Volume-IF - JantERmantER

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VOLUME
PSER:SCT:DPL-C1154:10
IF TECHNICAL CONDITIONS OF CONTRACT
&
SCOPE, DRAWINGS, ETC
JOB CONSTRUCTION OF 220M HIGH RCC SINGLE
FLUE BRICK LINED CHIMNEY INCLUDING
SUPPLY, ERECTION, COMMISSIONING ETC OF
EQUIPMENTS/ MATERIAL, COMPLETE.
CAPACITY 1x250 MW
PROJECT DPL, DURGAPUR, WEST BENGAL.
BHARAT HEAVY ELECTRICALS LIMITED
(A Govt Of India Undertaking)
POWER SECTOR – EASTERN REGION
PLOT – DJ 9/1, SECTOR II, SALT LAKE
KOLKATA – 700 091

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INDEX
CLAUSE DESCRIPTION
NO
1.0 BROAD SCOPE OF WORK
2.0 SITE VISIT
3.0 INSURANCE
4.0 TAXES, DUTIES ETC
5.0 SECURITY DEPOSIT
6.0 PERFORMANCE BOND
7.0 COMPLETION PERIOD
8.0 SCHEDULE OF SUPPLY
9.0 INTEREST BEARING RECOVERABLE ADVANCE
10.0 PAYMENT TERMS
11.0 PRICE VARIATION COMPENSATION (PVC)
12.0 OVER RUN CHARGE
13.0 GUARANTEE
14.0 LIQUIDATED DAMAGE/ COMPENSATION FOR DELAY
15.0 CONTRACT PRICE
16.0 MATERIAL DESPATCH CLEARANCE CERIFICATE (MDCC)
17.0 MATERIAL RECEIPT CERTIFICATE (MRC)
18.0 CONSIGNEE
19.0 DESPATCH
20.0 INSPECTION & JOINT VERIFICATION(AT CONTRACTOR’S WORKS)
21.0 INSPECTION & JOINT VERIFICATION (AT SITE)
22.0 QUALITY PLAN
23.0 DIVISIBLE CONTRACT
24.0 OTHER TERMS

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This volume shall be construed as part of tender document and shall be read along-with others
volumes of tender. In case of any conflict or inconsistency between the general and technical
conditions, the same shall be brought out by the bidder in writing to BHEL for clarification during
pre-bid discussions; failing which most stringent interpretation/ clause in favour of BHEL shall be
adopted and the same shall be binding to the bidder.
CLAUSE DESCRIPTION
NO
1.0 BROAD SCOPE OF WORK
The work to be done broadly under this specification comprises of design,
engineering, manufacturing, assembly, inspection, testing at manufacturer’s/ subvendor’s
works, painting, proper packing, transportation, delivery, handing over at
site of materials as detailed in the specification and elsewhere in the tender
document (as covered in Part-2 of price schedule, Volume-IIIA). However,
completeness of the supply for completion of the package is to be ensured by the
bidder.
2.0 SITE VISIT
Bidder should visit site and acquire full knowledge & information about site
conditions prevailing at site and in and around the plant premises at together with
all the statutory, obligatory, mandatory requirements of various authorities before
submission of the bid.
3.0 INSURANCE
3.1 BHEL shall arrange comprehensive MCE insurance policy covering transit risk &
loss. Bidder shall be responsible for timely intimation of loss/ damage/ theft to the
underwriter, assistance in lodging & settlement of claim for losses/ damages/ theft.
3.2 Other provisions of insurance shall be as stipulated under relevant clauses of GCC.
4.0 TAXES, DUTIES ETC
4.1 EXCISE DUTY
4.1.1 Excise duty actually incurred by seller/ contractor on self manufactured items
against the despatch made from his factory/ works constituting a sale under the
order/ contract, alone shall be reimbursed at actual against requisite documentary
evidence limited to the quoted value.
4.1.2 The invoice cum Excise Duty gate pass (Excise Invoice) should contain the name
of ultimate consignee as specified in the order/ contract.
4.1.3 No excise duty shall be payable by purchaser on inputs, bought out items, raw
materials and components consigned directly to site from sources other than seller/
contractor's factory/ works.
4.1.4 The seller/ contractor is required to ensure that excise duty is properly calculated
and paid and exemption and benefits are fully availed of.
4.1.5 Bidder to consider the benefit of CENVAT in their quoted basic price.
4.1.6 If the seller/ contractor claims/ obtains any refund of the excise duty paid and gets
reimbursed, the same shall be refunded to the purchases immediately.
4.1.7 Excise duty shall be paid at actual but restricted to the amount and percentage
shown in the order/ contract. Additional excise duty due to statutory variation, if
imposed after due date of submission of latest price offer and within contract period
including extension, if any (provided reason for extension is not attributable to
vendor), will be reimbursed at actual by BHEL.
4.1.8 No statutory variations shall be permissible beyond the contractual period.
4.2 CENTRAL SALES TAX
4.2.1 Central Sales tax shall be payable extra, limited to the quoted value on submission
of invoice, if the same is payable by the bidder to the respective Government
Authorities meeting all statutory requirements and availing all exemption/
concessions under the Central Sales Tax Act, 1956. Bidder shall show CST
separately in the invoice for inter-state sales at prevailing rate.
4.2.2 Sales tax on bought out items paid/ payable by bidder to the sub-vendors shall be
borne by bidder and shall not be invoiced to/ paid extra by BHEL.
4.2.3 BHEL proposes to make sale in transit as per Sec 6(2) (b) of the CST Act, 1956

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where goods are moving inter-state. “C” Form shall be issued and exchanged
against E-I/II Certificates based on quarterly transaction. The bidder is required to
submit his request within 10 (ten) days from the end of the quarter in the specified
format. No concessional forms shall be issued for goods moving within the state.
4.2.4 In order to obtain the benefit of Transit Sale exemption U/S 6(2), following mode of
documentation shall be followed.
4.2.4.1 FOR SELF MANUFACTURED ITEMS OF VENDORS
In case of BOP, steel & cement, vendor’s LR/ RR/ GR/ CN must the bear the name
of BHEL as `Consignee’. BHEL will endorse the following words on the back of
despatch documents, ie LR/ RR/ GR/ CN prior to the date of receipt of materials by
BHEL at site, ie after movement commences and before it terminate.
`Please deliver the goods to (State customer’s name & address), (State customer’s
CST No)’.
Name of authorized signatory of BHEL’s MM department: ____________
Date:
Signature:
____________
____________
4.2.4.2 FOR BOUGHT-OUT ITEMS OF VENDORS:
4.2.4.2.1 STEP-1
Sub-vendors’ LR/ RR/ GR/ CN must the bear the name of vendor as `Consignee’.
Vendor must endorse the following words on the back of despatch documents, ie
LR/ RR/ GR/ CN prior to the date of receipt of materials by vendor, ie after
movement commences and before it terminates.
`Please deliver the goods to (State BHEL’s site’s name & address), (State BHEL’s
CST No)’.
Name of authorized signatory of vendor: _________________________
Date:
Signature:
_________________________
_________________________
4.2.4.2.2 STEP-2
BHEL must endorse the following words on the back of despatch documents, ie LR/
RR/ GR/ CN prior to the date of receipt of materials by BHEL at site, ie after
movement commences and before it terminates.
`Please deliver the goods to (State customer’s name & address), (State customer’s
CST No)’.
Name of authorized signatory of BHEL’s MM department: ____________
Date:
Signature:
____________
____________
4.2.5 If documents are submitted through bank, issuance of “C” Form shall not be
insisted upon at the time of retirement of document(s).
4.2.6 BHEL, PSER is registered with the Sales Tax authority in the state under the
Central Sales Tax Act, 1956.
4.3 VALUE ADDED TAX
4.3.1 The bidder must be registered with the sales tax authority in the state for supply
from the state. The bidder must produce copy of the Registration Certificate issued

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by the Sales Tax Authority. The bidder must issue “TAX INVOICE” showing VAT
charged separately in case of supply from the state.
4.3.2 Bidder to consider the benefit of Input Credit of VAT in their offer.
4.3.3 VAT shall be payable extra, limited to the quoted value on all items supplied from
the state on submission of Invoice & as per tariff applicable, if the same is payable
by bidder to the respective Government authorities meeting all statutory
requirements and availing all exemption/ concessions under the state Value Added
Tax Act, 2003.The tax invoice pertaining to supplies made in a quarter must be
presented within that quarter so as to enable BHEL to take input credit within that
quarter. If BHEL is denied of the benefit of Input Credit due to late/ non submission
of “TAX INVOICE”, VAT shall not be paid at all.
4.3.4 BHEL is registered with Sales Tax authority in the state under the state Value
Added Tax Act, 2003 have the Registration Certificate.
4.4 COMMON FOR CST AND VAT
Any variation on ST/ VAT, if imposed subsequently by statutory authority, after due
date of submission of latest price offer as per NIT & TCN, as applicable, and within
the contract period including extension, if any, (provided reason for extension is not
attributable to vendor) shall be paid by BHEL on production of relevant supporting
document to the satisfaction of BHEL.
4.5 CUSTOMS DUTY
4.5.1 Customs Duty element for imported items shall be included in basic prices. No
variation in customs duty and exchange rate for imported items shall be payable by
purchaser.
4.5.2 Seller/ contractor shall arrange for his own import license, if required, since
purchaser will not provide any import license since purchaser will not provide any
import license. Therefore, seller/ contractor alone shall be responsible for any delay
in getting import license or non-availability of the same or completion of other
related formalities. Purchaser shall not be responsible for any financial liability,
whatsoever, on this account.
4.6 DIRECT TAX
Purchaser shall not be liable towards income tax of whatever nature including
variations thereof, arising out of this order/ contract, as well as tax liability of the
seller/ contractor and his personnel.
4.7 New tax & duties, if imposed subsequent to latest due date of offer submission, as
per NIT & TCN, as applicable, by statutory authority after due date of submission of
latest price offer and within the contract period including extension, if any (provided
reason for extension is not attributable to vendor), shall be reimbursed by BHEL at
actual on production of relevant supporting document to the satisfaction of BHEL.
However, the vendor shall obtain prior approval from BHEL before depositing new
taxes & duties.
4.8 Benefits of abolition and reduction of ED, CST & VAT on self manufactured items
will be passed on to BHEL.
4.9 All taxes & duties shall be paid, as applicable, limited to amounts indicated in the
break up prices as indicated above. These shall be directly paid by contractor to the
respective statutory authorities. Taxes and duties paid by sub vendors of contractor
will not be reimbursed by BHEL.
4.10 The seller/ contractor is required to ensure that taxes, duties etc, as applicable, are
properly calculated & paid and exemption and benefits, as applicable, are fully
availed of. BHEL shall not be held responsible on account of any fault on the part of
vendor in this regard.
4.11 Other than above, no taxes & duties are payable.
5.0 SECURITY DEPOSIT
Security deposit for this part of specification shall also be governed by the provision
of GCC. Alternately, bidder may submit bank guarantee equivalent to 100 % of
security deposit as per provision of GCC.
6.0 PERFORMANCE BOND
6.1 The bidder will have to execute a performance bond covering his entire scope of

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supply (Part-2 of the price schedule) to be kept valid as per terms of tender.
6.2 Performance bond shall be submitted as per tender provision.
7.0 COMPLETION PERIOD
Entire materials under the scope shall be dispatched to reach site within 29 (Twenty
nine) months from the date of confirmation/ intimation from BHEL in writing.
8.0 SCHEDULE OF SUPPLY
The vendor shall furnish the L-1, L-2/ L-3 schedule indicating break-up of supply of
various items under the specification matching with project schedule as referred in
the tender within the stipulated completion period.
9.0 INTEREST BEARING RECOVERABLE ADVANCE
Not applicable for this tender.
10.0 PAYMENT TERMS
10.1 For all items of work as per price schedule of main supply (Part-2), Volume-IIIA,
payment shall be made as per following break-up.
10.1.1 5 % of basic price against submission and approval of all design document, such as
data sheet, quality plan etc. Documents (required sets) required for such payment
are as follows.
10.1.1.1 Invoice in original.
10.1.1.2 Certificate of BHEL as regard to completion of activity.
10.1.2 80 % of basic price of materials supplied along with 100 % ED, CST & VAT, as
applicable, against dispatch document on pro-rat basis. Documents (required sets)
required for such payment are as follows.
10.1.2.1 Invoice/ excisable invoice in original.
10.1.2.2 LR/ RR (consignee copy).
10.1.2.3 Packing list.
10.1.2.4 MDCC enclosing QS note, test certificate.
10.1.2.5 Copy of letter, addressed to insurance company intimating dispatch.
10.1.3 15 % of basic price along with 100 % freight & other charge shall be released on
pro-rata basis against receipt of material at site. Documents (required sets)
required for such payment are as follows.
10.1.3.1 Invoice in original.
10.1.3.2 MRC issued by BHEL site.
10.2 10 % of gross bill amount except taxes & duties shall be retained from each bill
which shall be released along with final bill on completion of total chimney work.
Documents (required sets) required for such payment are as follows.
10.2.1 Invoice in original.
10.2.2 Certificate of BHEL site as regard to completion of activity.
10.3 In case freight component is not indicated by bidder in the price offer separately, 2
% of basic amount shall be taken into account as freight component and payment
will be made accordingly as per the payment terms.
10.4 Payment shall be made by BHEL site offices within 30 days of receipt of invoice
subject to its completeness in all respects as per BHEL’s procedure. All admissible
recovered/ adjustments etc shall be made from the interim payable amount.
10.5 BHEL, at discretion, any further split up the above percentages and effect payment
to suit the site condition, cash flow requirement, according to the progress of work.
10.6 No bills including RA bills will be paid to individual consortium partners in case of
consortium arrangement.
11.0 PRICE VARIATION COMPENSATION (PVC)
Not applicable for this part of tender.
12.0 OVER RUN CHARGE
No over run charge shall be applicable for this tender.
13.0 GUARANTEE
13.1 The contractor shall warrant that the (shall mean the goods and machinery/
components/ parts and spares etc specified in the contract/ order which the
contractor agreed to supply with the contract/ order to complete the jobs for
satisfactory working of stores, generating the parameters stipulated in the tender
document) supplied shall be free from all defects and faults in design, material,

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workmanship and manufacture and shall be of highest grade and consistent with
the established and generally accepted standards form the stores of the type
ordered in full conformity with the order/ contract, specification, drawing or samples,
if any.
13.2 The guarantee shall be valid for a period of 12 calendar months from the date of
completion of PG test of unit. Any approval or acceptance by BHEL/ owner therein,
shall not in any way limit the contractor’s liability. The contract’s liability in respect of
any complaints, defects and/ or claims shall be limited to be the furnishing and
installation of the replaced part free of charges, or the repair of the defective parts
only to the extent that such replacement or replacements are attributable to or arise
from faulty workmanship, material or design in the manufacture of the stores or at
the option of BHEL/ owner, to the payment of the value, expenditure and damages
as hereunder mentioned provided defect are brought to the notice of the contractor
within 3 months of their being first discovered during the guarantee period 3 months
from the date of expiry of the guarantee period.
13.3 The contractor shall, if required, replace, or repair the stores of such portion
thereof, as is rejected by BHEL/ owner free of cost at the site or at the option of
BHEL/ owner the contractor shall pay to BHEL/ owner value thereof at the order/
contract price and such other expenditure and damages, as may arise by reason of
the condition therein specified.
13.4 All replacement and repairs that BHEL/ owner shall call upon the contractor to
deliver or perform under the guarantee shall be delivered free of cost and
performed promptly and satisfactorily by the contractor within 3 months, if the
contractor so desires and BHEL/ owner agrees subject to import contract
regulation, the replaced parts can be taken over by him or his representative or the
same can be arranged to be dispatched by the contractor or his representative at
the contractor’s cost as he deems fit within a period of 3 months from the date of
replacement of stores/parts. At the expiry of this period no claim whatsoever, shall
be with BHEL/owner.
13.5 All replacement stores shall also be guaranteed as per above clause.
13.6 The decision of BHEL/ owner in this regard to contractor’s liability and the amount,
if any, payable under this guarantee shall be final and conclusive.
14.0 LIQUIDATED DAMAGE/ COMPENSATION FOR DELAY
As per the provision of GCC.
15.0 CONTRACT PRICE
Bidder shall quote rates/ price as per the format of Volume-IIIA. Separate order will
be placed for supply part as per the price components of respective schedules.
16.0 MATERIAL DESPATCH CLEARANCE CERIFICATE (MDCC)
16.1 MDCC shall be issued by BHEL/ owner or their authorized representative prior to
dispatch. In case the tests are not witnessed by BHEL/ owner/ owner’s
representative, the test certificates shall be submitted to owner through BHEL and
MDCC will be issued thereafter.
16.2 Copy of MDCC and other dispatch document shall accompany with every dispatch,
failing which the consignment shall not be allowed to enter the project premises.
17.0 MATERIAL RECEIPT CERTIFICATE (MRC)
MRC shall be issued by BHEL/ owner or their authorized representative after the
material is received at site in good condition.
18.0 CONSIGNEE
Shall be intimated to bidder on later date.
19.0 DESPATCH
19.1 Despatch shall only be made only by road transport after inspection and issue of
MDCC by BHEL/ owner.
19.2 Each package should carry the packing slip/ details of contents and should be put
inside a metal enclosure, properly fixed to the packing from outside.
19.3 No consignment shall be dispatched on SELF basis. Material shall be despatched
on pre-paid, door delivery basis.
19.4 The packing shall be in such as to ensure prevention of damage, corrosion,

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pilferage, deterioration, loss in transit or storage and road-worthy.
20.0 INSPECTION & JOINT VERIFICATION (AT CONTRACTOR’S WORKS)
Prior to dispatch, the materials would be offered by the contractor for joint
inspection at the contractor’s works as detailed in this tender specification for which
the contractor would serve the advance notice of 15 days for inspection call to
BHEL.
21.0 INSPECTION & JOINT VERIFICATION (AT SITE)
The contractor shall be intimated within 7 days from the date of receipt of each
consignment at site to depute their representative for joint inspection and
verification of the equipment/materials received at site. The contractor shall depute
their representative within 7 days from receipt of such intimation failing which BHEL
shall proceed with the inspection and verification of equipment/materials and
BHEL’s decision in this regard shall be final and binding to the contractor.
22.0 QUALITY PLAN
The bidder shall furnish the quality assurance plan for approval of BHEL/ owner.
23.0 DIVISIBLE CONTRACT
Notwithstanding anything stated elsewhere in this tender, the contract to be
awarded shall be on the basis of supply & erection contract (divisible contract) on
single source responsibility. In the mode of contracting on the basis of supply &
erection, the civil & erection portion of the contract will relate to the BOQ cum price
schedule of (1) Part-1 and supply portion of the contract will relate to the BOQ cum
price schedules of (1) Part-2.
But the two contract shall not in any way dilute the responsibility of the bidder for
the successful completion of the job as per tender specification and both the
contracts shall contain a cross-fall breach clause, namely that a breach in one
contract shall automatically be classified as a breach on the other contract which
will confer a right on BHEL to terminate the other contract at the risk and cost of the
bidder.
The title of the ownership of goods to be supplied shall pass on to the owner on
dispatch ex-works/ FOR destination. However till the scope is completed in all
respect and the plant/ equipment is taken over by the owner the goods shall remain
with the custody of the bidder.
24.0 OTHER TERMS
All other term & conditions of this specification shall be governed by the pertinent
provisions of GCC, as applicable.

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IF TECHNICAL CONDITIONS OF CONTRACT
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JOB CONSTRUCTION OF 220M HIGH RCC SINGLE
FLUE BRICK LINED CHIMNEY INCLUDING
SUPPLY, ERECTION, COMMISSIONING ETC OF
EQUIPMENTS/ MATERIAL, COMPLETE.
CAPACITY 1x250 MW
PROJECT DPL, DURGAPUR, WEST BENGAL.
BHARAT HEAVY ELECTRICALS LIMITED
(A Govt Of India Undertaking)
POWER SECTOR – EASTERN REGION
PLOT – DJ 9/1, SECTOR II, SALT LAKE
KOLKATA – 700 091

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CONTENTS
CLAUSE DESCRIPTION
NO
1.0 PROJECT SYNOPSIS AND GENERAL INFORMATION
2.0 SITE VISIT
3.0 SCOPE OF WORK
4.0 DEVIATIONS
5.0 DEWATERING
6.0 LAND
7.0 WATER
8.0 ELECTRICITY
9.0 GENERAL TECHNICAL REQUIREMENTS (CODES AND STANDARDS)
10.0 SERVICES TO BE RENDERED BY THE BIDDER
11.0 PROTECTION
12.0 QUALITY CONTROL & QUALITY ASSURANCE
13.0 QUALITY ASSURANCE PROGRAMME
14.0 HSE REQUIREMENTS (HEALTH, SAFETY AND ENVIRONMENT)
15.0 SPECIFIC REQUIREMENTS FOR ISO 9002
16.0 GENERAL REQUIREMENTS
17.0 GENERAL GUIDELINES FOR FIELD ACTIVITIES
18.0 PROJECT MANAGEMENT/ CONSTRUCTION MANAGEMENT
19.0 RESPONSIBILITY OF CONTRACTOR
20.0 TOOLS & PLANTS (TO BE PROVIDED BY CONTRACTOR)
21.0 INSURANCE
22.0 MATERIAL HANDLING OF CEMENT & STEEL
23.0 ISSUE OF MATERIALS
24.0 RETURN OF MATERIALS
25.0 CEMENT AND STEEL CONSUMPTION AND WASTAGE
26.0 RECONCILIATION OF BHEL ISSUED MATERIALS
27.0 RECOVERY OF MATERIAL
28.0 CONSTRUCTION OF TEMPORARY OFFICE, STORES ETC
29.0 CIVIL LABORATORY AT SITE
30.0 CONSTRUCTION SCHEDULE
31.0 COMPLETION PERIOD
32.0 LIQUIDATED DAMAGE
33.0 CERTIFICATE TOWARDS COMPLETION
34.0 GUARANTEE
35.0 INTEREST BEARING RECOVERABLE ADVANCE
36.0 OVER RUN CHARGES
37.0 REVISION ON ACCEPTED CONTRACT RATE
38.0 PRICE VARIATION CLAUSE
39.0 SECURITY DEPOSIT & PERFORMANCE BOND
40.0 CONTRACT PRICE
41.0 TAXES AND DUTIES
42.0 INTERIM PAYMENTS
43.0 METHOD OF MEASUREMENT
44.0 EXTRA/ ADDITIONAL ITEMS OF WORK
45.0 DESIGN OFFICE AND FABRICATION DRAWING
46.0 FABRICATION / GALVANISING
47.0 DIVISIBLE CONTRACT
48.0 OTHER TERMS
49.0 ANNEXURE-A

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This volume shall be construed as part of tender document and shall be read along-with others
volumes of tender. In case of any conflict or inconsistency between the general and technical
conditions, the same shall be brought out by the bidder in writing to BHEL for clarification during
pre-bid discussions; failing which most stringent interpretation/ clause in favour of BHEL shall be
adopted and the same shall be binding to the bidder.
CLAUSE DESCRIPTION
NO
1.0 PROJECT SYNOPSIS AND GENERAL INFORMATION
1.1 1 x 250 MW Thermal Power Plant is being set up at Durgapur by Durgapur Projects
Limited, using pulverised coal as the main fuel, to work as a peak load station
capable of two shift operation. The power plant will be installed as unit # 8 at
Durgapur Projects Power Station, Durgapur in Burdwan district, West Bengal, India,
as extension unit.
Durgapur city is disposed at 28048’ N latitude and 85033’45” E longitude located at
left bank of river Damodar, in the district of Burdwan at a distance of about 160 KM
from Kolkata. The plant site is 6 KM away from Durgapur Barrage located on the
river Damodar. The site is well connected by roads with important industrial centres
in the area. Broad gauge railway line of the Eastern Railway and good all-weather
roads connect Durgapur with Kolkata and nearby collieries.
Owner of the project: Durgapur Projects Limited (DPL).
Nearest Railway station: Durgapur.
Site is about 3 Km from Railway station.
The site is about 160 km from Kolkata.
Nearest port is Kolkata.
The nearest airport is Netaji Subhas International Airport, Kolkata.
1.2 Owner of the project: Durgapur Projects Limited (DPL).
1.3 APPROACH TO SITE
Nearest railway station: Durgapur.
Site is about 3 Km from railway station.
The site is about 160 km from Kolkata.
Nearest port is Kolkata.
The nearest airport is Netaji Subhas International Airport, Kolkata.
2.0 SITE VISIT
The contractor should visit 1x250 MW DPL project site and acquire full knowledge
and information about site conditions. The bidder must visit site, to acquaint himself
with the conditions prevailing at site and in and around the plant premises, together
with all the statutory, obligatory, mandatory requirements of various authorities
before submission of the bid.
3.0 SCOPE OF WORK
3.1 The work to be done under this specification comprises of construction of 220 M
high reinforced concrete single flue brick lined chimney complete with reinforced
concrete raft foundation, RC shell, insulation and provision of other accessories
including ash hoppers, external platforms, fabrication and fixing of flue duct inside
the chimney, GI discrete strakes, complete interior and air aviation obstruction
lighting system, lightning protection and grounding system, MS doors for access to
the shell, external platforms and inspection of the liners, MS ladders,
communication system components, embedments for installation of equipments
and fixtures and painting both internal and external of the chimney shell as well as
of all doors, ladders and other structural steel items in accordance with this
specification and approved drawings.

