. All equipment for testing at work site shall be supplied and erected by
the Contractor. Water for testing of pipeline shall be arranged by him. Damage during
testing shall be the Contractor's responsibility and shall be rectified by him to the full
satisfaction of the Employer’s Representative. Water used for test shall be removed
from pipes and not released to the excavated trenches. After the joints have
thoroughly set and have been checked by the Employer’s Representative and before
backfilling the trenches, the entire section of the sewer or storm water drain shall be
proved by the Contractor to be water tight. Before commencing the hydraulic test,
the pipelines shall be filled with water and maintained full for 24 hours by adding
water, if necessary, under a head of 0.6 m of water. The test shall be carried out by
suitably plugging the low end of the drain and the ends of connections, if any, and
filling the system with water. A knuckle bend shall be temporarily jointed at the top
end and a sufficient length of vertical pipe jointed to it so as to provide the required
test head; or the top end may be plugged with a connection to a hose ending in a
funnel which could be raised or lowered till the required head is obtained and fixed
suitably for observation. The pipeline shall be subjected to a test pressure of at least
2.5 m head of water at the highest point of the section under test. The tolerance of
two liters per centimeter of diameter per kilometer may be allowed during a period of
10 minutes. Any leakage including excessive sweating which causes a drop in the test
water level will be visible and the defective part of the work should be removed and
made good. If any damage is caused to the pipeline during the execution of work or
while cleaning/testing the pipeline as specified. The Contractor shall be held
responsible for the same and shall replace the damaged pipeline and re-test the same
to the full satisfaction of the Employer’s Representative.
Water for testing of pipeline shall be arranged by the Contractor.

Stop Cock and Bib Cock:

A bibcock (bib tap) is a draw off tap with a horizontal inlet and free outlet and
stopcock (stop tap) is a valve with a suitable means of connections for insertion in a
pipe line for controlling or stopping the flow. They shall be of specified size and shall
be of the screw down type. The closing device should work by means of a disc carrying
a renewable non-metallic washer, which shuts against water pressure on a seating at
right angles to the axis of the threaded spindle which operates it. The handle shall be
either crutch or butterfly type securely fixed to the spindle. The cocks shall open in
anti-clockwise direction. When the bib cocks and stop cocks are required to be
chromium plated, the chromium plating shall be of service Grade No. 2 conforming to
IS.1068. in finish and appearance, the plated articles shall be free from plating defects
such as blisters, pits, roughness and shall not be stained or discoloured.

These fittings shall be of brass heavy class; chromium plated (C.P.) and of approved
manufacture and pattern with screwed of flanged ends as specified. The fittings shall
in all respects comply with the requirements of IS.781. The standard size of brass
fittings shall be designated by the nominal bore of the pipe to which the fittings are
attached. A sample of each kind of fitting shall be approved by the Employer’s
Representative and all supplies made according to the approved samples.
All cast fittings shall be sound and free from laps, blow holes and fittings, both
internal and external surfaces shall be clean, smooth and free from sand etc. Burning,
plugging stopping or patching of the casting shall not be permitted. The bodies,
bonnets, spindles and other parts shall be truly machined and when assembled the
parts shall be axial, parallel and cylindrical with surfaces smoothly finished. The area
of the waterway of the fittings shall not be less than the area of the nominal bore.

The fittings shall be fully examined and cleared of all foreign matter before being
fixed. The fittings shall be fitted in the pipe line in a workman like manner. The joints
between fittings and pipes shall be made leak- proof. The joints and fittings shall be
leak proof when subjected to a pressure test approved by the Employer’s
Representative and the defective fittings and joints shall be replaced or redone.
Soak Pit:
Soak pit shall be constructed at the location specified by the Employer’s
Representative. Earthwork excavation shall be carried out to the exact dimensions.
Brick masonry lining with open joints shall be constructed in the pit upto 150 mm
below the outlet pipeline. Brick masonry in cement mortar 1:6 shall be constructed
above this level up to ground. Well burnt brick aggregates of nominal size 40 mm to 80
mm and coarse sand shall be filled within the chamber. Construction of pit lining and
filling of the brick ballast shall progress simultaneously.

Manholes:
Location:
Manholes shall be constructed at places approved by the Employer’s Representative.

Excavation:
Excavation, shoring, dewatering etc. for the pits of manholes, laying of pipes and
fittings/specials shall be done in accordance with Employer’s Requirements described
elsewhere in the document.

Bed Concrete:

The bed concrete for manholes shall be done in accordance with Employer’s
Requirements described elsewhere in the document.
Bricks:
Bricks to be used for construction of manholes shall conform to the relevant Indian
Standards. They shall be sound, hard, and homogeneous in texture, well burnt in kiln
without being vitrified, table moulded, deep red, cherry or copper coloured, of
regular shape and size and shall have sharp and square and parallel faces. The bricks
shall be free from pores, chips, flaws or humps of any kind. Bricks containing
ungrounded particles and/or which absorb water more than 1/6th of their weight
when soaked in water for twenty-four hours shall be rejected. Over burnt or under
burnt bricks shall be liable to rejection. The bricks shall give a clear ringing sound
when struck and shall have a minimum crushing strength of 50 kg/sq.cm. Unless
otherwise noted in drawings. The class and quality requirements of bricks shall be as
laid down in IS: 1077.

The size of the brick shall be 23.0 x 11.5 x 7.5 cm. unless otherwise specified; but
tolerance upto 3 mm in each direction shall be permitted. Only full size brick shall be
used for masonry work. Brick bats shall be used only with the permission of Employer’s
Representative to make up required wall length or for bonding. Sample bricks shall be
submitted to the Employer’s Representative for approval and bricks supplied shall
conform to approved samples. If required by the Employer’s Representative, brick
sample shall be tested as per IS : 3495 by Contractor. Bricks rejected by the
Employer’s Representative shall be removed from the Site within 24 hours.
Cement Mortar:
Mortar for brick masonry shall be prepared as per IS: 2250. Manholes shall be
constructed in brick masonry with cement mortar (1:2) unless otherwise specified.
Gauge boxes for sand shall be of such dimensions that one bag containing 50 kg. of
cement forms one unit. The sand shall be free from clay, shale, loam, alkali and
organic matter and shall be of sound, hard, clean and durable particles. Sand shall be
as approved by the Employer’s Representative. If required by the Employer’s
Representative Sand shall be thoroughly washed till it is free of any contamination.

For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry

conditions. Water shall then be added and mixing continued to give a uniform mix of
required consistency. Cement mortar shall be used within 25 minutes of mixing.
Mortar left unused in the specified period shall be rejected.

The Contractor shall arrange for tests on mortar samples if so required by Employer’s
Representative. Retendering of mortar shall not be permitted.

Brick Masonry:
All bricks shall be thoroughly soaked in clean water for at least one hour immediately
before being laid. The cement mortar for brick masonry work of manholes shall be in
the proportion specified in 5.15.5. Brick work 230 mm thick and over shall be laid in
English Bond unless otherwise specified. 115 mm thick brick work shall be laid with
stretchers. For laying bricks, a layer of mortar shall be spread over the full width of
suitable length of the lower course. Each brick shall be pressed into the mortar and
shoved into final position so as to embed the brick fully in mortar. Bricks shall be laid
with frogs uppermost.

All brickwork shall be plumb and square unless otherwise shown on drawing and true
to dimensions shown. Vertical joints in alternate courses shall come directly one over
the other and be in line. Horizontal courses shall be leveled. The thickness of brick
courses shall be kept uniform. For walls of thickness greater than 230 mm both faces
shall be kept in vertical planes unless otherwise specified. All interconnected
brickwork shall be carried out at nearly one level (so that there is uniform distribution
of pressure on the supporting structure) and no portion of the work shall be left more
than one course lower than the adjacent work. Where this is not possible, the work
shall be raked back according to bond (and not saw toothed) at an angle not exceeding
45 degrees. But in no case the level difference between adjoining walls shall exceed
1.25 M. Workmanship shall conform to IS: 2212.

Brick shall be so laid that all joints are well filled with mortar. The thickness of joints
shall not be less than 6 mm and not more than 10 mm. The face joints shall be raked
to a minimum depth of 12 mm by raking tools daily during the progress of work when
the mortar is still green, so as to provide a proper key for the plastering to be done.
When plastering is not required to be done, the joints shall be uniform in thickness
and be struck flush and finished at the time of laying. The face of brickwork shall be
cleaned daily and all mortar droppings removed. The surface of each course shall be
thoroughly cleaned of all dirt before another course is laid on top. If mortar in the
lower courses has begun to set, the joints shall be raked out to a depth of 12 mm
before another course is laid.

Cement Plaster:
All joints in masonry shall be raked to a depth of 12 mm with hooked tool made for
the purpose when the mortar is still green and in any case within 48 hours of its
laying. The surface to be rendered shall be washed with fresh clean water free from
all dirt, loose material, grease etc. and thoroughly wetted for 6 hours before
plastering work is commenced. Concrete surfaces to be rendered will however be
kept dry. The wall should not be too wet but only damp at the time of plastering. The
damping shall be uniform to get uniform bond between the plaster and the wall.

The proportion of the cement mortar shall be as approved on relevant drawings.

Cement shall be mixed thoroughly in dry condition and then just enough water added
to obtain a workable consistency. The quality of water, sand and cement shall be as
per relevant I.S. The mortar thus mixed shall be used immediately and in no case shall
the mortar be allowed to remain for more than 25 minutes after mixing with water.

Curing of plaster shall be started as soon as the applied plaster has hardened enough
so as not to be damaged. Curing shall be done by continuously applying water in a
fine spray and shall be carried out for at least 7 days.

Plastering shall be done on both faces of brick masonry in cement mortar (1:2) and 20
mm thick unless otherwise specified.

Plastering work shall be carried out in two layers, the first layer being 14 mm thick
and the second layer being 6 mm thick. The first layer shall be dashed against the
prepared surface with a trowel to obtain an even surface. The second layer shall then
be applied and finished leaving an even and uniform surface, trowel finished unless
otherwise approved by the Employer’s Representative.

Cement Concrete Channel:

The channel for the manhole shall be constructed in cement concrete of M15 grade.
Both sides of the channel shall be taken up to the level of the crown of the outgoing
sewer. They shall be benched up in concrete and rendered in cement mortar (1:1) of
20 mm thickness and formed to a slope of 1 in 12 towards the channel.

Pipe Entering or Leaving Manhole:

Whenever a pipe enters or leaves a manhole, bricks on edge must be cut to a proper
form and laid around the upper end of the pipe so as to form an arch. All around the
pipes, there shall be a joint of cement mortar (1:2) 13 mm thick between it and the
bricks.
 Cast Iron Steps:
Cast iron steps shall be as per IS: 5455. The steps shall be of grey cast iron of grade 15
as per IS: 210. The steps shall be clean, well cast and they shall be free from air and
sand holes, cold shuts and warping. The portion of the step which projects from the
wall of the manhole shall have a raised chequered design to provide an adequate non-
slip grip. C.I. steps shall weigh not less than 4.5 kg each and shall be of 150 mm x 375
mm overall dimensions. These steps shall be coated with a black bituminous
composition. The coating shall be smooth and tenacious. It shall not flow when
exposed to a temperature of 63 degrees C and shall not be brittle as to chip off at
temperature of 0 degree C.

Where the depth of invert of manhole exceeds 800 mm, cast iron steps of approved
pattern shall be fixed in the brick work at the interval of 300 mm vertically and
staggered at 380 mm horizontally centre to centre. In case of pipe diameter greater
than 600 mm, box type C.I. steps weighing 19 kg each shall be provided at 300 mm
vertically in channel of manhole.

Frame and Covers:

Frame and covers for manholes shall be of required type and dimensions as per the
relevant drawings prepared by the Contractor. Following information shall be clearly
marked on each cover.
i. Year of manufacture,

ii. Identification mark of the Employer: PROJECT DIRECTOR AND CHIEF ENGINEER.

iii. Arrow showing direction of flow.

(a) Cast Iron Frame and Cover:

The cast iron frame and cover shall be of grey cast iron as per IS: 1726. The general
requirements for casting and coating of CI frame and cover shall be as specified for CI
steps in Clause 5.15.10. The covers shall have a raised chequered design to provide an
adequate non-slip grip. The rise of the chequered shall not be less than 4 mm. The
locking device for the cover shall be provided as approved by the Employer’s
Representative. The CI covers for the load test shall be selected at one for every lot of
fifty or part thereof for each type and size manufactured and as approved by the
Employer’s Representative. The frame shall be fixed in cement concrete of M15 grade
all round and finished with neat cement. The manhole frame shall have 560 mm
diameter clear opening and shall weigh not less than 208 kg. Including cover. In case
of rectangular CI frame and cover of 900 mm x 600 mm clear opening, the total weight
shall not be less than 275 kg. In case of scraper manhole the frame shall have clear
opening of 1200 mm x 900 mm and shall weigh not less than 900 kg including cover.
The manhole cover and frame shall be painted with three coats of anti-corrosive paint
after fixing in position.

(b) Fiber Reinforced Concrete Frame and Cover:

Fiber reinforced concrete frame and cover shall be capable of withstanding load of 35
tonnes. The frame shall be fixed in cement concrete of M15 grade all around and
finished with neat cement. The fiber reinforced frame shall have clear opening of 560
mm diameter and weighing 102 kg. The cover shall have a minimum thickness of 100
 mm and weighing 78 kg. The fiber shall constitute 1% of the weight of the concrete in
the form of 50 mm to 100 mm long high tensile steel wires. For the cover, MS sheet
lapping of 18 gauge shall be provided to avoid damage to the edges. Similarly for
frame, MS angle/flat shall be provided along the edge. Both MS sheet and angle shall
be painted with black bituminous paint. The cover should have suitable lifting
arrangement. The fiber reinforced frame and cover shall be manufactured as
approved.

(c) Reinforced Cement Concrete Frame and Cover:

Reinforced cement concrete frame and cover for manholes shall be of required
dimensions and shape as shown on the drawing prepared by the Contractor. The
frame and cover shall be cast in cement concrete of M25 grade. Minimum cover to the
reinforcement shall be 40 mm. The edges of frame and covers shall be provided with
mild steel angles to avoid damages to the corners. These angles shall be painted with
black bituminous paint. The covers should have suitable lifting arrangement.

Drop Manhole:

When a sewer connects a main sewer, and where the difference in level between
water line (peak flow levels) of main line and the invert level of branch lines is more
than 600 mm or a drop of more than 600 mm is required to be given in the same sewer
line and it is uneconomical or impractical to arrange the connection within 600 mm, a
drop connection shall be provided for which a manhole shall be constructed as per
relevant drawing, incorporating a vertical drop pipe from the higher sewer to the
lower one. This pipe shall be provided outside the shaft and encased in concrete. A
continuation of the branch sewer should be built through the shaft wall to form a
rodding and inspection eye, which should be provided with a half blank flange. The
diameter of the back drop should be at least as large as that of the incoming pipe. The
drop pipe should terminate at its lower end with a plain or duck-foot bend turned so
as to discharge its flow at 45 degrees or less to the direction of the flow in the main
sewer. The pipe unless of cast iron should be surrounded with 150 mm thick concrete.
In the case of sewers over 450 mm in diameter the drop in level may be accomplished
by one of the following approved methods:

(a) A cascade;
(b) A ramp;
(c) By drops in previous manholes.

RCC Manhole:
M25 grade of concrete used for construction of RCC manhole shall have minimum
cement content of 360 kg/cum of concrete. Minimum cover to the reinforcement shall
be 50 mm.

Vent Shafts:
(a) General:
Vent shafts shall be erected at such places as approved by the Employer’s
Representative.

(b) Mild Steel Vent Shaft:

Mild steel vent shaft shall be of 150 mm diameter and 12.17 m height from ground
level with C.I. ornamental cap. This shall be fixed firmly and encased in cement
 concrete of M15 grade as shown on relevant drawing with necessary mild steel bolts,
plates etc. for foundation. The vent shaft shall be painted with one coat of silver paint
over one coat of red lead oxide paint. The vent shaft shall be connected to manhole
by 150 mm diameter glazed stoneware pipe encased by M10 concrete of 150 mm
thickness all around as approved by the Employer’s Representative.

(c) RCC Vent Shaft:

Reinforced cement concrete vent shaft shall be of M25 grade concrete, 200 mm
diameter at bottom and tapered to 100 mm diameter at top (both inside clear
openings) and 6 m height from ground level. The vent shaft shall be embedded in
concrete of M10 grade and anchored by 2 nos. of 16 mm diameter and 600 mm long MS
bars. The vent shaft shall be connected to manhole as specified in (b) above through a
brick masonry flue chamber.

Miscellaneous:
If any damage is caused to the other services such as water supply pipeline, sewer,
cable, etc. during the construction of manholes and erection of vent shafts, the
Contractor shall be held responsible for the same and shall replace the damaged
services to the full satisfaction of the Employer’s Representative.
SPECIFICATIONS
SECTION -7:

EARTHWORK
 SECTION -7:

EARTHWORK

Applicable Codes

The following Indian Standard Codes, unless otherwise specified herein, shall be
applicable. In all cases, the latest revision of the codes shall be referred to.

IS 3764 - 1992 Excavation work - Code of Safety.

IS 2720 Methods of test for soils:
(Part-1) - 1983 Part 1 Preparation of dry soil samples for various tests.
(Part-2) - 1986 Part 2 Determination of Water Content.
(0Part-4) - 1985 Part 4 Grain size analysis.
(Part-5) - 1985 Part 5 Determination of liquid and plastic limit.
(Part-7) - 1980 Part 7 Determination of water content - dry density relation using light
compaction.
(Part-9) - 1971 Part 9 Determination of dry density - moisture by constant weight of soil
method.
(Part-14) – 1983 Part 14 Determination of density index (relative density) of cohesion less
soils.
(Part-22) – 1978 Part 22 Determination of organic matter.
(Part-26) – 1987 Part 26 Determination of pH Value.
(Part-27) – 1987 Part 27 Determination of total soluble sulphates.
(Part-28) – 1974 Part 28 Determination of dry density of soils in place by the sand
replacement method.
(Part-33) – 1971 Part 33 Determination of the density in place by the ring and water
replacement method.
(Part-34) – 1972 Part 34 Determination of density of soil in place by rubber balloon
method.
(Part-38) – 1976 Part 38 Compaction control test ( Hilf Method ).

General:
The Contractor shall furnish all tools, plant, instruments, qualified supervisory
personnel, labour, materials, any temporary works, consumables, any and everything
necessary, whether or not such items are specifically stated herein for completion of
the work in accordance with the Employer’s Requirements.

The Contractor shall survey the site before excavation and set out all lines and
establish levels for various works such as grading, basement, foundations, plinth
filling, roads, drains, cable trenches, pipelines etc. Such survey shall be carried out by
taking accurate cross sections of the area perpendicular to established reference/grid
lines at 8m intervals or nearer, if necessary, based on ground profile and thereafter
properly recorded.

The excavation shall be carried out to correct lines and levels. This shall also include,
where required, proper shoring to maintain excavations and also the furnishing,
erecting and maintaining of substantial barricades around excavated areas and
 warning lamps at night.
Excavated material shall be dumped in regular heaps, bunds, riprap with regular
slopes within the lead specified and leveling the same so as to provide natural
drainage. Rock/soil & murrum excavated shall be stacked properly as approved by the
Employer’s Representative. As a rule, all softer material shall be laid along the center
of heaps, the harder and more weather resisting materials forming the casing on the
sides and the top. Rock shall be stacked separately. Top soil shall be stock piled
separately for later re-use.