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The chimney will be single flue reinforced concrete structure and flue will have first
class acid/ heat proof firebrick lining. This brick lining work will be supported on
internal RCC corbels at 10 mtr interval. Complete external surface of the chimney
shall be painted in alternate band of signal red and white colour starting with signal
red colour at the top and in line with aviation requirements. External painting shall
have acid and heat resisting properties confirming to IS-158, total dry film thickness
(DFT) shall be atleast 150 microns. Platforms on external surface of RCC
windshield with provision of personnel access shall be provided at maximum
twenty-five (25) metre interval. Suitable personnel access door and truck entry door
shall be provided. The top of roof slab and top of acid resistant bricks over the roof
shall be painted with two coats of ‘EXPILUX 5 coal tar epoxy paint’ over a thin coat
of the same paint as manufactured by Berger Paints (India). The overall DFT shall
be at least 230 microns. RCC hopper shall be provided at bottom level.
Arrangement shall be provided for measuring concentration of particulate matters.
NOX and SOX in the flue gas for monitoring and taking necessary measure for
pollution control. It will also have necessary arrangement for earthing during
construction. Access from ground to external platforms shall be provided with cage
ladder.
Receipt, unloading, erection, testing and commissioning of stack elevator and
electrical equipments, allied items, cabling, earthing, etc including lightening
protection system, communication system, aviation obstruction lighting system,
temporary aviation obstruction lighting system during construction of chimney, acid
and heat protection paints, are also under the scope of this of work. The complete
works have to be carried out by providing all labour, supervision, materials,
scaffolding, power, fuel, construction equipments, tools & plants, inspection,
measuring, testing instruments, supplies, transportation, storage, and all incidental
items not herein specifically mentioned but reasonably or found required for the
successful completion of work including contractor’s and where necessary
manufacturer’s expert supervision in strict compliance with the requirement of this
specification and approved construction drawing.
3.2 Any buried pipe/ cable/ trenches/ concrete structure coming in the working fronts
are to be removed safely by the contractor at no extra cost to BHEL.
3.3 The work to be performed under this specification consists of providing all labour,
materials, consumables, equipment, temporary works, temporary storage sheds,
material handling and storing of BHEL supplied items, temporary colony for labour
and staff, temporary site offices, constructional plants, fuel supply, transportation
and all incidental items not shown or specified but reasonably implied or necessary
for the completion of subject scope, all in strict accordance with the specifications
including revisions and amendments thereto as may be required during the
execution of work.
The scope shall also include setting up by the bidder a testing laboratory in the field
to carry out all relevant tests.
3.4 All quality standards, tolerances, welding standards and other technical
requirements shall be strictly adhered to. The bidder shall fully apprise himself of
the prevailing conditions at the proposed site, climatic conditions including
monsoon pattern, soil conditions, local conditions and site specific parameters and
shall include for all such conditions and contingent measures in the bid, including
those which may not have been specifically brought out in the specifications
4.0 DEVIATIONS
The bidder is required to submit with his offer in the relevant schedule/ format
without any ambiguity. Any assumptions, presumptions, deviations etc. indicated or
implied anywhere by the bidder except those indicated in the deviation schedule/
format will not be recognized and will not form a part of consideration / offer. In the
absence of such filled-up schedule/ format it will be understood and agreed that the
bidder’s offer is based on strict conformance to the specification and no negotiation

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would be allowed in this regard. BHEL reserve the right not to recognize any / all
deviations submitted after opening of the bid.
5.0 DEWATERING
The contractor shall ensure at all times that his work area & approach/ access
roads are free from accumulation of water, so that the materials are safe and the
erection/ progress schedule are not affected. No separate claim in this regard shall
be admitted by BHEL. No separate payments for dewatering of subsoil, surface
water or catchments water, if required, at any time during execution of the work
including monsoon period shall be considered by BHEL.
6.0 LAND
6.1 Availability of land within plant boundary is very limited and the contractor has to
plan and use the existing land considering the use of land by other
mechanical/electrical contractors and the storage of plant machineries and
materials. The existing land shall be shared by all erections agencies. The same
will be reviewed by BHEL and allotted to the extent available/ considered
necessary, depending upon the area availability. Contractor shall develop these
areas (including work areas as provided by BHEL/ customer) including grass/tree
cutting, leveling, grading etc. Material storage area, if more than the space allotted
to the bidder, shall have to be arranged by the bidder locally as a temporary
arrangement outside the project.
6.2 No land will be provided for labour colony inside the project premises to the
contractor to construct labour colony/ hutment. The contractor will have to make
temporary arrangement (at his own cost) outside the project premises the same in
consultation with customer/ BHEL.
6.3 The contractor will be responsible for handing back all lands, as handed over to
him.
6.4 Area for fabrication, batching plant and storage area for BHEL’s material shall be
provided as per availability free of cost as per enclosed Plot Plan.
7.0 WATER
7.1 BHEL will provide water connection at one point free of cost for construction as
well as drinking water. For further distribution of pipeline net work up to chimney
work spot are to be carried out by the bidder as per requirement at their own cost.
Contractor will submit enabling work plan showing batching plant, civil laboratories,
their own offices, temporary cement store (water tight) of 200 MT capacity, other
strores etc.and construct at their own cost.
7.2 Distribution network for construction and drinking water system within chimney area
shall be done by the bidder at his own cost.
7.3 The availability of water (construction as well as drinking) in customer project is
limited. The contractor shall ensure that no water is wasted. In this regard the
contractor shall take all necessary measure towards preservation of water.
7.4 BHEL shall not be responsible for any inconvenience or delay caused due to any
interruption of water supply and the contractor shall claim no compensation for
delay in work for such interruption. Contractor may make standby arrangement for
water for which no separate payment shall be made by BHEL.
8.0 ELECTRICITY
8.1 BHEL will provide construction power point on free of charge basis at LT voltage
level (3-Ph., 415-V) at around 200M from chimney area. Further distribution
(including laying of cables/ installation DBs and maintenance of the same) beyond
this point to be arranged by the contractor at his own cost. If any other voltage level
(other than normally available) is required, the same shall be arranged by the
contractor from power supply as above. Contractor will have to provide at his own
cost necessary calibrated energy meters (tamper proof, suitably housed in a
weather proof box with lock & key arrangement) at point of power supply along with
calibration certificate from authorized/ accredited agency for working out the power
consumption. In case of recalibration required for any reason the necessary
charges including replacement by calibrated meters is to be borne by contractor.

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Supply of electricity shall be governed by Indian Electricity Act and Installation
Rules and other Rules and Regulation as applicable. The contractor shall ensure
usage of electricity in an efficient manner and the same may be audited by BHEL
time to time. In case of any major deviation from normally accepted norms is
observed, BHEL will reserve the right to impose penalty as deemed fit for such
cases. No bare conductor (for the purpose of drawing electricity for construction
purposes) is allowed to be drawn within project premises.
8.2 The bidder shall have to provide earth leakage circuit breaker at each point
wherever human operated electrical drives/ T&Ps are deployed.
8.3 The power supply will be from the available grid. BHEL shall not be responsible for
any inconvenience or delay caused due to any interruption of power supply/
variation in voltage level and no compensation for delay in work can be claimed by
the contractor due to such non-supply on the grounds of idle labour, machinery or
any other grounds.
8.4 BHEL shall provide illumination on common erection approaches on a progressive
basis; however the bidder will have to arrange sufficient illumination at their work
areas.
8.5 The contractor should ensure that the work in critical areas is not held up in the
event of power breakdown. In the event of breakdown in the electric supply, if the
progress of work is hampered, it will be the responsibility of the contractor to step
up the progress of work after restoration of electric supply so that overall progress
of work is not affected.
8.6 The contractor shall have to make arrangement at their own cost for illumination
that will be required in the working area for execution of the work & safety of
workmen.
8.7 Bidder also will install DG SET back up system for emergency night illumination
and operation of passenger hoist during grid power failure or any emergency use of
passenger hoist throughout the construction period.
8.8 Bidder to provide temporary lightning arrestor along with ground earth-matting and
electrode while doing the RCC shell concreting.
9.0 GENERAL TECHNICAL REQUIREMENTS (CODES AND STANDARDS)
9.1 Except where otherwise specified, the plant/ equipment shall comply with
appropriate Indian Standard or an agreed internationally accepted Standard
Specification as mentioned elsewhere in tender, each incorporating the latest
revisions at the time of tendering. Where no internationally accepted standard is
applicable, the bidder shall give all particulars and details as necessary; to enable
BHEL to identify all of the plant/ equipment in the same detail as would be possible
had there been a standard specification.
9.2 Where the bidder proposes alternative codes or standards he shall include in his
tender one copy (in English) of each standard specification to which materials
offered shall comply. In such case, the adopted alternative standard shall be
equivalent or superior to the standards mentioned in the specification.
9.3 In the event of any conflict between the codes & standards referred above, and
requirements of this specification, the requirements which are more stringent shall
govern.
9.4 Tools used during erection and commissioning shall not be accepted except with
the specific approval of the engineer.
9.5 Wherever specified or required the plant/ equipment shall conform to various
statutory regulations such as Indian Boiler Regulation, Indian Electricity Rules,
Indian Explosive Act, Factories Act etc, wherever required, obtaining approval for
plant/ equipment supplied under the specification from statutory authorities shall be
the responsibility of the contractor.
10.0 SERVICES TO BE RENDERED BY THE BIDDER
10.1 Services for construction, fabrication, equipment erection, testing as well as trial run
& commissioning of various equipment and accessories under the contract shall
include but not be limited to the following.

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10.2 Collecting materials from store/open yard from time to time for fabrication / erection
as per the construction program and unloading of cement & steel as per flow of
consignment. The contractor shall be the custodian of all the materials issued till
the plant/equipment is officially taken over by the owner/ BHEL after complete
erection and commissioning. The contractor shall maintain adequate security
personnel and security measures for proper precaution and safety of material.
10.3 Deployment of all skilled and unskilled manpower required for erection supervision,
watch & ward, for commissioning and other services to be rendered under this
specification.
10.4 Deployment of all erection tools & tackle, construction machinery, transportation
vehicles and all other implements in adequate number and size, appropriate for the
erection work to be handled under scope of this specification except otherwise
specified.
10.5 Supply of all consumables, e.g. welding electrodes, etc as well as materials
required for temporary supports, scaffolding etc as necessary for such construction
work, unless specified other wise.
10.6 Providing support services for the contractor's erection staff eg construction of site
offices, temporary stores, residential accommodation and transport to work site for
erection personnel, watch and ward for security and safety of the materials under
the Contractor's custody etc. as required.
10.7 Maintaining proper documentation of all site activities undertaken by the contractor
as per the proforma mutually agreed with BHEL, submitting monthly progress
reports as also any such document as and when desired by BHEL/ owner, taking
approval of all statutory authorities e.g., Factory Inspector, Provident Fund authority
etc. for respective portions of work under the jurisdiction of such statutes of laws.
10.8 As part of overall project management activity, the contractor shall be responsible
for proper co-ordination of erection activities during various phases of execution of
the contract. The contractor shall identify a person designated as construction
manager, with whom BHEL shall interact on matters related to execution of the
contract. The construction manager shall be the single point contact person on
behalf of the contractor. BHEL shall interact with the construction manager only on
all matters on co-ordination between BHEL and the contractor. For timely
completion of work the contractor may have to work in one or more shifts. He will
not be eligible for any extra charge on this account.
10.9 The contractor shall confine all his field operations to those works which can be
reformed without subjecting the equipment and materials to adverse effects, during
inclement weather conditions, like monsoon, storms etc and during other
unfavourable construction conditions. No field activities shall be performed by the
contractor under conditions which might adversely affect the quality and efficiency
thereof, unless special precautions or measures are taken by the contractor in
proper and satisfactory manner in the performance of such works and with the
concurrence of the engineer. Such unfavourable construction conditions in no way
relieve the contractor of his responsibility to perform the works as per the schedule.
10.10 The contractor shall supply all the skilled workmen like mill-wright fitters, welders,
gas cutters, electricians, riggers, sarangs, erectors, carpenters, pipe fitters,
masons, laggers, tin-smiths, instrument machanics etc, in addition to other skilled,
semi-skilled and unskilled workmen required for all works of handling and
transportation from site store to erection site, erection, testing and commissioning
contemplated under this specification. Only fully trained and competent men with
previous experience on the job shall be employed. They shall hold valid certificates
wherever necessary. BHEL reserve the right to decide on the suitability of the
workers and the other personnel who will be employed by the contractor. BHEL
reserves the right to insist on removal of any employee of the contractor at any
time, if they find him unsuitable and the contractor shall forthwith remove him.
10.11 The supervisory staff employed by the contractor shall be technically qualified and
experienced in the area of work. They shall ensure proper out turn of work and
discipline on the part of labour put on the job by the contractor and in general see

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that the works are carried out in a safe and proper manner and in coordination with
other labour and staff employed directly by BHEL or other contractors of BHEL and
BHEL's client.
10.12 The contractor shall also furnish daily labour report showing by classification the
number of employees engaged in various categories of work a progress report of
work as required by BHEL engineer.
10.13 The work shall be executed under the usual conditions affecting major power plant
construction and in conjunction with numerous other operations at site. The
contractor and his personnel shall co-operate with other personnel, and other
contractors, co-ordinating his work with others and proceed in a manner that shall
not delay or hinder the progress of work as a whole.
10.14 The contractor's supervisory staff shall execute the work in the most substantial
and workman like manner in the stipulated time. Accuracy of work and aesthetic
finish are essential part of this contract. The contractor shall be responsible to
ensure that assembly and workmanship conform to the dimensions and tolerance
given in the drawing / instruction given by BHEL Engineer from time to time.
10.15 It is the responsibility of the contractor to engage his workman in shifts or on
overtime basis for achieving the target set by BHEL during erection, commissioning
and testing period. Contractor's quoted rate shall include all these contingencies.
10.16 Any other service, although not specifically called for but required for a contract of
the size and nature indicated in the specification.
11.0 PROTECTION
11.1 Equipment having anti-friction or sleeve bearings shall be protected by weather
tight enclosures. Coated surfaces shall be protected against impact, abrasion,
discoloration and other damages. Surfaces which are damaged shall be repainted.
11.2 Electrical equipments, controls and insulations shall be protected against moisture
and water damages. All external gasket surfaces and flange faces, couplings,
rotating equipment shafts, bearings and like items shall be thoroughly cleaned and
coated with rust preventive compound and protected with suitable wood, metal or
other substantial type covering to ensure their full protection. All exposed threaded
parts shall be greased and protected with metallic or other substantial type
protectors
11.3 All piping, tubing and conduit connections on equipment and equipment openings
shall be closed with rough usage covers or plugs. Female threaded openings shall
be closed with rough usage covers or plugs or forged steel plugs. The closures
shall be taped to seal the interior of the equipment. Open ends of piping, tubing and
conduit shall be sealed and taped.
11.4 All other consumables including wire brush, emery papers, painting brush etc to be
supplied by the contractor within the quoted rate.
12.0 QUALITY CONTROL & QUALITY ASSURANCE
Contractor’s Engineers and supervisors shall be adequately qualified and also
inclined to do a quality job. The quality assurance engineer shall co-ordinate all
aspects of quality control, inspection, implementation of quality assurance
procedures laid down in Quality Plan and technical specification by BHEL. He shall
fill up quality assurance log sheets/ formats and submit to BHEL for joint inspection
and acceptance. The contractor shall fill up, maintain & preserve the quality
records in computerized media. customer/ BHEL's authorized representative shall
be given free access at all time to such quality related records etc for inspection,
review etc.
13.0 QUALITY ASSURANCE PROGRAMME
13.1 The contractor shall arrange for suitable quality assurance program to control all
activities pertaining to the scope of work, as necessary. Such programs shall be
outlined by the contractor and shall be finally accepted by BHEL. A quality
assurance program of the contractor shall generally cover the following.
13.2 Organization structure and qualification data for key personnel of the contractor for
the management & implementation of the proposed quality assurance program.

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13.3 The procedure for source inspection, incoming raw material inspection, verification
of material purchased etc.
13.4 Field quality plan will detail out the quality practices and procedures etc to be
followed by the contractor’s site quality control organization, during various stages
of site activities from receipt of material /equipment at site.
13.5 Bidder to arrange temperature control at around 25˚ C during chimney raft, either
by sprinkling water on course aggregate or by using Ice, including all related
arrangements for providing, storing and mixing Ice with water, cooling of
aggregates etc.
14.0 HSE REQUIREMENTS (HEALTH, SAFETY AND ENVIRONMENT)
14.1 The contractor shall ensure the safety of all workmen, materials and equipment
either belonging to him or to others working at site. He shall observe safety rules
and codes applied by the customer/ BHEL at site without exception.
14.2 Passenger lift should have safety cage with multiple rope, i.e. with safety rope &
limit switch.
14.3 Safety nets with hand railings must be provided on all both inside & outside hanging
platform of slip-form equipment & hanging platform from brickwork.
14.4 Emergency vehicle must be provided & kept separately as stand-by.
14.5 T&P used by contractor should be tested quality bearing ISI marks. Necessary test
certificates to be produced by the contractor for all the T&P received by him at site
for acceptance by BHEL Engineer. BHEL will reject any T&P without IS test
certificate and the same cannot be utilized on job.
14.6 Only trained and experienced personnel to be used on the job. Signalling for rigging
operations must be given by workers who are possessing required skill and
experience in handling materials.
14.7 Non-conformity of safety rules and safety appliances will be viewed seriously and
BHEL has right to impose fines on the contractor on each incident/each nonconformity
as per details given below.
Safety measure
Fine (Rs)
14.7.1 Not wearing safety helmet & safety shoe. Will not be permitted to
enter the plant
14.7.2 Not wearing safety belt. Will not be permitted to
work at heights for erection
job.
14.7.3 Grinding without goggles. 25/workmen
14.7.4 Not using 24V supply for internal work. 500/case
14.7.5 Electrical plugs not used for hand machines. 100/case
14.7.6 Welding cables, electrical wires not insulated with 50/joint
proper/ standard.
14.7.7 Not removing scrap from platform. Actual cost for removal plus
30 %
14.7.8 Gas cutting without taking proper precaution/not 100/case
using sheet below per incidence.
14.7.9 Electrical winches having no guards earthed properly 500/case
etc.
14.7.10 Improper earthing of electrical T&P. 200/ equipment
14.7.11 Not protecting/locating the gas cylinder to avoid 100/cylinder
catching of fire.
14.7.12 Not providing earth leakage circuit breaker as per 1500/point
direction of BHEL.
14.7.13 Not slinging properly 200/case
14.7.14 Using damaged sling 200/case
14.7.15 Lifting cylinders without cage 500/case
14.7.16 Backfire arrestor 500/case
14.7.17 Life line 500/case
14.7.18 Fall arrestor 500/case

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14.8 Any other nonconformity noticed not listed above will also be fined. The decision of
BHEL engineer is final on the above. The amount will be deducted from running
bills of the contractor. The amount collected on the above will be utilised for giving
award to the employee who could avoid accidents by following safety rules. Also,
the amount will be spent for improving the safety at site.
14.9 The contractor shall also be responsible for provision of all safety notices and
safety equipment required both by the relevant legislation and BHEL/ customer, as
he may deem necessary.
14.10 The contractor will notify well in advance to BHEL/ customer his intention to bring to
the site any container filled with liquid or gaseous fuel or explosive or petroleum
substance or such chemicals, which may involve hazards. BHEL/ customer shall
have the right to prescribe the conditions, under which such container is to be
stored, handled and used during the performance of the works and the contractor
shall strictly adhere to and comply with such instructions. BHEL/ customer shall
have the right at his sole discretion to inspect any such container or such
construction plant/equipment for which material in the container is required to be
used and if in his opinion, its use is not safe, he may forbid its use. BHEL/ customer
shall entertain no claim due to such prohibition and BHEL/ customer shall not
entertain any claim of the contractor towards additional safety provisions/conditions
to be provided for/constructed as per the BHEL/ customer’s instructions.
14.11 Further, any such decision of the BHEL/ customer shall not, in any way, absolve the
contractor of his responsibilities and in case, use of such a container or entry
thereof into the site area is forbidden by the BHEL/ customer, the contractor shall
use alternative methods with the approval of the BHEL/ customer without any cost
implication to customer or extension of work schedule.
14.12 Where it is necessary to provide and/or store petroleum products or petroleum
mixtures and explosives, the Contractor shall be responsible for carrying-out such
provision and/or storage in accordance with the rules and regulations laid down in
Petroleum Act 1934, Explosives Act, 1948, and Petroleum and Carbide of Calcium
Manual published by the Chief Inspector of Explosives of India. All such storage
shall have prior approval of the BHEL/ customer. In case, any approvals are
necessary from the Chief Inspector (Explosives) or any statutory authorities, the
Contractor shall be responsible for obtaining the same.
14.13 All equipment used in construction and erection by Contractor shall meet Indian/
International Standards and where such standards do not exist, the Contractor shall
ensure these to be absolutely safe. All equipments shall be strictly operated and
maintained by the Contractor in accordance with manufacturer’s operation Manual
and safety instructions and as per Guidelines/Rules of customer in this regard.
14.14 Periodical examinations and all tests for all lifting/ hoisting equipment & tackles
shall be carried-out in accordance with relevant provisions of Factories Act 1948,
Indian Electricity Act 1910 and associated laws/ rules in force from time to time. A
register of such examinations & tests shall be properly maintained by contractor
and will be promptly produced as & when desired by BHEL/ customer or by the
person authorized.
14.15 The contactor shall be fully responsible for the safe storage of his and his subcontractor’s
radioactive sources in accordance with BARC/ DAE (Bhabha Atomic
Research Center/ Department of Atomic Energy, Govt of India) rules and other
applicable provisions. All precautionary measures stipulated by BARC/ DAE in
connection with use, contractor would take storage and handling of such material.
14.16 The contractor shall provide suitable safety equipment of prescribed standard to all
employees and workmen according to the need, as may be directed by BHEL/
customer who will also have right to examine these safety equipments to determine
their suitability, reliability, acceptability and adaptability.
14.17 Where explosives are to be used, the same shall be used under the direct control
and supervision of an expert, experienced, qualified and competent person strictly
in accordance with the Code of Practices/ Rules framed under Indian Explosives
Act pertaining to handling, storage and use of explosives.

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14.18 The contractor shall provide safe working conditions to all workmen and employees
at the Site including safe means of access, railings, stairs, ladders, scaffoldings etc.
The scaffoldings shall be erected under the control and supervision of an
experienced and competent person. For erection, the contractor only shall use
good and standard quality of material.
14.19 The contractor shall not interfere or disturb electric fuses, wiring and other electrical
equipment belonging to BHEL/ customer or other contractors under any circumstances,
whatsoever, unless expressly permitted in writing by customer to handle
such fuses, wiring or electrical equipment.
14.20 Before the contractor connects any electrical appliances to any plug or socket
belonging to the other contactor or BHEL/ customer, he shall fulfill following.
14.20.1 Satisfy BHEL/ customer that the appliance is in good working condition.
14.20.2 Inform BHEL/ customer of the maximum current rating, voltage and phases of the
appliances.
14.20.3 Obtain permission of BHEL/ customer detailing the sockets to which the appliances
may be connected.
14.21 The BHEL/ customer will not grant permission to connect until he is satisfied that:
14.21.1 The appliance is in good condition and is fitted with suitable plug;
14.21.2 The appliance is fitted with a suitable cable having two earth conductors, one of
which shall be an earthed metal sheath surrounding the cores.
14.22 No electric cable in use by contractor/ BHEL/ customer will be disturbed without
prior permission. No weight of any description will be imposed on any cable and no
ladder or similar equipment will rest against or attached to it.
14.23 No repair work shall be carried out on any live equipment. BHEL/ customer must
declare the equipment safe and a permit to work shall be issued by BHEL/
customer before the contractor carries out any repair work. While working on
electric lines/equipments whether live or dead, suitable type and sufficient quantity
of tools will have to be provided by contractor to electricians/ workmen/ officers.
14.24 The contractors shall employ necessary number of qualified, full time electricians/
electrical supervisors to maintain his temporary electrical installations.
14.25 The contractor shall employ trained safety officer to supervise day to day safety
aspects of the equipments and workmen, who will co-ordinate with BHEL/ customer
customer safety officer. In case of work being carried out through sub-contractors,
sub-contractor’s workmen/ employees will also be considered as the contractor’s
employees/ workmen for the above purpose.
14.26 In case any accident occurs during the construction/ erection or other associated
activities undertaken by the Contractor thereby causing any minor or major or fatal
injury to his employees due to any reason, whatsoever, it shall be the responsibility
of the contractor to promptly inform the same to BHEL/ customer in prescribed form
and also to all the authorities envisaged under the applicable laws.
14.27 BHEL/ customer shall have the right at his sole discretion to stop the work, if in his
opinion the work is being carried out in such a way that it may cause accidents and
endanger the safety of the persons and/or property, and/or equipments. In such
cases, the contractor shall be informed in writing about the nature of hazards and
possible injury/ accident and he shall comply to remove shortcomings promptly.
14.28 The contractor shall not be entitled for any damages/ compensation for stoppage of
work due to safety reasons above and the period of such stoppage of work will not
be taken as an extension of time for completion of the facilities and will not be the
ground for waiver of levy of penalty.
14.29 The contractor shall follow and comply with all safety rules of BHEL/ customer,
relevant provisions of applicable laws pertaining to the safety of workmen,
employees plant and equipment as may be prescribed from time to time without
any demur, protest or contest or reservation. In case of any inconformity between
statutory requirement and customer’s Safety Rules of BHEL/ customer referred
above, the later shall be binding on the contractor unless the statutory provisions
are more stringent.

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14.30 If the Contractor fails in providing safe working environment as per BHEL's Safety
Rules or continues the work even after being instructed in writhing to stop work by
BHEL Manager, the Contractor shall promptly pay to BHEL, on demand by BHEL
compensation at the rate of Rs. 5,000/- per day or part thereof till the instructions
are complied with and so certified by BHEL. However, in case of accident taking
place, causing injury, to any individual, the provisions contained in relevant
paragraph above shall also apply in addition to compensation mentioned in this
paragraph.
14.31 If the Contractor does not take all safety precautions and/or fails to comply with the
Safety Rules as prescribed by BHEL or under the applicable law for the safety of
the equipment and plant and for the safety of personnel and the Contractor does
not prevent hazardous conditions which cause injury to his own employees or
employees of other Contractors, or BHEL's employees or any other person who are
at Site or adjacent thereto, the Contractor shall be responsible for payment of
compensation to Employer as per the following schedule.
14.31.1 Fatal injury or accident causing death Rs.2,00,000.00/per person
14.31.2 Major injuries or accident causing 25% or more Rs 50,000.00/per person
permanent disablement to workmen or employees.
14.32 Permanent disablement shall have same meaning as indicated in Workmen's
Compensation Act. The compensation mentioned above shall be in addition to the
compensation payable to the workmen/employees under the relevant provisions of
the Workmen's Compensation Act and rules framed there under or any other
applicable laws as applicable from time to time. In case BHEL is made to pay such
Compensation then the Contractor is liable to reimburse BHEL such amount in
addition to the compensation indicated above.
14.33 In case BHEL/ customer is made to pay such compensation then the contractor is
liable to reimburse BHEL/ customer such amount in addition to compensation
indicated above.
14.34 These insurance covers for his workmen as well as his T & P have to be taken by
contractor prior to start of his work at the subject project and he shall make
available the Policy to BHEL site-in-charge for necessary verification before
commencement of work. However, irrespective of such verification/ acceptance, the
sole responsibility to maintain adequate insurance cover for his workmen, T&P,
assets etc. at all times during the period of contract shall lie with the contractor.
Regarding the aforesaid insurance cover, the contractor shall directly deal with the
Insurance Company for all matters regarding the insurance in his scope.
14.35 You will follow HSE policy of BHEL/ PSER and work as per the safety guidelines
which is in line with ISO:14001 and OHSAS:18001 standards. A list of the
guidelines which should be strictly followed by you as follows. Your scope shall not
be limited to the followings only but shall be guided by the HSE related policies/
guidelines of BHEL as revised to suit the requirement of the standards and
statutory requirements.
14.36 Nominate a safety officer who will supervise all the HSE aspects.
14.37 The safety officer will participate in all safety meeting conducted by BHEL.
14.38 Submit site safety plan indicating safety measures to be taken, fire fighting
equipments & PPE to be deployed.
14.39 Report every near miss incident to BHEL.
14.40 Report accident report immediately after the occurrence.
14.41 Obtain operation control procedures (OCPs) from BHEL for the work to be
executed
14.42 Follow factory act.
14.43 Every worker should use PPE as per his trade. All PPE should confirm to IS.
14.44 Conduct tool box meeting with workers everyday before start of work instructing
about the use of PPE. The outcome of the meeting to be recorded in a register.
14.45 Check fitness of PPE and lifting tackles weekly and record in a register which will
be verified by BHEL.

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14.46 No person below 18 years will be employed.
14.47 Deploy fire-fighting equipments and refill before expiry.
14.48 Keep fire extinguishers of adequate type near the hot job and near the electrical
machines.
14.49 Copy of valid test certificates of all T&Ps should be given to BHEL as soon as the
item enters the project, without which the T&P can not be allowed to be used.
14.50 No body will be allowed to work above 2 meters without safety belt/ harness with
lifeline secured to a fixed member.
14.51 Good housekeeping has to be maintained. All debris shall be removed from
workplace within shortest possible time.
14.52 Approach roads should not be blocked with cables, materials or debris.
14.53 First aid boxes have to be kept and maintained with all requisite materials as per
factory act.
14.54 Trained person has to be kept for giving first aid.
14.55 Adequate illumination shall be provided where working.
14.56 All vehicles should have backlight, reverse horn and reversing light.
14.57 Crane operator shall have proper license.
14.58 Crane should have reverse horn.
14.59 Only skilled person maintain and operate electrical items.
14.60 ELCB has to be used. No temporary connection shall be allowed.
14.61 All fuses shall have standard rating and capacity.
14.62 All power supply cables should be laid above 3 meter level or underground.
14.63 All hand lamps should be powered by 24 volts.
14.64 Water-logging of working area shall be removed.
14.65 For operating portable machines 3 pin plugs shall be used.
14.66 Oxygen & DA cylinders shall be separated labeling full or empty. Full cylinders shall
be kept upright.
14.67 Cylinders are not transported by rolling.
14.68 All oil drums shall be kept horizontal.
14.69 Excavated area shall be barricaded off with red & white tape.
14.70 Proper slope of excavation shall be maintained.
14.71 Proper sign board and illumination shall be maintained at excavated area.
14.72 Wherever possible safety net shall be provided.
14.73 Proper platform and hand rail has to be provided at the work place.
14.74 All electrical equipments shall be earthed at two points.
14.75 Temporary platform should be strong enough, have proper approach and hand rails
14.76 Above clauses are indicative only and not exhaustive. Other activities to maintain
strong HSE conditions at site which may be beyond above list of guidelines shall
have to be done by you.
14.77 The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at the Site. First-aid centre with Ambulance
facility shall be established and maintained at site by the main Civil vendor. All
other bidder of BHEL are expected to contribute towards establishing and
maintaining the facility and the sum of contributions should be proportionate to their
respective contract prices. This may be treated as mandatory stipulation and the
bidder should carryout due liasioning work with the Civil vendor directly for smooth
running of the first-aid centre. In the event of non-compliance of this, BHEL shall be
constrained to pay the contribution and recover the cost with 30% overhead from
the bill of the vendor.
14.78 It is imperative on the part of the contractor to join and effectively contribute in joint
measures such as tree plantation, environment protection, contributing towards
social up-liftment, conversion of packing woods to school furniture, keeping good
relation with local populace etc.
14.79 Round the clock experienced paramedical personnel with first aid facility & one
ambulance at site to be arranged by the bidder at his own cost. No medical facility
within / near the site shall be provided by BHEL. However, BHEl/ customer shall

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provide one room (without furniture) for use as first aid centre.
14.80 No staff quarter shall be provided by BHEL.
14.81 No borrow area for earth shall be arranged / provided by BHEL. The necessary
approach road, as required for disposal of earth, is included in the scope of work of
contractor.
14.82 All temporary approaches required for movement of cranes, trailers, trucks, transit
mixers, dumpers, etc shall be prepared / arranged by the contractor at his own cost.
14.83 The contractor shall solely be responsible for the safety, quality, & quantity of
material after it is handed over and issued to contractor by the BHEL.
14.84 Centralized reinforcement cutting/ bending yard should be located within 1000m
from the power house yard.
15.0 SPECIFIC REQUIREMENTS FOR ISO 9002
15.1 Contractors shall ensure that all their staff/ employees are exposed to periodical
training programmes conducted by qualified agencies/ personnel on ISO 9002
Standards.
15.2 Contractor shall ensure that the quality is maintained in all the works connected
with this contract at all stages of the requirement of BHEL.
15.3 Contractor shall ensure that all Inspection, Measuring and Testing equipment that
are used, whether owned by the contractors or used on loan, are calibrated by the
authorized agencies and the valid calibration certificate will be available with them
for verification by BHEL. A list of such instruments possessed by the contractor at
site with its calibration status is to be submitted to BHEL Engineer for control.
15.4 Contractor shall ensure that fitness certificate of the tools & plants, that are in use,
whether owned by contractor or issued on loan, are tested by authorised agency
and the valid fitness certificate is available for verification by BHEL.
15.5 Contractors shall arrange for the inspection of the works at various stages as
required by BHEL. The contractors shall take immediate corrective action for the
non-conformances if any, observed and pointed out by BHEL.
16.0 GENERAL REQUIREMENTS
16.1 The bidders are to consider this during quoting. BHEL is in the process of providing
the first-aid centre within the project premises with ambulance facility on no profit
no loss basis. The cost of running expenses will be shared between all the subcontractors
engaged within project. The pro-rata charges shall be determined by
the total contract price of the sub-contractor and no. of sub-contractors available
within the project. The bidders are to consider this during quoting.
16.2 Bidders to note that stipulations as per Govt. of West Bengal minimum wages Act
including House Rent Act & Height allowance Act are applicable for this project.
Any agency found to be violating these acts is liable for legal proceedings &
compensation as per law and recovery from the RA bill as per actual cost (+) 30 %
will be affected. Bidders to note that provisions & rules as per Factory Act (with
amendments) is implemented and the same is applicable for this project.
16.3 Since this is an extension unit, the construction area may be cordoned off by
providing a temporary fencing arrangement. Bidders to take special care that none
of his workmen ventures into the running plant area during any time of the day,
except for interface area working, for which separate procedure will be issued at the
time of execution.
16.4 Before starting the work at site the bidder to apply for gate pass for his workmen.
The application for gate pass shall be addressed to `The Chief Security Officer,
DPL, DPL Power Station’. The application for gate pass should be first routed
through authorized representative of BHEL and then by Project Department, DPL,
before proceeding to IR section of DPL. The application must accompany the
relevant & applicable documents like proof of residence, ESI no etc.
16.5 The site is under Factory Act and all relevant statutory provision/ liabilities etc are to
be taken care of by the bidder.
16.6 Labour Requirements
16.6.1 The contractor shall prepare and make available to the customer from time to time

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details of the numbers and trades of workmen whom the contractor proposes to
employ (whether directly or through sub-contractors) on the site throughout the
periods shown in the Project Schedule. Such details shall be in the form of a
periodic histogram, accumulative `S’ curve and summary line item tabulation or
such other form as customer may reasonably request and the contractor normally
utilizes.
16.6.2 As far as practicable, the Contractor shall give preference in the employment of
unskilled labourers at the Site to persons living locally in consultation with
customer’s IR Department.
16.7 Quality Assurance
16.7.1 All materials, components and equipments covered under the specification shall be
procured, manufactured, erected, commissioned and tested, as applicable, at all
stages as per comprehensive quality assurance program. An indicative program for
inspection/ test, to be carried out by the contractor, for some of the major items is
given in the respective technical specification.
16.7.2 Approved Field quality plan of BHEL/ customer will detail out the quality practices
and procedures etc to be followed by the contractor’s site quality control
organization, during various stages of site activities from receipt of material/
equipment at site.
16.7.3 Casting and forgings used for construction shall be of tested quality. Details of
results of chemical analysis, mechanical properties test result, as necessary, shall
be furnished.
16.7.4 All welding shall be carried out as per procedure drawn and qualified in accordance
with the requirements of ASME Section-1X/ BS4870 or other international
equivalent standard acceptable to BHEL/ customer.
16.7.5 All welders etc employed on any part of the contract at contractors’ work or at site
shall be qualified as per ASME Section-IX or BS 4871 or equivalent international
standard approved by BHEL/ customer. Such qualification test shall be conducted
in presence of BHEL/ customer.
16.7.6 All non-destructive examinations (NDT) shall be carried out in accordance with
approved international standard. NDT operators shall be qualified as per SNT-TC-
IA (of American society of non-destructive examination) Results of NDT shall be
properly recorded and submitted for approval.
16.7.7 All the purchase specifications for the major bought out items list of which shall be
drawn up by the contractor and finalized with BHEL/ customer shall be furnished to
BHEL for comments and approval before placement of orders.
16.7.8 BHEL/ customer reserves the right to carry out quality audit and quality surveillance
of the systems and procedures of contractor’s quality management. Contractor
shall provide all necessary assistance to enable BHEL/ customer to carry out such
audit.
16.7.9 Quality audit/approval of the results of test and inspection will not prejudice the right
of BHEL/ customer to reject an equipment service not giving the desired
performance and shall not in no way limit the liabilities and responsibilities of the
contractor in earning satisfactory performances of equipment/service as per
specification.
16.7.10 Repair/ rectification procedure to be adopted to make any job acceptable shall be
subject to the approval of BHEL/ customer.
16.7.11 All the latest relevant IS codes as per technical specification & requirement should
be available with contractor at site within 45 days from the date of LOI.
17.0 GENERAL GUIDELINES FOR FIELD ACTIVITIES
17.1 The contractor shall execute the works in a professional manner so as to achieve
the target schedule without any sacrifice on quality and maintaining highest
standards of safety and cleanliness.
17.2 The contractor shall co-operate with owner/ BHEL and other contractors working in
site and arrange to perform his work in a manner so as to minimise interference
with other contractor’s works. BHEL's engineer shall be notified promptly of any

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defect in other contractors’ works that could affect the contractor’s work. If
rescheduling of contractor’s work is requested by the owner's/ BHEL's engineer in
the interest of overall site activities, the same shall be compiled with by the
contractor. In all cases of controversy, the decision of BHEL shall be final and
binding on the contractor without any commercial implication.
17.3 The engineer shall hold weekly meeting of all the contractors working at site at a
time and a place to be designated by the engineer. The contractor shall attend such
meetings and take notes of discussions during the meeting and the decisions of the
engineer and shall strictly adhere to those decisions in performing this work. In
addition to the above weekly meeting, engineer may call for other meetings either
with individual contractors or with selected number of contractors and in such a
case the contractor, if called will also attend such meetings.
17.4 Time is the essence of the contract and the contractor shall be responsible for
performance of his work in accordance with the specified construction schedule. If
at any time the contractor is falling behind the schedule, he shall take necessary
action to make good of such delays by increasing his work to comply with the
schedule and shall communicate such action in writing to the engineer, satisfying
that his action will compensate for the delay. The contractor shall not be allowed
any extra compensation for such action.
17.5 The engineer shall however not be responsible for provision of additional labour
and or materials or supply of any other services to the contractor except for the coordination
work between various contractors as set out earlier.
17.6 The works under execution shall be open to inspection & supervision by BHEL's /
Owner's engineer at all times. The contractor shall give reasonable notice to BHEL
before covering up or otherwise placing beyond the reach of inspection any work, in
order that same may be verified, if so desired by owner/ BHEL.
17.7 Every effort shall be made to maintain the highest quality of workmanship by
stringent supervision and inspection at every stage of execution. Manufacturer's
instruction manual and guidelines on sequence of erection and precautions shall be
strictly followed. Should any error or ambiguity be discovered in such documents
the same shall be brought to the notice of BHEL's engineer. Manufacturer's
interpretation in such cases shall be binding on the contractor.
17.8 The contractor shall comply with all the rules and regulations of the local
authorities, all statutory laws including Minimum Wages, Workmen Compensation
etc. All registration and statutory inspection fees, if any, in respect of the work
executed by the contractor shall be to his account.
17.9 All the works such as cleaning, checking, levelling, blue matching, aligning,
assembling, temporary erection for alignment, opening, dismantling of certain
equipment for checking and cleaning, surface preparation, edge preparation,
fabrication of tubes and pipes as per general engineering practice at site, cutting,
grinding, straightening, chamfering, filling, chipping, drilling, reaming, scrapping,
shaping, fitting-up, bolting/ welding, etc as may be applicable in such erection and
necessary to complete the work satisfactorily, are to be treated as incidental and
the same shall be carried out by the contractor as part of the work.
17.10 It is the responsibility of the contractor to do the alignment etc if necessary,
repeatedly to satisfy engineer, with all the necessary tools & tackles, manpower etc.
The alignment will be complete only when jointly certified so, by the contractor's
engineer and BHEL. Also the contractor should ensure that the alignment is not
disturbed afterwards.
17.11 Equipment and material, in case wrongly installed, shall be removed and
reinstalled to comply with the design requirement at the contractor expense, to the
satisfaction of BHEL/ owner.
17.12 After identification of erection materials by BHEL at BHEL's store/ storage yard, it
shall be the responsibility of the contractor to take delivery of materials from BHEL's
store/ storage yard by contractor's own manpower and re-stack the leftover
materials as per erection sequence at BHEL store at their own cost. The entire
activities are to be carried out under supervision of BHEL's engineer.

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18.0 PROJECT MANAGEMENT/ CONSTRUCTION MANAGEMENT
To meet the need of construction management at site, contractor shall provide the
following services within quoted/ accepted rates.
18.1 PLANNING & MONITORING
18.1.1 The bidder shall prepare detail construction schedule (L-3) as per completion dates
given in this document. This schedule must include all milestone and key activities
for each subsystems/ components in the areas of engineering (wherever
applicable), procurement, manufacture (wherever applicable), despatch,
excavation/ construction/ erection. This network must conform to the overall project
schedule. The bidder should also ensure monitoring of these activities at least
weekly basis to start with and on daily basis whenever required by BHEL.
Sl
Work to be completed Period from
no
start of work
1 Completion of excavation, PCC Within 70 days
2 Completion of chimney raft casting & order placing for stack Within 135
elevator.
days
3 Completion of Inter form equipment erection (1st stage). Within 160
days
4 Completion of RCC shell concreting upto EL (+) 5 M. Within 190
days
5 Completion of electrical winch, passenger hoist external &
internal platform etc fixing (2nd & final stage of Interform
equipment erection), temporary lightening arrestor with
electrode, temporary aviation obstruction lighting system,
temporary communication system.
6 Completion of slip form concreting, dismantling of slip form
equipment (part), roof casting.
7 Completion of mini shell concreting & slip form equipment
dismantling (balance portion).
8 Completion of all corbel, internal painting, brick flue lining,
insulation, MS liner bands fixing, completion of permanent
earthing system and hopper including AR bricks completion,
and readiness for boiler light up.
9 Completion of erection of external platform, ladder, all
electrical installation. All MS doors & access doors and
sampling pot erection completion, rain water pipe fixing and
mini shell cap fixing, erection completion of stack elevator
with commissioning.
Within 220
days
Within 430
days
Within 480
days
Within 800
days
Within 930
days
10 Completion of external painting and all other finishing work Within 990
and completion of all chimney works in all respects. days
18.1.2 The bidder shall also prepare progress report indicating progress on key activities,
management summary for critical activities, list of actions requiring attention of
BHEL. This schedule is to be preferably made in MS PROJECTS, so that the same
is compatible with BHEL’s project management software.
18.1.3 The bidder will have to install one no PCs with the minimum specification of
(multimedia PC work station Pentium-Duo, 1 GHZ or above, 120 GB HDD, 1GB
RAM, 100 MBPS LAN card of HCL/ COMPAQ/ ZENITH or equivalent make with
window XP (professional) O/S and required software like MS Office 2007
Professional, AutoCAD 2007, PageMaker (7.0 etc), ADOBE PDF CREATOR with
one no laser jet printer compatible for A3 size printing (cartridge to be supplied as 1
cartridge per 4 months or depending on the requirement, whichever is less), one
nos. laser jet printer compatible for A4 size printing ((cartridge to be supplied as 1
cartridge per 4 months or depending on the requirement, whichever is less) with
power backup at places, as per instruction of BHEL for exclusive use of BHEL.
These computers, printers shall remain contractor’s property and they will be
allowed to take out the same after completion of the site works. The contractor shall

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provide data / information etc in prescribed formats for periodical updating of the
progress reports, material management reports, updating of network pertaining to
the contractor’s scope of work etc.
The contractor shall also provide one no computer operator and two numbers
service staff for miscellaneous service for BHEL’s exclusive use at site/ Kolkata for
material and document reconciliation, progress MIR & day-to-day documentation
etc. This facility to be provided from 2 nd month from LOI date till completion of site
works or as decided by BHEL. If contractor fails to provide computer/ printer or
personnel as per requirement, for a continuous period of thirty days or more, BHEL
shall have the right to deduct the amount as per following rates on prorate basis,
from contractor's RA bill or any other dues.
18.1.3.1 @ Rs.10, 000/- (Ten thousand)/ month for each computer operator.
18.1.3.2 @ Rs.9, 000/- (Nine thousand)/ month for each computer with printer.
18.1.3.3 @ Rs.7,000/- (Seven thousand)/ month for each service staff.
18.1.3.4 In the event of the contract period getting extended beyond the stipulated time for
reasons not attributable to the bidder, the deployment of above personnel shall be
reviewed by Construction Manager, BHEL for further continuation. If their services
are still utilized, the bidder will be reimbursed the actual expenditure incurred by the
bidder in providing the service limited to Rs 8000 per month for each computer
operator, and Rs 6000 per month for each service staff.
18.1.4 The contractor’s site office must have facilities of communications like Fax, E-mail,
and telephone with STD facility within a month from LOI.
18.2 PROGRESS REPORTING
18.2.1 The bidder shall submit daily, weekly and monthly progress reports for work force,
materials reports, consumables (gases/electrodes) report and other reports as per
pro-forma considered necessary by the BHEL.
18.2.2 The progress report shall indicate the progress achieved against planned with
reasons indicating delays, if any, and shall give the remedial actions which the
contractor intends to take to make good the slippage or lost time, so that further
works again proceed as per the original program and the slippage's do not
accumulate and effect the overall program.
18.2.3 The daily work force reports shall clearly indicate the work force deployed,
category-wise specifying also the activities in which they are engaged.
18.2.4 Weekly progress review meetings will be held at site during which actual progress
during the week vis-à-vis scheduled program shall be discussed or actions to be
taken for achieving targets. For discussions, the contractor shall present program of
subsequent week. The contractor shall constantly update/revise his work program
to meet the overall requirement.
18.2.5 Periodic progress reviews on the entire activities of execution in respect of supply
and works in scope of bidder will be held once in a month at Kolkata/ site. These
meetings will be attended by reasonably higher officials of the contractor and will be
used as a forum for discussing all areas where progress needs to be speeded up.
The contractor shall be further responsible for ensuring that suitable steps are
taken to meet various targets decided upon such meetings.
18.2.6 Two sets of color photographs in addition to colour photographs in the monthly
progress report (Matt paper, post card size for each area per month of the contract
execution period), depicting progress of the work, as directed by BHEL site
engineer is to be arranged by the successful bidder at his own cost.
18.2.7 Successful bidder has to provide for electronic/ computerized storing and reproduction/
printing/ plotting of various data, log sheets, protocols, measurements
etc. These may be stored in CD (as per requirement) and handed over to BHEL as
per requirement.
18.3 SITE ORGANIZATION
18.3.1 The contractor shall maintain a site organization of adequate strength in respect of
manpower, construction machinery and other implements at all time for smooth

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execution of the contract headed by a competent construction manager for site
operations with sufficient level of authority to take site decisions. The vendor will
submit organization chart (showing the name of Site-in-charge) with individual biodata
indicating various levels of experts to be posted for supervision in the fields of
supervision and execution, quality, material management, planning, safety, etc. The
organization shall be reinforced from time to time, as required to make up slippage
(if any) from the schedule without any commercial implication to BHEL. The
organization chart is to be submitted within 10 days from the date of LOI or as
directed otherwise by Project Manager/ Construction Manager, BHEL.
18.3.2 Following (minimum) engineering manpower with power plant construction
background to be deployed at site by the successful vendor.
18.3.2.1 Qualified safety officer (exclusive One no - from start of work.
for safety supervision)
18.3.2.2 Site supervising engineer Three nos - (1st civil engineer from the first
month, 2nd civil eng from Third month
onwards, 3rd engineer from 6th month after
start of work.
18.3.2.3 Engineer for quality inspection. One no. - from start of work.
18.3.2.4 Supervisor As required for satisfactory execution of work.
18.3.2.5 Material management, site enabling - one no.
18.3.2.6 Engineer/ supervisor for other functions like store & purchase, material
management, planning, fin, admn etc are to be provided as per site requirement
and not considered above.
18.3.2.7 In the event of non deputation of engineer/ supervisor/ BHEL shall reserve the right
to deduct Rs 40000.00 per man-month for engineer and Rs 30000.00 per manmonth
for the supervisor/ safety officer, from the date of deputation as indicated as
above/as per job requirement from RA bills. Further induction of manpower
regarding site supervisor & site engineer will be decided at site as per requirement.
18.3.2.8 BHEL reserves the right to reject or approve the personnel proposed to be
deployed by the contractor. The persons whose bio-data have been approved by
BHEL will have to be posted at site and deviation in this regard will not be permitted
unless specific & reasonable justification is made.
18.3.2.9 In addition to above, a well experienced qualified engineer to be designated, as
'Project Co-coordinator', shall be deployed by the contractor. Such engineer shall
have adequate exposure on the job and shall remain fully involved in all planning
activities, guidance etc to contractor's own team during the complete execution
period of contract.
18.3.2.10 The contractor should also submit to BHEL for approval a list of T&Ps along with
their fitness certificates. The tools & tackles shall not be removed from site without
written permission of BHEL.
18.3.2.11 The contractor should also submit network programs for the erection of various
items. These networks shall show the customer/ BHEL hold points (CHP), which
have to be cleared by customer/ BHEL, or their authorized representatives before
further erection can take place. These programs for the erection would clearly
identify responsibilities of the contractor and customer/ BHEL. It is the responsibility
of the contractor to get the Networks approved by BHEL within four weeks of the
date of finalization of award of work/ placement of LOI.
18.3.3 CONSTRUCTION MANAGEMENT
18.3.3.1 Based on the approved program the contractor shall submit a program of
construction/ erection/ commissioning for the implementation. These programs
would be amplified showing start of erection and subsequent activities and shall
form the basis for site execution and detail monitoring. The three monthly rolling
program with the first month's program being tentative based on the site condition
would be prepared based on these programs. The contractor shall also be involved
along with customer/ BHEL to tie up detailed resources mobilization plan over the
period of the contract matching with the performance targets.

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18.3.3.2 The program would be jointly finalized by the site in-charge of the contractor with
BHEL/ customer's project coordinator as well as the site-planning representative.
The erection program will also identify the sequential events matching financial
turnover.
18.3.3.3 The contractor is liable to furnish all documentary evidences towards payment of
Works Contract Tax as when required by BHEL.
19.0 RESPONSIBILITY OF CONTRACTOR
19.1 ACCOMMODATION FOR THE LABOUR/ STAFF
19.1.1 The contractor has to make his own arrangement for accommodation of his
workmen and other employees. BHEL/ customer shall not provide any facility in this
regard. As of now, no land will be provided by customer for construction of labour
colony. However, if felt necessary, bidder may make appeal to customer for
allotting some land for the same and subject to availability this may be allotted as
per the terms and conditions of customer.
In extreme exigency, subject to availability of residential accommodation from
customer within project premises, BHEL may arrange the same for the contractor’s
staff on chargeable basis. The charges to contractor by BHEL will be the same as
the charges levied by customer on BHEL. Such availability of the residential quarter
shall be subject to approval of customer.
19.2 TOOLS AND TACKLES, MEASURING AND MONITORING DEVICES.
19.2.1 The contractor shall provide all (excepting those in BHEL scope) required tools and
plants, monitoring and measuring devices (MMD) and handling & transportation
equipments for the scope of work covered under these specifications. Contractor
has to provide suitable cranes for material handling at BHEL/ client’s stores/
storage yard. BHEL’s crane will not be available for this purpose.
19.2.2 Tentative list of T&P to be deployed for respective packages, by the contractor for
successful completion of work is mentioned.
19.2.3 It may be noted that the list is not exhaustive and is only for general guidance. The
contractor is required to provide all necessary T&P (other than those specified to be
provided by BHEL) measuring (calibrated) instruments and handing equipments for
timely completion of the total works as per contract. In case of project requirement,
some activities may have to pre-pone. In such cases the contractor may have to
deploy additional T&P. The quoted rate shall be inclusive of such requirements.
19.2.4 In the event of any failure of the part of the contractor, BHEL may at his discretion
also terminate the contract on this ground and take out any or whole amount of the
contract from the scope of the contractor. In the event of failure of contractor to
deploy necessary and sufficient T&P/ IMTEs. BHEL will be at liberty to arrange the
same at the risk and cost of contractor including transportation cost of same from
any of BHEL site/ other agency and charges as applicable shall be deducted from
contractor's R/A bill. Decision of BHEL in this regard will be final and binding on the
contractor.
19.2.5 All tools and tackles to be deployed by the contractor for the work shall have the
prior approval of BHEL Engineer with regard to brand, quality and specification.
19.2.6 Contractor’s responsibilities with regard to operator, fuel, lubricants and daily upkeep
of T&P’s provided by BHEL is further detailed in relevant section.
19.2.7 Timely deployment of adequate quantity of T&P is the responsibility of the
contractor. The contractor shall be prepared to augment the T&P at short notice to
match the planned programme and to achieve the milestones.
19.2.8 Contractor shall maintain and operate his tools and plants in such a way that major
breakdowns are avoided. In the event of major breakdown, contractor shall make
alternative arrangements expeditiously so that the progress of work is not
hampered.
19.2.9 In the event of contractor failing to arrange the required tools, plants, machinery,
equipment, material or non-availability of the same owing to breakdown, BHEL will
make the alternative arrangement at the risk and cost of the contractor.