Clearing:
The area to be excavated / filled shall be cleared of fences, trees, plants, logs,
stumps, bush, vegetation, rubbish, slush, etc. and other objectionable matter. If any
roots or stumps of trees are encountered during excavation, they shall also be
removed. The material so removed shall be disposed off as approved by the
Employer’s Representative. Where earth fill is intended, the area shall be stripped of
all loose/ soft patches, top soil containing objectionable matter/ materials before fill
commences.

Excavation:
All excavation work shall be carried out by mechanical equipment unless, in the
opinion of Employer’s Representative, the work involved requires it to be carried out
by manual methods.

Excavation for permanent work shall be taken out to such widths, lengths, depths and
profiles as are shown on the drawings provided by the Contractor or such other lines
and grades as may be agreed with the Employer’s Representative. Rough excavation
shall be carried out to a depth of 150mm above the final level. The balance shall be
excavated with special care.

Soft pockets shall be removed below the final level and extra excavation filled up with
lean concrete as approved by the Employer’s Representative. The final excavation
should be carried out just prior to laying the blinding course.

To facilitate the permanent works the Contractor may excavate, and also backfill
later, outside the lines shown on the drawings provided by the Contractor as agreed
with the Employer’s Representative. Should any excavation be taken below the
specified elevations, the Contractor shall fill it up with concrete of the same class as
in the foundation resting thereon, up to the required elevation at no cost to the
Employer.

All excavations shall be to the minimum dimensions required for safety and ease of
working. Prior approval of the Employer’s Representative shall be obtained by the
Contractor in each individual case, for the method proposed for the excavation,
including dimensions, side slopes, dewatering, disposal, etc. This approval shall not in
any way relieve the Contractor of his responsibility for any consequent loss or damage.
The excavation must be carried out in the most expeditious and efficient manner. Side
slopes shall be as steep as will stand safely for the actual soil conditions encountered.
Every precaution shall be taken to prevent slips. Should slips occur, the slipped
material shall be removed and the slope dressed to a modified stable slope.
Rock:
General:
‘Rock’ means a natural aggregate of mineral crystals, which for its excavation would
normally require the use of heavy pneumatic/hydraulic breaker and/or cutting
 equipment or explosives. The term shall exclude any material that can be removed by
ordinary excavating machinery and which in any individual mass has a volume not
exceeding 1m3 or 0.25m3 where the net width of excavation is less than 2 m. Ordinary
excavating machinery means a hydraulic back hoe with rated output of 50 kW or less.

Before classification of material as rock the Contractor shall demonstrate to the

satisfaction of the Employer’s Representative his inability to excavate it without resort
to heavy percussion tools complete with rock bits, hydraulic wedges or blasting.
Excavation by the use of explosive will not normally be permitted except for pipeline.

Material shall not be classified as rock unless the Employer’s Representative has
agreed to such classification on the basis of such a demonstration before its
excavation. Excavations where rock has been encountered and classified as such shall
not be backfilled before examination of the excavated faces by the Employer’s
Representative to enable the extent of the rock excavation to be determined.

Excavation by the Use of Explosives

Unless otherwise stated herein, I.S. Specification “IS: 4081: Safety Code for Blasting
and related Drilling Operations” shall be followed. As far as possible all blasting shall
be completed prior to commencement of construction. At all stages of excavation,
precautions shall be taken to preserve the rock below and beyond the lines specified
for the excavation, in the soundest possible condition. The quantity and strength of
explosives used shall be such as will neither damage nor crack the rock outside the
limits of excavation. All precautions, as directed by Employer’s Representative, shall
be taken during the blasting operations and care shall be taken that no damage is
caused to adjoining buildings or structures as a result of blasting operations. In case of
damage to permanent or temporary structures, Contractor shall repair the same to the
satisfaction of Employer’s Representative at his cost. As excavation approaches its
final lines and levels, the depth of the charge holes and amount of explosives used
shall be progressively and suitably reduced.

The contractor shall obtain a valid Blasting License from the authorities concerned. No
explosive shall be brought near the work in excess of quantity required for a particular
amount of firing to be done; and surplus left after filling the holes shall be removed to
the magazine. The magazine shall be built as far possible from the area to be blasted.
Employer’s Representative’s prior approval shall be taken for the location proposed
for the magazine.

In no case shall blasting be allowed closer than 30 meters to any structure or to

locations where concrete has just been placed. In the latter case the concrete must be
at least 7 days old.
For blasting operations, the following points shall be observed.

i) Contractor shall employ a competent and experienced supervisor and licensed

blaster in-charge of each set of operation, who shall be held personally
responsible to ensure that all safety regulations are carried out.
ii) Before any blasting is carried out, Contractor shall intimate Employer’s
representative and obtain his approval in writing for resorting to such
operations. He shall intimate the hours of firing charges, the nature of
explosive to be used and the precautions taken for ensuring safety.
iii) Contractor shall ensure that all workmen and the personnel at site are
excluded from an area within 200 m radius from the firing point, at least 15
minutes before firing time by sounding warning whistle. The area shall also be
given a warning by sounding a distinguishing whistle.
iv) The blasting of rock near any existing buildings, equipment or any other
property shall be done under cover and Contractor has to make all such
necessary muffling arrangements. Covering may preferably be done by MS
plates with adequate dead weight over them. Blasting shall be done with small
charges only and where directed by Employer’s Representative; a trench shall
have to be cut by chiseling prior to the blasting operation, separating the area
under blasting from the existing structures.
v) The firing shall be supervised by a Supervisor and not more than 6 (six) holes at
a time shall be set off successively. If the blasts do not tally with the number
fired, the misfired holes shall be carefully located after half an hour and when
located, shall be exploded by drilling a fresh hole along the misfired hole (but
not nearer than 600 mm from it) and by exploding a new charge.
vi) A wooden tamping rod with a flat end shall be used to push cartridges home
and metal rod or hammer shall not be permitted. The charges shall be placed
firmly into place and not rammed or pounded. After a hole is filled to the
required depth, the balance of the hole shall be filled with stemming, which
may consist of sand or stone dust or similar inert material.
vii) Contractor shall preferably detonate the explosives electrically.
viii) The explosives shall be exploded by means of a primer, which shall be fired by
detonating a fuse instantaneous detonator (F.I.D) or other approved cables.
The detonators with F.I.D. shall be connected by special nippers.
ix) In dry weather and normal dry excavation, ordinary low explosive gunpowder
may be used. In damp rock, high explosive like gelatin with detonator and fuse
wire may be used. Underwater or for excavation in rock with substantial
accumulated seepage electric detonation shall be used.
x) Holes for charging explosives shall be drilled with pneumatic drills, the drilling
pattern being so planned that rock pieces after blasting will be suitable for
handling without secondary blasting.
xi) When excavation has almost reached the desired level, hand trimming shall
have to be done for dressing the surface to the desired level.
Any rock excavation beyond an over break limit of 75 mm shall be filled up as
instructed by Employer’s Representative, with concrete of strength not less
than M10. Stopping in rock excavation shall be done by hand trimming.
xii) Contractor shall be responsible for any accident to workmen, public or
Employer’s property due to blasting operations. Contractor shall also be
responsible for strict observance of rules, laid by Inspector of explosives, or
any other Authority duly constituted under the State and / or Union
Government as applicable at the place of excavation.

Stripping Loose Rock:

All loose boulders, detached rocks partially and other loose material which might
move therewith not directly in the excavation but so close to the area to be excavated
as to be liable, in the opinion of Employer’s Representative, to fall or otherwise
endanger the workmen, equipment, or the work shall be stripped off and removed
from the area of the excavation. The method used shall be such as not to render
unstable or unsafe the portion, which was originally sound and safe.
Any material not requiring removal in order to complete the permanent works, but
which, in the opinion of Employer’s Representative, is likely to become loose or
unstable later, shall also be promptly and satisfactorily removed.

Classification of Strata:

The decision regarding, classification of strata shall rest with the Engineer in charge
and his decision shall be final and binding to the contractor.

All the materials encountered in the excavation shall be classified as under: -

ORDINARY SOIL AND SOFT MURRUM:

These will include all materials of an earthy or sandy nature, which can be easily
ploughed or small shingle, and gravel, which can be easily removed.

HARD MURRUM:
This shall include all kinds of disintegrated rock or shale or inundated clay which can
be removed with a shovel without difficulty and which do not require blasting.

SOFT ROCK:
This shall include all materials which is rock or hard conglomerate, all decomposed
and whether rock, highly fissured rock old masonry and also soft rock boulders bigger
than 1/2 cubic meter and other varieties of rock. Which do not require blasting and
which can be removed with the pie crowbars wedges and hammer.

HARD ROCK:
This shall include rocks, occurring in masses, which could best be removed by chiseling
or by blasting.

Fill, Backfilling and Site Grading:

General:
All fill material shall be subject to the Employer’s Representative’s approval. If any
material is rejected by Employer’s Representative, the Contractor shall remove the
same forthwith from the site. Surplus fill material shall be deposited/disposed off as
directed by Employer’s Representative after the fill work is completed.
No earth fill shall commence until surface water discharges and streams have been
properly intercepted or otherwise dealt with to the approval of the Employer’s
Representative.

Material:
To the extent available, selected surplus spoil from excavations shall be used as
backfill. Backfill material shall be free from lumps, organic or other foreign material.
All lumps of earth shall be broken or removed. Where excavated material is mostly
rock, the boulders shall be broken into pieces not larger than 150 mm size, mixed with
properly graded fine material consisting of murrum or earth to fill the voids and the
mixture used for filling.
If fill material is required to be imported, the Contractor shall make arrangements to
bring such material from outside borrow pits. The material and source shall be subject
to the prior approval of the Employer’s Representative. The approved borrow pit areas
shall be cleared of all bushes, roots of trees, plants, rubbish, etc. Topsoil containing
foreign material shall be removed. The materials so removed shall be disposed of as
directed by Employer’s Representative. The Contractor shall provide the necessary
access roads to borrow areas and maintain the same if such roads do not exist.
Filling in pits and trenches around foundations of structures, walls, etc.
As soon as the work in foundations has been accepted and measured, the spaces
around the foundations, structures, pits, trenches, etc., shall be cleared of all debris,
and filled with earth in layers not exceeding 15 cm, each layer being watered,
rammed and properly consolidated, before the succeeding one is laid. Each layer shall
be consolidated to the satisfaction of Employer’s Representative. Earth shall be
ramming with approved mechanical compaction machines. Usually no manual
compaction shall be allowed unless the Employer’s Representative is satisfied that in
some cases manual compaction by tampers cannot be avoided. The final backfill
surface shall be trimmed and leveled to a proper profile to the approval of the
Employer’s Representative.

Plinth Filling:
Plinth filling shall be carried out with approved material as described hereinbefore in
layers not exceeding 15cm, watered and compacted with mechanical compaction
machines. The Employer’s Representative may, however, permit manual compaction
by hand tampers where he is satisfied that mechanical compaction is not possible. The
finished level of the filling shall be trimmed to the level/slope specified.

The thickness of each unconsolidated fill layer can in this case be upto a maximum of
300mm. The Contractor will determine the thickness of the layers in which fill has to
be consolidated depending on the fill material and equipment used and the approval
of the Employer’s Representative obtained prior to commencing filling.
The compacted surface shall be properly shaped, trimmed and consolidated to an even
and uniform gradient. All soft spots shall be excavated, then filled and consolidated.

Sand Filling in Plinth and Other Places:

Where backfilling is required to be carried out with local sand it shall be clean,
medium grained and free from impurities. The filled-in-sand shall be kept flooded with
water for 24 hours to ensure maximum consolidation. The surface of the consolidated
sand shall be dressed to required level or slope. Construction of floors or other
structures on sand fill shall not be started until the Employer’s Representative has
inspected and approved the fill.

Filling in Trenches:
Filling in trenches for pipes and drains shall be commenced as soon as the joints of
pipe and drains have been tested and passed. The backfilling material shall be
properly consolidated taking due care so that no damage is caused to the pipes.

Where the trenches are excavated in soil, the filling from the bottom of the trench to
the level of the center line of the pipe shall be done by hand compaction with
selected approved earth in layers not exceeding 8 cm; backfilling above the level of
the center line of the pipes shall be done with selected earth by hand compaction, or
other approved means in layers not exceeding 15 cm.

In case of excavation of trenches in rock, the filling up to a level 30 cm above the top
of the pipe shall be done with fine materials such as earth, murrum, etc. The filling
up to the level of the centerline of the pipe shall be done by hand compaction in
layers not exceeding 8 cm whereas the filling above the centerline of the pipe shall be
done by hand compaction or approved means in layers not exceeding 15 cm. The
filling from a level 30 cm above the top of the pipe to the top of the trench shall be
done by hand or other approved mechanical methods with broken rock filling of size
not exceeding 15 cm mixed with fine material as available to fill up the voids.
Filling of the trenches shall be carried out simultaneously on both sides of the pipe to
avoid unequal pressure on the pipe.

General Site Grading:

Site grading shall be carried out as indicated in the drawings and as approved by the
Employer’s Representative. Excavation shall be carried out as specified in the
Employer’s Requirements. Filling and compaction shall be carried out as specified
under Clause 2.7 and elsewhere unless otherwise indicated below.

If no compaction is called for, the fill may be deposited to the full height in one
operation and leveled. If the fill has to be compacted, it shall be placed in layers not
exceeding 225 mm and leveled uniformly and compacted as indicated in Clause 2.7
before the next layer is deposited.

To ensure that the fill has been compacted as specified, field and laboratory tests
shall be carried out by the Contractor.

Field compaction tests shall be carried out in each layer of filling until the fill to the
entire height has been completed. This shall hold good for embankments as well. The
fill will be considered as incomplete if the desired compaction has not been obtained.
The Contractor shall protect the earth fill from being washed away by rain or damaged
in any other way, the Contractor shall remove the affected material and make good.

If so specified, the rock as obtained from excavation may be used for filling and
leveling to indicate grades without further breaking. In such an event, filling shall be
done in layers not exceeding 50cms approximately. After rock filling to the
approximate level, indicated above has been carried out, the void in the rocks shall be
filled with finer materials such as earth, broken stone, etc. and the area flooded so
that the finer materials fill up the voids. Care shall be taken to ensure that the finer
fill material does not get washed out. Over the layer so filled, a 100 mm thick mixed
layer of broken material and earth shall be laid and consolidation carried out by a 12-
ton roller. No less than twelve passes of the roller shall be accepted before
subsequent similar operations are taken up.

Fill Density:
The compaction, under the plant road area and building plinths shall comply with
minimum 95% compaction by Standard Proctor at moisture content differing not more
than 4% from the optimum moisture content. The Contractor shall demonstrate
adequately by field and laboratory tests that the specified density has been
obtained. In other areas the soil should be backfilled and compacted suitably as
specified by the Engineer.

Timber Shoring:
Close timbering shall be done by completely covering the sides of the trenches and
pits generally with short, upright members called 'polling boards'. These shall be of
minimum 25 cm x 4 cm sections or as approved by the Employer’s Representative. The
boards shall generally be placed in position vertically side by side without any gap on
each side of the excavation and shall be secured by horizontal walling of strong wood
at maximum 1.2 meter spacing, strutted with bullies or as approved by the Employer’s
Representative. The length of the bully struts shall depend on the width of the trench
or pit. If the soil is very soft and loose, the boards shall be placed horizontally against
each side of the excavation and supported by vertical walling, which in turn shall be
suitably strutted. The lowest boards supporting the sides shall be taken into the
ground and no portion of the vertical side of the trench or pit shall remain exposed, so
as to render the earth liable to slip out.
Timber shoring shall be 'close' or 'open' type, depending on the nature of soil and the
depth of pit or trench. The type of timbering shall be as approved by the Employer’s
Representative. It shall be the responsibility of the Contractor to take all necessary
steps to prevent the sides of excavations, trenches, pits, etc. from collapsing.

Timber shoring may also be required to keep the sides of excavations vertical to
ensure safety of adjoining structures or to limit the slope of excavations, or due to
space restrictions or for other reasons. Such shoring shall be carried out, except in an
emergency, only under instructions from the Employer’s Representative.

The withdrawal of the timber shall be done carefully to prevent the collapse of the pit
or trench. It shall be started at one end and proceeded with, systematically to the
other end. Concrete or masonry shall not be damaged during the removal of the
timber.
In the case of open timbering, the entire surface of the side of trench or pit is not
required to be covered. The vertical boards of minimum 25 cm x 4 cm sections shall
be spaced sufficiently apart to leave unsupported strips of maximum 50 cm average
width. The detailed arrangement, sizes of the timber and the spacing shall be subject
to the approval of the Employer’s Representative. In all other respects, the
Employer’s Requirements for close timbering shall apply to open timbering.

In case of large pits and open excavations, where shoring is required for securing
safety of adjoining structures or for any other reasons and where the planking across
sides of excavations/pits cannot be strutted against, suitable inclined struts supported
on the excavated bed shall be provided. The load from such struts shall be suitably
distributed on the bed to ensure no yielding of the strut.

Dewatering:
The Contractor shall ensure that the excavation and the structures are free from
water during construction and shall take all necessary precautions and measures to
exclude ground/rain water so as to enable the works to be carried out in reasonably
dry conditions in accordance with the construction planning. Sumps made for
dewatering must be kept clear of the excavations/trenches required for further work.
The method of pumping shall be approved by Employer’s Representative, but in any
case, the pumping arrangement shall be such that there shall be no movement of
subsoil or blowing in due to differential head of water during pumping. Pumping
arrangements shall be adequate to ensure no delays in construction. The dewatering
shall be continued for at least (7) seven days after the last pour of the concrete. The
Contractor shall, however, ensure that no damage to the structure results on stopping
of dewatering.

The Contractor shall study the sub-soil conditions carefully and shall conduct any tests
necessary at the site with the approval of the Employer’s Representative to test the
permeability and drainage conditions of the sub-soil for excavation, concreting etc.,
below ground level.

The scheme for dewatering and disposal of water shall be approved by the Employer’s
Representative. The Contractor shall suitably divert the water obtained from
dewatering from such areas of site where a buildup of water in the opinion of the
Employer’s Representative obstructs the progress of the work, leads to unsanitary
conditions by stagnation, retards the speed of construction and is detrimental to the
safety of men, materials, structures and equipment.

When there is a continuous inflow of water and the quantum of water to be handled is
considered in the opinion of Employer’s Representative, to be large, a well point
system- single stage or multistage, shall be adopted. The Contractor shall submit to
the Employer’s Representative, details of his well point system including the stages,
the spacing, number and diameter of well points, headers etc., and the number,
capacity and location of pumps for approval.

Rain Water Drainage:

Grading in the vicinity of excavation shall be such as to exclude rain/ surface water
draining into excavated areas. Excavation shall be kept clean of rain and such water as
the Contractor may be using for his work by suitably pumping out the same. The
scheme for pumping and discharge of such water shall be approved by the Employer’s
Representative.
SPECIFICATIONS
SECTION -8:

INTAKE STRUCTURE
 SECTION -8:

INTAKE STRUCTURE
CONSTRUCTION OF INTAKE STRUCTURE

 Construction of coffer dam or islands which shall be temporary enclosure built to

exclude water from the working area and to permit free access to the area during the
construction of foundations and sub-structure. OR develop barge/pontoon/ any
alternative methodology for construction of foundations and sub-structure.

 Structure made of pile foundation in M-35 grade concrete done by suitable method of
empty boring as per relevant IRC/ IS stipulation in all type of strata (predominantly in
rock) with all required plant and machineries.

 Pump House on top with minimum 7.5 m height, 1.2 mt wide gallery outside intake
structure & RCC top slab with gantry provision, RCC pump house floor supported on
ISMB girder for pipe support and Chequered plates as per drawing.

 150 m long, 7.5m wide steel fabricated approach bridge, with on pile foundation, pile
cap, piers, pier cap, wing wall, abutment, return wall, pipe support structures in M-25
grade concrete, rail track with trolley to transfer machineries, cable tray.