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19.2.10 The T&P to be arranged by the contractor shall be in proper working condition and
their operation shall not lead to unsafe condition. The movements of cranes and
other equipments should be such that no damage/ breakage occurs to foundations,
other equipments, material, property and men. All arrangements for the movement
of the T&P’s etc. shall be the contractor’s responsibility.
19.2.11 Normally, for welding use of welding generators/ rectifiers only is permitted. The
use of welding transformers will be subject to the approval of BHEL Engineer.
19.2.12 The contractor at his cost shall carry out periodical testing of his construction
equipments and calibration of measuring & monitoring devices (MMDs). Test /
calibration certificates shall be furnished to BHEL. MMDs shall be calibrated only at
accredited laboratory as per the list available with BHEL or any other laboratory
approved by BHEL.
19.2.13 T&P and IMTE/ MMD once deployed cannot be taken out without the written
consideration of Construction Manager of BHEL.
19.2.14 The requirement of the T&Ps deployed by the contractor for the work shall be
reviewed by Construction Manager after sufficient work progress is made during
execution of the contract including extensions, if any and BHEL may accord
permission for release of the cranes based on requirement for the work.
19.2.15 The contractor shall ensure deployment of reliable and calibrated instrument,
measuring, and test equipment (IMTE). The IMTE shall have test calibration
certificate from authorized/ Govt approved agencies. The contractor shall also keep
provision of alternate engagement for such IMTE so that the work does not suffer
when a particular IMTE is sent for calibration. Re-testing/ re-calibration shall also be
arranged by the contractor at their own cost at regular interval during the period of
use as advised by BHEL.
19.3 CONSUMABLES
19.3.1 Tentative list of major consumables to be provided by the contractor for respective
packages of work under the scope is indicated in Annexure – VI.
19.3.2 The contractor shall provide all consumables required for carrying out the work
covered under these specifications excepting those, which are specifically indicated
as BHEL scope.
19.3.3 All consumables to be used for the work shall have prior approval of BHEL
Engineer with regard to brand and quality specifications. Test reports / certificates
in respect of these consumables, wherever applicable, shall be submitted to BHEL
Engineer.
19.4 PRIMERS & PAINTS
19.5 WELDING ELECTRODES, FILLER WIRES FOR WELDING AND GASES
19.5.1 All the required welding electrodes as approved by BHEL shall be arranged by
contractor at his cost. It shall be the responsibility of the contractor to obtain prior
approval of BHEL, before procurement, regarding manufacturer, type of electrodes
etc. on receipt of the electrodes at site, it shall be subject to inspection and
approval by BHEL regarding type of electrodes, batch number, date of expiry etc.
Batch test certificates shall be made available for verification & record before the
actual use of the welding consumables.
19.5.2 BHEL reserves the right to reject the use of any electrodes, if found non-acceptable
because of bad quality, deterioration in quality due to improper storage, shelf life
expiry, unapproved type / band etc.
19.5.3 Filler wires, for Tig welding of pressure parts & piping of Packge B, to the extent
supplied by the manufacturing units of BHEL alongwith the components/
equipments only shall be provided by BHEL free of cost. Contractor shall at his cost
meet requirements of tig filler wires, if any, beyond these free issue of BHEL.
19.5.4 All the required gases like argon, oxygen, acetylene etc. shall be arranged by the
contractor at his cost. Nitrogen gas, if required, for chemical cleaning / preservation
of boiler and piping system of Packge B will be provided by BHEL free of charge.
19.6 FIELD/ SITE OFFICE
19.6.1 The contractor shall make his own arrangements for field offices and stores for

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accommodating necessary equipments, tools room for execution of the work. Only
open space will be provided by BHEL/ customer, free of charges within the project
premises as per the availability of space.
In addition to his site office, the contractor shall arrange a temporary stores near
the site of erection for temporary storage of small materials like fasteners, gaskets,
valve and fittings and other instruments. The necessary structural steel, sheeting,
racks etc. for this work shall be arranged by the contractor at his cost.
19.6.2 On completion of work, all the temporary buildings, structures, pipelines, cables etc.
shall be dismantled and leveled and debris shall be removed as per instruction of
BHEL by the contractor at his cost. If contractor is failed to do so, BHEL will get the
job done through other agency and the cost will be recovered from the contractor.
The decision of BHEL Engineer in this regard shall be final. However, the scope of
dismantling and leveling the area is limited only to the contractor’s site office, yard
and other spaces occupied by the contractor.
20.0 TOOLS & PLANTS (TO BE PROVIDED BY CONTRACTOR)
20.1 Tentative list of T&P to be deployed by contractor for successful completion of work
is detailed below. This supersedes corresponding Annexure of Volume-1E
20.2 It may be noted that the list is not exhaustive and is only for general guidance. The
contractor is required to provide all necessary T&P (other than those specified to be
provided by BHEL) measuring (calibrated) instruments & handing equipments for
timely completion of total work as per contract. In case of project requirement,
some activities may have to pre-pone. In such cases the contractor may have to
deploy additional T&P. Quoted rate shall be inclusive of such requirements.
However, contractor shall submit deployment plan of all T&P along with tender bid.
20.3 In the event of any failure of the part of the contractor and as a result progress of
work suffered, BHEL may at his discretion also terminate the contract on this
ground and take out any or whole amount of the contract from the scope of the
contractor. In the event of failure of contractor to deploy necessary and sufficient
T&P/ IMTEs. BHEL will be at liberty to arrange the same at the risk & cost of
contractor including transportation cost of same from any of BHEL site/ other
agency & charges as applicable shall be deducted from contractor’s RA bill.
Decision of BHEL in this regard will be final & binding on contractor.
20.4 Following Major T&Ps to be arranged by contractor within the time as indicated
against each T&P.
Major T&P items
Mobilisation time (from
the date of written
intimation by BHEL)
20.4.1 1 no hydra (10/ 12 T cap). within 30 days.
20.4.2 Two numbers PLC based automatic batching plant with
printing facility (15 cum/ hr) – to be commissioned at site.
However, vendor may mobilize one batching plant
provided he has tie-up arrangement with other vendor for
supply of ready mixed concrete during chimney raft
casting.
Within 60 days.
20.4.3 2 nos transit mixer (4.5/ 5/ 6 M3 capacity) Within 60 days.
20.4.4 2 nos concrete pump (20 cum/ hr min capacity & lift Within 60 days.
70M). Can be taken out after completion of raft casting.
20.4.5 1 no air compressor. Within 45 days.
20.4.6 2 nos self priming dewatering pump 5 HP (diesel/ Within 20 days.
electric).
20.4.7 2 nos self priming dewatering pump 2 HP (diesel/ Within 15 days.
electric).
20.4.8 2 no multi stage high lift water pump (for curing) (lifting
height shall be 300 metre). One shall be working and
other will be stand by.
Within 150 days.

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20.4.9 1 no hydraulic excavator/ poclain. Within 20 days.
20.4.10 1 no dozer. Within 20 days.
20.4.11 1 no pneumatic hammer. As per site requirement
20.4.12 4 nos dumper. Within 20 days.
20.4.13 1 nos reinforcement bending machine. Within 20 days.
20.4.14 1 nos reinforcement cutting machine. Within 20days.
20.4.15 1 no compression testing machine (200 T cap). Within 75days.
20.4.16 Other civil lab equipment with proper (15 M x 6 M) shed. Within 75days.
20.4.17 1 no total station. Within 20 days.
20.4.18 1 no theodolite 1 second accuracy. Within 20 days.
20.4.19 2 nos auto level & staff. Within 20 days.
20.4.20 1 nos DG set (180 KVA). Within 130 days.
20.4.21 72 nos concrete cube moulds. Within 40days.
20.4.22 Inter form equipment set including hydraulic spare pump, Within 130days
10% spare jack, epoxy painted MS shutter plate,
materials and passenger hoist with safety block (safety
devices), hanging platform for inside and outside, safety
ropes etc complete - 1 set.
20.4.23 1 no drinking water tank – 3000 lit. Within 30 days.
20.4.24 Radioset – 1 no (VHF/UHF.) Within 120 days.
20.4.25 Portable fire extinguishers as below:
Within 60 days
Soda acid – 3 sets.
Dry chemical powder – 2 sets
CO2 – 2 sets.
Water & sand bucket(4 buckets in one stand) – 2 sets.
Fire hose with nozzle (50 M length) – 2 sets.
20.5 T&P shown in the above mentioned list are minimum requirement. Mobilisation
period shown above for major T&Ps have to be adhered and no change will be
permitted without written approval of Construction Manage, BHEL. Further
requirement will be reviewed time to time at site and vendors will provide additional
T&P/ equipments to ensure completion of entire work within schedule time without
any financial implication to BHEL. All other T&Ps shall be provided by the
contractor without any extra cost to customer/ BHEL. Vendor will give advance
intimation & certification regarding capacity etc prior to dispatch of heavy
equipments.
20.6 All T&P and all IMTEs, which are required for successful and timely execution of
the work covered within the scope of this tender, shall be arranged and provided by
the contractor at his own cost in working condition.
21.0 INSURANCE
20.1 BHEL shall arrange insurance coverage for the material and properties of BHEL/
customer covering the risks during transit, storage, erection and commissioning.
20.2 The contractor shall be responsible for timely submission of loss/damage/theft to
the underwriter, assistance in lodging & settlement of claim for losses/ damages/
theft/ lodging of FIR with police.
20.3 It is the entire responsibility of the contractor to insure his workmen against
accident and injury while at work as required by the relevant rules and to pay
compensation, if any, to their workmen as per workmen's compensation act. The
contractor has also to insure his staff against accident/injury. The contractor has to
take insurance cover for his tools and plants, assets etc.
20.4 These insurance covers have to be taken prior to start of work at the subject project
and he shall make available the policy to BHEL site-in-charge for necessary
verification before commencement of work. However, irrespective of such
verification/ acceptance, the sole responsibility to maintain adequate insurance
cover for his workmen, T&P, assets etc at all times during the period of contract
shall lie with the contractor. Regarding the aforesaid insurance cover, the contractor
shall directly deal with the Insurance Company for all matters regarding the

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insurance in his scope.
22.0 MATERIAL HANDLING OF CEMENT & STEEL
22.1 Cement, steel (reinforcement TMT bar, MS round for under ground earthing and
structural rolled steel sections like plate, beams, channels, angles) will be issued
free of cost by BHEL for use in the work covered in this contract.
22.2 Consignment of steel/ cement will be directly issued to the contractor as received
by BHEL, on weighment basis from its supplier, as per delivery challan of the
supplier.
22.3 It would be the responsibility of the contractor to keep in constant contact with
BHEL/ site to find out the delivery status, arrival of the consignments and arrange
for escort to accompany the truck/ trailor for transportation of above materials by
BHEL’S supplier, if necessary. The lorry, truck way bill for the consignment as shall
be received by BHEL would be handed over to the contractor immediately for
unloading of materials including all arrangement for necessary gate passes etc.
Unloading of cement and steel from trailer/truck/wagon is in the scope of the
contractor and contractor’s quoted rate shall be inclusive of the same
The arrangement for unloading of cement and steel with necessary cranes and
workmen is the responsibility of the contractor.
22.4 Payment of all demurrages that may result due to contractor’s fault/ delay would be
the responsibility of the contractor. If BHEL have to make payment of demurrage
together with freight, the amount so paid as demurrages for the reasons stated
above, shall be recovered from the bills of the contractor. The decision of BHEL’s
engineer in this regard will be final and binding on the contractor. However the
contractor has to clear all such charges, if any in this regard and complete the job
without waiting for BHEL’s decision.
22.5 It would be the responsibility of the contractor to sign on the delivery book
acknowledgement slip of supplier/ transport authorities etc.
22.6 Consignments coming on Sundays and holidays are also required to be handled
/unloaded by the contractor. Since the offices and stores will probably remain
closed on such days, it will be the responsibility of the contractor to contact BHEL
Engineers at their residence and obtain instructions.
22.7 Since the consignments are expected to arrive during any time of the day or night,
the contractor shall have his workmen round the clock at site as well as other
places as required to unload the materials immediately on arrival.
22.8 Unloading of materials at the storage yard or at places designated by BHEL,
stacking & restacking, shifting & re-shifting, using contractor’s own cranes, trailers
and other equipments with the valid road permit for their operation, unloading and
stacking etc shall be responsibility of the contractor under this contract. All
materials/equipments shall be stacked, stored above ground level by use of
concrete or wooden sleepers. No materials shall remain on ground at any time. All
concrete or wooden sleepers required for stacking the materials shall be arranged
by the contractor at his own cost. All other material handling equipments like
winches, d-shackles, slings of various sizes, max puller, pulley blocks, jacks, trucks,
tailors etc. required for such material handling of steel, cements etc. shall be
arranged by the contractor within quoted/accepted rates.
22.9 It will be the responsibility of the contractor to submit computerized account of all
such consignments of materials received by them, daily to BHEL.
22.10 BHEL reserve the right to recover from the contractor any loss arising out of
damage/ theft or any other causes of the materials issued to him at any point.
22.11 Open land (very limited space) for storage shall be provided by BHEL on free of
cost basis. Temporary barbed wire fencing of the open storage yard is to be done
by the contractor and is included under the scope of his work. The contractor shall
also remove grass, bushes, trees etc wherever required off the land provided to
him and shall make proper continuous up-keepment of the open yard /land by

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removing grass, bushes trees etc. and same is included under the scope of his
work & no extra payment shall be made to the contractor in this regard. The bidder
shall make complete arrangement of necessary security personnel, to safeguard all
such materials in his custody. Materials issued will be used only for construction of
permanent work. The contractor shall take care of material issued by BHEL and
shall protect the same from theft, damage and weathering.
22.12 The contractor shall construct waterproof cement stores (Capacity minimum 200
MT) for storing and stacking of cement at his own cost.
22.13 The contractor shall in no case be entitled for any compensation or damages on
account of any delay in supply or non-supply thereof for all or any such material.
22.14 Clotting of cement and excessive rusting of steel must be avoided. In case, due to
any cause attributable to the contractor, such clotting of cement and/or rusting of
steel occur rendering the same unusable, then such quantity of cement /steel shall
be recovered from the interim payment at the penal rate specified in the tender.
22.15 No material shall be issued to the contractor except as those indicated above i.e.
cement and steel unless otherwise expressly provided for in the contract.
Contractor will have to make his own arrangement at his own cost for procurement
of any other material as required for the works and of such quality as acceptable to
BHEL.
22.16 The contractor shall maintain proper computerized store account for all the BHEL
issued materials and shall give three copies of monthly computerised reconciliation
statement of such account to the BHEL.
22.17 The contractor shall carry out in complete association with BHEL, the material
management functions and execution like day to day update of materials, issued to
the contractor, accounting for surplus/ scrap material returned etc. These functions
shall also be carried out through computerised system utilizing suitable software.
The contractor shall provide experienced software personnel to associate on
dedicated basis for efficient discharge of the same.
22.18 The contractor shall solely be responsible for the safety & quality of material after it
is handed over and issued to contractor by BHEL.
22.19 BHEL issued materials shall not under any circumstances taken out of the project
site unless otherwise permitted by BHEL.
22.20 All the necessary lifting tackles, cranes, hydra, tools & plants including tractors,
trailers, trucks, pulley blocks, jacks, winches, wire ropes etc, of suitable capacities
and other equipments incidental to carry out this work shall have to be arranged by
the contractor at his cost. BHEL Engineer reserves the right to inspect lifting tackles
and equipment before allowing their use. Such approval however shall not relieve
the responsibility of the contractor to ensure safe handling of equipment taking the
precautions to avoid any accident and damage to other equipment and personnel.
22.21 No separate rate will be applicable for the above jobs. The contractor shall organise
necessary escort, as required, time to time during the transport of steel material
from stock-yard of supplier to site with in quoted rate.
23.0 ISSUE OF MATERIALS
23.1 ISSUE OF CEMENT
23.1.1 Cement as received from the manufacturer/ stockiest will be issued free of cost to
the contractor. The theoretical weight or each bag of cement for issued purposes
will be considered as 50 kg, the contractor shall be accountable for the cement
issued to him on this notional weight only. No claim whatsoever will be entertained
because of difference between theoretical and actual weight of the bags of cement.
23.1.2 The empty cement bags duly accounted for against issue shall be the property of
the bidder and the same shall be disposed by the bidder as per statutory regulation
prevailing in the project.
23.2 ISSUE OF STEEL
23.2.1 The steel shall be issued to the contractor free of cost on the following basis.
23.2.1.1 Rolled steel section ISMB, angles, plates, channels - Weighment basis (unit - MT).
23.2.1.2 Reinforcement steel (TMT bars) and MS round for under ground earthmat -

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Weighment basis (unit - MT).
23.2.2 All the steel (reinforcement TMT bar, MS round for under ground earthmat and
structural rolled steel sections like plate, beams, channels, angles and SS liner
plate) issued by the BHEL shall be properly accounted for. The total quantity of
steel required for the work will be calculated from the approved Bar Bending
schedule, fabrication drawings, approved laps, chairs and lugs. The measurement
for payment as well as for accounting shall be based on the sectional weights as
indicated in the following IS specifications.
IS: 808-1964 Beams, Channels and Angles
IS: 1730-1961 Plates, Sheets and Strips
Reinforcements Fe-500 confirming to IS: 1786. or grade-1 of IS:432 (part-I)
23.2.3 In case any such sectional weights are not available in the above documents, the
manufacturer recommendation shall be binding.
23.2.4 The steel issued to the contractor shall be mainly in standard length and sections
as received from the supplier. However, the contractor shall be bound to accept the
steel in length as available in the project stores no claims for extra payment
because of issue of non-standard length will be entertained.
23.2.5 In case MS flats as required in the fabrication of structures are not available, the
contractor shall cut such width out of the available MS plates to make flats at no
extra cost till such material is available and procured by BHEL.
23.2.6 The contractor shall satisfy himself of the quality and quantity of the materials at the
time of taking delivery from BHEL/ customer stores. No claims whatsoever will be
entertained by BHEL because of quality or quantity after the materials are taken by
the contractor from BHEL/ customer stores.
23.2.7 The contractor shall submit to the engineer, a statement indicating estimated
quantity of cement and steel required at least two months in advance. In addition,
the contractor shall also furnish the estimated requirement of cement and steel
during a month by the third week of the previous month indicating his requirement.
23.2.8 Bidders to ensure that no lamination material are taken over by them from BHEL.
Fabrication wastage, if any due to above, shall not be compensated by BHEL
23.2.9 Bidder to note that all fasteners like MS/ HT/ HSFG bolts/ nuts, lock nuts, washers
etc shall be supplied by the bidder as per applicable item of BOQ-cum price
schedule.
23.2.10 Bidder to note that cement and steel required for his enabling job like store/ site
office etc shall be arranged at his own cost. All TG staging material shall be
arranged by contractor at his own cost. Bidder shall do the design for its structure
just immediately after receipt of TG deck drawing and obtain approval from BHEL.
24.0 RETURN OF MATERIALS
24.1 RETURN OF CEMENT
Sealed cement bags remaining unused and in perfectly good condition at the time
of completion or termination of the contract shall be returned promptly, (within 15
days from assessment) if BHEL/ Engineer is satisfied of the physical condition of
the cement. Return of such cement to the project stores/ place as identified within
the project area by Engineer/ BHEL will not be entitled to handling and incidental
charges. Surplus sealed and good conditioned cement bags will be taken back on
weighment basis.
24.2 RETURN OF STEEL INCLUDING SCRAP
24.2.1 All surplus steel and all wastage materials will be taken back on weighment basis.
24.2.2 Surplus, unused and un-tampered steel shall be sorted dia-wise and returned
separately for a place directed by BHEL/ engineer within the project area; Return of
such materials will not be entitled to any handling and incidental charges.
24.2.3 All wastage/ scrap (including wastage, unusable scrap) shall be returned to the
stores on weighment basis and a receipt obtained for material accounting
purposes. Return of such material will not be entitled to any additional cost due
handling and transportation and incidental charge.

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24.2.4 Scrap for reinforcement steel and structural steel shall be returned separately
25.0 CEMENT AND STEEL CONSUMPTION AND WASTAGE
25.1 CEMENT CONSUMPTION
25.1.1 The theoretical consumption of cement shall be based on the following.
25.1.2 For design mix concrete as per approved design mix.
25.1.3 For nominal mix concrete work, as per minimum cement as specified or as
approved by Engineer-in-charge.
25.1.4 For item of works, where volume mix is permitted in writing by the BHEL, for
masonry works, plaster other miscellaneous items, the cement consumption shall
be governed by the “Statement of Cement Consumption” attached to Delhi
schedule of Rates of CPWD-DSR-2007 unless otherwise specified in the
specifications or the drawing of contract of contract or mutually agreed by Engineerin-charge
and contractor.
25.1.5 Actual consumption= Issue – Surplus/unused quantity of cement returned in good
condition by contractor to store. (No sweep cement will be taken back by BHEL).
25.2 CEMENT WASTAGE
25.2.1 Allowable wastage – One and half percent (+1.5%) of theoretical consumption of
cement unless specified otherwise in the technical specification.
25.2.2 For any material issued by BHEL to the contractor free of cost, and which is not
accounted for by the contractor to BHEL, then recovery for such material shall be
effected at penal rates.
25.2.3 Sl Cement consumption
Basis of issue
no
& penal
recovery
C-1 Theoretical consumption (without considering any wastage Free
or loss).
C-2 Actual consumption being Limited to plus one and half Free
percent (+1.5%) of aforesaid theoretical consumption
towards allowable wastage.
C-3 Actual consumption beyond one and half percent (+1.5%) of Penal rate
above (C-1).
25.3 REINFORCEMENT STEEL & EARTHING MS ROUND CONSUMPTION
25.3.1 The theoretical consumption of various diameter of reinforcement and earthing MS
round shall be based on approved construction drawing and bar bending schedule.
Weight shall be calculated considering the sectional weights as per Indian
standards. No extra cost shall be payable to the contractor for any deviation in
weights for the different procedures adopted for issue and calculation of the
theoretical consumption including rolling tolerances.
25.3.2 Actual consumption = Issue – Surplus.
25.3.3 Surplus = Un-tampered and unused quantity of steel returned by the contractor to
BHEL store along-with relevant documents.
25.3.4 Wastage = Actual consumption – Theoretical consumption.
25.4 REINFORCEMENT STEEL & EARTHING MS ROUND WASTAGE
25.4.1 Allowable wastage – (+4%) of the theoretical consumption shall be considered as
allowable wastage. Wastage is further classified as cut pieces and scrap measured
as per actual weighment basis including rolling tolerance. Invisible wastage (loss of
materials due to gas cutting, straightening of edges etc) shall be limited to 0.5 %
(zero point five percent) of theoretical consumption and shall be considered for
reconciliation purposes only. But this invisible wastage shall be considered to be
included in allowable wastage (i.e. five percent)
25.4.2 Wastage and scrap shall be as per actual weighment basis.
25.4.3 Sl Reinforcement steel & earthing rod M S round
Basis of issue
no
& penal
R-1 Theoretical consumption (without considering wastage and
scrap or loss)
recovery
Free

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R-2 Wastage limited to plus four percent (+4%) of aforesaid Free
theoretical consumption (R-1) towards allowable wastage.
R-3 Wastage beyond four percent (+4%) of the theoretical Penal rate
consumption above (R-1).
25.5 STRUCTURAL STEEL MATERIALS CONSUMPTION
25.5.1 The theoretical consumption of various sections shall be based on approved
drawings. Weights shall be calculated considering the sectional weights as per
Indian standard as mentioned in relevant clause. No extra shall be payable to the
contractor for any deviation in weights for the two different procedures adopted for
issue and calculation of the theoretical consumption including rolling tolerances.
25.5.2 Actual consumption = Issue – Surplus.
25.5.3 Surplus = Untempered, unused, uncut quantity of steel returned by the contractor to
BHEL store.
25.5.4 Wastage = Actual consumption – Theoretical consumption.
25.6 STRUCTURAL STEEL WASTAGE
25.6.1 Allowable wastage – 4 % (four percent) of the theoretical consumption shall be
considered. Wastage is further classified as cut pieces and scrap measured as per
actual weightment basis including rolling tolerance. Invisible wastage (loss of
materials due to gas cutting, straightening of edges etc) shall be limited to 0.5 %
(zero point five percent) of theoretical consumption and shall be considered for
reconciliation purposes only. But this invisible wastage shall be considered to be
included in allowable wastage (i.e. five percent).
25.6.2 Sl Structural steel materials
Basis of issue
no
& penal
recovery
S-1 Theoretical consumption (without considering any wastage, Free
scrap or loss) as per specification & drg.
S-2 Wastage limited to plus four percent (+4%) of the aforesaid Free
theoretical consumption (S-1) towards allowable wastage.
S-3 Wastage beyond four percent (4%) of the aforesaid Penal rate
theoretical consumption (S-1).
25.7 All wastage reinforcement, MS round (for earthing), structural steel shall be
returned to BHEL.
26.0 RECONCILIATION OF BHEL ISSUED MATERIALS
26.1 The contractor shall submit a reconciliation statement of cement and steel issued to
him with each RA bill.
26.2 At the time of submission of bills, the contractor shall properly account for the
material issued to him as specified herein to the satisfaction of BHEL certifying that
the balance material are available with contractor’s custody at site.
26.3 At the time of submission of bills by the contractor, if it is noticed by BHEL that the
wastage is high and calls recovery at the penal rate, then BHEL will proceed for
recovery for the excess wastage as per penal recovery rates as specified.
26.4 The approved drawings/ bar bending schedules are to be considered for the
purpose of reconciliation of materials.
27.0 RECOVERY OF MATERIAL
27.1 If wastage exceeds the specified limit, the recovery of excess wastage shall be
made from monthly RA bill at the penal rate stipulated below.
27.2 PENAL RATE OF MATERIALS
Item
Penal rate (Rs)
27.2.1 Cement (OPC/ PPC/ PSC). 6,500/- per MT.
27.2.2 Reinforcement steel and earthing rod etc. 58,000/- per MT.
27.2.3 Structural steel. 65,000/- per MT.
28.0 CONSTRUCTION OF TEMPORARY OFFICE, STORES ETC
28.1 The contractor shall arrange at his own cost cleaning and grass removing of area
allotted, construction of his temporary office/ stores, cement godown, fabrication
yards etc. and also the watch and ward of all the above. Materials required for the

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same shall be provided by contractor at his own cost.
28.2 Customer/ BHEL will provide space for fabrication yard within plant premises.
However; during execution, based on actual site conditions, requirement and layout
and approaches, the above may change suitably.
29.0 CIVIL LABORATORY AT SITE
29.1 Contractor shall establish and maintain civil laboratory at site with equipments as
listed in Annexure `A`
29.1.1 Setting time of cement, compressive strength of cement, concrete cubes, bricks
etc.
29.1.2 Water absorption test of bricks.
29.1.3 Earth compaction test (proctor density/ dry density and optimum moisture content,
etc).
29.1.4 Conducting of test for setting time and compressive strength of cement.
29.1.5 Sieve analysis of fine aggregates and coarse aggregates.
29.1.6 Bulking test of fine aggregates.
29.1.7 Sieve analysis, moisture content, specific gravity and crushing strength of course
aggregates
29.1.8 Rapid moisture meter
29.2 Other than above mentioned test, any testing required to be carried out at site as
per Quality Plan and technical specification have to be arranged by contractor for
all the works at his own cost.
30.0 CONSTRUCTION SCHEDULE
30.1 Entire work shall be carried out in accordance with the construction schedule within
the stipulated completion period. Within 30 days of LOI, the contractor shall discuss
with BHEL site engineer & furnish the (L-3) construction schedule based on
milestones as per clause 14.1.1 for approval.
30.2 Contractor will establish mix design within 40 days from the date of LOI.
31.0 COMPLETION PERIOD
The entire work under this scope shall be successfully completed in all respect
within 33 months from the date of start of work as certified by BHEL engineer at
site.
The contractor shall mobilize at site and start the work within 30 days from date of
written clearance by Construction Manager, BHEL, customer site.
32.0 LIQUIDATED DAMAGE
As per the provision of GCC.
33.0 CERTIFICATE TOWARDS COMPLETION
The work under the scope of the contractor shall be deemed to have been
completed in all respects only when so certified by BHEL. The decision of BHEL in
this regard shall be final and binding on the contractor.
34.0 GUARANTEE
34.1 Even though the work will be carried out under supervision of BHEL, the contractor
will be responsible for the quality of workmanship, quality of materials/ items and
design for which the contractor is responsible.
34.2 The contractor shall guarantee the work executed under the scope of the contract
for a period of 12 (twelve) months from the date of start of guarantee period as
certified by the Engineer (ie on completion of total work under scope and/ or taking
over by BHEL) and shall rectify free of cost all defects due to faulty supply or work
done. In case the contractor fails to repair/ replace the defective works within the
time specified by the Engineer, BHEL may proceed to undertake the repairs/
replace such defective works at contractor’s risk and cost without prejudice to any
other rights and recover the same from security deposit/ other dues.
35.0 INTEREST BEARING RECOVERABLE ADVANCE
Not applicable for this tender.
36.0 OVER RUN CHARGES
No over run charges shall be paid to the contractor in the event the completion

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period is extended for any reason whatsoever.
37.0 REVISION ON ACCEPTED CONTRACT RATE
No revision of rates shall be applicable in the event the completion period is
extended for any reason whatsoever.
38.0 PRICE VARIATION CLAUSE
38.1 FOR CIVIL CONSTRUCTION PART (PART-IA OF PRIICE SCHEDULE)
As per provision of GCC vide clause no 2.17.3 under column `A’ for civil packages.
38.2 FOR ERECTION, COMMISSIONING PART (PART-IB OF PRICE SCHEDULE)
As per provision of GCC vide clause no 2.17.3 for mechanical packages.
39.0 SECURITY DEPOSIT & PERFORMANCE BOND
39.1 Security deposit shall be applicable for Part-IA & Part-IB together as per relevant
clause of GCC (Volume-IB).
39.2 Performance bond is applicable for Part-IB of price schedule value as per following
terms.
39.2.1 In addition to the security deposit the contractor shall provide to BHEL bank
guarantee of an approved nationalized bank for an amount equal to 5 % of the
stated price as performance bond (under the terms of a bond) within 30 days from
the date of LOI and the terms of the said bond shall be such as shall be approved
by BHEL. The bond shall remain valid until 6 month after the expiry of warranty/
guarantee period. The obtaining of such guarantee and the cost of bond to be so
entered into shall be at the expense in all respects to the contractor.
39.2.2 BHEL reserve the right of forfeiture of the above bond in addition to other claims
and penalties in the event of the contractor’s failure to fulfil any of the contractual
obligations or in the event of termination of contract as per terms and conditions of
contract. BHEL reserve the right to set off this bond against any claim of any other
contract with BHEL.
40.0 CONTRACT PRICE
40.1 The bidder shall quote their rates strictly in accordance with prescribed rate
schedule of Volume-III/IIIA.
40.2 The quantities of the various items mentioned in the BOQ cum rate schedules of
items of Volume-IIIA are approximate, based on very preliminary information and
may vary to any extent or to be deleted altogether. The quoted rates of each item
will remain firm throughout the period of execution including extension, for reasons
whatsoever, as long as variation in the total value of the work executed under any
part of the this contract including extra items, if any, but excluding any price
variation, remains within +/- 30 % (plus/minus thirty percent) of the awarded price
as per LOI/ WO.
41.0 TAXES, DUTIES ETC
41.1 TDS under Income Tax, VAT etc, if any, shall be deducted at prevailing rates on
Gross Invoice Value from the running bills unless Exemption Certificate from the
appropriate authority/ authorities is furnished.
41.2 All taxes (except Service Tax including Educational Cess and other Cess, if any),
Works Contract Tax under VAT ACT, charges royalties, duties, Octroi, any State
or Central Levy and other taxes for materials obtained for the work and for the
Execution of the contract shall be borne by the contractor and shall not be payable
extra. Any increase of the same at any stage during execution of the contract shall
have to be borne by the contractor. Quoted rates/ price of the bidder shall be
inclusive of all such requirements after taking the Input Credit, if any, as per
provisions of the state VAT Act. The contractor is responsible to furnish all
documentary evidences towards payment of Works Contract Tax as and when
required by BHEL. Submission of Tax Invoice is a must after grossing up the bills
as the price is inclusive of VAT.

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41.3 The contractor has to make his own arrangement at his cost for completing the
formalities, if required, with state VAT Act authorities, for bringing their materials,
plants and machinery at site for the execution of the works under this contract,
Road Permit/ Way Bill, if required, shall be arranged by the contractor and BHEL-
PSER will not supply any Road Permit/ Way Bill for this purpose. The contractor
must be a Registered Dealer with the state VAT Act, if not registered yet and a
copy of the said Registration Certificate along with TIN Number must be provided to
site RAO.
41.4 Service Tax: Finance Act, 2007 introduced a new sub-clause (zzzza) to Section 65
(105) which provided for levying Service Tax on execution of Works Contract with
effect from 01-06-07.
Notification No 32/2007-Service Tax provides an option (of composition) to the
person liable to pay Service Tax in relation to works contract service to pay an
amount equal to 4.12 % of the gross amount charged for the Works Contract
instead of normal rate provided in the Sec 66 of the Act. However, this option of
paying service tax @4.12 % (at present) on gross value can be exercised prior to
payment of Service Tax in respect of said Works Contract and the option so
exercised shall be applicable for the entire works contract and shall not be
withdrawn until the completion of said works contract.
The contractor shall furnish proof of Service Tax registration with Central Excise
Division covering the services as well as exercising the aforesaid option ie the
Composition Scheme under Notification 32/2007 under this contract.
Contractor is allowed to include the value of free issue of materials mainly steel,
cement & other materials, supplied under supply contract based on monthly
consumption basis to enable them to comply with Notification 23/2009–ST for
arriving at Gross Amount charged .
Alternatively:
Vendor can avail Notification 29/2007–ST, dated 22-05-2007 where the “Taxable
Service is value of works contract service determined shall be equivalent to the
gross amount charged for the works contract less the value of transfer of property
in goods involved in the execution of the said works contract.
As such, Service Tax as legally leviable & payable by the contractor under the
above provisions of applicable law/ act, shall be paid by BHEL-PSER on
contractor’s gross bill.
Registration should also bear endorsement for the premises from where the billing
shall be done by the Contractor on BHEL-PSER for this project.
BHEL-PSER will not be held to be responsible for non-compliance of various
Service Tax rules, being framed from time to time.
41.5 New tax & duties, if imposed subsequent to latest due date of offer submission (as
per NIT and subsequent TCN, if any), by statutory authority during contract period
(including extension, if the same is not attributable to the contractor), shall be
reimbursed by BHEL on production of relevant supporting document to the
satisfaction of BHEL. However, the vendor shall obtain prior approval from BHEL
before depositing new taxes and duties.
42.0 INTERIM PAYMENTS
42.1 For all items of work as per Volume-III, Price Schedule, interim payment shall be
limited to 95 % of the gross value of interim bill on item rate basis which will be
prepared and submitted by the contractor on the basis of measurement sheet duly
checked and signed by BHEL and/ or customer engineers. All admissible

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recoveries/ adjustments etc shall be made from the interim payable amount. The
balance 5 % shall be payable along with final bill.
42.2 Out of above mentioned 95 % of gross bill value, 0.5 % shall be paid after
ratification by BHEL engineer on compliance of house keeping, work area
illumination by bidder. Also 0.2 % of above mentioned 95 % gross bill value shall be
paid after certification by BHEL engineer on compliance of HSE activities at site.
42.3 Contractor’s RA bill, complete & correct in all respects, certified by BHEL/ customer
engineer, shall be paid within 30 days of date receipt of bill.
42.4 Customer/ BHEL site at its discretion may further split up the above percentages of
break up and effect payment to suit the site condition, cash flow requirement,
according to the progress of work. BHEL reserve the right to release payment
through electronic mode, for which bidder shall comply with requisite formalities
42.5 Such payment as above shall be effected only on certification by BHEL against
completion of each stage.
43.0 METHOD OF MEASUREMENT
IS 1200 in conjunction of IS code 3385 shall be adopted. In case the item of
measurement is not available in the IS 1200, the standard procedure adopted in
CPWD shall be adopted. In case the same is also not available in CPWD, the
measurement of the work done will be based on the mutual agreement between
BHEL and contractor. In all the above cases, the interpretation of BHEL will be final
and binding to the contractor.
44.0 EXTRA/ ADDITIONAL ITEMS OF WORK
If any extra or additional items, which are not incorporated in the BOQ schedule,
have to be executed by the contractor, the rate of such extra or additional work
shall be as per the following:
a) If rates for such items cannot be derived from the rate schedule of this contract
as mentioned above, but are covered under CPWD, DSR-2007 schedules of
rates. Contractor shall be quote against the relevant item as indicated in BOQ.
b) If the items are not covered under above schedule, the rate of such items shall
be derived, by a duly approved committee, if possible, from the available rates,
agreed upon in the rate schedule of this contract.
c) If the items are not covered under above schedule, the rate of such items shall
be derived, by a duly approved committee, based on the rates to be agreed
upon mainly on the basis of prevailing market rates for which all documentary
evidences, as required by BHEL shall have to be produced by the contractor.
Decision of BHEL in such cases shall be final and binding on the contractor.
45.0 DESIGN OFFICE AND FABRICATION DRAWING
45.1 Since time is the essence of the contract, the contractor must indicate the location
of their design office where from such detailed activities will be made operative. It
is preferred that the contractor have establishment / liason office at Delhi /Noida
with a co-ordinator for better co-ordination with BHEL-PEM.
45.2 Contractor shall submit progress report pertaining to fabrication drawing, by 7th of
each month, drawing-wise, section-wise cumulative bill of materials for which
engineering drawing has been issued to them and status of fabrication drawing.
46.0 FABRICATION / GALVANISING
46.1 All the fabrication of structural steel items (except nuts/ bolts) shall be done in
fabrication yard inside project premises. Bidders to note that all fasteners like
MS/HT/HSFG bolts, nuts, lock nuts, washers etc. shall be supplied by bidder as per
technical specification/ drawings and BOQ items.
46.2 Bidder, at his own cost, shall supply electrodes required for fabrication, erection of
structural steel as per specification and approval of BHEL.
46.3 However, in case of exigency as considered fit by BHEL, BHEL may permit the
contractor to get some specific portion of fabrication/ galvanizing work done at

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qualified shop (s) outside the project premises. For steel to be issued to the
contractor for such purpose, 50% of the value of such steel as worked out as per
BHEL’s procurement rates shall be furnished by the contractor in the form of BG.
Such BG shall be returned depending on the receipt of fabricated/ galvanized steel
back to site
47.0 DIVISIBLE CONTRACT
Notwithstanding anything stated elsewhere in this tender, the contract to be
awarded shall be on the basis of supply & erection contract (divisible contract) on
single source responsibility. In the mode of contracting on the basis of supply &
erection, the civil & erection portion of the contract will relate to the BOQ cum price
schedule of (1) Part-1 and supply portion of the contract will relate to the BOQ cum
price schedules of (1) Part-2.
But the two contract shall not in any way dilute the responsibility of the bidder for
the successful completion of the job as per tender specification and both the
contracts shall contain a cross-fall breach clause, namely that a breach in one
contract shall automatically be classified as a breach on the other contract which
will confer a right on BHEL to terminate the other contract at the risk and cost of the
bidder.
The title of the ownership of goods to be supplied shall pass on to the owner on
dispatch ex-works/ FOR destination. However till the scope is completed in all
respect and the plant/ equipment is taken over by the owner the goods shall remain
with the custody of the bidder.
48.0 OTHER TERMS
48.1 While bidder's scope include deployment of all resources, like T&P, materials,
consumables, manpower including supervision etc for proper completion of the
subject job and no sub-contracting for execution of the job is allowed by BHEL,
depending on project's requirement and on prior acceptance of BHEL, bidder may
associate agencies for deployment of skilled/ un-skilled manpower only for site
execution. Bidder should arrange all resources, like T&P, materials, consumables,
supervision etc directly for the subject job.
48.2 All other term & conditions of this specification, not mentioned above shall be
governed by the pertinent provisions of GCC.

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ANNEXURE - A
LIST OF EQUIPMENTS FOR CIVIL SITE LABORATORY
SL NAME OF TEST NAME OF EQUIPMENT SIZE OF IS REF
NO
EQIPMENT
CONCRETE TESTING EQUIPMENT
1 Initial & final setting time, Vicat Apparatus with Standard
IS
Consistency of cement desk pot
5513
2 Shrinkage of cement, Auto Le Chatelier's appratus Standard
IS
Clave Test
Auto Clave Equipment
5514
3 Abrasion value test Los Angles Abrasion Standard
IS
testing machine
2386
4 Aggregate Impact value test Aggregate Impact value Standard
IS
testing machine with
9377
blow counter
5 Aggregate crushing value Crushing value Standard
IS
test
apparatus
2386
6 Flakiness index Thickness gauge for Standard
IS
measuring flakiness
2386
index
7 Elongation Index Elongation guage Standard IS
2386
8 Bulk density, voids and Measuring cylinders 3, 5,10 & 15 liters
bulking appratus
cylinders
9 Concrete Compressive test Digital Compressive 2000KN capacity IS
Testing Machine with
2505
2000 KN capacity.
10 Cement motor cube casting Mortor Cube mould 70.6 x 70.6 x 70.6
mm, minimum 06
sets desired.
11 Concrete Cube casting Concrete Cube Mould 150x150x150mm,
minimum 20 sets
desired
considering TG
Raft major
concereting
activity.
12 Workability of concrete Slump cone Standard, atleast
04 nos
13 Specific gravity of aggregates Pycnometer Standard, atleast
02 nos
14 Cement mortor cube Motorised vibration Standard
vibrating
machine for cement
testing
15 Course agregate Sieve
analysis (Concrete & Road
Works)
Sieve set 450mm dia GI
Frames Size: 125
mm, 90 mm, 75
mm, 63 mm, 53
mm, 40 mm, 20
mm, 16 mm, 12.5
mm, 10 mm, 4.75
mm, Pan and
cover
IS
10086
IS
10086
IS 456
IS 383
IS
4031
IS 383

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16 Fine agregate sieve analysis Sieve set 200 mm dia Brass IS 383
sieves; Size 4.75
mm, 2.36 mm,
1.18 mm 600
micron, 300
micron, 150
micron, 75 micron,
75 micron, Pan
and cover
17 Seive Shaker Motorised Sieve shaker Mfg. Catalogue
18 Silt content check Sand silt content beaker Standard
19 Ultrasonic pulse velocity test UPV appratus for Standard
concrete
SOIL TESTING EQUIPMENT (LEVELLING & GRADING)
1 Liquid limit test Liquid limit apparatus Standard IS
2 Core Cutter test core cutter appratus Rammer, 6 nos of
std core cutter
mould, dolly
3 Proctor density test Std proctor Compaction Standard
apparatus
4 Moisture Content Rapid moisture meter Standard, atleast
PROCESS CONTROL ACCESSORIES
1 Hot air oven Temperature range 50°
C to 300° C
04 nos
600x600x600mm
(min.size)
2 Electronic balance 3 nos 600gx0.01g, 10g
and 50 kg
3 Physical balance 5 kg capacity Weights upto 5 kg
4 Thermometer Temperature range 0° C Digital
to 150° C
5 Poker Thermometer Temperature range 0° C 02 nos each
(Concrete Road)
to 50° C & 150° C required
6 Measuring jars 2 nos set of each size 100ml, 200ml,
500ml & 1000 ml
7 Gauging trowlers 4 nos 100mm & 200 mm
with wooden
handle
8 Sptula 2 nos each size 100mm & 200 mm
with long blade
wooden handle
9 Stainless steel scoop 2 nos each 2 kg and 5 kg
10 Vernier calipers 2 nos each 12" and 6" Sizes
11 Digital pH meter 01 nos .01 mm least
count
12 Digital micrometer 01 nos 0.01 mm least
count
13 Digital paint thickness meter 02 nos 500 micron Range
for steel
14 GI tray 02 nos each 600x450x50mm,
450x300x40mm,
300x250x40mm
15 Electric morter mixer 01 nos 0.25 CUM
capacity
16 Rebound hammer test 01 nos Digital Rebound
hammer
2720
IS
2720
IS
2720
IS
2720
IS
13311

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17 Screw Gauge 02 nos 0.1 mm-10mm,
Least count 0.05
18 Digital paint thickness meter 02 nos 150 micron range
for masanory/concrete
painting measurement

THE DURGAPUR PROJECTS LIMITED
DURGAPUR PROJECTS POWER STATION
1 X 250 MW EXTENSION UNIT-8
VOLUME--II B
RCC SINGLE FLUE CHIMNEY
SPECIFICATION NO. PE-TS-360-620-C001
BHARAT HEAVY ELECTRICALS LIMITED NEW DELHI

SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION -
REV.NO. 0 DATE 18.09.2010
SHEET
OF
PROJECT TITLE :
1 X 250 MW (TPS)
EXTENSION UNIT-8
NO. OF UNITS
: ONE UNIT
RATING
: 250 MW
LOCATION :
DURGAPUR,
WEST BENGAL

SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION -
REV.NO. 0 DATE 18.09.2010
SHEET
OF
PREAMBLE
This Tender document contains three (3) volumes. The bidder shall meet
the requirement of all three volumes.
VOLUME – II
This volume is subdivided into following sections:
Section-A: This section outlines the scope of enquiry.
Section-B: This section provides “Project Information”.
Section-C: This section indicates the technical requirements specific to
the contract not covered in the section-D.
Section-D: This section comprises of technical specification.

SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION -
REV.NO. 0 DATE 18.09.2010
SHEET
OF
INDEX
VOLUME -II B
SECTION DESCRIPTION SHEET NO.
Section-A SCOPE OF ENQUIRY 3
Section-B PROJECT INFORMATION 3
Section-C SPECIFIC TECHNICAL 12
REQUIREMENTS
i) CIVIL
ii) ELECTRICAL
iii) Chimney Elevator
Section-D 1) SPECIFICATION FOR CIVIL, STRUCTURAL 22
AND ARCHITECTURAL WORKS
2) SPECIFICATION FOR ELECTRICAL WORKS

TITLE:
SCOPE OF WORK
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - A
REV.NO. 0 DATE 18.09.2010
SHEET
OF
VOLUME – II B
SECTION-A
SCOPE OF WORK
SPECIFICATION NO. PE-TS-360-620-C001

1.0.0 SCOPE
TITLE:
SCOPE OF WORK
Scope of Work
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - A
REV.NO. 0 DATE 18.09.2010
SHEET
OF
1.1.0 The chim ney will be si ngle f lue r einforced concrete st ructure of 220 metres
height. Flue w ill ha ve f irst c lass a cid/heat proof firebrick lining. This brick
lining w ork w ill be s upported on i nternal R CC c orbels a t 10 Metres i nterval.
Apart from aviation warning light, complete external surface of the windshield
shall be pa inted i n a lternate ba nd of s ignal r ed a nd white c olour starting with
signal red c olour a t t he t op a nd i n l ine w ith a viation r equirements. E xternal
painting shall have acid and heat resisting properties confirming to IS-158, total
dry thickness(DFT) shall be atleast 150 microns. Platforms on external surface
of R CC w indshield w ith pr ovision of pe rsonnel a ccess s hall be pr ovided at
maximum t wenty-five (2 5) metre i nterval. Suitable pe rsonnel access door and
truck entry door shall be provided. The top of roof slab and top of acid resistant
bricks ove r t he r oof s hall be pa inted w ith t wo c oats of ‘ EXPILUX 5 C OAL
TAR EPOXY PAINT’ over a t hin coat of t he same paint a s manufactured by
M/s. Berger Paints (India). The overall DFT shall be at least 230 microns. RCC
hopper shall be provided at bot tom l evel. A rrangement s hall be pr ovided f or
measuring concentration of particulate matters. NO X AND SO X in the flue gas
for monitoring and taking necessary measure for pollution control. It will also
have necessary arrangement for e arthing dur ing c onstruction. A ccess f rom
ground to external platforms shall be provided with cage ladder.
1.1.1 The w ork t o be done unde r t his specification comprises of c onstruction of
220M high Reinforced Concrete single flue brick lined Chimney complete with
reinforced concrete raft foundation, R.C shell, insulation and provision of other
accessories including ash hoppers, external platforms, fabrication and fixing of
flue duc t i nside t he c himney, G .I. di screte s trakes, complete interior and Air
Aviation O bstruction l ighting s ystem, l ightning pr otection a nd grounding
system, M.S. doors for access to the shell, external platforms and inspection of
the liners, M .S. l adders, c ommunication s ystem c omponents, e mbedments f or
installation of equipments and fixtures and painting both internal and external of
the chimney shell as well as of all doors, ladders and other structural steel items
in accordance with this specification and approved drawings.
1.1.2 The supply, erection, testing and commissioning of chimney Elevator are in the
scope of t his w ork. T he t enderer s hall m ake pr ovision to accommodate
chimney e levator w ithin t he a nnular s pace of R .C.C. Shell a nd a ll C ivil a nd
structural s teel w orks r equired f or e rection, t esting a nd c ommissioning of t he
elevator s hall be i n t he s cope of t his w ork. T he t enderer s hall provide all
necessary ope nings of r equired s izes i n R .C.C. s hell (along with bird
screen/louvres w herever appl icable) and platforms and shall al so consider all
loads exterted by t hese s ystems on R .C.C. s hell or on i ts c omponents i n hi s
design without any extra cost to the purchaser.

TITLE:
SCOPE OF WORK
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - A
REV.NO. 0 DATE 18.09.2010
SHEET
OF
1.1.3 The scope unde r t his spe cification covers t he c onstruction of Single flue
Reinforced Concrete Chimney including providing all labour,
supervision, materials, scaffolding, power, fuel, construction equipments, tools
and plants, supplies, transportation, storage, insurance and all incidental items
not he rein s pecifically m entioned but r easonably i mplied or w hich m ay be
found necessary for successful completion of the work including c ontractor's,
and where necessary manufacturer's expert supervision in strict compliance with
the requirements of this specification and approved construction drawings. The
tendered amount shall be for the chimney to be completed in all respect as per
this specification for the purpose required.
1.1.4 The suc cessful t enderer sha ll ha ve t o prepare ba r be nding schedule & s chedule of
embedments and get the same approved by t he Engineer. T he detailed fabrication
drawings for doors, flue ducts, ladders, M.S. staircases, hand rails and other fixtures
shall also be prepared by the successful tenderer and got approved from the Engineer
before undertaking the actual fabrication or erection of construction.
1.1.5 The contractor shall prepare, at his own cost, the detailed working drawings showing
all details of the formwork staging (adequacy to be supported by design calculations)
and other arrangements for the concreting work and submit six copies of the same for
the a pproval of t he E ngineer-in-Charge / consultants a nd onl y on t he receipt of the
approval of the consultants the work shall be taken up.
1.1.6 The contractor shall prepare, at his own cost, the detailed working drawings showing
all Electrical details and Elevator details.
2.0.0 TENDER DRAWINGS
2.1.1 The f ollowing dr awing w hich f orms pa rt of T ender D ocuments are indicative and
give ove rall di mensions, a nd s ome ot her typical de tails of t he w ork r equired t o be
done under this contract. The accessories shown in the drawings are also indicative :
S. NO. DRG. NO. TITLE
1. PE-DG-360-620-C001 GENERAL ARRANGE MENT OF
CHIMNEY.
2.1.2 The drawings and specifications furnished are to be considered as explanatory of each
other. S hould anything a ppear in one drawing that is not described in the other, no
advantage s hall be t aken of s uch om ission. S hould a ny di screpancies, how ever,
appear, or should any misunderstanding of drawings or as to the dimensions or quality
of the materials or the due a nd i mproper e xecution of t he w orks or a s t o t he
measurements or quality or valuation of the works executed under this contract or as

TITLE:
SCOPE OF WORK
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - A
REV.NO. 0 DATE 18.09.2010
SHEET
OF
extra t hereupon, the sam e sha ll be cl arified by t he E ngineer-in-charge or hi s
authorised r epresentative a nd hi s e xplanation s hall be binding upon the contractor.
Directions as given by the Engineer-in-charge or his author ised representatives being
considered ne cessary f or t he pr oper c ompletion of t he work as i mplied by t he
specifications a nd dr awings, e ven t hough s uch w orks a nd things are not specially
shown and described in the said drawings and specifications shall be binding on the
contractor. Supplementary dimensions or dr awings m ay be gi ven by t he
Engineer/Engineer-in-charge in addition to those already given and changes may also
be effected in them and the contractor shall have to execute the works on the basis of
the s upplementary dr awings or c hanged dr awings and specifications without any
additional claim whatsoever.
3.0.0 DOCUMENTS MUTUALLY EXPLANATORY AND SECTION C.
3.1.0 Contractor shall read the parts of t he specification relevant to the contract and
shall ignore the other parts of t he sp ecification. In cas e of amb iguity between
BOQ, part C and part D of specification, the following priority for acceptance of
items may be followed :-
a) BOQ b) Part C c) Part D
3.2.0 GENERAL
3.2.1 The ove rall c oordination f or a ll w orks s pecified i n t he s cope of work will be the
responsibility of t he c ontractor. T he c ontractor shall also provide adequate
supervisory personnel for works executed under his Scope of Work.
3.2.2 Any clarification from customer/customer's representative shall have to be furnished
by the contractor.

TITLE:
PROJECT INFORMATION
SPECIFICATION NO.PE-TS-360-620-C001
VOLUME - II B
SECTION - B
REV.NO. 0 DATE 18.09.2010
SHEET
OF
VOLUME – II B
SECTION-B
PROJECT INFORMATION

TITLE:
PROJECT INFORMATION
SPECIFICATION NO.PE-TS-360-620-C001
VOLUME - II
SECTION - B
REV.NO. 0 DATE 18.09.2010
SHEET
OF
DURGAPUR PROJECTS POWER S TATION: 1 X 250 MW E XTENSION UNI T-8 is
being set up by THE DURGAPUR PROJECT LIMITED.
The B idder s hall acquaint himself by a visit to the s ite, if f elt ne cessary, with the
conditions prevailing at site before submission of the bid. The information given here in
under is for general guidance and shall not be contractually binding on BHEL/Owner. All
relevant site data /information as may be necessary shall have to be obtained /collected by
the Bidder.
APPROACH TO SITE
Durgapur city is disposed at 28º48’ N latitude and 85 º 33’45” E longitudes located at the
left bank of river Damodar, in the district of Burdwan at a distance of about 160 KM from
Kolkata. T he pl ant s ite i s 3 K M a way f rom Durgapur Barrage located on the river
Damodar. The site is well connected by roads with important industrial centres in the area.
Broad Gauge Railway line of the Eastern Railway and all-weather roads connect Durgapur
with Kolkata and nearby collieries.
The equipment will be normally transported by road only and under exceptional cases by
rail. The m aterial c onsignments s hall be a s pe r the re strictions of ra il a nd road
transportation prevailing in the country.
Nearest ports of entry are Kolkata and Haldia.