 Bank protection work in 100 mt x 100 mt means construction of RCC pedestal 600
width x 450 mm high, RCC patta grid @ 5 m c/c along sloping length and vertically 25
m c/c on base of 100 mm th. PCC. 450 mm thick Uncoursed rubble masonry in cement
mortar 1:5 with hard stone shall be provided with 6 gauge wire net on river slope as
per drawing including necessary dressing of surface preparation etc. completed.

Work shall be done as per relevant IS/ IRC/ AWWA/ other international standards,
getting it approved from competent authority and as directed by Engineer In Charge
on turnkey basis including various components (not specifically mentioned in this
description but necessary for the project) to ensure safe and smooth operation of the
facilities. Details specification for constructing pile based intake structure as given
below:

DETAILED SPECIFICATIONS FOR COFFER DAM AND BORED RCC PILES FOR INTAKE
STRUCTURE: -
1.0 COFFER DAM: -

Work includes construction of coffer dam or islands which shall be temporary

enclosure built to exclude water from the working area and to permit free access to
the area, during the construction of foundations and sub-structure. The item includes
the diversion of water course during the construction of coffer dams if it is necessary.
The coffer dam may either be made of earth, timber or sheet piling whichever is
found suitable as per site conditions with enough working space around& as directed
by Engineer in charge. Contractor can also utilize barge/pontoon for construction of
foundations and sub-structure.

The work include to provide three layers of sand bags and polyethylene plastic sheet
on outside of sloping length of cofferdam to prevent water seepage. Also work
includes pumping out water from the cofferdam during laying of the foundation for the
intake structure or pier as required during the entire actual execution of the work.
 The dewatering done by any convenient methods, deploying pumping sets of required
capacity in working conditions with all accessories to run the sets as required
from commencement of work till its completion and until the foundation structures
and all concrete work of sub-structure, superstructure is completed. All the trenches
for foundation shall be kept free from water till the concrete in foundation has
reached initial setting.

Before the execution of work contractor shall submit the detailed drawings and design
showing the details of his proposed method of coffer dam or island construction and
other detailed design shall have to be approved from the Engineer-in-Charge from
time to time.

The rate of the item includes the cost of construction and maintenance of any coffer
dam, bunds, dams, or other devices etc. necessary for diverting the flow of water or
any such item of any sort, whatsoever required to prevent water entering the
foundation trenches. No extra rate shall be paid for removing any stuff of any sort
outside which might find access by blowing or for any other reasons, whatsoever
from the sides or bottom of foundation or from elsewhere when dewatering
operations are in progress the contractor shall make all arrangements for necessary
plant such as pumps, engines and other machineries and all other materials
required in this connection.

It is envisaged that the task could be completed within one working season. However,
in case, if task could not be completed within one season, the coffer dam shall have to
be maintained for more working seasons in the event the foundation and sub-structure
work being not completed in single working season. The rates shall include the
provision of reconstruction of coffer dam as per the requirements for any subsequent
one or more working seasons if necessary. The contractor shall not claim for extra
payments for increase of work as due to such additional requirements. The rate
includes all these operations necessary plants, machineries, labour, and maintenance
etc. completed. The work shall be followed as per IRC/IS/ international stipulations.
Removal of the coffer dam shall be done within period of one month of completion of
works and at least 15 days prior to testing and commissioning. Contractor also may
construct barge/pontoon for pile driving and other construction facilitation The complete
work to be executed as mentioned in “Schedule B-1” or as directed by the Engineer in
Charge.

1.1 TEMPORARY STRUCTURE: -

Work includes construction of temporary structure like barge, pontoon or any other
structural steel based arrangements instead of coffer dam which shall be utilized to
facilitate drilling/ boring of piles during the construction of foundations and sub-
structure/ superstructure. The item includes requisite structural members and access
facilities as per site conditions with enough working space around & as directed by
Engineer in charge.

Before the execution of work contractor shall submit the detailed drawings and design
showing the details of his proposed method of such construction and other detailed
design shall have to be approved from the Engineer-in-Charge from time to time.
The rate of the item includes the cost of construction and maintenance of any other
structure etc. necessary for constructing intake structure, whatsoever required. No
extra rate shall be paid for removing any stuff of any sort outside which might find
access by blowing or for any other reasons, whatsoever from the sides or bottom of
foundation or from elsewhere when dewatering operations are in progress the
contractor shall make all arrangements for necessary plant such as pumps, engines
and other machineries and all other materials required in this connection.

It is envisaged that the task could be completed within one working season. However,
in case, if task could not be completed within one season, the arrangement shall have
to be maintained for more working seasons in the event the foundation and sub-
structure work being not completed in single working season. The rates shall include
the provision of reconstruction of such structure as per the requirements for any
subsequent one or more working seasons if necessary. The contractor shall not claim
for extra payments for increase of work as due to such additional requirements. The
rate includes all these operations necessary plants, machineries, labour, and
maintenance etc. completed. The work shall be followed as per IRC/IS/ international
stipulations. Removal of the structure shall be done within period of one month of
completion of works and at least 15 days prior to testing and commissioning. The
complete work to be executed as mentioned in “Schedule B-1” or as directed by the
Engineer in Charge.
 DETAILED SPECIFICATIONS FOR R.C.C. BORED PILE WORK:
1.0 PURPOSE

This document defines the scope of works for RCC bored cast-in- situ piles and its
specific requirements including pile foundation system for the proposed Intake
Structure of Water Supply Project.

2.0 CODES, STANDARDS & SPECIFICATION:

IS: 456-2000 : Codes of Practice for Plain And Reinforced Concrete

IS 1893-2002 : Code of Practice for Earthquake Resistant Structures
Code of Practice for Structural Safety of Buildings: Loading Standards
IS 875-1987 :
(Parts 1 To 3)
IS 800-1984 : Code of Practice for General Construction in Steel.

IS 3370 : Code of Practice For concrete structures for the storage of liquids

IS 5525-1969 : Code for Practice for Reinforcement Detailing

IS 1080 : Code of Practice for Design and Construction of Shallow Foundations

Code of Practice for Design and Construction of Foundations- General

IS 1904 :
Requirements
IS 2950 : Code of Practice For Design Of Raft Foundations
Specification of Concrete Masonry Units: Hallow and Solid Concrete
IS 2185-Part I :
Blocks

SP: 22 : Explanatory Handbook on codes for Earthquake Engineering

Explanatory Handbook for Code of Practice for plain and Reinforced

SP: 24 :
Concrete
SP16-1980 : Design Aids For Reinforced Concrete To IS 456
SP34-1987 : Handbook On Concrete Reinforcement Detailing
Standard Specifications and Code of Practice for Road bridges- Section
IRC 78-2000 :
VII-Foundations and substructure.
IS 5620 - 1985 Design criteria for Low Head Slide Gates
IS 2974 - 1992 Code of Practice for Design of Machine Foundations
Standard Specification and code practice for road bridges Section II-
IRC : 6-2000
Loads and Stresses
SCOPE

3.0 General

The Contractor shall carry out the works in accordance with a method statement
which has been approved by GWSSB. Providing RCC bored cast in situ piles as per
design carried out by the bidder, vetted by any reputed Engineering Institutes/
Consultant and submitting to GWSSB for review before commencement of piling work.
All jobs to be completed within the specified time period mentioned in the tender.
Supply of all materials is also included in contractor’s scope.

The scope in general consists of designing the RCC pile foundation basis the soil
 investigation report/ recommendation, which shall be provided to the successful
bidder. The party has to carry out the design of the pile foundation basis the soil
report after the award of the contract and get the design vetted by reputed
Engineering Institutes/ Consultant duly approved by GWSSB within the quoted rates.
For the purpose facilitating the bidders to provide their techno commercial offer the
diameter of piles have been assumed 1500 mm dia. and height of pile approximately
43 meters. The quantities mentioned in the schedule of rates are approximate and
actual payment shall be made basis the actual executed quantities based on the
approved design.

3.2 Surveying and Staking:

The Contractor shall be required to employ an approved Licensed Surveyor who will
set up the positions of the piles as shown in the pile layout plans of the detailed
design. The Contractor will be responsible for the accuracy of location and positioning
of each pile. Any errors in setting out and any consequential loss to the Employer will
be made good by the Contractor to the satisfaction of the Engineer.

The Contractor shall preserve the pegs set out by the Surveyor. Should any peg be
displaced or lost it must be replaced by a Licensed Surveyor to the approval of the
Engineer. Upon completion of all piling works, the Contractor shall produce as-built
Drawings showing the positions of all piles as installed. The positions of piles shall be
verified by a Licensed Surveyor.

It is the express responsibility of the contractor to bring to site all surveying

instruments necessary for the marking out, fixation of levels, etc. and conduct these
survey operations himself with utmost accuracy. The contractor shall put-up stable
bench marks etc. as necessary for the work. GWSSB officials will remain present when
this work is being carried out and will inspect all these operations with the
Contractor’s assistance. The contractor shall be entirely responsible for accurate
setting out of the work and he shall at his own expense make good any defects arising
from errors in line and levels.

4.0 DESIGN CONSIDERATIONS:

4.1 Structural Design:

The piles shall have necessary structural strength consideration all the load effects
and their structural capacity examined. The self load of pile or lateral load due to
earthquake, water current force etc. on the portion of free pile up to scour level
should be duly accounted for as per Relevant standards of IS: 2911 (Part I/ Sec.2) or
relevant IRC code and specific requirements shall be considered to design of piles.

Permanent steel casing/liner should be provided at least up to maximum scour level.

The thickness of casing/liner should not be less than 8 mm.

4.2 Reinforcement:

4.2.1 The reinforcements in pile should be provided complying with the requirements of
relevant IS standards or IRC: 112. The minimum longitudinal reinforcement should not
be less than 0.4% nor greater than 2.5% of the cross sectional area of the cast in situ
concrete bored pile.
4.2.2 Clear cover to the main reinforcement shall be 50 mm. This shall be increased to 75
mm in case of aggressive soils and ground water conditions.

4.2.3 The minimum clear distance between the vertical bars should not less than 100 mm
for the full depth of cage. The bars shall be so placed as not to impede the placing of
concrete.

4.2.4 The lateral ties in the reinforcing cage should not less than 150 mm center to center.

4.2.5 The minimum diameter of the lateral ties shall be 6 mm.

LOAD ON THE STRUCTURE AND THEIR COMBINATIONS:

Dead Loads (DL)

The dead loads to be considered for design shall be based on unit weights of different
materials as per IS: 1911 – 1967/IS: 456-2000 / IS: 875 (Part I) – 1987. A general point load of
10 KN shall be considered on all floor beams in static analysis.

Live Loads (LL)

Following live loads shall be considered for design.

Live Load on pump house roof : 1.50 kN/m2

Live load on floors supporting

Equipment such as pumps, blowers,
Compressors, valves, etc. : 10.00 kN/m2

Live load on all other floors

Walkways, stairways and platforms. : 5.00 kN/m2

In the absence of any suitable provisions for live loads in I.S. Codes or as given above for any
particular type of floor or structure, assumptions made must receive the approval of GWSSB
prior to starting the design work. Apart from the specified live loads or any other load due to
material stored, any other equipment load or possible overloading during maintenance or
erection / construction shall be considered and shall be partial or full whichever causes the
most critical condition.

Equipment Loads

Loads arising due to equipment during operational conditions including impact shall be
considered as permanent dead loads and include self-weight of the equipment. Load
indicated below are tentative. Bidder shall design the structure based on the loads of
equipment offered by him, subjected to minimum load provided in data sheet.

Crane Loads

EOT crane of required capacity shall be erected within the pump house. Columns shall be
designed for load of this crane. The column shall also take into account the load of gantry
girder and crab load. The bridge end on bank side shall also be equipped with crane to
facilitate lifting of pump and placing it on vehicle.

The crane and wheel loads shall be obtained from crane manufacturer prior to design.

Wind Load:

Wind loads shall be as per I.S. 875 Part III Latest Revision.
 Earthquake load:

This shall be computed as per latest I.S. 1893 Part 1 to 4. An importance factor of 1.5 shall be
considered for design.

Design dead and live load under earthquake condition.

The relevant normal loading to be considered in combination with seismic loads shall be as
per relevant codes.

Uplift Pressure

Substructure shall be subjected to uplift pressures due to ground water rising up to maximum
water level under normal, extreme environmental load combinations. Computations shall be
based on buoyant weight of soil plus full uplift pressure.

Soil pressure

Soil pressure on walls shall be calculated using active/at-rest pressure coefficients up to the
foundation level based on buoyant weight of soil plus full uplift pressure.

Combination of loads

Structure shall be designed to resist the worst combination of the basic loads / stresses under
test and working conditions; these include dead load, live load, wind load, seismic load,
stresses due to temperature changes, shrinkage and creep in materials, dynamic loads,
impact load and

other specific loads

Each structural element of the building shall be designed for one of several possible loading
schemes obtained by arranging the basic loads into various possible combinations and
multiplying by appropriate load factors as provided in IS 456: 2000 or IS 800 as appropriate.

PUMP HOUSE

The design of pump houses shall be carried out after detailed analysis of the structure has
been completed for various loadings and their combinations. The detailed analysis shall
comprise of static as well as dynamic loads. Dynamic load applied by pumps shall be provided
by pump manufacture prior to the design of the pump floor and it should be taken into
account in design.

The pump house shall be analyzed by dividing it in to two separate components with
appropriate compatibility conditions established at their interface.
Pump house (electrical floor & motor floor) , Substructure (i.e. Intake well piles) Intake
structure and substructure shall be designed according to IRC 78-2000 and stipulations given
in other relevant IRC/ IS code.

Electrical Panel Floor

An electrical panel floor of 2.5 m width shall be constructed at the periphery of the intake
well pump floor at the level of shown in drawing or stated in data sheet or elsewhere in the
tender. Minimum Thickness of the electrical panel floor shall be 150 mm. Live load of Min 6
kN/m2 or as per actual requirement shall be applied while designing the slab.

PUMP HOUSE SUPERSTRUCTURE

The pump house superstructure comprising of columns, floor beams, roof beams, and lintel
beams shall be idealized using prismatic beam elements. Fixity for columns shall be
considered at the level of top of raft or at the top of internal/external walls depending on
the location of their founding. Analysis shall be done for the various primary load cases as
specified earlier. The load combinations to be considered and corresponding partial safety
factors shall be as given above.

The EOT crane is considered to be placed so as to cause maximum reaction for columns.

Stability analysis

In addition to the structural analysis, following stability checks shall be performed.

a) Check for overturning

A minimum factor of safety of 1.5 against overturning shall be considered. The sub soil
pressures on the pump house substructure, along the longitudinal axis of the pump house are
self-balancing. This check shall be performed along transverse direction of the pump house,
when the area behind the pump house is backfilled, and there is no water in one of the sump
bays.
The stability of a structure as a whole against overturning shall be ensured so that the
restoring moment shall be not less than the sum of 1.2 times the maximum overturning
moment due to the characteristic dead load and 1.4 times the maximum overturning moment
due to the characteristic imposed loads. In cases where dead load provides the restoring
moment, only 0.9 times the characteristic dead load shall be considered. Restoring moment
due to imposed loads shall be ignored.

b) Check for uplift.

Factor of safety against uplift under static condition shall be minimum 1.2. Buoyancy shall be
checked under normal operating / maintenance conditions, i.e. when any one of the sump
bays is isolated and does not contain water.

Construction Requirements

The intake sub structure shall be constructed in M35 grade concrete and reinforcement steel
should be of CRS Fe 500 grade.

Reference Drawings

General Arrangement of Intake Structure and Pump House

GENERAL SPECIFICATION

In order to provide a dependable drawl of water from source it is contemplated to

construct Intake structure with pump house, Approach Bridge and bank protection works near
Tiskari Jungle. This will be used to draw water from the source in which there is fluctuation
in water level or when it is proposed to draw water at the most desirable depth.

CONSTRUCTION OF INTAKE STRUCTURE

a) The intake structure shall be provided for drawl of water from more than one level
to cope up with seasonal variations of depth of water. Inlet pipe shall be placed below the
Minimum water level so that sufficient water is always available for drawl.

b) The Intake structure, Inlet pipes and other structures under/ above water and
above bed level shall be well protected against possible damages from the moving objects.
 Under mining of foundation due to water current or overturning pressure due to
deposits of silt against one side of an intake structure are to be avoided.

d) The entrance of large objects into the intake well shall be prevented by MS screen
with square opening. Fine screen for exclusion of small fish and other objects shall be placed
at the accessible point. Submerged ports in the intake well shall be provided in such a way
that the rate of flow of inlet water through the port hole is greater than the rate of maximum
discharge from the well at the lowest level of water in the reservoir.

Intake foundation shall rest on any soil including rocks. In case a pile is founded on
rock there shall be adequate embedment and even all round seating.

The piles/piers shall as far as possible be dig true and vertical by drilling/ excavating
materials uniformly from inside the dredge holes. If necessary, Kent ledge shall be placed in
any orderly and safe manner and in such a way that it does not interfere with dredging
operation. Eccentric Kent ledge shall also be used for rectification of tilt with the approval of
Engineer-in-charge / Consultant. Dewatering of well as means for sinking is discouraged and it
shall be avoided if sand blows are expected. It may, however, be resorted to under special
circumstances on specific permission of the Engineer-in-charge / Consultant.

Blasting shall not be permitted. Explosives shall not generally be used as an aid for
well digging but in cases where explosives become imperative, prior approval of the Engineer-
in-charge /dam authority/ Consultant shall be obtained.

The dredged materials shall be dumped as far as away from the intake well point as
possible and then continuously and simultaneously removed. In case the river stream flows
along one edge of the well being dug, the dredged material shall not be dumped on the dry
side of the bank.

The Piles/piers after being drilled/ excavated to its final position and after ensuring
that the soil properties of the founding strata do not significantly differ from these adapted in
design shall be suitably anchored at bottom.

At all subsequent stage of drilling/ excavating the piles/piers shall be maintained in

truly vertical position without any eccentricity from the designed center line as far as
practicable. The verticality shall be frequently checked with then plumb bobs along the
inside surface of the staining after first making safe with the help of straight edge that the
structure itself is straight in a vertical direction.

The structure shall be uniformly seated at the founding strata as shown in the drawing
by the Engineer-in-charge/ Consultant.

The contractor shall make his own arrangement for necessary labours, pump engines, electric
motor, crane, drilling/ boring machine/ excavators and other suitable machinery and device
required for speedy and satisfactory work on site.

The water during dewatering shall have to be disposed or satisfactorily in confirm with rules
in force and approved by the Engineer.

The disposal of water shall in no case damage the adjoining properties for carrying out the
work of masonry, cement concrete plaster, pointing etc. below water level.
In case of dewatering with all engines, contractor shall have to arrange free oil, diesel etc. at
his own cost and in case of electric motor. Contractor shall have to arrange for any pay the
necessary charge for power consumption to the concerned department.

For satisfactory completion of work to the required depth, contractor must have to bring
necessary machineries, heavy dewatering set, expert man power having equipment such
oxygen masks etc.

4.0 GENERAL SPECIFICATION

In order to provide a dependable source of water to the existing population as well as

the future growth of population it was decided to construct to use water from
Madhuban dam reservoir near Tiskari Jungle Village. Intake well with pump house
Approach Bridge and feeding channel are proposed to construct for taking water from
above reservoir.
Water works intake shall be a device or structure placed in a surface water source to
permit the withdrawal of water from the source. They will be used to draw water from
the reservoirs in which there is either or wide fluctuation in water level or when it is
proposed to draw water at the most desirable depth.