TITLE:
PROJECT INFORMATION
SPECIFICATION NO.PE-TS-360-620-C001
VOLUME - II
SECTION - B
REV.NO. 0 DATE 18.09.2010
SHEET
OF
1. Owner DURGAPUR PROJECTS LIMITED (DPL)
2. Owner Consultant DEVELOPMENT CONSULTANTS PRIVATE LIMITED
3. Project Title 1 X 250 MW Extension Unit-8 at Durgapur Projects Power
Station
4. Location 3 Km from Durgapur Barrage
5. Nearest Railway Stn. Durgapur
6. Ambient Air Temperature
a. Maximum refer ANNEXURE I
b. Minimum refer ANNEXURE I
7. Relative Humidity
a. Maximum refer ANNEXURE I
b. Minimum refer ANNEXURE I
8. Rainfall
a. Maximum Rainfall refer ANNEXURE I
9. Wind Data
a. Basic wind speed at 10m height
47 m/sec
b. Wind pressure As per IS: 875 Part III-1984
10. Seismic Zone Zone III as per IS: 1893-2002

TITLE:
TECHNICAL SPECIFICATION FOR
REINFORCED CONCRETE
CHIMNEY
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUBSECTION : I
REV.NO. 0 DATE 18.09.2010
SHEET
OF
VOLUME – II B
SECTION-C
SPECIFIC TECHNICAL REQUIREMENTS
FOR CIVIL WORKS
SPECIFICATION NO. PE-TS-360-620-C001

TITLE:
TECHNICAL SPECIFICATION FOR
REINFORCED CONCRETE
CHIMNEY
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUBSECTION : I
REV.NO. 0 DATE 18.09.2010
SHEET
OF
1.0 BRIEF DESCRIPTION
.
The chimney will be single flue reinforced concrete structure of 220 m etres height.
Flue will have first class acid/heat proof firebrick lining. This brick lining work will
be supported on internal RCC corbels at 10 M etres i nterval. A part f rom a viation
warning l ight, c omplete e xternal s urface of t he w indshield s hall be pa inted i n
alternate band of signal red and white colour starting with signal red colour at the top
and i n l ine w ith a viation r equirements. E xternal pa inting s hall ha ve acid and heat
resisting properties c onfirming to IS-158, t otal dr y t hickness(DFT) sha ll be atleast
150 microns. Platforms on e xternal s urface of R CC w indshield w ith pr ovision of
personnel access sha ll be provi ded at maximum twenty-five (25) m etre int erval.
Suitable personnel access door and truck entry door shall be provided. The top of roof
slab and top of acid resistant bricks over the roof shall be painted with two coats of
‘EXPILUX 5 COAL T AR E POXY P AINT’ ove r a t hin coat of t he same paint as
manufactured by M/s. Berger P aints ( India). The ove rall D FT sha ll be at l east 230
microns. RCC hoppe r s hall be pr ovided a t bot tom l evel. A rrangement shall be
provided for measuring concentration of particulate matters. NO X AND SO X in the
flue gas for monitoring and taking necessary measure for pollution control. It will also
have necessary arrangement for earthing during construction. Access from ground to
external platforms shall be provided with cage ladder.
The grade level slab shall be of r einforced c oncrete w ith a n i ronite f inish. T he
chimney shall have a suitable foundation system depending upon soil characteristics.
Apart from aviation warning light, the complete external surface of the wind shield
shall be painted in alternate band of red and white colour and in line with aviation
requirements, out of which the top 50 metre of paint shall have acid and heat resistant
properties and rest of the surface shall be painted with water proof cement paint or
synthetic enamel paint.
The c himney r oof s lab if re quired shall be of r einforced concrete t reated for w ater
proofing and protected by a layer of acid resistant tiles laid in acid resistant mortar.
Suitable personnel access door and truck entry door shall be provided. A personnel
access hatch in the of slab, liner access hatches, rain water drainage system, flue acid
drainage, bird screens or louvers on the ventilation openings shall also be provided.
Arrangement shall be provided for m easuring c oncentration of pa rticulate m atters,
Nox & Sox in the flue gas for monitoring and taking necessary measure for pollution
control. It w ill a lso have necessary arrangement f or el ectrical pow er suppl y ,
distribution boards, socket outlets, power and control cabling raceways system, stair
and platform lighting, lightening protection and earthing system.
Stack elevator will be provided to run along outside surface of wind shield.

TITLE:
TECHNICAL SPECIFICATION FOR
REINFORCED CONCRETE
CHIMNEY
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUBSECTION : I
REV.NO. 0 DATE 18.09.2010
SHEET
OF
Galvanised mild steel discrete strakes shall be provided over the required length of
the chimney at the t op, i f f ound ne cessary f rom w ind t unnel s tudies f or c himney
model.
2 0 APPROACH TO WORK SITE
The contractor sha ll make his ow n arrangements at his ow n cost f or t he ne cessary
approach r oads f or t ransport of m aterials t o s ite of w ork. N o extra charge will be
paid.
3.0 DAMAGES TO THE OTHER STRUCTURE AND PLANT
The contractor shall be totally held responsible for any loss or damages caused by an
any act of t he c ontractors, l abour or hi s s ub-contractor's l abour i ncluding but not
limited t o c overed/open bl asting t o t he e xisting s tructures and plant or any other
structures or plant that may be under construction/erection by any other agency at this
site during the entire period covered by this contract along with time extension if any.
Any permission given by the Engineer to the contractor to carry out such work, such
as blasting etc. shall not be construed to be waiver of the Contractor's responsibility.
In such cases the amount in respect of loss of damage. shall be considered as final and
binding on the contractor & shall stand recoverable.
4.0 DE-WATERING
No separate pa yments f or de watering of sub -soil or surf ace water if re quired or
removal of slush at any time dur ing c onstruction w ork i ncluding m onsoon pe riods
would be made and the rates quoted by the Tenderers for various items under in Vol.
III are deemed to be inclusive of cost of such dewatering & removal of slush where
necessary.
5.0
FORM WORK
The c himney s hell s hall be c onstructed by us ing s lip f orm technique only. The
contractor s hall be a llowed t o us e f orm w ork a s pe r hi s own design subject to
however that the design shall conform to the most acceptable practice for such type of
work a nd t he r elevant I S s pecification. T he de sign shall also be approved by the
Engineer-in-charge. T he re sponsibility of f orm s triking period shall re st with
contractor subject to however t hat t he sam e sha ll not be l ess t han the minimum
recommended under the relevant IS specification.
6.0 EMBEDDING FIXTURES IN CONCRETE
6.1 Proper steel templates shall be used for fixing anchor bolts, pipe sleeves etc. to ensure
that they are fixed precisely as per dimensions shown on dr awings. S uch templates
are subject to the Engineer’s approval.

TITLE:
TECHNICAL SPECIFICATION FOR
REINFORCED CONCRETE
CHIMNEY
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUBSECTION : I
REV.NO. 0 DATE 18.09.2010
SHEET
OF
6.2 The contractor shall exercise great care to ensure that these inserts are accurately held
in position and maintained undisturbed during placing and vibrating of concrete and
that pipe sleeves do not get filled in with concrete. I f found desirable the Engineer
may direct the contractor to tie or weld the inserts to the reinforcement to ensure that
are maintained undisturbed. All such works shall be done by the contractor at no extra
cost.
6.3 The contractor shall ensure that the anchor bolts, inserts etc. are properly protected as
under-
a) From w eather by a pproved m eans s uch a s w hite l ead putty and wrapping them
with gunny ba g or c anvas or by ot her m eans a s directed by the engineer.
However before actual fixing in position the anchors shall be cleaned of all oil and
grease and the protruding positions sha ll aga in be cl eaned and grease af ter
concreting is over.
b) From damage due to movement of contractor's labour staff, materials and
equipment a nd pr oviding s uitable gua rds a round t hem a s di rected by the
Engineer-in- charge.
6.4 In the event of pockets, bolts, pipe sleeves, channels and other inserts not being found
in correct position whole work shall be liable to be rejected.
6.5 Removal of bolt hole pockets shall only be done by w elding. In no c ase burning of
bolt hol e f orms s hall be pe rmitted on r emoval of f orms, the pockets shall be
temporarily pl ugged by t he hessian c ement ba gs or ot her m ethod t o prevent them
from getting filled in with dust debris, concrete etc.
7.0 QUALITY ASSURANCE PLAN
The contractor shall submit Quality Assurance Plan for complete works after awards
of contract and shall get for the same approved by employer/owner.
8.6 SUPERVISION BY CUSTOMER OR THEIR CONSULTANT
The owner or his r epresentative m ay depute t heir r epresentatives f or che cking and
supervision of important stages of work. The contractor shall be required to provide
all f acilities f or ins pection of w orks by the customer/consultants or the ir
representatives w ithout a ny c ost i mplication t o t he e mployer or E ngineer. Any
defects in quality of w ork, or de viations f rom dr awings s pecifications, poi nted out
during s uch i nspection s hall be m ade good by the contractor in the same way as
pointed out the Engineer without any cost implications.

TITLE:
TECHNICAL SPECIFICATION FOR
REINFORCED CONCRETE
CHIMNEY
9.0 SURVEY EQUIPMENT
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUBSECTION : I
REV.NO. 0 DATE 18.09.2010
SHEET
OF
9.1 The contractor shall have on s ite a good num ber of accurate survey instruments such as
levels, theodolite, staffs, measuring devices, survey umbrellas, etc. to ensure s mooth.
progress of work.
10.0 SPECIFICATIONS AND CODES
10.1 All works shall be carried out strictly in accordance with the technical specifications
unless ot herwise a pproved by t he E ngineer i n w riting. W here not s pecified i n t he
technical specifications the relevant latest Indian Standards Codes shall be followed.
10.2 Field quality s hall be a dhered t o s trictly i n a ccordance w ith t he s tandards a nd
applicable codes various checks during the process of work at different stages shall be
performed according to the checklist. Tests wherever required for these checks shall
be c onducted by t he c ontractor a t his own cost i n pr esence of t he E ngineer. T he
record of all such checks shall be jointly signed by the Engineer and the contractor
and maintained with the Engineer.
10.3 Any deviations in execution of t he w orks a s a r esult of c hances i n s pecifications.
contract dr awings, i naccurate w orkmanship, t ype, s ize or gr ade of m aterials to be
used etc sha ll be f irst discus sed by the cont ractor w ith the Engineer at site and
feasibility of s uch non -conformances possible ascertained. The cont ractor sha ll
initiate the matter by submitting a Non Conformance Request (NCR). The contractor
shall not proceed with construction or pr eparation of dr awings or pur chase of
materials or r emedial measures for de fective work not c onforming t o s pecifications
without the approval in writing by Engineer on the NCR submitted by the contractor.
10.4 Proprietary Items: All proprietor, items of m aterials s pecified/required as pe r ite m
description s hall be pr ocured f rom t he m anufacturers/reputed s uppliers only after
obtaining the approval of Engineer. Unpriced copies of such order shall be submitted
to the Engineer for any follow up action as deemed fit by the Engineer.
11.0 TECHNICAL INSTRUCTIONS
i) The successful tenderer on receipt of letter of intent shall prepare a de tailed
work pr ogramme i ncluding i tems of w ork w ithin t he ove r a ll time period
allowed and shall submit the same to the Engineer for approval. The drawings
as listed in section 'A' are enclosed with the tender documents.
ii)
iii)
The work ha s t o be t aken up i mmediately on i ssue of w ork or der/letter of
intent/telex and completed within the scheduled time of completion.
The work has to be carried out according to priority that may be fixed by the
site Engineer at site.

iv)
TITLE:
TECHNICAL SPECIFICATION FOR
REINFORCED CONCRETE
CHIMNEY
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUBSECTION : I
REV.NO. 0 DATE 18.09.2010
SHEET
OF
The m aterials a nd w orkmanship m ust be of good qua lity a nd a ccepted
standards and specifications.
v) All materials for construction are to be procured by the contractor and should
conform to relevant I.S. specification.
vi)
vii)
viii)
The site Engineer reserves the right to reject a ny material not upt o the
specifications.
Unless specified other otherwise rates quoted under the contractor shall apply
for works irrespective of lifts and leads. R ates shall also. include providing
scaffolding and its subsequent removal.
After completion of the work the buildings and areas around them should be
cleared all rubbish debris etc. and handed over in fit condition for occupation.
12.0 INSULATION
12.1 The heat insulation to be fixed on t he inner surface of shell shall be semi-rigid resin
bonded f ibrous m aterial c onforming t o I S: 819, or e quivalent with a maximum
coefficient of thermal conductivity of 0.52 MW/CM/Deg. C at a mean temperature of
100 deg. C . The Insulation material shall have a delivered density of 100 K g/Cu.M
for resin-bonded rock wool or 64 Kg/Cu.M for resin-bonded glass wool. Thickness of
the insulation as specified in BOQ 's is the minimum as installed.
12.2 No negative tolerance shall be pe rmitted i n t he bul k de nsity of i nsulation. T he
insulation s hall be i n t he f orm of s labs w rapped on t he i nner s urface of shell with
galvanized wire mesh as specified. The insulation should not be affected by acid and
should be free from any impurities which may cause corrosion.
12.3 The i nsulation should be a ble t o s ustain s tructural vi brations a nd s hould not s ettle
under these conditions during erection, construction and operation in any case. The
insulation shall also be suitable tied to prevent dislocation under adverse conditions.
Care sh ould be t aken i n t he s election of t he i nsulation m aterial t o e nsure t hat t he
material can safely withstand the l ong term expos ure to the maximum flue gas
temperature without deterioration or break-down. Slag Wool insulation shall not be
acceptable.
12.4 Unbounded wool shall be of Type–I loose, glass wool in conformance with IS: 3690
or T ype-I l oose r ock W ool i n c onformance W ith I S: 3677. The insulation shall be
packed to achieve a density of 64 Kg/Cu.M in case of glass wool and 100 kg/Cu.M in
case of rock Wool. Bonded and unbonded insulation shall be of the same material.
12.5 The insulation material shall be tested for its stipulated characteristics and properties
listed i n t his s pecification a nd I S : 8183 a nd t he dr awing a ccordance w ith the IS:

TITLE:
TECHNICAL SPECIFICATION FOR
REINFORCED CONCRETE
CHIMNEY
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUBSECTION : I
REV.NO. 0 DATE 18.09.2010
SHEET
OF
3144 and IS: 3346 a nd/or a s directed by t he Engineer at the Contractor's own cost.
The tests shall be conducted in the presence of the Engineer and the reports of such
testing shall be submitted to the Engineer before application of the material.
12.6 The insulated material shall be protected against weather at all times from delivery up
to completion of work. Insulation material shall not be stacked directly on the
ground. The contractor shall provide covered storage for insulation material
accessories to the satisfaction of the Engineer.
13.0 CONSTRUCTION
13.1 INSULATION
13.1.1 The fixing details shall be as per specification, approved drawings and the directions
of the Engineer.
13.1.2 T he i nsulation s hall be pr ovided i n m ore t han one l ayer and the joints staggered.
Each layer shall be minimum 25 mm thick.
13.1.3 P articular care shall be taken to ensure that all semi rigid resin bonded fibrous slabs
are tightly butted. The insulation shall be tightly secured to the exterior of the liner or
the inner surface or the shell or on and other surface leaving no air gap at the interface
13.1.4 P ins and studs shall be anchored/fixed to the surface receiving insulation at 500 mm
centers maximum horizontally and vertically. Pins and studs shall be minimum 10
gauge and plated. These shall be 25 m m longer than the thickness of insulation.An
alternative arrangement with anchor f asteners i nstead of pins can also be m ade as
approved by the engineer incharge.
13.1.5 The insulation shall be impaled on the studs and secured in place with 63 mm round
or square metal plated speed washers.
13.1.6 20 gauge galvanized wire netting shall be wrapped continuously over external surface
of the insulation. The wire mesh shall be 25 mm hexagonal conforming to IS: 3150.
All joints in the mesh shall be lapped in minimum of 150 mm and tied with 16-gauge
soft annealed wire at 300 mm centers. Lacing will not be permitted.
13.1.7 The insulation shall be fixed after painting the inner surface of the shell with acid and
heat resistant paint.
14.0 COATING S YSTEM O N S TRUCTURAL F RAMING: Acid and heat r esistant
paint as per IS: 158 for surfaces which are not insulated nor protected by galvanising,
high temperature f ormulation for pot entially hot s urfaces m ainly platform framing
system. Two coats of finish paint on two coats of primer is to be applied on complete
framing system other than flues.

TITLE:
SPECIFIC TECHNICAL
REQUIREMENTS FOR
ELECTRICAL WORKS
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUB SECTION: II
REV.NO. 0 DATE: 18.09.2010
SHEET 1 OF 6
VOLUME – II B
SECTION-C
SPECIFIC TECHNICAL REQUIREMENTS
FOR ELECTRICAL WORKS
SPECIFICATION NO. PE-TS-360-620-C001

TITLE:
SPECIFIC TECHNICAL
REQUIREMENTS FOR
ELECTRICAL WORKS
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUB SECTION: II
REV.NO. 0 DATE: 18.09.2010
SHEET 2 OF 6
1.00 ELECTRICAL SYSTEM
1.01 415V, normal and emergency AC power supply for chimney shall be derived
from main plant power supply system. Emergency supply shall feed 20% of
platform lighting, 50% of staircase lighting, aviation obstruction lighting and
elevator load. All other loads shall be connected on normal power supply.
1.02 Ambient temperature for design of all equipment shall be considered as 55
deg. C which is likely to be encountered inside the chimney.
1.03 The distribution boards of chimney shall comprise switch-fuse units of
appropriate ratings. Emergency board shall have two incomers, one from
emergency supply and other from normal AC distribution board itself. Autochangeover
scheme shall be provided in emergency board to enable
changeover to healthy source on failure of any source.
1.04 Dry type isolating transformer of Dyn connection shall be provided in
emergency board to obtain neutral lead, in case 3 phase 3 wire emergency
supply is derived from main plant.
1.05 Various platforms shall be illuminated by 70/150W HPSV well glass lighting
fixtures. Staircase lighting shall be with 70W HPSV well glass fixtures.
Average illuminations level of 150 lux shall be maintained on equipment and
50 lux on platforms/staircases. Lighting system shall be controlled through
MCB provided in lighting panel.
1.06 A lighting panel each shall be located at grade level and at other in between
levels as required. All distribution boards, aviation lighting controls, etc. shall
be located at grade level only. At each platform, 1 No. 63A, 415V welding
receptacle and 1 No. 15A, 240V receptacle shall be provided. Wiring
installation for lighting fixture shall be of PVC insulated copper/aluminum
wires through galvanized steel conduits.
1.07 Aviations obstruction lighting system shall conform to the requirements of the
latest rules and regulations of the International Civil Aviation Organization
(ICAO), National Airports Authority (NAA) and Directorate of Air Routes
and Aerodromes (DARA). The type of aviation obstruction lighting system
shall be of high intensity aviation obstruction lights having an intensity of
4000 to 200000 cd depending upon background illuminance. The aviation
obstruction lighting system shall be of type FTB205 and FTC 110N of Flash
Technology Corporation of USA or equivalent. A minimum of three levels
will be provided with aviation obstruction lights and there will be four lights
per level The obstacle lights shall flash simultaneously at a rate between 40
and 60 per minute. Aviation obstruction lighting shall be provided as per the
approved drawings. Aviation obstruction lighting shall be complete with
lights, photo cell, controller, special cables, etc.

TITLE:
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SPECIFIC TECHNICAL
REQUIREMENTS FOR
SECTION - C SUB SECTION: II
REV.NO. 0 DATE: 18.09.2010
ELECTRICAL WORKS
SHEET 3 OF 6
1.08 A temporary aviation obstruction lighting system shall be provided during
construction of the chimney.
1.09 Cables from distribution board to lighting panels/receptacles shall be 1100V
grade, PVC/XLPE insulated armoured aluminum conductor with a minimum
size of 4 mm 2 Cables shall be laid on galvanized sheet steel cable trays. Cables
shall be terminated using double compression type cable glands and cable
lugs.
1.10 Lightning protection system shall comprise minimum 3 vertical air
terminations for each flue liner, horizontal air termination and minimum 4
Nos. of down conductors spaced 90 degrees apart routed all along chimney
height and connected to the earthing system. Above ground level, earthing and
lightning protection system shall comprise galvanized steel strips. These
materials provided at top 12 meters shall have additional coating of 2 mm
thick seamless lead cover or it shall be of stainless steel to take care of
corrosion. Chimney earthing system shall be inter connected to main plant
earthing system.
1.11 Communication system comprising of telephone socket at every internal
platform level and at grade level, necessary wiring installation, junction boxes
etc. shall also be provided. Requirement of telecommunication system as per
pt. no. 18 of spec no. –DCPL-K9A01, doc. no.- V.II-D2/S-XXIV:22 (pg.330)
are to be complied with.
1.12 For various equipment, the technical requirements and practices shall conform
to the relevant clauses of the main plant electrical specification and customer
specification no. –DCPL-K9A01, doc. no.- V.II-D2/S-XXIV:30-33 (pg.338 to
341).
2.00 ELECTRICAL EQUIPMENT SCOPE
The Bidder’s scope of supply, installation, testing and commissioning shall
include but not be limited to the following:
2.01 Lighting of chimney as per specification no. PE-DG-XXX-558-0004
including aviation obstruction lighting system and 15A industrial switch
socket & 63A welding socket.
2.02 Lightning protection & earthing of chimney as per specification no. PES-509-
02A Rev. 0 and PE-DG-XXX-509-0004. Also refer enclosed typical drawing
of Lightning Protection and Earthing system drg. No. PE-DG-179-620-7272
REV.1
2.03 Power Distribution Boards
:
2.03.1 415 V, 3∅, 4 wire AC distribution board (ACDB) as per specification no.
PES-506-05. 415 V, 3∅, 3 wire AC Emergency Lighting distribution board
(ELDB) & Lighting panels (LP) as per Specification no. PES-558-01A .
2.04 Power & control cables HRPVC, armoured, FRLS type 1100 V grade as per
specification no. Section E18 Volume II Part B.

TITLE:
SPECIFIC TECHNICAL
REQUIREMENTS FOR
ELECTRICAL WORKS
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C
SUB SECTION: II
REV.NO. 0 DATE: 18.09.2010
SHEET 4 OF 6
2.05 PVC insulated 1100V grade stranded copper conductor lighting wires.
2.06 Aviation obstruction lighting system :
2.06.1 Supply and installation of single obstruction lights with fixtures ( LED
BASED with 20 years maintainance free life) equivalent to Type ‘B’ Low
intensity aviation obstruction lights as per ICAO, at location as per approved
drawings, complete with all accessories and suitable supporting arrangement
to withstand high wind pressure.
2.06.2 Supply and installation of red flashing aviation obstruction lights at different
floor levels as per aviation obstruction lighting system conforming to the
requirements of the latest Indian Standard IS-4998 & International civil
aviation organisation (ICAO) and approved drawings.
2.06.3 Supply and installation of medium intensity flashing light with fixtures (
LED BASED with 20 years maintainance free life) equivalent to Type ‘B’
Medium intensity aviation obstruction lights as per ICAO, at location as per
approved drawings, complete with all accessories and suitable supporting
arrangement to withstand high wind pressure.. The flash frequency shall be
40-60/min.
2.07 The lighting system also includes supply and installation of GS Cable Trays,
GI conduits, conduits fitting, weatherproof junction boxes, lead coated
flexible conduits (PLICA make), all accessories viz. supports, clamps,
mounting structure/brackets etc. to make the installation complete.
Supporting structure for the above shall be hot dip galvanised.
2.08 Temporary obstruction lighting system :
2.08.1 Temporary obstruction lighting shall be provided by the bidder during
construction as per specification requirements. The fixture shall be
equivalent to Type B, Low intensity Light , minimum 4 nos. on the upper
most part of the chimney.
2.08.2 Power for these lights shall be obtained from the construction power system
including cable, cabling & maintenance by bidder.
2.09 Painting and lead coating shall be carried out as per specification
requirements.
2.10 Communication System
Telephone sockets at 0.0 M and at every platform for connection of telephone
handset shall be provided. Purchaser will provide necessary connection to the
JB at 0.0 M from telephone exchange. Bidder shall provide telephone cable
(as per ITD specification) installed in independent G.I. conduit and wired
upto junction boxes with telephone socket.
2.11 Photo Electric light detector along with timer & contactor etc. shall be
supplied and installed to monitor the aviation obstruction lighting system.
2.12 Any item or work either supply of equipment or erection material which have
not been specifically mentioned but are necessary to complete the work for
trouble free and efficient operation of the plant shall be deemed to be
included within the scope of this specification and shall be provided by the
tenderer without any extra charge.
2.13 All equipment offered shall have suitable provision for termination and
connection of power, control and special cables and shall also be complete

TITLE:
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SPECIFIC TECHNICAL
REQUIREMENTS FOR
SECTION - C SUB SECTION: II
ELECTRICAL WORKS
SHEET 5 OF 6
with cable boxes, double compression nickel-chromium plated brass cable
glands (heavy duty type), solderless tinned copper crimping cable lugs etc.
2.14 The size of two nos. down conductors for earthing are 50 x 6 mm GS flat
extending at different platforms for electrical equipment earthing. These
down conductor are in addition to lightning down conductor.Total four nos.
down conductor shall be provided
2.15 Various drawings, data, calculations, test reports, test certificates, operation
and maintenance manuals etc. as specified shall be furnished after award of
contract for approval of purchaser/customer/consultant.
2.16 Make of equipment/components shall be subject to
purchaser/customer/consultant approval after award of contract without any
commercial or delivery implications to the purchaser.
2.17 Bidder shall quote for mandatory spares for electrical equipment as per
attached list. Bidder may further note that purchaser reserves the right to
delete any item/ all items from the list after award of contract.
2.18 Bidder shall furnish list of recommended spares for 3 years for all electrical
equipments with unit prices.
2.19 Start-up & commissioning spares for electrical equipment shall be supplied
on as required basis and cost for the same shall be included in the main
equipment cost.
2.20 Bidder shall furnish List of Erection & maintenance tools & tackles with the
offer.
2.21 Bidder shall furnish unpriced “Price Schedule” for electrical equipments with
the offer.
2.22 All equipment shall be suitable for the power supply fault levels and other
climatic conditions mentioned in the enclosed project electrical information.
2.23 Bidder shall furnish electrical load requirements for normal 415V AC &
Emergency 415V AC after award of contract.
2.24 The final technical particulars of various electrical equipment/ components/
items shall be subject to purchaser/consultant/customer approval after award
of contract.
2.25 The detailed Schedule of Equipment is enclosed in the form of Electrical
Equipments BOQ.
2.26 Various drawings/ documents for electrical equipments for chimney shall be
prepared by bidder after award of contract for approval of
purchaser/customer/consultant.
REV.NO. 0 DATE: 18.09.2010
3.00 EQUIPMENT & SERVICES TO BE PROVIDED BY PURCHASER FOR
ELECTRICAL & TERMINAL POINTS
3.01 Power cables for incomer to 415 V AC Distribution Board (ACDB) and AC
Emergency Lighting distribution board (ELDB). However, termination of
incomer power cables in ACDB & ELDB shall be carried out by bidder.
ACDB & ELDB shall be located inside the chimney. Bidder to note that the
second incomer to ELDB shall be derived from ACDB by the bidder. Cable
glands and lugs shall be supplied by the bidder.
3.02 Cable trench, cable trays/GI pipes up to the boundary limit of the chimney
i.e. 3M away from outer shell. Bidder shall coordinate with the purchaser for

TITLE:
SPECIFIC TECHNICAL
REQUIREMENTS FOR
ELECTRICAL WORKS
layout and matching.
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - C SUB SECTION: II
REV.NO. 0 DATE: 18.09.2010
SHEET 6 OF 6
4.00 OTHER REQUIREMENTS
4.01 In case of any deviation the bidder shall indicate the same clause by clause in
enclosed deviation schedule. In the absence of duly filled in schedules, it will
be construed that the offer confirms strictly to the specification.
4.02 Bidder shall furnish duly filled in data sheets (enclosed with specification) for
electrical equipments after the award of contract for approval. Technical data
sheet of any other electrical equipment if required by the purchaser shall be
furnished to the contractor after award of contract to enable them to furnish
the same.
4.03 The bidder shall furnish signed and stamped copy of the specification as a
token of acceptance and submit the same along with the technical offer.
Further, Quality plan shall be subject to BHEL/customer/consultant approval
after award of contract without any commercial or delivery implication.
Inspection shall be carried out as per approved Quality Plan approved during
detailed engineering.
4.04 Bidder shall furnish details of aviation obstruction lights with catalogues.
4.05 Bidder shall furnish all drawings/data/catalogues as indicated in different
electrical equipment specifications along with the offer in sufficient nos. as
indicated in the civil part of the specification.
4.06 The minimum illumination level shall be provided as indicated below :
- Ground Floor, platforms, stairs & landings 50 LUX
- Area of different distribution boards 150 LUX
4.07 In case of any conflict between various sections of the specification, decision
of the Purchaser shall be final and binding on the bidder.