CONSTRUCTION OF INTAKE WELL

a) The Intake well, Inlet pipes and other structures under water and above bed
level shall be well protected against possible damages from the moving objects.
c) Under mining of foundation due to water current or overturning an intake
structure are to be avoided.
d) The entrance of large objects into the intake well shall be prevented by MS Jail
screen.

Intake structure pile foundation shall rest on any soil including rocks.
Blasting shall not be permitted. Explosives shall not generally be used as an aid for
foundation digging but in cases where explosives become imperative, prior approval of
the Engineer-in-charge /dam authority/ Consultant shall be obtained.
The dredged materials shall be dumped as far as away from the intake well point as
possible and then continuously and simultaneously removed. In case the river stream
flows along one edge of the well being dug, the dredged material shall not be dumped
on the dry side of the bank.
The pile foundation after being bored to its final position and after ensuring that the
soil properties of the founding strata do not significantly differ from these adapted in
design shall be suitably plugged at its bottom.
At all subsequent stage of excavating the wells shall be maintained in truly vertical
position without any eccentricity from the designed centre line as far as practicable. A
temporary timber frame work shall be provided to guide the staining work in the initial
stages. The verticality shall be frequently checked with then plumb bobs.
The intake structure shall be uniformly constructed at the founding strata as shown in
the drawing by the Engineer-in-charge/ Consultant.

The contractor shall make his own arrangement for necessary labours, pump engines,
electric motor, crane, excavators and other suitable machinery and device required for
speedy and satisfactory work on site.

The water during dewatering shall have to be disposed or satisfactorily in confirm with
rules in force and approved by the Engineer.

The disposal of water shall in no case damage the adjoining properties for carrying out
the work of cement concrete plaster, pointing etc. below water level.

In case of dewatering with all engines, contractor shall have to arrange free oil, diesel
etc. at his own cost and in case of electric motor. Contractor shall have to arrange for
any pay the necessary charge for power consumption to the concerned department.
For satisfactory completion of work to the required depth, contractor must have to
bring necessary machineries, heavy dewatering set, expert man power having
equipment such oxygen masks etc.

General Specifications for Raw Water Pump House: -

The pump house shall be constructed above the Intake well. The floor of Pump House
with RCC beams shall be constructed to withstand the load of eleven numbers of Pumps,
Motors, Column Pipes, Delivery Pipes, Valves and other electrical accessories, H.O.T.
crane etc. as well as part of the load coming from the Approach Bridge which shall rest
on the floor at one end. The pump floor and RCC beams shall be M25 concrete and CRS
Fe-500 bars. The RCC walls of the Pump House shall be minimum 200 mm thick. The
columns shall be constructed to support the RSJs over which EOT crane shall be fixed
for lifting the Pumps, Motors, Pipes, Valves, and Electrical Accessories as well as to
support RCC roof beams. The columns, bracings, Ties, Lintels, Chajja, RCC roof beams
and roof slab shall be of RCC concrete of not leaner than M25 and CRS bars.

The Rolling Shutter shall be of MS Collapsible Shutter of 3.5 m x 5.0 m size.

There shall be adequate ventilation in the Pump House. The aluminum section window
size of each window shall be minimum 63.50x38.10x1.95 mm

One Low Tension (L.T.) Panel Board Platform shall be provided at 2.50 M above the floor
level. The Platform of Panel Board shall be of RCC slab of M25 grade concrete and CRS
Fe 500 grade bars supported by one RCC beam at the inner side

General Specifications for RCC APPROACH BRIDGE

One RCC “Approach Bridge” of 7.5 m clear width and with Structural Steel Truss Bridge,
as per drawings and specifications from the Intake well.

Raw Water Pipe Lines, one shall be laid along R.H.S. of the bridge from Raw Water
Pump House on the Intake structure up to the bank. Clear width of the bridge for
movement of Trolley, for carrying, Pumps; Motors, Pipes, Specials, Valves, Electrical
accessories and other materials to and from the Pump House as well as for walk way of
maintenance and other personnel shall be 3.0 meters.

The “Approach Bridge” and allied works shall be –2000, IRC: 78 –2000, IS 800-
2007, IS 808 and other relevant IS and IRC Codes. The structural steel bridge shall rest
on long Girders as per approved design and drawings. These long girders shall rest on
the Pier/pile with a top cap for providing the elastomeric neoprene bearings or suitable
base plate connection. The RCC Pier shall rest on the RCC foundation to be constructed
at a suitable point under the bed level as per design and approved drawing.

ABUTMENT: -
Abutment shall be constructed in reinforced cement concrete. Abutment shall be
 constructed to withstand the load and forces transferred from the super structure and
the load and forces on the pier itself apart from the effect of its self-weight.
The width of the abutment shall be sufficient to accommodate: -
The bearing leaving an offset of 150 mm. beyond them. The space for jacks to lift the
super structure for repair / replacement of bearings etc. Drainage arrangement for the
water on the cap.
The Abutment caps shall be suitable and reinforced to take care of concentrated point
loads dispersing in Abutment.
The minimum width of cap at the top of Abutments of slab and girder bridges just below
the caps shall be 1.20 meters.

Laminated Elastomeric (Neoprene) Bearings: -

The Laminated Elastomeric (Neoprene) Bearings consist of rubber Layers with steel
Plates Vulcanized altogether in order to ensure a bond on their connection faces. The
steel plates shall be completely embedded in the rubber to prevent any corrosion.
Bearings shall be stored under cover away from sunlight, heat, oil and chemical and
shall be handled and stacked carefully. Damaged bearings with bend steel interleaving
plates and partially deboned layers shall not be accepted. The bearing shall be got
approved by the Engineer-in-Charge / Consultant before use.

Installation of Elastomeric (Neoprene) Bearings:-

The concrete surface on the top of the pier cap was Elastomeric (Neoprene) Bearings
are to be placed shall be true to line and level. One 6 mm thick bedding of 1:2 cement
mortar (1 cement and 2 fine dry sharp sand) shall be constructed over the pier cap for
installation of the bearing. Whole installation work and the bearing shall be carried out
as per approved specifications as contained in I.R.C Code (83-part-1) and as per
direction of the Engineer-in-Charge/Consultant.

5.0 Minimum Requirement of Piling Equipment:

The equipment and accessories must be capable of safely, speedily and efficiently
installing piles to the design requirements at the project site. Sufficient units of
equipment and accessories must be provided to keep to the agreed construction
schedule. Equipment of piling means by hydraulic self propelled or manual rotary
piling rig or any other required equipment to complete the entire job as per the time
schedule provided in this tender document. The Contractor shall mobilize sufficient
spares; cutting tools (e.g. flat teeth bits, round shank bits, holders, etc) to avoid any
stoppage of work. Full Technical details of piling rigs and accessories in the form of
catalogues, data sheets, Piling procedure, piling programme and accessories etc. to be
provided by the contractor at no Extra cost to the client.

6.0 BORED CAST IN-PLACE PILES

The Contractor shall carry out the works in accordance with a method statement
which has been approved by the Engineer. This method statement shall include, inter
alia, length of casing/liner, details of the constituent materials of any drilling fluid
used for stabilization, the method of inspection, details of the concrete design mix,
concreting method, the minimum time between the completion of one pile and the
 commencement of the next, and the pattern of construction.

Unless otherwise described in the Specifications, reinforcement and concrete shall

comply with the requirements in Specification on Concrete for Structures. The
Contractor shall ensure that damage does not occur to completed piles through his
method of working. The Contractor shall submit to the Engineer in charge a pile
installation programme. The proposed sequence and timing of pile installation shall be
such that the installation works shall not cause any damage to adjacent piles. Piling
works shall not commence until approval of the Engineer has been obtained. No bored
pile excavation shall commence within 8m of any concreted pile which has not been
cured for 24 hours.

6.1 Pile Excavation

6.1.1 Pile size and length

The Contractor shall carry out own tests along the proposed intake alignment to
determine the bedrock level. Probing of bedrock shall be carried out along the
proposed intake line at intervals to be agreed by the Engineer.

6.1.2 Boring near recently Cast Piles

Piles shall not be bored next to other piles which have recently been cast less than
24 hours or contain unset concrete, whichever longer to avoid damage to any of
these piles.

6.1.3 Stability of Boreholes

It is held that the Contractor has allowed in the unit rate of the pile for the
implementation of all necessary measures, including the provision of all materials,
labour and machineries for maintaining the stability of the sides of boreholes during
bored pile installation and successful completion of the piles. The Contractor shall
submit his proposed methods for agreement prior to commencement of boring
operations.

Irrespective of the presence of ground water, the sides of all boreholes shall be kept
intact and no loose material shall be permitted to fall into the bottom of the
boreholes. The Contractor's boring equipment shall be able to sink a steel
casing/liner to support the sides of all boring.

If the sides of boreholes are found to be not stable, steel casing/liner shall be driven
into stable stratum. The borehole shall be filled with drilling fluid to a level
sufficiently to stabilize the boreholes. Steel casing/liner of appropriate size and
length in conjunction with stabilizing fluid or other alternatives of sufficient strength
shall be used to support the sides of the borehole and permit boring operations to
proceed smoothly and safely. The proposed drilling fluid mix must be submitted to
the Engineer for approval.

Excavations shall not be exposed to the atmosphere longer than is necessary and shall
be covered at all times when work is not in progress. Pile excavated shall be cast
within 24 hours unless otherwise agreed by the Engineer.

6.1.4 Stability of bore by casing method

Where the use of casing is required to maintain the stability of a bore, the bottom of
casing shall be kept a minimum of one meter or more below the unstable strata to
 prevent the inflow of soil and the formation of cavities in the surrounding ground.

Casings shall be thin walled mild steel cylindrical casing, spirally welded or other
similar construction. The dimensions and quality of the casing shall be adequate to
withstand without damage or distortion all handling, construction and ground stresses
to which they will be subjected, including preventing concrete from within the pile
from displacing soft soil or soil squeezing in and displacing fresh concrete. The casings
shall have an internal diameter not less than the specified pile diameter. They shall be
free of significant distortion, of uniform cross-section throughout each continuous
length and free from internal projections and encrusted concrete which might prevent
the proper formation of piles. The joints of casings shall be reasonably watertight.

If casings are damaged during installation in a manner which prevents the proper
formation of the pile, such casings shall be withdrawn from the bore before concrete
is placed, repaired if necessary or other action taken as may be approved to continue
the construction of the pile.

All reasonable steps shall be taken to prevent the spillage of drilling fluid on the site
in areas outside the immediate vicinity of boring. Discarded drilling fluid shall be
removed from the site without delay. In disposal of unwanted drilling fluid, the
Contractor shall comply with relevant government regulations and shall propose a
proper disposal method to be approved by the Engineer.

6.1.5 Inspection of Pile Excavation

All pile excavations shall be inspected for their full length before concreting. The
Contractor shall provide all the apparatus necessary for the inspection.

Inspection shall be carried out either from the ground level or below ground level at
the sole discretion of the Engineer prior to concrete being placed in the borehole. For
such inspection to be carried out safely, the Contractor shall provide all facilities and
assistance to enable the said inspection to be done. In the course of inspection any
loose or soft material in the borehole which is likely to affect the performance of the
pile shall be removed to the satisfaction of the Engineer.

In the case of inspection from ground level, the base of the boring shall be inspected
by approved method for wet hole and by means of a light for dry hole to ensure that
all loose, disturbed and/or remoulded soil is removed and that the sides of the boring
will remain stable during the subsequent concreting operations. The verticality and
position of the boring shall be checked to ensure that they meet the specified
tolerances.

Inspection below ground level shall be carried out for piles with shafts of 760mm (2'6")
diameter and above. For this purpose the Contractor shall, apart from providing other
safety measures, also provide the required facilities such as an approved type of a
steel safety cage with an air-line, lifting cable and hoist, gas detector, lights, etc. to
enable descent into and ascent from the borehole to be carried out safely without any
danger to life. In this regard the safety precautions described inrelevant IS or IRC
standards. “Safety Precautions and Procedures for the Construction and Descent of
Machine-BoredShafts for Piling and Other Purposes” shall generally be followed, unless
otherwise directed by the Engineer.

6.1.6 Cleaning Out

Upon completion of boring the excavation shall be cleaned of all loose, disturbed and
or remoulded soil and sediment soil to expose a firm base of undisturbed material
 using a suitable and effective method to be approved by the Engineer.

Continuity of Construction

A pile constructed in a stable soil with the use of casing or other support shall be
bored and concreted without prolonged delay to ensure that the soil characteristics
are not significantly altered. Surplus earth resulting from piling operations shall be
used where required or removed from site as directed by the Engineer.

Surface Water

All boreholes shall be protected from the possibility of any surface water entering the
hole from time to time and until the hole is completed and ready to be concreted.

6.1.7 Dewatering

Dewatering of accumulated water in all locations on job site from whatever source or
cause until the virtual completion of the entire work shall be done by the contractor
at his own expense and shall not be separately paid for. The rates quoted by the
contractor shall be deemed to be inclusive of this.

7.0 CONCRETE:

Unless otherwise stated, concrete used shall comply with Specification on Concrete for
Structures and as approved by the Engineer. The grade of concrete for Pile shall be 35
(characteristic strength of 35 N/mm2 at 28 days) with minimum cement content of
400kg per cubic meter of concrete. The cement for concrete shall be Sulphate
resistant cement OR Ordinary Portland Cement. Concrete admixture shall only be used
with the permission of the Engineer, and shall be used strictly in accordance with
Specification on Concrete for Structures.

The contractor shall provide own batch plant at site for Ready mixed concrete OR
procure standard Ready mixed concrete for the proposed piling works and complete
details of the mix proportions and workability have been submitted to him for prior
approval. The Contractor shall ensure that the Engineer shall have access to the
supplier's mixing plant at all times for inspection and checks on quality of concrete
supplied. Each load shall be accompanied by a delivery note stamped with the time of
mixing and stating the consignee and quantities of each material in the mix including
water and additives.

7.1 Testing of Cube:

Close control of the mixing of the concrete shall be exercised and cube strength tests
shall be carried out in accordance with IS codes (IS 2911 Part 1/Sec 2).The cube
testing shall be done as per IS 456. The test cubes shall be made from a representative
batch of concrete as that used for the piling works and each cube shall be properly
marked and identified with details relating the specimen to the borehole in which the
concrete is used. Test shall be carried out by Government approved lab. Test results
shall be submitted to the Engineer within 48 hours after testing.

The Contractor shall not carry out the specified cube strength tests without prior
notice to the Engineer. The tests must be witness by the Engineer or his
representative. The contractor shall provide sufficient quantity of all necessary
equipment at site to carry out these tests

The allowable slump shall be as per relevant latest revision of IS codes (IS 2911 Part
 1/Sec 2). The Engineer-in-charge may allow marginal adjustment in water/cement
ratio to obtain concrete of good workability. The other concrete specifications shall
be as per relevant clauses of “Design, Construction & Installation of Bored cast-in-
situ piles forming part of this tender. The concrete for piles shall be as specified in
the design requirement with suitably enriched cement content to permit a high
slump mix. Alternatively, the Contractor may incorporate an approved set retarding
additive into the mix to ensure extended workability of the concrete after
placement. It is held that the Contractor has included these provisions in the unit
rate for the pile.

If the concrete cubes as tested failed to satisfy the criteria as prescribed in

Specification, the Contractor shall undertake all necessary additional and
consequential remedial/compensatory Work to the approval of the Engineer. Any
piling work rejected by the Engineer not truly constructed and installed in accordance
with this Specification shall be replaced or rectified by the Contractor to the approval
of the Engineer and this include reinstallation of piles, and the design and construction
of a modified foundation and also constructing of additional compensation piles.

7.2 Concreting in Wet Hole:

Immediately after the boring for the pile has been completed, approval to commence
concreting shall be sought and, when this has been obtained, concreting shall start
forthwith and continue without interruption. All cast-in-situ concrete shall be dense
homogeneous and method for produce concrete approved by the Engineer.

Concrete to be placed under drilling fluid shall place using a tremie concrete pipe in
accordance with relevant standard. Where discrepancies arise, the provisions of this
specification shall take precedence.

Alternative methods of placing concrete such as the use of a drop bottom bucket or
hose from a concrete pump will not be accepted by the Engineer. At no stage concrete
be permitted to discharge freely into drilling fluid.

Before placing concrete contractor to ensure that there is no accumulation of

contaminated drilling fluid, silt or other deleterious material at the base of the bore.
Contaminated drilling fluid could impair the free flow of concrete from the tremie
pipe and affecting the performance of the pile.

The tremie concrete pipe shall consist of a series of metal pipes with internal
diameter not less than 250mm. The receiving hopper shall have a capacity at least
equal to that of the pipe it feeds. At all times, a sufficient quantity of concrete shall
be maintained within the pipe to ensure that the pressure from concrete exceeds that
from the water or drilling fluid.

The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe
shall extend to the base of the bore and a sliding plug or barrier placed at the
discharge outlet of the pipe to prevent direct contact between the first charge of
concrete in the tremie pipe and drilling fluid.

The tremie pipe outlet shall be kept at least 1.5 meters below the surface of the
concrete at all stages in the pour. The Contractor shall develop a system of level
checks for the concrete and pipe outlet to ensure that this requirement is met. The
tremie pipe shall be withdrawn upward gently behind the concrete level, and shall not
be subject to any shock or violent movement either in dislodging the concrete within
the pipe or for any other reason.

Concrete placement shall be halted should a delay or breakdown occur during the
 concreting operation which in the opinion of the Engineer, could cause a cold joint,
entrapment of latency in the tremie concrete, or otherwise lead to defective
concrete. Before the remainder of the pile shaft can be concreted, the pile shall be
dewatered and the top surface of the tremie concrete cut back to sound concrete and
cleaned of all laitance and weak concrete. The remainder of the pile shall either be
cast by tremie or in the dry, as directed by the Engineer. If this remedial work cannot
be carried out due to construction difficulty, the Contractor will need to construct a
replacement pile.

The concrete for each pile shall be from the same source. The Contractor is to ensure
that the supply from whatever source (ready-mixed) is of sufficient quantity so that
concrete for each pile shall be placed without such interruption.

All holes bored shall be concreted within the same day. In the event of rain, the
Contractor is to provide adequate shelter to keep the hole dry and to concrete under
cover.
The method of placing and the workability of concrete shall be such that a continuous
monolithic concrete shaft of the full cross-section is formed. The method of placing
shall be approved by the Engineer. The Contractor shall take all precautions in the
design of the mix and the placement of concrete to avoid arching of the concrete in
the pile shaft. No spoil, liquid or other deleterious matter shall be allowed to
contaminate the concrete.

When casings/liners are withdrawn as concreting proceeds, a sufficient head of

concrete shall be maintained to prevent the entry of ground water which may cause
reduction of cross-section of the pile. No concrete shall be placed after the bottom of
the casing or lining has been lifted above the top of the concrete. Concrete shall be
placed continuously as the casing is extracted until the desire head of concrete is
obtained.

Adequate precautions shall be taken in all cases where the withdrawal of casing could
result in excess heads of water or drilling fluid. Excess pressure heads are caused by
the displacement of water or fluid by concrete as the concrete flows into its final
position against the wall of the shaft. Precautions such as the use of two or more
discontinuous lengths of casing (double casing) shall be deemed an acceptable method
of construction in this case.

In the event of the ground water level being higher than the required pile head cut-off
level shown in the contract drawings, the Contractor shall submit his proposals for
agreement prior to placing concrete. The pile head shall not be let below the ground
water level unless adequate and agreed precautions are taken.

The top of the pile shall be brought above the required cut-off level by an amount
sufficient to ensure a sound concrete at cut-off level and the surplus removed to
ensure satisfactory bonding of the pile head to the structure.

The actual volume of concrete used for each pile must be measured with the
calculated volume required. If the difference between these two volumes indicates a
possible necking, the Contractor shall propose and carry out appropriate tests and
measures to the approval of the Engineer to ensure the adequacy of the pile. Any
consequences causing the pile rejected by the Engineer due to supply of concrete
shall be on contractor's own risk.

7.3 Tolerances:

(a)Position:
 The pile heads shall be positioned as shown on the Drawings within a maximum
deviation of 75mm in either direction from its design position.
(b)Verticality:
For bored cast-in-situ piles, the maximum permitted deviation of the finished pile
from the vertical at any level is 1 in 150. The contractor shall demonstrate to the
satisfaction of Engineer the pile verticality is within the allowable tolerance.
(c)Correction:
Should piles be installed outside these tolerances affecting the design of the structure,
the Contractor shall propose remedial design and carry out immediate remedial
measure to the approval of the Engineer.

7.0 REINFORCEMENT

All reinforcement shall be as per the drawings. The reinforcement shall be assembled
and tied together and made up into cages sufficiently rigid to withstand handling
without damage and distortion. Where indicated in Data Sheet-A, the reinforcement
bars shall be coated with anti-corrosion fluid as specified. The method of application of
coating shall be such that there are no holidays. After fabrication of the cage all
surfaces which become exposed due to scrapping, welding etc. shall be recoated. All tie
wires, stiffener bars, spreader forks, lacings etc. used to fabricate the cage shall also
be coated similarly.
Where the number and diameters of reinforcement bars change as per the drawing, laps
of reinforcement bars shall be as indicated on the drawing. Joints in longitudinal bars, if
unavoidable, shall be made by lapping. Laps shall be tack-welded as approved by the
ENGINEER to prevent distortion of the reinforcing cage. The number of joints in
longitudinal steel bars shall be kept to a minimum and staggered. Joints in
reinforcement shall be such that the full strength of each bar is effective across the
joint and shall be made such that there is no detrimental displacement of the
reinforcement during the construction of the pile. Mechanical splices if and as approved
by the ENGINEER may be used for jointing reinforcement bars of same diameters.
The projecting lengths of the longitudinal bars beyond the pile cut-off level shall be
equal to a minimum of 24 times bar diameter or such other length as shown on the
drawings.
The lateral links or helical reinforcement shall fit closely around the main longitudinal
bars and be fixed to them by soft annealed 16 gauge black iron wire, the free ends of
which shall be turned towards the center.
Concrete cover over all reinforcement including lateral links or helical shall be 50mm
unless shown otherwise on the drawing. Suitable and adequate cover blocks shall be
provided. The cover blocks shall be circular with a concentric hole of adequate size to
allow lateral reinforcement to pass through and allow free rotation. The cover blocks
shall be manufactured of concrete of grade higher than that of concrete designated for
the pile, using the same grade and type of cement. Alternately, the cover block shall be
of more durable material approved by the ENGINEER which will not lead to corrosion of
the reinforcement or spalling of the concrete cover. The cover blocks shall be placed all
along the length of the reinforcement cage with adequate number in the upper portion
over the length of the temporary casing. The cover blocks shall be aligned for smooth
lowering of the cage into the pile bore and for lifting of the temporary casing without
displacing the reinforcement cage from its seated position.
Stiffener bars, spreader forks and lacings within the reinforcement cage shall be
provided to prevent twisting or any type of distortion of the reinforcement cage during
its lifting, handling and lowering into the pile bore. These shall be placed in a manner
and pattern such that the inside dimension of the reinforcement cage is adequate for
concentric placement of the tremie pipe and its operation without disturbing the cage
during concreting.
Corrosion resistant Steel reinforcement: The reinforcement shall confirm to IS: 1786,
 Fe-500 grade. The reinforcement shall be Corrosion resistant steel and it shall Approved
vendor of GWSSB. Normally be mild steel in the form of round bars, conforming to IS:
432-Grade 1 unless specified otherwise.
Welding: Field welding of reinforcing bars will not be permitted without the written
consent of the Engineer-in-Charge. Where welding is permitted it must be at staggered
locations. Tests shall be made to provide that the joints are of the full strength of bars
connected. Welding of reinforcement shall be done in accordance with the
recommendation of IS: 2751.
Storage: The steel reinforcement shall be stored in such a way as to avoid distortion
and to prevent deterioration and corrosion.
General: General construction details and workmanship relative to reinforcement
including bar bonds, lap splices and installation shall be in accordance with I S:2502 -
Code of Practice for Bonding and Fixing of Bars for concrete reinforcement, as well as
the detailing of reinforcement given in I S:456. Hot bending of bars shall not be
allowed. The number of sizes, shape and position of all the reinforcement shall, unless
otherwise directed or authorized by the Engineer-in-Charge, be strictly in accordance
with the drawings. The reinforcement shall be adequately secured and held in position
by metal chairs and spacers. Ties of inter-sections shall be made with 16 SWG soft black
annealed binding wire. The contractor must obtain the approval of the Engineer-in-
Charge for the reinforcement placed, before any concrete is placed in the forms. The
reinforcement of this time shall be free from loose rust or scale or other coating that
will destroy or reduce bond. Concrete spacer blocks of the same strength as parent
concrete shall be used to ensure correct cover to the reinforcement. This clear cover
shall be as shown on the drawings or as per instructions of the Engineer-in-Charge. All
the reinforcing bars shall be so tied as to form a rigid cage to prevent displacement
before or during concreting.

9.0 PILE TESTING:

9.1 SCOPE

This Specification covers the requirement and methods of testing of a single pile for
evaluating its safe capacity in:

9.2 VERTICAL LOADING (COMPRESSION):-

Equipment and Test Set-up: The test pile shall be decided by the Engineer-in-Charge. It
may be one of the working piles or a separate test pile. The head of the test pile shall
be brought to the proper level and provided with a pile cap with a level and plane
surface and with adequate space for proper seating of a jack and dial gauges. Test pile
surface shall be prepared for testing purposes on the expiry of one week after casting
the pile.

Loading Systems: Loading shall be applied by the reaction method consisting of a

hydraulic jack centrally against a loaded platform. Supports of the platforms shall be
adequately designed. Special anchor piles or any other suitable type of anchorage
systems may be used. However, use of the uplift capacity of neighboring piles for
providing the reaction shall normally not be permitted. The loading system shall be
adequate to ensure that the test can be carried up to the specified limit. The reaction
to be made available for the test shall be at least 25% greater than the maximum
jacking force required.

Measuring system: The load applied on the pile shall be recorded on a calibrated
pressure gauge mounted on the jack.
 a) Settlement of the pile shall be recorded by dial gauges suspended datum bars.
Four dial gauges of 0.01 mm sensitivity shall be positioned on four corners
around the pile.

b) The datum bars shall have rigid supports preferably of concrete pillars or
steel sections, embedded well into the ground. The supports shall be located
more than three times the pile diameter, subject to a minimum of 1.5 m,
clear away from the pile face and also sufficiently away from the supports of
the loaded platform to avoid any disturbance on these accounts. Movements
near the supports of the datum bar shall be avoided while the test is in
progress.

9.3 METHOD OF CONDUCTING TEST:

The test shall be carried out by the direct method of loading in successive increments or
by the cyclic loading method as specified and as described by the Engineer-in-Charge.

Direct Method of Loading in Successive Increments: The test shall be carried out as per
the procedure outlined.

a) The load shall be applied to the pile top in increments of about of fifth of the
rated capacity of the pile or as specified. Settlement readings shall be taken
before and after the application of each new load increment and at 2, 4, 8,
15, 30, 60 minutes and at every two hours until application of the next load
increment.

b) Each stage of loading shall be maintained till the rate of movement of the pile
top is not more than 0.2 mm per hour or until two hours have elapsed,
whichever is later.

c) Further loading shall then be continued as in (a) above till one of the
following occurs:

i) Yield of soil-pile system occur causing progressive settlement of the pile

exceeding a value of one tenth of the pile diameter.
ii) The loading on the pile top equals twice the rated capacity or as
specified in the case of a separate test pile and 1.5 times the rated
capacity of the pile in case of a working pile.

d) Where yielding of the soil does not occur, the full test load shall be
maintained on the pile head for 24 hours or more if necessary and settlement
readings shall be taken at 6 hours interval during the period.

e) Unloading shall be carried out in the same steps as loading. A minimum of half
hour shall be allowed to elapse between two successive stages of load
decrement. The final rebound shall be recorded 6 hours after the entire test
load has been removed.

f) If so directed by the Engineer-in-Charge, loading and unloading cycles shall

be carried out for all load stages within the assumed working load.

g) Assessment of Safe Load The safe capacity of the pile shall be the least of the
following values

i) Load corresponding to settlement specified in specific requirements

which is based on the nature and type of structure.
ii) 50 percent of the final load at which the total displacement equals 10
 percent of the pile diameter in case of uniform diameter piles and 7.5
percent of bulb diameter in case of under-reamed piles.

9.4 CYCLIC LOADING TEST:

The test shall be carried out as per procedure outlined by IS: 2911-(Part-IV) and as
described :

a) The load shall be applied to the pile top in increments of about one fifth the
estimated safe capacity of the pile or as specified. Settlement readings shall
be taken before and after the application of each new load increment at 2, 4,
8, 15, 30,60 minutes and at every two hours until application of the next load
increment.

b) Alternate loading and unloading shall be carried out at each stage and the
total and net settlements recorded as specified. If so directed by the
Engineer-in-Charge, more than one cycle of loading and unloading shall be
carried out at any or all of the stages.

c) Each stage of loading or unloading shall be maintained till the rate of

movement of the pile top is not more than 0.2 mm per hour provided that the
minimum period if two hours for loading and one hour for unloading. The
following load stages shall be maintained for longer periods as given below:
i. At load of 1.5 time assumed safe capacity (for routine test only) –24 hours
ii. At load of twice assumed safe capacity (for initial test only) –24 hrs.

The loading shall be continued till one of the following occurs:

i. Yield of the soil pile system occur causing progressive settlement
exceeding one tenth of the pile diameter.
ii. The loading on the pile top equals twice the estimated safe load in case
of a separate test pile and 1.5 times the rated capacity of the pile in case
of a working pile.

ASSESSMENT OF SAFE LOAD

The safe capacity of the pile shall be the least of the following:
i) Load corresponding to settlement specified in specific requirements which is
based on the nature and type of structure.
ii) Half of the final load at which the total settlement equals one tenth of the
pile diameter.

9.5 LATERAL LOADING: LATERAL LOADING TEST

 Equipment and Test Set -up

Test Pile: The test pile shall be decided by the Engineer-in-Charge. It may be one
of the working piles or a separate test pile. The test pile shall be cut off at the
proper level and provided with a cap with vertical plane sides having an adequate
area for proper seating of the jack and dial gauges.

Loading System:
Loading shall be applied by a hydraulic jack of adequate capacity, abutting the pile
horizontally and reacting against the suitable system. The reaction may be provided
by the wall of the excavated pit when the test is being conducted below ground
level or by a neighboring pile in which case thrust pieces shall be inserted on either
end of the jack to make up the gap.
Measuring System :
Lateral load applied on the pile shall be measured by a calibrated pressure gauge
mounted on the jack, having a least count of 500 kg. Deflection of the pile head shall
be measured by dial gauges, fixed to datum bars and having a least count of 0.01 mm.
The datum bars shall be provided with rigid supports as described in Clause 2.1.3.2 (b)
above.

METHOD OF CONDUCTING TESTS :

The test shall be carried out in accordance with the provisions of IS:2911-(Part-IV)
and as detailed below:

 Loading shall be applied in increments of 500 kgs or as specified.

 Each stage shall be maintained for a period till the rate of movement of the
pile head is not more 0.2 mm/hr or 1 hr whichever is greater.

Loading shall be continued till one of the following occurs:

 Deflection of the pile head exceeds 12 mm.

 The applied load on the pile is twice the assumed lateral load capacity of the pile
in case of a separate test pile and 1.5 times the rated capacity in the case of a
working pile.

ASSESSMENT OF SAFE LOAD:

The safe load shall be the smaller of the following:
i) Half of the final load for which the total deflection is 12 mm.
ii) Load corresponding to 5 mm total deflection.
Note: The deflection is at the cut off level of the pile.

9.6 PULL OUT:

PULLOUT CAPACITY OF PILES
• Test Pile:
The test pile shall be decided by the Engineer-in-Charge. The test shall be
conducted on separate pile installed specifically for this purpose. The test pile
shall be built up to the proper length and the head provided with suitable
arrangements for anchoring the load applying system.
• Loading System
Load shall be applied using an approved reaction system. Uplift force on the pile
may be applied directly to the test pile or through a level system. The reaction
may be provided by neighboring piles or blocks may be constructed for the
purpose. A hydraulic jack shall be used for load application.
• Measuring System
Load applied by jack shall be measured by a calibrated pressure gauge with a
least count of 1000 kgs. Movement of the pile shall be measured by dial gauges,
fixed to datum bar and having a least count of 0.01 mm. Aminimum of two dial
gauges, placed diametrically opposite shall be used. Datum bars shall be
provided with rigid supports as described in 2.1.3.2 (b) above.

METHOD OF CONSTRUCTING TEST:

Loading shall be applied to the pile top in increments of one fifth the rated
capacity of pile. Each stage shall be maintained for a period till the pile head is
not more than 0.2 mm/hr or one hour, whichever is greater.
 Loading shall be continued till one of the following occurs:
a) Yield of soil pile system occurs causing progressive movement of the
pile exceeding 12 mm.
b) The loading on the pile top equals twice the estimated safe load or as specified.

9.7 COMBINED VERTICAL AND LATERAL LOADING

Equipment and Test set -up:

The equipment and test set up shall be same as described in Clause 3. In addition
platform shall be constructed on the pile top, and loaded to 1.0 times the pile capacity
in vertical loading. The pile shall be first subjected to the full vertical load. The lateral
load shall commence after all settlements due to the vertical load have ceased and
while the full vertical load is in position.

9.8SPECIAL TYPE OF LOADING SUCH AS VIBRATORY LOADINGS

This shall include evaluating the pile response to vibratory loads, both horizontal and
vertical in nature. The test set up and method of conducting the test shall be covered
under specific requirements.

All testing shall be performed in accordance with the following codes and the provision
of these specifications IS: 2911-(Part IV) – Code of Practice for design and construction
of pile foundations –Load Test on Piles.

9.9 GENERAL

 Any number of test piles and working piles as specified in the schedule of items
or at the discretion of the ENGINEER shall be subjected to load tests. The
CONTRACTOR shall provide everything necessary including equipment,
measuring devices, jacks, structural framework, kentledges etc. This includes
installation of test piles also and concreting of pile cap either temporary or
permanent over single or group of piles for testing the piles. The pile cap
concreting will not be paid for separately.
 Load tests shall in general be carried out as per IS: 2911(Part IV) except as
modified herein or directed otherwise by the ENGINEER.
 Piles to be load tested shall be so designated on the drawings or specified/
selected by ENGINEER in the field.
 Test load shall be applied to the piles by any suitable means preferably by a
properly calibrated hydraulic jack with a remote control pump. Test load
applied to the piles shall be such that a constant load is maintained under
increasing settlement.
 The required reaction may be derived from either a loaded platform or
anchor piles. Anchor piles shall not be closer than 6 times the pile diameter
on either side. Working piles shall not be used as anchor piles. Anchor piles,
if provided, shall be at CONTRACTOR's cost.
 Load tests shall in general be carried out not earlier than 28 days from the time
of casting the pile and may be performed concurrently with the pile installation
operations if permitted by the ENGINEER.
 The design and arrangement of application of loading etc. for all types of load
tests, shall be submitted to the ENGINEER for approval.
 All load tests shall be conducted under the supervision of the ENGINEER. All
responsibilities for conducting the tests safely and properly shall rest with the
CONTRACTOR.
9.10 CALIBRATION OF EQUIPMENT:

The CONTRACTOR shall ensure, that all the equipment/ instruments are properly
calibrated, at the start of the tests, to reflect the correct values. If so demanded
by the ENGINEER, the CONTRACTOR shall have all or such specific instruments
tested at an approved testing laboratory at the CONTRACTOR's cost and the test
report shall be submitted to the ENGINEER. If the ENGINEER desires to
witness/inspect such tests, the CONTRACTOR shall arrange for this and also provide
such access and facilities for inspection as are required.

9.11 INITIAL LOAD TESTS

Immediately on mobilization to site, the CONTRACTOR shall prepare to install piles

for conducting initial vertical load (downward and pull-out) and lateral pile load
tests.
In case the cut-off is below ground level, a suitable excavation shall be made to
provide access to the level after breaking off the unsound concrete as specified
earlier in Clause 13.0.

For the compression type of test, the pile head shall be cut off level and capped by
a R.C. cap to provide a horizontal plane bearing surface upon which a steel plate
shall be placed. Earth from under the pile cap shall be scooped out so that pile cap
has no soil support. Thereafter, the kentledge and all other accessories outside the
pit pertaining to and necessary for conducting the test shall be set up. An easy
access to the pile test head shall be provided.

If the pile test head is below the ground water level, the CONTRACTOR shall
provide suitable sumps and dewater the pit so as to render the pit dry enough to
enable conducting the test. Any dewatering will be considered as part of the test
and the CONTRACTOR shall not be separately paid for the same.

The test load shall be so applied that it reaches the pile in a static manner. The
loading may be applied directly by kentledge or jacking against a reaction system
provided by means of kentledge, tension piles or ground anchors. Where kentledge
is used it shall be supported on a properly designed frame or gantry such that there
is no possibility of the load tilting or collapsing. The foundations of this frame or
gantry should be sufficiently far away from the test pile so as not to affect its
behavior to any significant extent. Where tension piles or ground anchors are used,
they shall be located a minimum distance of three times the test pile size from the
centre of the test piles to the centre of the pile/ anchor.

The displacement of the test pile shall be related to a fixed datum. This may
consist of a reference beam (datum bar) supported by two foundations positioned
outside the zones of influence of the reaction support area. The deflection
measuring equipment must be set up in such a way that any tilting of the test pile
will not cause errors in the measurements. Dial gauges shall be used for measuring
deflection. The least count of the dial gauges shall be at least 0.02mm. At least
two but preferably four dial gauges shall be used and shall be placed at diagonally
opposite corners.

The reference bars for the strain gauges shall be adequately rigid and on firm
supports. The supports for the reference bars shall be so located that they are
beyond the zone of influence ofthe loaded test pile (equal to three times the pile
size from pile edge) and the zone of influence of kentledge supports. The bars shall
 be adequately stiffened and placed on supports in a manner such that any effect
due to ambient temperature variations and vibrations due to traffic etc. are
minimized. The reference bars and strain gauges shall not be exposed to direct sun
and the pit shall be protected by tarpaulin sheets while the test is in progress.

The total test load shall be three (3) times the estimated safe load carrying
capacity of the pile or failure, whichever is earlier, and shall be applied in equal
increments of 20 percent of the estimated safe load. Unloading may however be in
higher decrements with total number not less than five. At each load increment,
pile deflection shall be observed accurate to 0.02mm at an interval of 1, 5, 10, 15,
25, 35, 50 and 60 minutes and thereafter at half hourly intervals, upto a time when
the rate of deflection of the pile top reduces to 0.1mm in half hour or 0.2mm in
one hour. The load increment in any case shall be maintained for 1 hour at least.
The design load as well as the final load shall be maintained for 24 hours at least.
At these load increments, after the first hour, deflection readings shall be taken at
every one hour interval.

During the release stage, each load decrement shall be maintained at least for 30
minutes and readings of deflection noted. When the load is fully released to zero,
measurements of rebound shall be continued till the deflection of the pile top is
not more than 0.1 mm per half hour.

Initial cyclic tests shall be carried out to determine skin friction and point
resistance of piles. This shall be carried out as per IS:2911 (Part-IV). However, each
cycle of loading and unloading shall be repeated allowing a time interval of 10
minutes between the end of one cycle and the beginning of the next.