SPECIFIC TECHNICAL
REQUIREMENT
SPECIFICATION NO.PE-TS-360-620-C001
VOLUME II B
SECTION C SUB-SECTION III
REV. 0 DATE:
SHEET
SUB SECTION – III
STACK ELEVATOR

PEM-6666-0
TITLE SPECIFICATION NO. PE-TS-360-620-C001
SYSTEM DESCRIPTION AND VOLUME II B
SCOPE OF WORK FOR SECTION C SUB SECTION : III
STACK ELEVATOR REV 0 DATE
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1.00 SYSTEM DESCRIPTION
One (1) no. Rack and pinion type stack elevator is required for installation inside multi-flue or
outside single flue chimney. The stack Elevator is normally used for the movement of the
maintenance personnel and for materials such as refractory bricks, etc. for maintenance of
chimney.
2.0 SCOPE OF SUPPLY AND SERVICES
The scope of supply and services covered under the specification are broadly described below:
- One No. Rack and Pinion type stack elevator complete with all other accessories and
associated steel work.
- Drive motor and control panel for Stack elevator
- Control Panel
- Equipment earthing
- All power and control cables, trailing cables
- Limit switches
- Over speed governor
- Alarm push button in the cage connected to battery operated alarm at elevator base.
- Reverse phase relay connected to prevent operation of the cab with improper phase
rotation or failure in any phase of power supply.
- Continuous duty electrical torque motor recoil cable reels or cable trolley or any
equivalent arrangement to maintain electrical power service to all electrical components of
the elevator for complete travel of stack elevator.
- One auxiliary panel shall be provided and mounted on the graded level enclosure
equipped with a main ON-OFF selector switch, main contactor, breaker, relays, control
transformer and fuses, tone frequency transmitter or equivalent arrangement, , terminal
blocks and all other accessories required for normal operation of the elevator.
- One main control panel shall be furnished and mounted on top of the cab. Panel shall be
in enclosure equipped with necessary equipment like rectifier, battery charger charger,
tone frequency receiver, contactors, breakers, control transformer and fuses, thermal
overload relays, and all other equipment and accessories required for normal operation of
the elevator.
- Cab shall be controlled by semi automatic floor selection control system. Cab shall be
furnished with 240 V grounding receptacle, emergency alarm push button with normally
open contact, indicating light, limit switches, and all other necessary control devices
required to ensure safe and continuous cab operation. One trailing cable shall connect
the main control panel to aux. Panel at ground level. Cable shall supply the cab necessary
power supply requirements. Cable guides shall be installed at every 6 m intervals to avoid
entanglement of this cable. Control signal between the aux. Panel at ground level, the

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TITLE SPECIFICATION NO. PE-TS-360-620-C001
SYSTEM DESCRIPTION AND VOLUME II B
SCOPE OF WORK FOR SECTION C SUB SECTION : III
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main control panel on the cab and the landings shall be provided with tone frequency
receiver or any other equivalent arrangement by trailing control cable.
- Each landing assembly shall include a limit switch and push button control station installed
and wired to a landing junction box.
- All power cable and race way shall be provided and installed by the bidder for
interconnection of the main control panel, auxiliary panel and landing junction boxes.
Trailing cables shall be as per relevant IS/IEC standard.
- Bidder shall provide, install and connect a system equipment ground to owner’s chimney
grounding system. Equipment grounding system shall electrically connect panels and
junction boxes which contain electrical devices, motors and elevator platform and
structures. Raceway system shall not be considered as an equipment ground.
- All enclosures containing electrical devices shall be provided with 240 V, single phase
heaters with adjustable thermostat control.
- Cab shall be equipped with a 240 V AC interior light and duplex outlet.
- Cable accessories as required to install the cables in bidder’s scope shall be provided by
the bidders.
- Complete erection, testing and commissioning including all erection materials,
consumables and other tools and tackles required for erection along with commissioning
spares.
- All inserts, anchor bolts, sleeves, anchoring steel and any other items required to
complete the job satisfactorily shall be in bidder’s scope.
- First fill of lubricant and consumables shall be in bidder’s scope.
- Satisfactory running and maintenance of elevator for a continuous period of 30 days
including training of owner’s operators.
- Supply of One complete set of special maintenance tools and tackles shall be in bidder’s
scope.
- Any other equipment or accessories not specified, but required for the satisfactory
operation of chimney elevator shall be in bidder’s scope.
- Recommended spares including instrumentation for 3 years of normal operation of stack
elevator. ( List to be furnished by the bidder and for which order shall be placed separately
by owner as per their requirements)
3.0 SPECIFIC REQUIREMENTS
- The equipment supplied, erected and commissioned shall meet the technical requirements
of respective Section –D and Data Sheet-A.
- Bidder shall note that all QP and Field quality plans shall be subject to purchaser’s
approval.
- All equipment offered shall have suitable provision of termination and connection of power
and control cables inclusive of cable boxes, lugs and glands, etc.

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SYSTEM DESCRIPTION AND VOLUME II B
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- All the equipment shall be suitable for the power supply fault level and other climatic
conditions as indicated in project information.
- The bidder shall guarantee the rating and performance parameters of the system/equipment
offered in accordance with specification requirements.
- It is the responsibility of bidder to arrange license for operation of chimney elevator from
statutory body of that area before handing over.
- Bidder shall furnish deviation (clause wise) in the deviation schedule. In absence of dully filled
deviation list, it will be presumed that offer is exactly in line with the technical specification.
- Bidder shall furnish duly filled data sheet –B alongwith the offer. In absence of same, offer shall
be treated as incomplete.
- Bidder shall offer the stack elevator considering prevailing statutory and regulatory requirements
of project location.
- Bidder shall indicate degree of protection of various electrical equipment in the offer.
- Makes of all bought out items shall subject to purchaser’s approval after award of contract.
- All drawings/documents shall subject to purchaser’s approval after award of contract.

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TITLE SPECIFICATION NO. PE-TS-360-620-C001
TECHNICAL SPECIFICATION FOR VOLUME II B
STACK ELEVATOR SECTION C SUB SECTION III
REV 0 DATE
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1.00.00 DESIGN AND CONSTRUCTION
1.01.00 Stack Elevator - General
1.01.01 The stack elevator including mechanical and electrical components shall be installed
outside/inside Single flue/ multi flue chimney. Since chimney is a free standing structure,
deflection of chimney top is expected during the normal operation, so the design of the elevator
shall be in such a way that the elevator operation will be safe even with the expected maximum
deflection of the chimney structure. The stack elevator shall lift a pay load as indicated against
rated load as mentioned in Data sheet-A or its nearest as per manufacturer’s present standard
in addition to the weight of the car and its accessories and shall travel at a rated speed as
indicated in the data sheet-A. Travel of the elevator car, number of landings and levels shall be
as per Data sheet-A attached to this section.
1.01.02 Stack elevator mechanical and electrical operating devices and trailing cable shall be designed
for operation indoors/out door with dusty and high humidity conditions and shall operate equally
well in any ambient temperature encountered in the site conditions. Additionally, all mechanical
and electrical components of the elevator shall be designed to withstand without damage a
temperature of 100 o C when the elevator is not operating.
1.01.03 Cage earthing shall be done through trailing cable.
1.01.04 Stack elevator shall be attached to the chimney shell using expansion type anchor bolts drilled
in to chimney shell. Elevator shall be capable of operating from the ground floor to the top
platform with intermediate stops at all platforms. Landing for elevator parking shall be one (1)
metre above the stack ground floor. Suitable concrete/brick steps leading to the landing for
entry to cabin shall also be provided,
1.01.05 The stack elevator shall be designed in line with recommendations contained in the latest
editions of the applicable codes and standards.
1.02.00 Equipment Specification
1.02.01 Enclosures
1.02.02 Mast
1.02.03 Cab
A three-sided enclosure with one access door shall be provided at graded level. At each
platform landing above graded level, a one sided enclosure with access door shall be provided.
Enclosures shall be fabricated from tubular steel and expanded metal or wire mesh, 2.1 m high
and one coat of epoxy primer coated. Enclosure access doors shall be electrically and
mechanically interlocked so that they remain closed and locked except when the Cab is at the
landing. Doors shall be bi-parting and swinging type.
Base of three-sided enclosure shall be securely anchored to the grade level floor slab using
expansion type anchors.
Mast shall be provided in sections approximately 1.52 m in lengths considering of tubular
sections and/or structural shapes welded together to form a frame work to which the rack is
bolted. Mast shall be securely anchored to the concrete chimney walls.

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TITLE SPECIFICATION NO. PE-TS-360-620-C001
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Cab frame shall be fabricated from tubular steel and enclosed with expanded metal or wire
mesh.
Cab floor shall be of skid resistant glass fibre reinforced plywood or approved equal. Cab shall
be attached to a framed structure and form integral part with the drive mechanism located atop
the cab.
Framed structure shall include guide rollers and safety hooks to ensure positive engagement of
the rack and pinion to prevent cab disengagement in case of roller failure.
1.02.04 Buffers
Sufficient numbers of buffers of spring loaded/hydraulic type shall be fitted below the cab. The
buffers shall be capable of stopping the cab without permanent damage or deformation to
themselves or any other part of the equipment. The number of buffers shall be so fixed as to
ensure proper sharing of impact loads by all of them.
1.02.05 Drive unit and safety Device
Drive unit located on the top of the cab shall be complete with Ac squirrel cage induction motor,
reduction gear, drive pinion and an over speed governor. Drive unit shall incorporate an electric
disc brake and an external manual brake release. The brake on the electric motor will be of the
electromagnetic single disc self-adjusting type with the mechanical compression spring being
held off by the electromagnet.
The hoist shall be provided with a centrifugal brake to prevent accidental tripping of safety
device when the cage shall be taken to the ground by gravity in case of power failure.
1.02.05 Power and Control
All electrical components furnished with the elevator shall be completely wired, energised and
checked. Necessary power distribution arrangement shall be provided by the contractor to feed
the electrical power to the elevator.
All electrical control devices shall be in enclosures. Equipment furnished shall also include the
following:
a) Momentary contact push button for raise lower control.
b) Reversing combination motor starter with a moulded case circuit breaker for the motor.
Starter shall be equipped with three thermal overload relays for motor protection. Operating
handle for the combination starter circuit breaker shall be accessible from inside the cab and
shall also serve as an emergency stop switch.
c) Electrical and mechanical interlocks on cab access door and landing level enclosure doors.
d) Over travel protection, emergency stop push button, over speed governors.
e) All electrical and mechanical interlocks on cab access door and landing level enclosure doors,
phase reversal protection shall be provided.
f) An alarm push button shall be provided in the cage connected to a battery-operated alarm at the
elevator base. Simultaneous alarm shall also sound at the plant control room in the event of any
fault in the stack elevator for which one potential free contact shall be provided in each elevator
for audiovisual alarm in PCR for “Stack Elevator fault” indication.

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g) Reverse phase relay connected to prevent operation of the cab with improper phase rotation or
failure in any phase in the power supply.
h) Continuous duty electric torque motor recoil cable reels as required to maintain electrical power
service to all elevator electrical components throughout the limits of travel.
i) One auxiliary panel shall be furnished and mounted on the grade level enclosure. Panel shall
be equipped with a main ‘ON-OFF’ isolating switch, main contactor, relays, control transformer
and fuses, tone frequency transfer, terminal blocks and all other accessories required for normal
operation of the elevator.
j) One main control panel shall be furnished and mounted on the top of the cab. Panel shall be
equipped with necessary, equipped like rectifier, battery, charger, tone frequency receiver,
contactors, MCBs, control transformer and fuses, thermal overload relays, and all other
equipment and accessories required for normal operation of the elevator.
k) Control cabinets shall be sheet steel enclosed and shall be dust, weather and vermin proof.
Sheet steel used shall be cold rolled and at least 2.0 mm thick and properly braced to prevent
wobbling. Degree of protection of the control cabinets shall be IP-52 as per IS:2147. Control
cabinets shall be provided with hinged door(s) with padlocking arrangement. All doors,
removable covers and plates shall be gasketed all around with neoprene gaskets, louvers,
when provided, shall have screeners and filters. The screens shall be of fine wire mesh made
of brass or GI wire. Suitable cable gland plate shall be supplied fitted on to this gland plate. All
cable glands shall be screwed on type and made of brass.
l) Each motor to be controlled from the control cabinet shall be provided with 3 pole isolating
switch. HRC fuses, contactors of AC4 duty class with thermal overload relays with single
phasing preventer and other equipment required for satisfactory control motor. The isolating
switch and contractor shall be rated at least 20% more than the connected motor full load
current. Motors of 0.2 KW and above shall be rated for 415 V 3 Phase and below 0.2 KW will
be 240 V single phase supply.
m) The controllers and resistors for motors shall conform to IS-8544 (latest edition) and IS-2959
(latest edition) and shall be continuously rated for 150% full load current of the motor. Switches
shall be hand operated, air breaker heavy duty, quick make, quick break type conforming to IS-
4064. The rating of switch shall be so chosen as to get complete protection by associated O/L
relay or fuse under all normal / abnormal conditions such as full load, overload, locked rotor,
short circuit. The incoming power supply isolating switch shall be inter-locked with the control
cabinet door so as to prevent opening of the door when the switch is closed. Device for
bypassing the door interlock shall also be provided. Switch handle shall have provision for
locking in both fully open and fully closed positions.
n) All fuses shall be of the HRC cartridge type mounted on plug in type of fuse base having a
prospective current rating of not less than 80 KA. Fuses shall be provided with visible operation
indicators to show that they have operated. All accessible live connections shall be adequately
shrouded and it shall be possible to change fuses with the circuit alive without danger of contact
with live metal.
o) Contractor shall provide dry type transformers with class B insulation for control power supply,
lighting and space heating. Control supply will be 240 V AC. Transformer for control supply
shall be provided with a control tap at 110 V, which will be earthed. Power and control supply to
individual drives and users shall be distributed with separate isolating switches and primary and
secondary fuses.

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TITLE SPECIFICATION NO. PE-TS-360-620-C001
TECHNICAL SPECIFICATION FOR VOLUME II B
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p) All push buttons shall be of push to actuate type having 2 “NO” and 2 “NC” self reset contacts.
They shall be provided with integral escutcheon on plate engraved with their functions. Push
button contacts shall be rated for 5 Amp at 415 V AC and 1 Amp. Inductive breaking at 250 V,
DC. Mushroom type emergency push button to open the main contactor shall be provided in
the operator’s cabin and two on the bridge platform within easy reach indicating lamps shall be
of the filament type and low watt consumption lamps shall be provided with series resistors.
q) Strip type space heaters of adequate capacity shall be provided inside in each cabinet.
r) Control cabinets shall be supplied completely wired. All wiring shall be carried out with 650 V
grade PVC insulated, stranded conductors. Power circuits shall be wired with stranded
aluminum conductors of adequate sizes to suit the rated circuit shall be wired with stranded
copper conductors of sizes not small than 1.5 Sq.mm. Control circuits shall be isolated from
power circuits.
s) Cab shall be controlled by a semi-automatic floor selection control system. Cab shall be
furnished with 240 Volt grounding type receptacle, emergency alarm push button with a
normally open contact rated 0.5 ampere at 220 VDC volts, indicating light, limit switches, and all
other necessary control devices required to ensure safe and continuous cab operation. One
trailing cable shall connect the cab main control panel to the auxiliary panel at ground level.
Cable shall supply the cab with all power requirements. Cable guides shall be installed at every
6 metres to avoid entanglement of this cable. Control signals between the auxiliary panel at
ground level and the main control panel on the cab. Will be provided with the tone frequency
receiver. However control and interlocks from the landings shall be connected to the auxiliary
panels located at ground level through fixed armoured cables. The power and control cables
and training power cables shall be FRLS type.
s) Each landing assembly shall include a limit switch for door interlock and push button control
station installed and wired to a landing junction box.
t) Cable trolley with cable guides for recoil of cable on to cable reel to maintain electrical power
service to all elevator components through out the limits of travel.
u) Contractor shall furnish, install, and connect a system equipment ground to the Owner’s existing
chimney ground system. System equipment ground shall electrically connect panels and
junction boxes, which contain electrical devices, motors, and elevator platforms and support
structure. Raceway system shall not be considered as an equipment ground.
v) All enclosures containing electrical devices shall be provided with 240 Volt, single-phase space
heaters with adjustable thermostat control.
w) All power cables and race way shall be furnished and installed by the Contractor for
interconnection of the main control panel, auxiliary panel and landing junction boxes etc.
Conductors included in the cable shall be as required to energise all electrical equipment
furnished with the elevator. Transmission of alarm signals is done by means of tone frequency
equipment. Hence communication conductors are not required.
6.03.07 Electric Motor
Elevator drive motor shall be squirrel-cage induction type designed and fabricated to conform to
the requirements indicated below.

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Motor shall be designed for operation at the required speed: 415 Volts, 3 phase, 50 hertz. And
shall be suitable for full voltage starting, S4 duty class as per IS-4722 with CDF of 25% and
maximum number of 120 starts per hour in 55 Deg. C ambient temperature. Motor shall be
tested at the factory to determine that it is free from electrical or mechanical defects.
6.03.08 Raceway
a) General
Complete raceway system for the elevator shall be furnished and installed in accordance with
this section and the Contractor’s shop drawings as reviewed and accepted by the Engineer-in-
Charge. The Contractor shall provide drawings for acceptance showing the routing of conduit
and wiring for the control circuits associated with the elevator.
Raceway system is defined to include conduit and all related materials and devices required to
support, secure and provide a complete system for support and protection of electrical cable
and wiring.
b)Materials
Raceway shall be rigid galvanized steel conduit, provided in accordance with IS-1653 (latest
edition).
Steel conduit, couplings, and elbows shall be hot-dip galvanized rigid mild steel. Each length of
threaded conduit shall be complete with a coupling on one end and a thread protector on the
other. Thread protector shall have sufficient mechanical strength to protect the threads during
normal handling and storage. Flexible conduits shall be plastic jacketed, liquid tight galvanized
steel.
Galvanised iron or galvanized cast steel fittings shall be used with galvanized steel conduit.
Fittings installed outdoors or in damp locations shall be sealed and gasketted. Outdoor fittings
shall be of heavy cast construction.
6.03.09 PVC Insulated FRLS Cable
a) Materials
Electrical part of this specification shall be referred for FRLS cable. Unless specified otherwise,
Contractor shall submit to the Engineer-in-Charge four copies of the manufacturer’s test report
on each cable furnished. Conductor accessories including terminal materials like glands, lugs
etc. makers, tying materials and cable support shall be furnished and installed. Wire
termination materials for conductors 10 Sq. mm and larger shall be pressure or bolted type.
Terminals for conductors smaller than 10 Sq. mm shall be an insulated pressure connection in
the shape of a ring.
b) Installation
6.03.10 Earthing
Power and control cable shall be routed as required by the drawings. Cables pulled into the
wrong conduit or cut too short shall be replaced. Cables removed from one conduit shall not be
installed in another conduit.
a) General

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Earthing system furnished and installed and include a complete earthing system for the
elevator. Earthing equipment and materials shall be furnished and installed in accordance with
the reference codes and standards these specification and the contractor’s shop drawings as
reviewed and accepted by the Engineer-in-Charge.
b) Materials
The earthing of all electrical items being supplied by the Bidder shall be in his scope. For
earthing the various equipment, conductor sizes shall be as listed below:
i) MCCs Motor above 90 KW : 50 x 6 Sq.mm G.I. flat
ii) Motors above 30 KW, upto
75 KW and lighting panel/
control panels/auxiliary panels : 25 x 6 Sq. mm G.I. flat
iii) Motor above 5 KW upto 30 KW : 25 x 3 mm G.I. flat
iv) Motors upto 5 KW and misc. : 8 SWG GI wire
Small item like conduits,
Junction boxes etc.

PEM-6666-0
TITLE SPECIFICATION NO. PE-TS-360-620-C001
TECHNICAL SPECIFICATION FOR
VOLUME: IIB
STACK ELEVATOR
SECTION C
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1.00.00 DESIGN AND CONSTRUCTION
1.01.00 Stack Elevator - General
1.01.01 The stack elevator including mechanical and electrical components shall be installed inside Single flue/
multi flue chimney. Since chimney is a free standing structure, deflection of chimney top is expected
during the normal operation, so the design of the elevator shall be in such a way that the elevator
operation will be safe even with the expected maximum deflection of the chimney structure. The stack
elevator shall lift a pay load as indicated against rated load as mentioned in Data sheet-A or its nearest
as per manufacturer’s present standard in addition to the weight of the car and its accessories and shall
travel at a rated speed as indicated in the data sheet-A. Travel of the elevator car, number of landings
and levels shall be as per Data sheet-A attached to this section.
1.01.02 Stack elevator mechanical and electrical operating devices and trailing cable shall be designed for
operation indoors/out door with dusty and high humidity conditions and shall operate equally well in any
ambient temperature encountered in the site conditions. Additionally, all mechanical and electrical
components of the elevator shall be designed to withstand without damage a temperature of 100 o C when
the elevator is not operating.
1.01.03 Cage earthing shall be done through trailing cable.
1.01.04 Stack elevator shall be attached to the chimney shell using expansion type anchor bolts drilled in to
chimney shell. Elevator shall be capable of operating from the ground floor to the top platform with
intermediate stops at all platforms. Landing for elevator parking shall be one (1) metre above the stack
ground floor. Suitable concrete/brick steps leading to the landing for entry to cabin shall also be provided,
1.01.05 The stack elevator shall be designed in line with recommendations contained in the latest editions of the
applicable codes and standards.
1.02.00 Equipment Specification
1.02.01 Enclosures
1.02.02 Mast
1.02.03 Cab
A three sided enclosure with one access door shall be provided at graded level. At each platform landing
above graded level, a one sided enclosure with access door shall be provided. Enclosures shall be
fabricated from tubular steel and expanded metal or wire mesh, 2.1 m high and one coat of epoxy primer
coated. Enclosure access doors shall be electrically and mechanically interlocked so that they remain
closed and locked except when the Cab is at the landing. Doors shall be bi-parting and swinging type.
Base of three sided enclosure shall be securely anchored to the grade level floor slab using expansion
type anchors.
Mast shall be provided in sections approximately 1.52 m in lengths considering of tubular sections and/or
structural shapes welded together to form a frame work to which the rack is bolted. Mast shall be securely
anchored to the concrete chimney walls.
Cab frame shall be fabricated from tubular steel and enclosed with expanded metal or wire mesh.
Cab floor shall be of skid resistant glass fibre reinforced ply wood or approved equal. Cab shall be
attached to a framed structure and form integral part with the drive mechanism located atop the cab.
Framed structure shall include guide rollers and safety hooks to ensure positive engagement of the rack
and pinion to prevent cab disengagement in case of roller failure.

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1.02.04 Buffers
One cabin fan, two recessed fluorescent lamp fittings and one number receptacle with duplex outlet (5A,
240V each) to be provided alongwith one number emergency light with battery and charger.
Cab roof shall be provided with an escape hatch electrically interlocked with the hoist control system.
Tubular steel hand rail shall enclose the cab roof for maintenance operations.
Cab door and landing level enclosure doors shall be electrically and mechanically interlocked to prevent
the cab from being operated unless the cab door and landing level enclosure doors are fully closed and
to prevent doors from being opened while the cab is in motion.
Other accessories such as cab control station, load plate, etc. to be provided in the cab.
Sufficient numbers of buffers of spring loaded/hydraulic type shall be fitted below the cab. The buffers
shall be capable of stopping the cab without permanent damage or deformation to themselves or any
other part of the equipment. The number of buffers shall be so fixed as to ensure proper sharing of impact
loads by all of them.
1.02.05 Drive unit and safety Device
drive unit located on the top of the cab shall be complete with Ac squirrel cage induction motor, reduction
gear, drive pinion and an over speed governor. Drive unit shall incorporate an electric disc brake and an
external manual brake release. The brake on the electric motor will be of the electromagnetic single disc
self adjusting type with the mechanical compression spring being held off by the electromagnet. In the
event of power failure, the brake will be automatically applied and will stop the cab. A hand lever, which
can be operated from the cage, is to be provided to enable the occupants to ease the brake and lower the
cage to the bottom level. Motor shall be connected to a reduction worm gear, which drives the pinion.
An over speed governor in constant mesh with the rack by means of frame hardened steel pinion is
incorporated to protect the cab against over speed during the cab downward motion. At the predetermined
speed higher than normal, the centrifugal action of the governor pawl will actuate the
incorporated brake mechanism and stop the downward motion of the cab gradually. The brake should
remain locked on following this action and has to be manually reset before normal elevator operation can
be resumed.
A remote control shall be provided for testing the safety device to ensure that no individual is in the cab
during the test.
The drive system shall be designed so that it will be capable to operate smoothly without any tendency to
rock or judder with all vertical, horizontal forces as well as the moments through the rack.
The hoist shall be provided with a centrifugal brake to prevent accidental tripping of safety device when
the cage shall be taken to the ground by gravity in case of power failure.
1.02.05 Power and Control
All electrical components furnished with the elevator shall be completely wired, energised and checked.
Necessary power distribution arrangement shall be provided by the contractor to feed the electrical;
power to the elevator.
All electrical control devices shall be in enclosures. Equipment furnished shall also include the following:
a) Momentary contact push button for raise lower control.
b) Reversing combination motor starter with a moulded case circuit breaker for the motor. Starter shall be
equipped with three thermal overload relays for motor protection. Operating handle for the combination
starter circuit breaker shall be accessible from inside the cab and shall also serve as an emergency stop
switch.
c) Electrical and mechanical interlocks on cab access door and landing level enclosure doors.
d) Over travel protection, emergency stop push button, over speed governors.