For the initial lateral pile load test pairs of piles for lateral load tests shall be
driven. Lateral load test shall be conducted as per IS:2911 (Part-IV). The total test
load shall be three (3) times the estimated safe load carrying capacity of the pile or
failure, whichever is earlier. Load shall be applied at cut-off level.

Piles specified for pull out test shall be subjected to pull-out force equal to (2)
times the estimated safe load carrying capacity of the pile in equal increments of
not more than 2.5 tonne till the rise exceeds 12mm whichever is earlier. A graph of
pull out force and the corresponding rise of pile top shall be plotted immediately.

If the initial test pile(s) which is (are) load tested fails (fail) to attain the specified
safe structural capacity of piles and if this can be attributed to defective
workmanship and/or negligence on the part of the CONTRACTOR, the OWNER
reserves the right to terminate the contract and to award the contract to other
parties. In such an event, all costs of mobilization, installation and testing of test
pile(s) and any other work in connection with the test piles, shall be borne entirely
by the CONTRACTOR.

While executing the pile bore for all test piles, a record of bore log and Standard
Penetration Tests shall be maintained over the continuous length of boring in an
approved format. Subsoil samples and rock cuttings shall be collected and
systematically preserved as per Clause 9.3 above.

9.12 LOAD TESTS ON WORKING PILES

These tests shall be carried out on piles selected by the ENGINEER after they have
been cast. Tests to be carried out on working piles shall essentially be ordinary
 compression type. The test will be similar to that conducted on initial test piles,
except that the test load on pile shall be limited to 1.5 times the safe pile
capacity. The maximum settlement during test loading shall not exceed 12mm.

The working pile shall be considered to have stood the test satisfactorily if total
settlement under final test load is not more than 12mm and net (residual)
settlement after removal of test load not more than 6 mm.

If the pile does not satisfy these requirements and if this can be attributed to
defective workmanship or negligence on the part of the CONTRACTOR, all costs of
the load test, the cost of providing and installing additional piles, cost of
additional or enlarged pile caps and other work necessitated because of the
defective pile, shall be at the cost of the CONTRACTOR.

9.13 RECORDS OF LOAD TEST RESULTS

Within 48 hours of completion of each test, the CONTRACTOR shall furnish a copy
of all recorded test data to the ENGINEER. Upon completion of pile load tests, the
CONTRACTOR shall furnish the ENGINEER at no extra cost with a pile test report in
triplicate and this shall include the following information where applicable.

a) Identification of working pile/test pile as per drawing.

b) Co-ordinate axes of pile, elevation of bottom of pile, cut off level of pile, type
of pile, pile size.
c) Pile Bore log Records.
d) SPT results
e) Deviation from designated location/ alignment.
f) Jack gauge calibration curves from approved Test House.
g) Tabulation of loads and settlement readings during the loading and unloading
of the pile.
h) Graphic representations of the test results in the form of time-load-
settlement curves.
i) Graphic analysis of Initial Cyclic test results to separate skin friction and end
bearing as set out in IS:2911 (Part-IV).
j) Remarks concerning any unusual occurrences during installation or test
loading of the working piles/ test piles.

9.14 INDIRECT INTEGRITY TESTS FOR PILES

The ENGINEER may desire to get bored cast in situ piles subject to integrity tests
by indirect methods through another agency. The CONTRACTOR shall give all co-
operations in getting such tests conducted. The ENGINEER reserves the right to
give due weightage and consideration to results of these tests which will affect
the integrity of the installed piles.

9.15 Recording of Data:

Full record of pile load test results shall be submitted in triplicate to the Engineer-in-
Charge immediately on completion of each test. The record shall also include the plots
of load-settlement (for various stages of loads) characteristics of pile and also the
interpretation of the pile load test curve as per criteria for safe loads mentioned in
the specifications for testing concrete piles forming a part of this tender. Any special
observations shall be duly explained by the contractor.
Daily site records shall be maintained by the Contractor for the installation of piles
against each Rig and shall contain the number and dimension of the pile, depth bored
( including depth in soft / hard rock ), time taken for boring, concreting and empty
boring ( cut-off level) , chiseling and where the pile is wet or dry.

Sample bore log in the initial stage or when major variation occur should be shown.
When drilling mud is used, amount of bentonite needed for stabilization of bore,
specific gravity of the fresh supply and contaminated mud in the bore hole before
concreting shall be checked and recorded regularly. Concrete volume actually cast per
pile against required volume and actual cement consumption. Detail of any
obstruction encountered its nature, depth and obstruction time. Any deviation from
the designated location alignment or load capacity of any pile shall be noted.

Typical data sheet in triplicate for facility of recording piling data to be prepared by
the Contractor before starting of actual piling operation at site and information to be
recorded against each pile in the data sheet shall be signed by the contractor and
countersigned by GWSSB. One copy of the data sheet shall be retained by the
Contractor and the other two copies to be submitted to GWSSB for records & future
reference.

At least six photographs are to be taken by the party depicting progress of the job in
every week and a set of same to be separately submitted for review and record to
GWSSB.

A competent supervisor shall be present to record the necessary information during

the installation of piles. The data to be recorded shall include:

a) The dimensions of the piles, including the reinforcement detail and the
mark of the pile.

b) The boring method employed.

c) The type of soil in which pile is terminated

d) The depth bored.

d) The depth of water table.

e) When drilling mud is used, the specific gravity of the fresh supply and
contaminated mud in the borehole before concreting is taken up, in case of
first few piles and subsequently at suitable interval of piles.
f) The time taken for concreting.

g) The cut-off level/working level

h) The consumption of cement.

i)
j) Any other important observations.

Any deviation from the designed location, alignment or load carrying capacity of any
pile shall be noted and promptly reported to the Engineer-in-Charge.
 APPENDIX – 1

PILE LOAD TEST RECORD

Vertical / Lateral / Pull Out Test

Pile No…………………… Date of ……………… WT of Hammer ……………………..

Type……………………… Driving……………….. AVR. Drop of Hammer…………….

Total No. of
Diameter (cm)……………. Casting……………….. Blows…………………..

Length below Commence of Test Sum of Temporary Compression

in cms

G.L. (M)………………… ………………………… ……………………………………….

Completion of
Location………………… Test…… Ground level …………………………

Settlement( AVR.Settleme
Totaltime Loadoff( Total Rebound(m
Date Time Load Deflection)G nt(Deflection) Remarks
(hr) T) load(T) m)
auge (mm) (mm)
Total Net
 STANDARD SPECIFICATION FOR MATERIALS FOR REINFORCED CONCRETE PILES:-

1.0 GENERAL:

1.1 Scope:

This specification establishes the material specification of reinforced cement concrete

to be used in pile foundation. Any special requirements as shown or noted on the
drawings shall govern over the provisions of these specifications. All materials which
may be used in the Plain or Reinforced Cement Concrete work shall be of Standard
quality conforming to IS or IRC or equivalent and shall have IS certification mark as far
as possible unless otherwise approved by the Engineer-in-Charge. The contractor shall
get all materials approved by Engineer-in -Charge prior to its procurement and before
actual use. The Engineer-in-Charge shall have the right to determine whether all or
any of the materials offered or delivered for use in the works are acceptable. Any
material brought to site and not conforming to specification and instruction of
Engineer-in -Charge shall be rejected and the contractor shall have to remove the
same immediately from site at his own expense.

For specific work requirements concerning design and construction or otherwise

modifying or supplementing the provision of this specification, refer to the specific
requirements. In case of conflict between specific requirements and provision of this
specification, former shall govern.

1.2 Definitions:

1.2.1 Reference to IS or IRC Codes shall always mean reference to the latest issue of the
relevant standards including all its amendments up to date.

1.3 Codes:

All design and construction shall be performed in accordance with the IRC and Indian
Standard Code of Practice for Plain and Reinforced Concrete IS: 456 & IS: 2911

2.0 MATERIALS FOR CONCRETE:

2.1 Cement.

2.1.1 General:

The cement used shall be Sulphate Resistant Cement or Ordinary Portland Cement
conforming to relevant latest IS version. The vendor of the same shall be approved by
GWSSB.

2.1.2 Tests after Delivery:

Each consignment of cement may, after delivery on the site at the discretion of the
Engineer-in-Charge, be subjected to any or all of tests and analysis required by the
relevant Indian Standard Specifications. Facilities for testing shall be provided by
contractor at his own cost.

2.1.3 Storage on the Site:

The cement shall be stored in a suitable weather-tight building and in such a manner
 as to permit easy access for proper inspection to prevent deterioration due to
moisture and to minimize warehouse deterioration. Cement of different type and
brands shall be kept in separate storage. All accepted cement stored on the site shall
be arranged in batches, and used in the same order as received from the
manufacturer. The contractor shall maintain a cement register, in which all entries
shall be completed day to day showing the quantities received, date of receipt, source
of dispatch, type of cement, etc. and also the daily cement consumption on site. The
register shall be accessible to the Engineer-in- Charge for his verification.

2.1.4 Rejection of Cement:

The Engineer-in-Charge may reject any cement as a result of any tests thereof,
notwithstanding the manufacturer’s certificate. He may also reject cement which has
deteriorated owing to inadequate protection from moisture or due to intrusion of
foreign matter or other causes. Any cement which is considered defective by the
Engineer-in-Charge shall not be promptly removed from the site of the work by the
contractor at his own expense.

2.2 Aggregates for Concrete:

2.2.1 General:

Coarse and fine aggregates for concrete shall conform in all respect to IS: 383,
“Specification for Coarse and Fine Aggregates from Natural Sources for Concrete”.
Aggregates shall be obtained from a source known to produce those satisfactory for
concrete. Aggregates shall consist of naturally occurring sand and granite/basalt trap
stone, crushed or uncrushed, or a combination thereof. They shall be chemically inert,
hard, strong, dense, durable, clean and free from veins, adherent coatings and shall
be of limited porosity. Flaky and elongated pieces shall not be used. The source of
aggregates shall be approved by the Engineer-in-Charge and shall not be changed
during the course of the job without his approval. Rejected aggregates shall be
removed from the work site by the contractor at his own expense.

2.2.2 Deleterious Materials:

Aggregates shall not contain any harmful materials such as iron pyrites, coal, mica,
shale or similar laminated materials, clay, alkali, soft fragments, sea shells, organic
impurities etc. in such quantities as to affect the strength or durability of the
concrete. In addition to the above, for reinforced concrete, any material which might
cause corrosion of the reinforcement and aggregates which are chemically reactive
with the alkalis of cement shall not be used. The maximum quantities of deleterious
materials in the aggregates, as determined in accordance with IS: 2386 (Part-II)
“Methods of Test for Aggregates for Concrete”, shall not exceed the limits given in
Table-I of IS: 383. The sum of the percentages of all deleterious materials shall not
exceed five. Deleterious materials also include material passing 75 micron IS sieve.

2.2.3 Coarse Aggregates:

Coarse aggregate is aggregate most of which is retained on 4.75 mm IS sieve. These

may be obtained from crushed or uncrushed granite/basalt trap stone as per Cl. 2.3.1
and may be supplied as single sized or graded aggregates given in Table-II of IS: 383.
The Engineer-in-Charge may allow all-in-Aggregate to be used provided they satisfy
the requirements of clause 4.4 and T able-IV of IS 383.

2.2.4 Fine Aggregates:

Fine aggregate is aggregate most of which passes 4.75 mm IS Sieve but not more than
 10% pass through 150 microns IS Sieve. These shall comply with the requirements of
grading zones I, II and III and given in Table-III of IS: 383. Fine aggregate conforming to
grading zone IV shall not be normally used in reinforced concrete unless tests have
been made by the contractor to ascertain the suitability of the proposed mix
proportion and approved by the Engineer-in-Charge. Fine aggregate shall consist of
natural sand resulting from natural disintegration of rock and which has been
deposited by streams or glacial agencies, or crushed stone sand or crushed gravel
sand.

2.2.5 Sampling and Testing:

In case of doubt the Engineer-in-Charge may require the contractor to carry out tests,
at the contractor’s expense in accordance with – IS: 516 – Method of Tests for
Strengths of Concrete; and IS: 2386- Method of Tests for Aggregates for Concrete.

2.2.6 Storage of Aggregates:

The contractor shall at all times maintain at the site of work such quantities of
aggregate as are considered by the Engineer-in -Charge to be sufficient to ensure
continuity of work. Each type and grade of aggregate shall be stored separately on
hard firm ground having sufficient slope to provide adequate drainage to rain water.
Any aggregate delivered to site in a wet condition or becoming wet at site due to rain
shall be kept in storage for at least 24 hrs. to obtain adequate drainage, before it is
used for concreting, or the water content of mix must be suitably adjusted as directed
by Engineer-in-Charge.

2.3 Water:

Water to be used for concrete shall be clear and free from injurious amounts of Oil,
Acid Alkali, Organic matters or other harmful substances in such amount that may
impair the strength or durability of structure. Potable water shall generally be
considered satisfactory for mixing and curing concrete. The Engineer-in-Charge may
require the contractor to prove at latter’s expense, that the concrete mixed with
water proposed to be used should not have a compressive strength, lower than 90% of
the strength of concrete mixed with distilled water. The Engineer-in -Charge may
require the contractor to get the water tested from an approved laboratory at his own
expenses and in case the water contains any sugar or an excess of acid, alkali, any
injurious salts, etc. the Engineer-in-Charge may refuse to permit its use.

3.0 Admixtures :

3.1 Admixtures such as CICO grade I or KIM (KRYTON make) or equivalent may be used in
concrete only with the approval of Engineer-in-Charge.

4.0 Reinforcement :

4.1 Corrosion resistant Steel reinforcement

4.1.1 The reinforcement shall confirm to IS: 1786, Fe-500 grade. The reinforcement shall be
Corrosion resistant steel and it shall be either “TISCON CRS” from TISCO or HSCR-M
from Vizag Steel or HCR from SAIL-M normally be mild steel in the form of round bars,
conforming to IS: 432-Grade 1 unless specified otherwise.

4.1.2 Hard-Drawn Steel wire Fabric :

 When specified in the drawings, hard drawn steel wire fabric shall be used conforming
to IS: 1566, It shall be of approved type and of the weights and dimensions shown in
the drawings.

4.2 Welding:

4.2.1 Field welding of reinforcing bars will not be permitted without the written consent of
the Engineer-in-Charge. Where welding is permitted it must be at staggered locations.
Tests shall be made to provide that the joints are of the full strength of bars
connected. Welding of reinforcement shall be done in accordance with the
recommendation of IS: 2751.

4.3 Storage:

4.3.1. The steel reinforcement shall be stored in such a way as to avoid distortion and to
prevent deterioration and corrosion.

4.4 Other Specifications:

4.4.1 General construction details and workmanship relative to reinforcement including bar
bonds, lap splices and installation shall be in accordance with I S:2502- Code of
Practice for Bonding and Fixing of Bars for concrete reinforcement, as well as the
detailing of reinforcement given in I S:456.

4.4.2 Hot bending of bars shall not be allowed.

4.4.3 The number of sizes, shape and position of all the reinforcement shall, unless
otherwise directed or authorized by the Engineer-in-Charge, be strictly in accordance
with the drawings. The reinforcement shall be adequately secured and held in position
by metal chairs and spacers. Ties of inter-sections shall be made with 16 SWG soft
black annealed binding wire.

4.4.4 The contractor must obtain the approval of the Engineer-in-Charge for the
reinforcement placed, before any concrete is placed in the forms. The reinforcement
of this time shall be free from loose rust or scale or other coating that will destroy or
reduce bond.

4.4.5 Concrete spacer blocks of the same strength as parent concrete shall be used to ensure
correct cover to the reinforcement. This clear cover shall be as shown on the drawings
or as per instructions of the Engineer-in-Charge.

4.4.6 All the reinforcing bars shall be so tied as to form a rigid cage to prevent displacement
before or during concreting.
 SUPPLY AND FABRICATION OF STRUCTURAL STEEL

1.0 GENERAL

1.1 This specification covers the general requirements for supply where specified,
fabrication and delivery at site of structural steel.

1.2 This specification also covers design of all connections and substituted members,
preparation of all shop fabrication drawings, inspection and shop painting of structures.

2.0. APPLICABLE CODES & SPECIFICATIONS

The following specifications, standards and codes are made a part of this
specification. All standards, specifications and codes of practices referred to herein
shall be the latest editions including all applicable official amendments and revisions.

In case of discrepancy between this specification and other documents referred to

herein, this specification shall govern.

(A) Material
IS: 808 : Dimensions for Hot Rolled Steel sections
Covered Electrodes for Manual Metal Arc Welding of Carbon
IS: 814
: and Carbon Manganese Steel
IS: 1161 : Steel Tubes for structural purposes
IS: 1239 : Mild steel tubes, tubular and other wrought steel fittings
 : Part 1 - Mild steel tubes
Part 2 - Mild steel Tubular and other wrought steel pipe

: fittings
Hexagon Head Bolts, Screws and Nuts of product (Parts 1 to
IS: 1363
: 3) Grade C (Size range M5 to M64)
Technical Supply Conditions for Threaded Fasteners (All
IS: 1367
: Parts)
IS : 1852 : Rolling and Cutting Tolerances for Hot Rolled Steel Products
IS : 1977 : Structural Steel (Ordinary Quality)
IS : 2062 : Steel for General Structural Purposes
Ready Mixed Paint, Air drying, Red Oxide Zinc Chrome and
IS : 2074
: Priming
IS : 3502 : Steel Chequered Plate
IS : 3757 : High Strength Structural Bolts
IS : 5369 : General Requirements for Plain Washers and Lock Washers
IS : 5372 : Taper Washers for Channels
IS: 5374 : Taper Washer for I Beams
IS : 6610 : Heavy Washers for Steel Structures
Structural Steel-micro alloyed (medium and high strength
IS : 8500
: qualities)
(B) Codes Of Practice :
IS : 800 : Code of Practice for General Construction in Steel
Code of practice for design, fabrication and erection of
IS : 803
: vertical mild steel cylindrical welded storage tanks
Code of practice for use of steel tubes in general building
IS : 806
: construction
IS : 816 : Code of Practice for use of Metal Arc Welding for General
 construction in Mild Steel
IS : 822 : Code of Procedure for Inspection of Welds
Recommended Practice for Radiographic examination of
IS : 1182
: Fusion - Welded Butt Joints in Steel Plates
IS : 1200 : Method of Measurement in Building Civil Engineering Works
Code of Practice for Painting of (Parts 1 & 2) Ferrous Metals
IS : 1477
: in Buildings
IS : 2595 : Code of Practice for Radiographic Testing
IS : 3658 : Code of Practice for Liquid Penetrant Flaw Detection
IS : 4000 : High strength bolts in Steel Structures - Code of Practice
Code of Practice for Magnetic Particle Flaw Detection of
IS : 5334
: Welds
IS : 7215 : Tolerances for Fabrication of Steel Structures
Recommendations for Metal Arc Welding of Carbon and
IS : 9595
: Carbon Manganese Steel

3.0 STEEL MATERIALS

Steel materials shall comply with the specifications laid down under clause 2.0 and/or
as called for on the design drawings.

All materials used shall be new, unused and free from defects. Steel conforming to IS:
1977 shall be used only for the following:

 Fe 310-0(St 32-0): for general purposes such as door/ window frames, grills,
steel gates, handrails, fence posts, tee bars and other
non-structural use.

 Fe 410-0(St 42-0): for structures not subjected to dynamic loading other than wind
loads such as: Platform roofs, foot over bridges, building etc.

 Fe410-0(St 42-0): grade steel shall not be used

a) if welding is to be employed for fabrication.
b) if site is in severe earthquake zone.
c) if plastic theory of design is used.

4.0 USE OF STEEL SUPPLIED BY THE PURCHASER

The VENDOR/CONTRACTOR shall use steel supplied by the PURCHASER judiciously

and to the best advantage so as to minimize splicing and wastage. All steel materials
remaining after completion of the report, whether in the form of balance pieces or
unutilized prime steel, shall be returned to the PURCHASER's stores by
the VENDOR/CONTRACTOR at his own cost. An unaccountable wastage upto a
maximum of 1% of the fabricated steel will be allowed. This wastage does not include
the balance cut lengths/pieces of steel returned to the PURCHASER.

5.0 DRAWINGS PREPARED BY THE OWNER

Drawings appended with the tender document is for information purpose only. All
necessary detailing and preparation of drawings will be in the scope of the
Contractor. It shall be clearly understood that these drawings are not intended to
show connection details, thickness of members, cuts, notches, bends and such other
details.

6.0 DRAWINGS PREPARED BY THE VENDOR/CONTRACTOR

6.1 The VENDOR/CONTRACTOR shall prepare all fabrication and erection drawings for the
entire work. All the drawings for the entire work shall be prepared in metric units.
The drawings shall preferably be of one standard size and the details shown there in
shall be clear and legible.

6.2 The VENDOR/CONTRACTOR shall not commence detailing unless ENGINEER's design
drawings are officially released for preparation of shop drawings. The
VENDOR/CONTRACTOR shall be responsible for the correctness of all fabrication
drawings. Fabrication drawings shall be revised by the VENDOR/CONTRACTOR to
reflect all revisions in design drawings as and when such revisions are made by the
ENGINEER.

6.3 All fabrication drawings shall be submitted to the ENGINEER for approval.

6.4 No fabrication drawings will be accepted for approved by the

VENDOR/CONTRACTOR's qualified structural engineer and accompanied by
an erection plan showing the location of all pieces detailed. The
VENDOR/CONTRACTOR shall ensure that connections are detailed to obtain ease in
erection of structures and in making field connections.

6.5 Fabrication shall be started by the VENDOR/ CONTRACTOR only after ENGINEER's
approval of fabrication drawings. Approval by the ENGINEER of any of the drawings
shall not relieve the VENDOR/CONTRACTOR from the responsibility for correctness of
engineering & design of connections, workmanship, fit of parts, details, material,
errors or omissions of any and all work shown thereon. The ENGINEER's approval shall
constitute approval of the size of members, dimensions and general arrangement but
shall not constitute approval of the connections between members and other details.

6.6 The drawings prepared by the VENDOR/CONTRACTOR and all subsequent revisions
etc. shall be at the cost of the VENDOR/CONTRACTOR for which no separate payment
will be made.

7.0 FABRICATION

7.1 General

All workmanship and finish shall be of the best quality and shall conform to the best
approved method of fabrication. All materials shall be finished straight and shall be
machined/ground smooth true and square where so specified. All holes and edges
shall be free of burrs. Shearing and chipping shall be neatly and accurately done and
all portions of work exposed to view shall be neatly finished. Unless otherwise
directed/ approved, reference may be made to relevant IS code for providing
standard fabrication tolerance. Material at the shops shall be kept clean and
protected from weather.

7.2 Connections

7.2.1 Shop/field connections shall be as per approved fabrication drawings.

7.2.2 In case of bolted connections, taper washers or flat washers or spring washers shall
be used with bolts as necessary. In case of high strength friction grip bolts, hardened
washers be used under the nuts or the bolt heads whichever are turned to tighten the
bolts. The length of the bolt shall be such that at least one thread of the bolt
projects beyond the nut, except in case of high strength friction grip bolts where this
projection shall be at least three times the pitch of the thread.

7.2.3 In all cases where bearing is critical, the unthreaded portion of bolt shall bear on the
 members assembled. A washer of adequate thickness may be provided to exclude the
threads from the bearing thickness, if a longer grip bolt has to be used for this
purpose.

7.2.4 All connections and splices shall be designed for full strength of members or loads
indicated on ENGINEER's design drawings. Column splices shall be designed for the
full tensile strength of the minimum cross section at the splice.

7.2.5 All bolts, nuts, washers, electrodes, screws etc. shall be supplied/brought to site
10% in excess of the requirement in each category and size. Rates shall cover the
cost of this extra quantity.

7.2.6 All members likely to collect rainwater shall have drain holes provided.

7.3 Straightening

All materials, shall be straight and, if necessary, before being worked shall be
straightened and/or flattened by pressure and shall be free from twists. Heating or
forging shall not be resorted to without the prior approval of the ENGINEER in
writing.

7.4 Cutting, punching, drilling, welding and fabrication tolerances shall be

generally as per relevant IS codes.

7.5 Rolling and Forming

Plates, channels, R.S.J. etc., for circular bins, bunkers, hoppers, gantry girders,
etc., shall be accurately laid off and rolled or formed to required profile/ shape as
called for on the drawings. Adjacent sections shall be match-marked to facilitate
accurate assembly, welding and erection in the field.

7.6 High Strength Friction Grip Bolting

7.6.1 Inspection after tightening of bolts shall be carried out as stipulated in the
appropriate standards depending upon the method of tightening and the type of bolt
used.

7.7 Welding

7.7.1 Welding procedure shall be submitted to ENGINEER for approval. Welding shall be
entrusted to only qualified and experienced welders who shall be periodically tested
and graded as per IS 817, IS: 7310 (Part 1) and IS: 7318 (Part 1).

7.7.2 While fabricating plated beams and built up members, all shop splices in each
component part shall be made before such component part is welded to other parts
of the members. Wherever weld reinforcement interferes with proper fit-up between
components to be assembled for welding, these welds shall be ground flush prior to
assembly.

7.7.3 Approval of the welding procedure by the ENGINEER shall not relieve the
CONTRACTOR of his responsibility for correct and sound welding without undue
distortion in the finished structure.

7.7.4 No welding shall be done when the surface of the members is wet nor during periods
of high wind.

7.7.5 Each layer of a multiple layer weld except root and surface runs may be moderately
peened with light blows from a blunt tool. Care shall be exercised to prevent scaling
or flaking of weld and base metal from overpeening.
 No welding shall be done on base metal at a temperature below -5 Deg.C. Base metal
shall be preheated to the temperature as per relevant IS codes.

7.7.6 Electrodes other than low-hydrogen electrodes shall not be permitted for
thicknesses of 32 mm and above.

7.8 Inspection of Welds

All welds shall be inspected for flaws by any of the methods described under clause 8
"Inspection". The choice of the method adopted shall be determined by the
PURCHASER/ENGINEER.

The correction of defective welds shall be carried out as directed by the ENGINEER
without damaging the parent metal. When a crack in the weld is removed, magnetic
particle inspection or any other equally positive means as prescribed by the
ENGINEER shall be used to ensure that the whole of the crack and material upto 25
mm beyond each end of the crack has been removed. Cost of all such tests and
operations incidental to correction shall be to the VENDOR/CONTRACTOR's account.

7.9 Tolerances

The dimensional and weight tolerances for rolled shapes shall be in accordance with
IS:1852 for indigenous steel and equivalent applicable codes for imported steel. The
tolerances for fabrication of structural steel shall be as per IS:7215.

7.10 End Milling

Where compression joints are specified to be designed for bearing, the bearing
surfaces shall be milled true and square to ensure proper bearing and alignment.

8.0 INSPECTION

8.1.1 The VENDOR/CONTRACTOR shall give due notice to the PURCHASER/ENGINEER in

advance of the works getting ready for inspection. All rejected material shall be
promptly removed from the shop and replaced with new material for the
PURCHASER's/ENGINEER's approval/ inspection. The fact that certain material has
been accepted at the VENDOR/CONTRACTOR's shop shall not invalidate final
rejection at site by the PURCHASER/ENGINEER if it fails to conform to the
requirements of these specifications, to be in proper condition or has fabrication
inaccuracies which prevents proper assembly nor shall it invalidate any claim which
the PURCHASER may make because of defective or unsatisfactory materials and/or
workmanship.

8.1.2 No materials shall be painted or dispatched to site without inspection and

approval by the PURCHASER/ ENGINEER unless such inspection is waived
in writing by the ENGINEER.

8.1.3 The VENDOR/CONTRACTOR shall provide all the testing and inspection
services and facilities for shop work except where otherwise specified.

8.1.4 For fabrication work carried out in the field the same standard of
supervision and quality control shall be maintained as in shop fabricated
work. Inspection and testing shall be conducted in a manner satisfactory
to the ENGINEER.

8.2 Inspection and tests on structural steel members shall be as set forth below:
8.2.1 Material Testing

If mill test reports are not available for any steel materials the same shall
be got tested by the VENDOR/CONTRACTOR to the ENGINEER's satisfaction
to demonstrate conformity with the relevant specification.

8.3 Tests on Welds

8.3.1 Magnetic Particle Test

Where welds are examined by magnetic particle testing, such testing shall
be carried out in accordance with relevant IS codes. If heat treatment is
performed, the completed weld shall be examined after the heat
treatment. All defects shall be repaired and retested. Magnetic particle
tests shall be carried out using alternating current. Direct current may be
used with the permission of the ENGINEER.

8.3.2 Liquid Penetrant Inspection

In the case of welds examined by Liquid Penetrant Inspection, such tests

shall be carried out in accordance with relevant IS Code. All defects
shown shall be repaired and rechecked.

8.3.3 Radiographic Inspection

All full strength butt welds shall be radio graphed in accordance with the
recommended practice for radiographic testing as per relevant IS code.

8.4 Dimensions, Workmanship & Cleanliness

Members shall be inspected at all stages of fabrication and assembly to

verify that dimensions, tolerances, alignment, surface finish and
painting are in accordance with the requirements shown in the
VENDOR/CONTRACTOR's approved fabrication drawings and the
ENGINEER's drawings.

8.5 Test Failure

In the event of failure of any member to satisfy inspection or test

requirement, the CONTRACTOR shall notify the ENGINEER or his
authorised representative. The VENDOR/CONTRACTOR must obtain
permission from the ENGINEER before repair is undertaken. The quality
control procedures to be followed to ensure satisfactory repair shall be
subject to approval by the ENGINEER.

8.6 The ENGINEER has the right to specify additional testing as he deems
necessary, and the additional cost of such testing shall be borne by the
PURCHASER, only in case of successful testing.

8.7 The VENDOR/CONTRACTOR shall maintain records of all inspection and

testing which shall be made available to the ENGINEER or his authorized
representative.

9.0 SHOP MATCHING

For structures like bunkers, tanks, etc. shop assembly is essential. For
other steel work, such as columns along with the tie beams/bracings
 may have to be shop assembled to ensure satisfactory fabrication,
obtaining of adequate bearing areas etc. if so desired by the ENGINEER.
All these shop assemblies shall be carried out by VENDOR/CONTRACTOR
at no extra cost to the PURCHASER.

10.0 DRILLING HOLES FOR OTHER WORKS

As a part of this Contract, holes in members required for installing

equipment or steel furnished by other manufacturers or other
contractors shall be drilled by the VENDOR/CONTRACTOR at no extra
cost to the PURCHASER. The information for such extra holes will be
supplied by the PURCHASER/ENGINEER.

11.0 MARKING OF MEMBERS

After checking and inspection, all members shall be marked for

identification during erection. This mark shall correspond to
distinguishing marks on approved erection drawings and shall be legibly
painted and stamped on it. The erection mark shall be stamped with a
metal dye with figures at least 20 mm high and to such optimum depth
as to be clearly visible.

11.1 All erection marks shall be on the outer surface of all sections and near
one end, but clear of bolt holes. The marking shall be so stamped that
they are easily discernible when sorting out members. The stamped
marking shall be encircled boldly by a distinguishable paint to facilitate
easy location.

11.2 Erection marks on like pieces shall be in identical locations. Members

having lengths of 7.0 m or more shall have the erection mark at both
ends.

12.0 ERRORS

Any error in shop fabrication which prevents proper assembling and

fitting up of parts in the field by moderate use of drift pins or moderate
amount of reaming will be classified by the ENGINEER as defective
workmanship. In case ENGINEER rejects such material or defective
workmanship, the same shall be replaced by the materials and
workmanship conforming to the ENGINEER's requirements by
VENDOR/CONTRACTOR free of cost at site.

13.0 PAINTING

13.1 All fabricated steel material, except those galvanised shall receive
protective paint coating as specified in specification

13.2 Galvanizing of fabricated steel wherever specified, shall be as per specification.

14.0 METHOD OF MEASUREMENT

14.1 For the purpose of payment, the weight of the actual completed structures shall
be calculated from the approved drawings for different items of work. The
VENDOR/CONTRACTOR shall submit to the PURCHASER relevant material list
containing weight of each item.

14.2 No allowances will be permitted for bolts, nuts, washers, studs, screws etc,
galvanizing, welding or for rolling margins. One tonne for the purpose of payment
 shall mean ONE METRIC TONNE i.e. 1000 Kg.

14.3 The weight of a member made out of standard rolled section such as beams,
channels, angles, etc. shall be based on the standard IS:808 without deductions for
holes, notches, bevel cuts, etc. Where a component consists of a cut joist or
channels, the full weight of the rolled section shall be considered only if more than
half the depth of the original section is used. Otherwise, only half the section unit
weight shall be considered for calculation of the weight of the components.
Deductions shall be made in the weight of gussets/plates for cuts and notches of
900 sq. cm. or larger.

14.4 For gussets/plates used in trusses, bracings, columns, beams, etc, the area shall be
that of the minimum circumscribing rectangle except as stated in 14.3 above.

14.5 The weight of any built-up members shall be based on the weight of each
component.
 PAINTING OF STRUCTURAL STEEL

1.0 SCOPE

1.1 This specification covers the general requirements for painting structural steel work
involving the supply and delivery of all necessary materials, labour, scaffolding,
tools and equipment. This document covers the aspects of surface treatment,
application of primer paint and finish painting.

2.0 APPLICABLE CODES AND SPECIFICATIONS

The following Standard Specifications and Codes of Practice are made a part of this
Specification. All standards and codes referred to herein shall be the latest editions
including all applicable official amendments and revisions.

In case of discrepancy between this specification and those referred to herein, this
specification shall govern.

IS: 102  Ready Mixed paint, Brushing, Red Lead, Non-setting, Priming.
Ready Mixed paint, brushing, grey filler for enamels for use over
IS: 110 
primers.
Ready Mixed paint, Brushing, Finishing, Exterior Semi gloss for
IS: 117 
general purposes, to Indian Standard colors.
Ready Mixed paint, Brushing, Bituminous, Black, Lead
IS: 158 
free,acid,alkali and heat resisting.
IS: 159  Ready Mixed paint, Brushing, Acid resisting.
IS:341  Black Japan, Types A, B and C
 Codes of Practice for painting of ferrous metals in buildings.
IS: 1477  Part I - Pretreatment
 Part II - Painting
IS: 2074  Ready Mixed paints, Red Oxide Zinc chrome priming.
IS:2339  Aluminum paint for general purposes, in Dual container
Specification for enamel, synthetic, exterior, type 1, Undercoating
IS:2932 
(b) finishing
IS:2933  Specification for enamel, exterior, type 2,undercoating, (b) finishing
IS: 5905  Sprayed aluminum and zinc coatings on Iron and Steel.
IS: 6005  Code of practice for phosphate of Iron and Steel.
Specification for ready mixed paint, brushing, bituminous,black,and
IS: 9862 
lead free, acid, alkali, water & chlorine resisting.
IS: 13183  Aluminum paint, Heat resistant.
SIS-05-5900  Swedish Standard

3.0 SURFACE TREATMENT

3.1 All the surfaces of steelwork to be painted shall be thoroughly cleaned of all loose
mill scale, rust, grease, dirt and other foreign matter. The type of surface
treatment shall be as specified in the respective item of work. The workmanship
shall generally conform to the requirements of IS 1477-Part I.

3.2 Oil and grease removal shall be carried out either by solvent cleaning or by using
alkali type degreasing agents. To remove grease material, the surface shall be
cleaned with solvents
 containing emulsifier. After cleaning, the surface shall be washed with water. When
the surface has cement pelts or salts, the cleaning shall be done with strong alkalis.
After cleaning, water rinsing and subsequent passivation by dilute chromic acid
rinsing shall be carried out to ensure that no traces of alkali are left on the surface.
The procedure for cleaning by above mentioned methods shall be as per
manufacturer’s instructions.

3.3 Degusting and descaling of steel shall be carried out either manually, mechanically
or chemically.

3.3.1 Manual or Hand Tool Cleaning

Loose mill scale, loose rust and loose paint shall be removed by wire brushing,
scrapping, chipping and rubbing with abrasive paper or steel wool. This method
shall not be employed when the surface has firmly adhering mill scale. After hand
tool cleaning, the surface shall be rubbed with sand paper so as to ensure that no
loose material exists and the surfaces shall be dusted off.

3.3.2 Mechanical Cleaning

3.3.2.1 Power Tool Cleaning

This shall be carried out by employing power operated wire brushes. Power tool
cleaning shall be resorted to only if sand/shot blasting is not possible/permissible
and high quality of surface preparation is required.

The surface prior to such cleaning shall be cleaned of dust, grease etc. and heavier
layers of rust shall be removed by chipping.

The powertool cleaning shall remove loose mill scale and rust by adopting very
thorough scrapping, grinding and machine brushing. After the surfaces are cleaned
by compressed air, it shall have a pronounced metallic sheen.

3.3.2.2 Flame Cleaning

Hard mill scale and rust shall be removed through Oxy- acetylene flame. The work
shall be carried out by trained workmen to ensure that only mill scale is removed
without affecting the parent steel. The work shall be carried out carefully on
welded surfaces so that the strength of weld is not affected due to heating.

3.3.3 Sand Blasting and Shot Blasting

3.3.3.1 Sand/shot blasting shall be resorted to only after removal of grease, oil and other
contaminants. The work shall be carried out by impinging under pressure of air, a
jet of sharp sand or granulated steel (steel grits) on to the metal surface. The
process shall ensure complete removal of rust and firmly adhering mill scale.
Special care shall be taken on weld areas to remove flux and spatter. Blasting shall
ensure an even color of the surface and the surface shall have silver grey color.
Precautions shall be taken when sand or shot blasting of light gauge steel surfaces
to ensure that buckling does not occur to continuous impingement of sand or steel
shots under high velocity.

3.3.3.2 Sand/shot blasting shall be adopted for structures, which are exposed to corrosive
conditions for which superior paint protection is to be adopted. The finished
surfaces shall conform to the requirements of Sa 2½ or Sa 3 as per Swedish Standard
SIS-05-5900 as specified in the item of work.
3.3.3.3 As Sandblasting causes dust nuisance necessary clearance shall be obtained by the
CONTRACTOR from Competent authorities prior to commencing Sand blasting.

3.4 Chemical Cleaning (Pickling)

3.4.1 The cleaning shall be done by pickling in sulphuric, hydrochloric or phosphoric

acids. Pickling shall be carried out in accordance with detailed procedure as given
in IS 6005.

3.4.2 Washing after pickling shall remove all traces of the acids. All work pieces shall be
thoroughly inspected and in particular the inaccessible corners.

4.0 MATERIALS
4.1 Primer Paint

4.1.1 Anti-corrosive primers shall be either lead based or lead free types. Red lead primer
shall conform to IS 102 and red oxide zinc chrome primer shall conform to IS 2074.

4.2 Finish Paint

4.2.1 Synthetic enamel painting for undercoat and finish coat shall conform to IS 2932/IS
2933.

4.2.2 Acid, alkali and heat resistant bituminous paint shall conform to IS 158.

4.2.3 Acid, alkali, water and chlorine resisting bituminous paint shall conform to IS 9862.

4.2.4 Heat resistant aluminum paint shall conform to IS 13183.

4.2.5 Epoxy primer and epoxy paint shall be of the type as specified in the item of work
from an approved manufacturer.

4.2.6 Chlorinated rubber based paint shall be of the manufacture as specified or any
equivalent approved manufacture.

4.3 All the materials shall be of the best quality from an approved manufacturer.
CONTRACTOR shall obtain prior approval of the ENGINEER for the brand of
manufacture and the colour/shade prior to procurement for usage in the works.

4.4 Primer and finish paints shall be compatible with each other to avoid cracking and
wrinkling. As such it is recommended that the primer and finish paint shall be from
the same manufacturer.

4.5 The colour and shade shall conform to IS Standards referred to in Appendix 'D' of IS
1477 -Part II. To facilitate choosing the correct shade/number from the alternatives
available, CONTRACTOR shall adopt trial painting in small patches in consultation
with and as directed by the ENGINEER.

4.6 All paint delivered to the fabrication shop/site shall be ready mixed, in original
sealed containers, as packed by the manufacturer. Thinner shall not be permitted
for usage unless specifically directed by the ENGINEER.

4.7 Paints shall be stirred thoroughly to keep the pigment in suspension.

4.8 CONTRACTOR shall at his own cost arrange for testing of paints as per relevant Indian
Standards in standard laboratory whenever OWNER wants the tests to be carried out
for each batch of paints. Test results shall be submitted to the OWNER for obtaining
approval.
5.0 WORKMANSHIP

5.1 The type and the number of coats of the primer paint and finish paint shall be as
specified in the respective items of work.

5.2 Painting shall be carried out only on thoroughly dry surfaces.

5.3 No painting shall be done in frosty/foggy weather or when the humidity is high
enough to cause condensation on the surface to be painted. Paint shall not be
applied when the temperature of the surface to be painted is at 5°C or lower.

5.4 Primers shall adhere to the surface firmly and offer a key to the subsequent coats.

5.5 The application of paint film shall serve the twin purpose of protecting the steel from
corrosion and giving the decorative appearance. A paint which gives the steel
adequate protection over a long period together with good appearance shall
therefore be adopted.

5.6 Workmanship shall generally conform to requirements specified in IS: 1477-Part II.

5.7 It is essential to ensure that immediately after preparation of the surfaces, the first
coat of primer paint shall be applied by brushing and working it well to ensure a
continuous film without "holidays". After the first coat becomes hard dry a second
coat of primer shall be applied by brushing to obtain a film free from holidays.

5.8 Structural steel surfaces shall be given the first coat of primer at shop and the second
coat after it is erected in position. Further, any abraded surfaces of the first coat
during transport from shop to site and during erection shall be provided with a touch-
up coat of the primer.

5.9 The dry film thickness of each coat of primer shall be not less than 25 microns.

5.10 Application of finishing paints shall be carried out within the shortest possible time
interval after primer since the primer coats are too thin to give adequate corrosion
protection to the steel surface over a long duration.

5.11 Filler coats shall be applied to fill dents and to obtain a smooth finish wherever
necessary. Only factory prepared filler suitable for steelwork shall be used. Fillers
prepared by whiting and linseed oil by craftsmen at site shall never be used as such
fillers may be unbalanced and incompatible with primer and finishing coats.
Application of filler shall be done with good `putty knife' and necessary skill. Filler
applied shall be just sufficient to fill the depression or unevenness and it shall be
restricted to the minimum. It shall be applied in thin layers. In filling depression or
unevenness, due as many coats as are necessary may be applied allowing each layer
to dry hard. The hardened coat shall be cut down by wet rubbing before the
subsequent coat is applied. Where necessary, filler coats shall be applied over the
undercoats also.

5.12 Painting shall be carried out either by brushing or by spraying. CONTRACTOR shall
procure the appropriate quality of paint for this purpose as recommended by the
manufacturer.

5.13 After the second coat of primer is hard dry, the entire surface shall be wet rubbed
cutting down to a smooth uniform surface. When the surface becomes dry, the
undercoat of paint of optimum thickness shall be applied by brushing/spraying with
minimum of brush marks. The coat shall be allowed to hard-dry. The under coat shall
then be wet rubbed cutting down to a smooth finish, taking adequate care to ensure
that at no place the undercoat is completely removed. The surface shall then be
 allowed to dry.

5.14 The first finishing coat of paint shall be applied by brushing or by spraying and
allowed to hard-dry. The gloss from the entire surface shall then be gently removed
and the surface dusted off. The second finishing coat shall then be applied by
brushing or by spraying.

5.15 At least 24 hours shall elapse between the applications of successive coats. Each
coat shall vary slightly in shade and the ENGINEER shall be approved this.

5.16 Minimum dry film thickness of each coat of finish paint of synthetic enamel shall be
25 microns. Minimum dry film thickness of other finish paints shall be as specified in
the respective item of work.

5.17 The thickness of film shall be measured by an Elcometer to be supplied by the

CONTRACTOR. The CONTRACTOR shall calibrate the Elcometer frequently for
different settings. Necessary calibrating accessories should be kept ready for
calibration/testing of Elcometer at any time.

5.18 Epoxy primer and epoxy paint shall be applied within the specified pot life all as
per recommendations of the manufacturer.

5.19 Surfaces inaccessible after assembly shall receive two coats of primer prior to assembly.

5.20 Surfaces inaccessible after erection, including top surfaces of floor beams supporting
grating or chequered plate shall receive one additional coat of finish paint over and
above the number of coats specified prior to erection.

5.21 Portion of steel members embedded/to be encased in concrete shall not be painted.
Joints to be site welded shall have no shop paint for atleast 50mm from the welding
zone. Similarly, the steel surfaces shall not be painted in areas where connection is
by use of friction grip bolts. On completion of the joint, the surfaces shall receive
the painting as specified.

5.22 Maintenance painting of steel structures will become necessary if the painting
already carried out shows signs of chalking, hairline cracking, deep checking, fine
checking, and peeling, blistering and rusting. The breakdown of a paint film is
progressive from the top finish paint to the primer coat and the object of
maintenance painting is to renovate periodically to effectively check the breakdown
and protect the steel surfaces from corrosion. It is essential that same quality of
paint as specified earlier need be adopted to ensure compatibility. The general
workmanship for maintenance painting shall conform as per Clause. 7 of IS 1477-Part
II.

5.23 CONTRACTOR shall provide suitable protection as necessary to prevent paint finishes
from splashing on equipment, floors, walls etc.
 ERECTION OF STRUCTURAL STEEL
1.0 SCOPE

This specification covers the general requirements for erection of structural steel. It
covers the supply and delivery of all necessary materials, labour, scaffolding, tools,
tackles, equipment and everything that is necessary for the satisfactory completion
of the job on schedule.

2.0 APPLICABLE CODES & SPECIFICATIONS

2.1 The following specifications, standards and codes are made a part of this
specification. All standards, specifications and codes of practice referred to herein
shall be the latest editions, including all applicable official amendments and
revisions.

2.2 In case of discrepancy between this specification and other documents referred to
herein, this specification shall govern. In case of discrepancy between tender
drawings and this specification, the tender drawings shall govern.

2.3 Structural

(a) IS:800 Code of Practice for General Construction in Steel

(b) IS:801 Code of Practice for Use of Cold Formed Light Gauge Steel
Structural Members in General Building Construction
(c) IS:806 Code of Use of Steel Tubes in General Building Construction
(d) IS:7205 Safety Code for Erection of Structural Steel Work
(e) IS:7215 Tolerances for Fabrication of Steel Structures
(f) IS:4000 High Strength Bolts in Steel Structure - Code of Practice
(g) AISC Specifications for Design, Fabrication and Erection of Buildings

3.0 ERECTION SCHEME

3.1 Each Bid shall be accompanied by a broad erection scheme with dates and
estimated completion time for various parts of the work prepared by CONTRACTOR
after a thorough study of the Bid drawings and the site conditions. This erection
scheme shall describe the methods proposed to be employed by CONTRACTOR for
transporting his equipments, tools, tackles, gas cylinders, electrodes and all that is
necessary to site, unloading, transporting within the site, handling, assembling,
hoisting and erecting of the structural steel components and the type, capacity and
quantity of equipment that CONTRACTOR proposes to bring to site for all these
operations. The scheme shall also indicate the strength and trade wise composition
of the work force and supervisory personnel that will be deployed by CONTRACTOR
for the various operations.

4.0 ERECTION PROGRAMME

4.1 Within two weeks of the acceptance of his Bid, the successful CONTRACTOR shall
submit, a detailed erection programme. This programme shall be accompanied by a
layout plan identifying the areas proposed for unloading, main storage, subsidiary
storage, assembly and the transportation of equipment and fabricated material
between the storage and work areas. The layout shall clearly indicate the points at
which proposed erection begins, direction in which it is proposed to progress, the
deployment of equipment, access route for cranes to reach work areas, etc. The
locations and extent of site offices and stores, labour quarters if any, layout of
electrical cables and water pipes

from the tap-off points shall also be indicated in detail on the above layout. Full
 details of the method of handling, transport, hoisting and erection including false
work/staging, temporary bracing, guying, etc. shall be furnished by CONTRACTOR in
this erection programme along with complete details of the quantity and capacity
of the various items of erection equipment that will be used. A site organization
chart showing the number of supervisory personnel, and the number and
composition of the various gangs shall also accompany the erection programme.

4.2 Any modifications to the erection programme directed by ENGINEER for the reasons
of inadequacy of the quantity and/or capacity of the erection equipment, erection
personnel and supervisors, temporary bracing, guying etc., or safety of the erection
methods, or stability of the erected portions of structures, or unsuitability of the
erection sequence due to interference with the work of other agencies shall be
incorporated by CONTRACTOR and the work shall be carried out in accordance with
the revised programme. Approval by ENGINEER shall not relieve CONTRACTOR from
the responsibility for the safe, sound, accurate and timely erection of structural
steel work as required by ENGINEER/OWNER. CONTRACTOR shall also make no extra
claims for bringing additional equipment to site for erection, if so directed by
ENGINEER. CONTRACTOR shall be deemed to have visualized all erection problems
while bidding for the work and no additional compensation shall be claimed on this
account.

5.0 SITE OPERATIONS

5.1 An experienced and qualified Superintendent shall be in full time charge of the job.

5.2 CONTRACTOR shall complete all preliminary works at site well before the arrival of
structural steel, such as establishment of a well equipped and adequately staffed
site office, stores, unloading gantry, unloading and pre-assembly yard, labour
quarters if any, electrical and water connections, electrical winches, derricks,
cranes, compressors, all tools and tackles, rivet guns, welding sets, torque
wrenches, spud wrenches, staging, etc. as well as experienced erection and
supervisory personnel as part of this contract and any other work that may be
necessary so as to start erection immediately after the arrival of the first batch of
steel at site.

5.3 CONTRACTOR shall furnish at his own expense, the necessary non-inflammable
staging and hoisting materials or equipment required for the erection work and
shall remove and take them away after completion of the jon. CONTRACTOR shall
also provide necessary passageways, fences, safety belts, helmets, lights and other
fittings to the satisfaction of OWNER/ENGINEER and to meet the rules of local
authorities and for protection to his men and materials. A licensed electrician shall
be kept on the job for the entire duration of the work to maintain CONTRACTOR's
electrical equipment and connections.

5.4 CONTRACTOR shall protect all existing plant, structures, piping, conduits,
equipment and facilities against damage during erection. Any damage caused by
CONTRACTOR shall be rectified entirely at CONTRACTOR's cost, to the satisfaction
of OWNER/ENGINEER. If work has to be carried out adjacent to existing switchyards
or electrical installations, which are live, CONTRACTOR must ensure suitable safety
precautions in consultation with ENGINEER.

5.5 If a portion of the work of the project area cannot be made available to
CONTRACTOR for his activities due to operations being carried out by other
agencies, he shall suitably modify his sequence of operations so as to continue work
without interruption. CONTRACTOR shall work in coordination with other agencies
working on the project site and plan his work suitably so as not to hinder the
progress of construction at site.
6.0 ACCEPTANCE OF STEEL, ITS HANDLING & STORAGE

6.1 CONTRACTOR shall carefully check the steel to be erected at the time of
acceptance. Any fabrication defects observed should be brought to the notice of
OWNER/ ENGINEER.

6.2 No dragging of steel shall be permitted. All shall be stored 300mm above ground on
suitable packing to avoid damage. It shall be stored in the order required for
erection, with erection marks visible. All storage areas shall be prepared and
maintained by CONTRACTOR. Steel shall not be stored in the vicinity of areas where
excavation or grading will be done and, if so stored temporarily, this shall be
removed by CONTRACTOR well before such excavation and/or grading commences
to a safe distance to avoid burial under debris.

6.3 Scratched or abraded steel shall be given a coat of primer specified for protection
after unloading and handling prior to erection. All milled and machined surfaces
shall be properly protected from rust/corrosion by suitable coating and also from
getting damaged.

7.0 ANCHOR BOLTS & FOUNDATIONS

7.1 CONTRACTOR shall carefully check the location and layout of anchor bolts
embedded in foundations constructed, to ensure that the structures can be properly
erected as shown on the drawings, any discrepancy in the anchor bolts/foundation
shall be reported to ENGINEER.

7.2 Leveling of column bases to the required elevation may be done either by providing
shims or three nuts on the upper threaded portion of the anchor bolt. All shim stock
required for keeping the specified thickness of grout and in connection with
erection of structures on foundations, crane brackets or at any other locations shall
be of good M.S. plates and shall be supplied by CONTRACTOR at his cost.

7.3 A certain amount of cleaning of foundations and preparing the area is considered
normal and shall be carried out by CONTRACTOR at not extra cost.

7.4 Where beams bear in pockets or on walls, bearing plates shall be set and levelled as
part of the work. All grouting under column base plates or beam bearing plates will
be carried out by CONTRACTOR, unless the grouting is specifically excluded from
the CONTRACTOR’S scope.

8.0 ASSEMBLY & CONNECTIONS

8.1 Field connections may be effected either by riveting, bolting, welding or by use of
high strength friction grip bolts as specified and as shown on the design and
erection drawings.

8.2 All field connection work shall be carried out in accordance with specification. All
bolts, nuts, washers, rivets, electrodes required for field connections shall be
supplied by Erector free of cost.

8.3 All assembling shall be carried on a level platform.

8.4 Drifts shall be used only for drawing the work to proper position and must not be
used to such an extent as to damage the holes. Size of drifts larger than the
nominal diameter of hole shall not be used. Any damaged holes or burrs must be
rectified to the satisfaction of ENGINEER.
8.5 Corrections of minor misfits and reasonable amount of reaming and cutting of
excess stock from rivets shall be considered as a part of erection. Any error in
the shop, which prevents proper fit on a moderate amount of reaming and
slight chipping or cutting, shall be immediately reported to ENGINEER.

9.0 ERECTION

9.1 All structural steel shall be erected as shown on the drawings. Proper size steel
cable slings, etc., shall be used for hoisting. Guys shall not be anchored to
existing structures, foundations, etc. unless so permitted by ENGINEER in
writing. Care shall be taken to see that ropes in use are always in good
condition.

9.2 Steel columns in the basement, if any, are to be lowered and erected carefully
with the help of a crane and/or derrick without damaging the basement walls
steel or floor.

9.3 Structural steel frames shall be erected plumb and true. Frames shall be lifted at
such points that they are not liable to buckle and deform. Trusses shall be lifted
only at node points. In the case of trusses, roof girders, all of the purlins and
wind bracing shall be placed simultaneously and the columns shall be erected
truly plumb on screed bars over the pedestals. All steel columns and beams shall
be checked for plumb and level individually before and after connections are
made. Temporary bracings shall be introduced wherever necessary to take care
of all loads to which the structure may be subjected, including erection
equipment and the operation thereof. Such bracings shall be left in place as long
as may be required for safety and stability.

9.4 Chequered plates shall be fixed to supporting members by tack welding or by

countersunk bolts as shown/specified in relevant drawings and/or as directed by
ENGINEER. The edges shall be made smooth and no burrs or jagged ends shall be
left. While splicing, care should be taken so that there is continuity in pattern
between the two portions. Care should also be taken to avoid distortion of the
plate while welding. The erection of chequered plates shall include:

(a) Welding of stiffening angles/vertical stiffening ribs

(b) Cutting to size and making holes to required shape wherever necessary to
allow service piping and/or cables to pass through
(c) Splicing as shown in relevant drawing
(d) Smoothening of edges
(e) Fixing of chequered plates by tack welding or by countersunk bolts
(f) Providing lifting hooks for ease of lifting.

9.5 As erection progresses, the work shall be securely bolted to take care of all
dead load, wind, seismic and erection stresses.

9.6 No riveting or welding or final bolting shall be done until the structure has been
properly aligned and approved by ENGINEER. No cutting, heating or enlarging of
the holes shall be carried out without the prior written approval of ENGINEER.

9.7 Test certificates shall be furnished by CONTRACTOR.

10.0 INSPECTION
ENGINEER/OWNER or their authorized representatives shall have free access to
all parts of the job during erection and all erection shall be subjected to their
approval. In case of faulty erection, all dismantling and re-erection
required will be at CONTRACTOR's cost. No paint shall be applied to rivet
 heads or field welds or bolts until these have been approved by ENGINEER.

11.0 TOLERANCES

Tolerances mentioned below shall be achieved after the entire structure or part
thereof is in line, level and plumb. The tolerances specified below do not apply
to steel structures where the deviations from true position are intimately linked
with and directly influence technological process. In such cases, the tolerances
on erected steel structures shall be as per recommendations of process
technologists/suppliers which will be indicated in the drawings.

12.0 PAINTING
12.1 After steel has been erected, all bare and abraded spots, rivet heads, field welds,
bolt heads and nuts shall be spot painted with primer. Before paint is applied, the
surface shall be dry and free from dust, dirt, scale and grease. All surfaces
inaccessible after erection shall receive two coats of the approved paint before
erection.

13.0 METHOD OF MEASUREMENT

13.1 For the purpose of payment, the weight of the actual, completed structures shall be
calculated from the approved drawings for different items of work. CONTRACTOR
shall submit to OWNER relevant material list containing weight of each item.

13.2 No allowance will be permitted for weights of rivets, bolts, washers, screws etc. in
calculating the weight of the completed structure. No allowances will be permitted
for galvanizing, welding or for rolling margins. One tonne for the purpose of payment
shall mean ONE METRIC TONNE i.e. 1000 Kg.

13.3 The weight of a member made out of standard rolled sections such as beams,
channels, angles, etc. shall be based on the weight of the member given in IS 808,
without deducting for holes, notches, bevel cuts, etc. Where a component consists of
a cut joist or channel, the full weight of the rolled section shall be considered only if
more than half the depth of the section is used. Otherwise only half the section unit
weight shall be taken. Deductions shall be made in the weight of gussets/plates
including chequered plates for skew cuts, notches and openings of 900 sq.cm. or
larger.

13.4 For gussets/plates used in trusses, bracings, columns, beams etc. the area shall be
that of the minimum circumscribing rectangle, except as stated in clause 13.3 above.

13.5 The weight of any built-up member shall be separated into the weight of each
component.

13.6 Erection bolts installed by erector may be left in position on completion of erection;
however, no additional payment shall be made either for supply or use of such bolts.
If erection bolts are removed after erection is complete, holes shall be plug welded
and ground smooth. No extra payment shall be made for such plug welding.

14.0 CLEAN UP OF WORK SITE

14.1 During erection, the CONTRACTOR shall without any additional payment, at all times
keep the working and storage areas used by him, free from accumulation of waste
materials or rubbish. Before completion of erection, he shall remove or dispose of in
a satisfactory manner all temporary structures, waste and debris and leave the
premises in a condition satisfactory to OWNER/ENGINEER.