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e) All electrical and mechanical interlocks on cab access door and landing level enclosure doors, phase
reversal protection shall be provided.
f) An alarm push button shall be provided in the cage connected to a battery operated alarm at the elevator
base. Simultaneous alarm shall also sound at the plant control room in the event of any fault in the stack
elevator for which one potential free contact shall be provided in each elevator for audio visual alarm in
PCR for “Stack Elevator fault” indication.
g) Reverse phase relay connected to prevent operation of the cab with improper phase rotation or failure in
any phase in the power supply.
h) Continuous duty electric torque motor recoil cable reels as required to maintain electrical power service to
all elevator electrical components throughout the limits of travel.
i) One auxiliary panel shall be furnished and mounted on the grade level enclosure. Panel shall be
equipped with a main ‘ON-OFF’ isolating switch, main contactor, relays, control transformer and fuses,
tone frequency transfer, terminal blocks and all other accessories required for normal operation of the
elevator.
j) One main control panel shall be furnished and mounted on the top of the cab. Panel shall be equipped
with necessary, equipped like rectifier, battery, charger, tone frequency receiver, contactors, MCBs,
control transformer and fuses, thermal overload relays, and all other equipment and accessories required
for normal operation of the elevator.
k) Control cabinets shall be sheet steel enclosed and shall be dust, weather and vermin proof. Sheet steel
used shall be cold rolled and at least 2.0 mm thick and properly braced to prevent wobbling. Degree of
protection of the control cabinets shall be IP-52 as per IS:2147. Control cabinets shall be provided with
hinged door(s) with padlocking arrangement. All doors, removable covers and plates shall be gasketed
all around with neoprene gaskets, louvers, when provided, shall have screeners and filters. The screens
shall be of fine wire mesh made of brass or GI wire. Suitable cable gland plate shall be supplied fitted on
to this gland plate. All cable glands shall be screwed on type and made of brass.
l) Each motor to be controlled from the control cabinet shall be provided with 3 pole isolating switch. HRC
fuses, contactors of AC4 duty class with thermal overload relays with single phasing preventer and other
equipment required for satisfactory control motor. The isolating switch and contractor shall be rated
atleast 20% more than the connected motor full load current. Motors of 0.2 KW and above shall be rated
for 415 V 3 Phase and below 0.2 KW will be 240 V single phase supply.
The controllers and resistors for motors shall conform to IS-8544 (latest edition) and IS-2959 (latest
edition) and shall be continuously raed for 150% full load current of the motor. Switches shall be hand
operated, air breaker heavy duty, quick make, quick break type conforming to IS-4064. The rating of
switch shall be so chosen as to get complete protection by associated O/L relay or fuse under all normal /
abnormal conditions such as full load, overload, locked rotor, short circuit. The incoming power supply
isolating switch shall be inter-locked with the control cabinet door so as to prevent opening of the door
when the switch is closed. Device for bypassing the door interlock shall also be provided. Switch handle
shall have provision for locking in both fully open and fully closed positions.
m) All fuses shall be of the HRC cartridge type mounted on plug in type of fuse base having a prospective
current rating of not less than 80 KA. Fuses shall be provided with visible operation indicators to show
that they have operated. All accessible live connections shall be adequately shrouded and it shall be
possible to change fuses with the circuit alive without danger of contact with live metal.
n) Contractor shall provide dry type transformers with class B insulation for control power supply, lighting
and space heating. Control supply will be 240 V AC. Transformer for control supply shall be provided
with a control tap at 110 V which will be earthed. Power and control supply to individual drives and users
shall be distributed with separate isolating switches and primary and secondary fuses.
o) All push buttons shall be of push to actuate type having 2 “NO” and 2 “NC” self reset contacts. They shall
be provided with integral escutche on plate engraved with their functions. Push button contacts shall be
rated for 5 Amp at 415 V AC and 1 Amp. Inductive breaking at 250 V, DC. Mushroom type emergency
push button to open the main contactor shall be provided in the operator’s cabin and two on the bridge
platform within easy reach indicating lamps shall be of the filament type and low watt consumption lamps
shall be provided with series resistors.
p) Strip type space heaters of adequqte capacity shall be provided inside in each cabinet.
q) Control cabinets shall be supplied completely wired. All wiring shall be carried out with 650 V grade PV
Cinsulated, stranded conductors. Power circuits shall be wired with stranded aluminium conductors of
adequate sizes to suit the rated circuit shall be wired with stranded copper conductors of sizes not small
than 1.5 Sq.mm. Control circuits shall be isolated from power circuits.

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r) Cab shall be controlled by a semi-automatic floor selection control system. Cab shall be furnished with
240 Volt grounding type receptacle, emergency alarm push button with a normally open contact rated 0.5
ampere at 220 VDC volts, indicating light, limit switches, and all other necessary control devices required
to ensure safe and continuous cab operation. One trailing cable shall connect the cab main control panel
to the auxiliary panel at ground level. Cable shall supply the cab with all power requirements. Cable
guides shall be installed at every 6 metres to avoid entanglement of this cable. Control signals between
the auxiliary panel at ground level and the main control panel on the cab. Will be provided with the tone
frequency receiver. However control and interlocks from the landings shall be connected to the auxiliary
panels located at ground level through fixed armoured cables. The power and control cables and training
power cables shall be FRLS type.
s) Each landing assembly shall include a limit switch for door interlock and push buttom control station
installed and wired to a landing junction box.
t) Cable trolley with cable guides for recoil of cable on to cable reel to maintain electrical power service to
all elevator component through out the limits of travel.
u) Contractor shall furnish, install, and connect a system equipment ground to the Owner’s existing chimney
ground system. System equipment ground shall electrically connect panels and junction boxes which
contain electrical devices, motors, and elevator platforms and support structure. Raceway system shall
not be considered as an equipment ground.
v) All enclosures containing electrical devices shall be provided with 240 Volt, single-phase space heaters
with adjustable thermostat control.
w) All power cables and race way shall be furnished and installed by the Contractor for interconnection of
the main control panel, auxiliary panel and landing junction boxes etc. Conductors included in the cable
shall be as required to energise all electrical equipment furnished with the elevator. Transmission of
alarm signals is done by means of tone frequency equipment. Hence communication conductors are not
required.
6.03.07 Electric Motor
Elevator drive motor shall be squirrel-cage induction type designed and fabricated to conform to the
requirements indicated on the drawings.
Motor shall be designed for operation at the required speed: 415 Volts, 3 phase, 50 hertz. And shall be
suitable for full voltage starting, S4 duty class as per IS-4722 with CDF of 25% and maximum number
of 120 starts per hour in 55 Deg. C ambient temperature. Motor shall be tested at the factory to
determine that it is free from electrical or mechanical defects.
Motor nameplate KW rating shall not be exceeded when the equipment is operating within the limits of
the maximum load requirements.
Motor shall have sealed Class B nonhygroscopic insulation IIS-325) or equivalent international
standard included two additional dips and bakes of epoxy varnish or vacuum impregnation. Insulation
system shall be the motor manufacturer’s standard premium insulation offering.
Motor shall be totally enclosed and furnished with cast iron frame, brackets, gasketed conduct box and
fan cover. Motor shall be furnished with grease prelubricated, double-shielded, anti-friction bearings
having life rating of not less than 42,500 hours under coupled service retirements. All exposed metal
surfaces shall be protected with a polyester paint or coating which is moisture and corrosion resisdtant.
Motor shall be provided with internal 240 Volt AC single-phase space heaters or an alternate heating
system to prevent condensation within the motor during extended periods of idleness. Motorheating
system shall be acceptable to the Engineer-in-Charge.
Motor and driven equipment shall be direct coupled or belted as required, and mounted on a common
baseplate with coupling or belt guard. Motor shall be completely assembled, lubricated, and ready for
operation.
Intent of these specifications is that the motor supplied be designed and constructed for the intended
service. Motor construction and duty cycle shall conform with all requirements of applicable safety
codes and standards for the service. For additional requirements Volume-IIF shall be referred to.

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6.08.08 Raceway
a) General
Complete raceway system for the elevator shall be furnished and installed in accordance with
this section and the Contractor’s shop drawings as reviewed and accepted by the Engineer-in-
Charge. The Contractor shall provide drawings for acceptance showing the routing of conduit
and wiring for the control circuits associated with the elevator.
Raceway system is defined to include conduit and all related materials and devices required to
support, secure and provide a complete system for support and protection of electrical cable
and wiring.
Raceway shall be furnished and installed as required to extend raceway which has been
installed under separate specifications for entry for circuits to the chimney facilities from
external plant area. Raceway shall be provided for all cable and wiring installed under these
specifications.
b) Materials
Raceway shall be rigid galvanized steel conduit, provided in accordance with IS-1653 (latest
edition).
Steel conduit, couplings, and elbows shall be hot-dip galvanized rigid mild steel. Each length
of threaded conduit shall be complete with a coupling on one end and a thread protector on the
other. Thread protector shall have sufficient mechanical strength to protect the threads during
normal handling and storage. Flexible conduits shall be plastic jacketed, liquid tight galvanized
steel.
Galvanised iron or galvanized cast steel fittings shall be used with galvanized steel conduit.
Fittings installed outdoors or in damp locations shall be sealed and gasketed. Outdoor fittings
shall be of heavy cast construction.
Bushings shall be provided at the termination of all conduit not terminated in hubs and
couplings, insulated bushings with insulating inserts metal housings shall be provided on
conduit 32 mm diameter and larger. Insulated bushings shall be grounding type standard
bushings shall be galvanized.
One interior and one exterior locknut shall be provided for all conduit terminations not provided
with threaded hubs and couplings. Lockouts shall be designed to securely bond the conduit to
the box when tightened. Locknuts shall be constructed that they will not be loosened by
vibration.
Raceway supports shall be galvanized steel materials. Hanger rods shall be 13 mm diameter
threaded steel rods. Supports for conduits in single runs or groups of two shall be one-hole
cast metal straps and clamps-backs unless other types are acceptable to the Engineer-in-
Charge. Supports for banks of three or more conduits shall be constructed of support
channels with associated conduits clips. Supports channels for galvanized steel conduit shall
be hot-dip galvanized after fabrication.
Junction box enclosure, type, and material shall be as indicated on the drawings or as stated in
these specifications. Junction boxes, pull boxes, and cabinets shall not have knockouts.
Junction boxes for indoor service shall be of sheet steel hot-dip galvanized after fabrication
and shall be dust resisting enclosure. Except as indicated otherwisde in these specifications,
all junction boxes for use in outdoor or damp locations shall be galvanized malleable iron or
equivalent cast ferrous metal. Junction boxes and outlet boxes installed on the exterior shall
be galvanized steel.

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Outlet boxes, switch boxes, and associated fittings shall be galvanized iron or equivalent cast
ferrous metal.
c) Installation
Contractor shall field route conduit according to the general routing indicated on the drawings
reviewed and accepted by the Engineer-in-Charge and shall coordinate conduit locations with
other equipment and structures. Wherever practical, conduit shall be routed so that, except
where it is changing elevation or being lowered to enter equipment, the lowest part of the
conduit, including its associated supports and appurtenances, is at least 2.05 metres above
the closest walking surface beneath it. Conduit, including its associated supports and
appurtenances, routed above work areas, walkways and platforms, shall be at least 2.05
metres above the closest walking surface beneath it may be routed a reasonable disdtance
away from the supporting wall of ceiling, so long as the specified support is provided,
interference with other equipment and structures is avoided, and the routing is acceptable to
the Engineer-in-Charge. Conduit including its associated supports and appurtenances, which
must be routed closer than 2.05 metres above the closest walking surface beneath it shall be
routed as closer than 2.05 metres above the closest walking surface beneath it shall be routed
on the inside wall of the concrete chimney. Conduit which is stubbed up shall remain plugged
until the conduit is extended. Conduit field routing shall be acceptable to ther Engineer-in-
Charge. Routing not acceptable shall be rerouted and replaced without expenses to the
Owner.
Moisture pockets shall be eliminated from conduits. If water cannot drain to the natural
opening in the conduit system, a hole shall be drilled in the bottom of a pull box or a “C-type”
conduit fitting provided in the lower part of the conduit run.
Metal conduit shall be joined by threaded conduit couplings with the conduit ends butted. Use
of running threads will not be permitted. Where metal conduit cannot be joined by standard
threaded couplings, conduit unions or split couplings may be used if both material and location
are acceptable to the Engineer-in-Charge. Only ground seat type watertight unions shall be
used where the union may be submerged.
Run of conduit shall not contain more than the equivalent of four quarter bends, including
those immediately at outlets or fittings. Bends in conduit shall be made without reducing the
internal diameter of the conduit. Use of a pipe tee or vise for bending conduit will not be
permitted. Inside radius of conduit bends shall be not less than six times the inside diameter of
the conduit. Conduits deformed or crushed in any way shall be removed from the job site.
Plane of all conduit ends shall be square with the center line. Where threads are required,
they shall be cut and cleaned prior to conduit reaming. Ends of all conduits shall be reamed to
remove all rough edges and burrs. Cutting oil shall be used in threading operations, the dies
shall be kept sharp, and provisions shall be made for chip clearance. All steel conduit, after
threading, shall be regalvanised by an acceptable galvanizing process. Contractor shall
supply this protective material and shall apply it in the field.
Conduit shall be securely fastened to all boxes and cabinets. Threads on metallic conduit
shall project through the wall of the box to allow the bushing to butt against the end of the
conduit. Lockouts both inside and outside shall then be tightened sufficiently to bond the
conduit securely to the box.
Precautions shall be taken to prevent the accumulation of water, dirt, or concrete in the
conduit. Conduit in which water or other foreign materials have been permitted to accumulate
shall be thoroughly cleaned or, where such accumulations cannot be removed by methods
acceptable to the Engineer-in-Charge, the conduit shall be replaced.
Equipment and devices which move in relation to the supply conduit due to vibration, normal
operation of the mechanism, or thermal expansion shall be connected to the supply conduit
using not more than 760 mm of flexible conduit adjacent to the equipment or device.

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Expansion fittings shall be installed between rigidly mounted fittings in vertical raceway.
Distance between expansion fittings in any individual raceway shall not exceed 15 metres.
All conduit runs shall be rigidly supported. Each conduit shall be supported within 300 mm of
junction boxes and fittings. Support spacing along conduit runs shall be as follows:
Conduit Size
Maximum Distance
Between Supports
Small than 40 mm dia. : 1.5 metres
40 mm dia. And larger : 3 metres
Cabinets and boxes shall be rigidly mounted. Mounted on concrete shall be with bolts and
expansion anchors. Mounting on steel shall be by drilled and tapped screw holes, or by
special support channels welded to the steel, or by both. Cabinets shall be leveled and
fastened to the mounting surface with not less than 7 mm air space between the enclosure and
mounting surface. All mounting holes in the enclosure shall be used. Except as prevented by
the location of other work, all junction boxes and outlet boxes shall be centered on structures.
Conduit openings in steel boxes shall be made with a hole saw or shall be punched. Cable
support boxes shall be installed to be accessible from platforms and to limit the distance
between vertical cable supports to the lengths specified as described in Clause 6.03.09.
Where supports for raceway, boxes, and cabinets are mounted on concrete surfaces, they
shall be fastened with expansion shell anchors with externally split expansion shells, single
cone expander and anchor break off grooved checking cones.
Contractor shall be responsible for all openings for passage of electrical raceways. Required
openings not provided during chimney construction shall be provided by the Contractor using a
hacksaw, a hole saw, or a core drill subject to the acceptance by the Engineer-in-Charge.
Opening in concrete for single conduits shall be cut by the Contractor with core drills and the
conduits shall be grouted in place after being installed.
Field cutting of grating will be allowed only where specially acceptable to the Engineer-in-
Charge. Alternate routing of raceways should be used to avoid conflict with grating. If held
cutting is absolutely necessary, the openings shall be made at divisions or ends of grating
sections. Openings shall be square and shall be neatly finished. Rough spots shall be ground
until smooth and regalvanised as required. Openings in grating shall be sawed, not burned.
Openings that have been cut through masonry or concrete for the passage of raceways shall
be finished by grouting around the conduis.
Welding shall completely fuse the welded member to the supporting steel and shall be neat in
appearance. Clamps shall be used for making attachments to structural steel for installation
purposes wherever possible. Welded lugs will be permitted only when specifically accepted by
the Engineer-in-Charge. All temporary supports which have been welded to the structural
steel shall be removed as promptly as possible. After removal, the roughened surface of the
steel shall be ground smooth and a protective primer paint applied equal to that which was
initially applied in the shop.
Unfinished runs of raceways shall not be used. Supports and connections for each raceway
run shall be completed prior to the pull-in of any pulling line or conductor.
6.03.08 PVC Insulated FRLS Cable
a) Materials

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Volume : II –F of this specification shall be referred for FRLS cable. Unless specified
otherwise, Contractor shall submit to the Engineer-in-Charge four copies of the
manufacturer’s test report on each cable furnished. Conductor accessories including terminal
materials like glands, lugs etc. makers, tying materials and cable support shall be furnished
and installed. Wire termination materials for conductors 10 Sq. mm and larger shall be
pressure or bolted type. Terminals for conductors smaller than 10 Sq. mm shall be an
insulated pressure connection in the shape of a ring.
b) Installation
Power and control cable shall be routed as required by the drawings. Cables pulled into the
wrong conduit or cut too short shall be replaced. Cables removed from one conduit shall not
be installed in another conduit.
Only lubricants recommended by the cable manufacturer and acceptable to the Engineer-in-
Charge shall be used.
Outside of each cable reel shall be carefully inspected and protruding nails, fastenings, or
other objects which might damage the cable shall be removed. Thorough visual inspection
for flaws, breaks, or abrasions in the cable sheath shall be made as the cable leaves the reel,
and the pulling speed shall be slow enough to permit this inspection. Damage to the sheath
or finish of the cable shall be sufficient cause for rejecting the cable. Cable damaged in any
way during installation shall be replaced by and at the expense of the Contractor.
Pulling tension of any cable shall not exceed the maximum tension recommended by the
cable manufacturer. Pulling mechanisms of both the manual and power types used by the
Contractor shall have the rated capacity clearly marked on the mechanism. Whenever the
capacity of the pulling mechanism exceeds the recommended pulling tension of the cable as
given by the cable manufacturer, a dynamometer shall be used to indicate the tension on the
cable and the indicator shall be constantly watched. If any excessive strain develops, the
pulling operation shall be stopped at once and the difficulty determined and corrected.
Extreme care shall be exercised during the installation of all cable to prevent tension and
bending conditions in excess of the manufacturer’s recommendations. Permanent radius of
bend after cable installation shall b e in accordance with the cable manufacturer’s
recommendations.
Cable supports and securing devices shall have bearing surfaces located parallel to the
surfaces of the cable sheath and shall be installed to provide adequate support without
deformation of the cable jacket or insulation. Adequate cable end lengths shall be provided
and properly installed in junction boxes to avoid longitudinal strains and distorting pressures
on the cable at conduit bushings.
Final inspection shall be made after all cables are in place, and where supports and bushings
deform the cable jacket, additional supports shall be provided as directed by the Engineer-in-
Charge. Additional cable protection such as a wrapping of light rubber belting, friction tape, or
similar material, may be required. Cables in vertical runs shall be supported as indicated on
the drawings.
Not less than 8 mm shall be allowed in each 15 metres vertically supported length of
conductor for expansion and contraction.
Contractor shall identify the ends of all power and control circuits. He shall also identify all
circuits in pull boxes. Each maker shall bear the number of the corresponding circuit
according to the drawings.
Splices shall not be made in conductors.
Terminations shall be in accordance with the following requirements:

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i) Train cable in place and cut squarely to required length, Avoid sharp bends.
ii)
iii)
iv)
Remove necessary amount of cable jacket and insulation without damage to the
conductor.
Install terminals or connectors as required, ensuring a firm metal-to-metal contact.
If the connection requires insulation, (i.e. cable connects to insulated conductors),
apply three half-lapped layers of insulating tape over the joint, extending to two cable
diameters over the cable jacket and a similar distance over any other insulation or
connection requiring insulation.
6.03.09 Earthing
Insulated conductors shall be tested after installation with a 1000 volt megger or an eqivalent
testing device and shall indicate approximately infinite resistance between conductors of the
same circuit and between conductors and ground. Equipment and labour required for testing
shall be provided by the Contractor. Any circuit failing to test satisfactorily shall be replaced
or repaired and retested as directly by the Engineer-in-Charge.
a) General
Earthing system furnished and installed and include a complete earthing system for the
elevator. Earthing equipment and materials shall be furnished and installed in accordance with the
reference codes and standards these specification and the contractor’s shop drawings as reviewed and
accepted by the Engineer-in-Charge.
b) Materials
The earthing of all electrical items being supplied by the Bidder shall be in his scope. For earthing the
various equipment, conductor sizes shall be as listed below:
i) MCCs Motor above 90 KW : 50 x 6 Sq.mm G.I. flat
ii)
Motors above 30 KW, upto
75 KW and lighting panel/
control panels/auxiliary panels : 25 x 6 Sq. mm G.I. flat
iii) Motor above 5 KW upto 30 KW : 25 x 3 mm G.I. flat
iii)
Motors upto 5 KW and misc.
Small item like conduits,
Junction boxes etc.
The earthing strip/wire shall be connected to the earthing mat by the Bidder provided in the
chimney area. Clamps and other hardware of iron or steel used with the grounding system
shall be hot-dip galvanized. Bolts, washers and nuts shall be hot-dip galvanized steel.
Installation
Exposed conductors shall be installed inconspicuously in vertical or horizontal positions on
supporting structures. When located on irregular supporting surfaces or equipment, the
conductors shall run parallel or normal to dominant surfaces.
Conductors routed over concrete steel or equipment surfaces shall be kept in close contact
with those surfaces by using fasteners located at intervals not to exceed one (1) metre.

PEM-6666-0
TITLE SPECIFICATION NO. PE-TS-360-620-C001
TECHNICAL SPECIFICATION FOR
VOLUME: IIB
STACK ELEVATOR
SECTION C
REV 0 DATE
SHEET
OF
Damaged earth system conductors or cables shall be repaired or replaced by the Contractor as
directly by the Engineer-in-Charge.
Earth connections except equipment earthing connections shall be made by electric arc
welding. Bolted connections shall be used for earthing equipment.
Earthing bushings within all enclosures, including equipment enclosure, shall be wired together
and connected internally to the enclosure earthing lug at earthing bus with bare conductor.
Electrical equipment shall be earthed. Large equipment will be furnished with a earthing bus.
Most other equipment will be furnished with earthing pads and/or earthing lugs. Earthing
connection surfaces shall be cleaned immediately prior to connection. Contractor shall provide
all earthing material required but not furnished with the equipment. Where the earth conductor
is included with the power conductors in the motor circuit raceway a compression type earth
conductor termination shall be used and connected to the motor frame inside the motor
terminal housing. Where the earth conductor is not included with the power conductors in the
motor circuit raceway, the motor frame shall be earthed to the earth grid.
Suitable earthing facilities acceptable to the Engineer-in-Charge shall be furnished on motors
not so equipped. Earthing facilities shall consist of compression type earth conductor
termination bolted to the motor frame and providing a minimum of joint resistance. Conduit
system is not considered to be a earthing conductor. No earthing conductor shall be smaller in
size than 4 Sq. mm unless it is a part of an acceptance cable assembly.
7.00.0 INSPECTION AND TESTING
7.01.0 The following specific test as applicable shall be carried out by the Contractor as minimum
requirement for the elevators.
7.01.01 All materials used in manufacture of various components shall be of tested quality
and shall conform to relevant standards / specifications.
7.01.02 All welding shall be carried out as per welding procedures qualified as per ASME
Section-IX. Welding procedures shall be forwarded for approval. Only welders
qualified as per ASWME Section-IX shall be employed for welding.
7.01.03 All NOT operators should be qualified as per SNT-TC-IA.
7.01.04 All forgings shall be subjected to ultrasonic test to ensure free from internal defects.
7.01.05 All welds shall be subjected to dye-penetration test and visual examination.
7.01.06 All forged components shall be subjected to DP/MPI after machining.

PEM-6666-0
TITLE SPECIFICATION NO. PE-TS-360-620-C001
TECHNICAL SPECIFICATION FOR VOLUME II B
STACK ELEVATOR SECTION C SUB SECTION : III
REV 0 DATE
SHEET 1 OF 1
Data Sheet–A
1 Designation : Rack and Pinion type Stack Elevator
2 Type of loading : Passenger-cum-goods
3 Quantity : One (1) No.
4 Carrying Capacity : 400 Kg
5 Operating Speed : 40 m/min (Approx)
6 Dimension of lift and lift well/cut out : As per requirement (Bidder to furnish)
7 No. of landings : 07 Nos. including Ground
8 Total vertical travel : 215 m, to suit the chimney height
9 Electrical power supply system : 415 V, 3 ph, 4 wire, 50 Hz
10 Other accessories : As required

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
1.01.00 ELEVATOR PARTICULARS
i) Load Carrying Capacity in Kg
ii) Type of loading for which the
stack elevator is designed
iii) Type of stack elevator
iv) Rated Load in Kg
v) Speed in metre/minute
vi) Chimney height in metre
vii) Total travel height in metre
viii) No. of floors to be served
ix) Elevations of the floors to be served
x) Method of control
xi) Details of indicators and control
xii) Weight of cab complete without load in Kg
xiii) Weight of hoist cab in Kg
xiv) Efficiency of Elevator
1.02.00 GROUND ENCLOSURE
i) Size of the enclosure
(Length x breadth x height)
ii) Material of construction
iii) Size of landing entrance
iv) Method of door operation
v) Electrical & mechanical interlocking
Of the door provided.
vi) Method of fixing enclosure to chimney
vii) Any other details not covered above
1.03.00 LANDING ENCLOSURES
viii) Size of the enclosure
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
(Length x breadth x height)
ix) Material of construction
x) Size of landing entrance
xi) Method of door operation
xii) Electrical & mechanical interlocking
Of the door provided.
xiii) Method of fixing enclosure
xiv) Any other details not covered above
1.04.00 MAST
i) Material of mast
ii) Section of mast
iii) Size of each piece of mast
iv) Method of fixing of mast
v) Type of mast
1.05.0 CAB
i) Internal size
(Length x breadth x height)
ii) Material of construction
iii) Type of floor
iv) Size of the cab door
v) Method of operation of cab door
vi) Electrical & mechanical interlocking provided
vii) Escape hatch, electrically interlocked
viii) Guide roller and safety hooks provided
ix) Arrangement of light/fan inside the cab.
x) Indicators & controls inside the cab.
1.06.00 ELEVATOR DRIVE UNIT
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
i) Location of drive unit
ii)
Name of components of drive unit
1.07.00 DETAILS OF ELECTRIC MOTOR
i) Manufacturer
ii) Equipment driven by motor
iii) Type
iv) Frame size, type & designation
v) Maximum load considered for
Sizing of motor
vi) Margin considered for sizing motor
vii) Rated power in KW
viii) Service factor
ix) Speed in rpm
x) Rated voltage in V
xi) Current at rated voltage
- Full load
- Locked rotor
xii) Insulation class
xiii) Type of bearing and type of lubricant
xiv) Space heater rating
xv) Duration considered for specified
Ambient temperature
xvi) Applicable standard to which motor conforms
xvii) Degree of protection
xviii) Efficiency at rated output
xix) Power factor
xx) Type of mounting
1.08.00 DETAILS OF REDUCTION GEAR
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
i) Make
ii) Material of the gears and hardness in BHN
iii) Type of gear
iv) Gear ratio
v) Gear power transmitted
vi) Input and output speed
1.09.0 DETAILS OF DRIVE AND PINION
i) Material
ii) Hardness
iii) Fixing arrangement
1.10.0 DETAILS OF RACK
i) Material
ii) Hardness
iii) Fixing arrangement
1.11.00 SAFETY DEVICE
i) Make
ii) Type of safety device
iii) Speed at which the safety device
Come into action
iv) Method operation
v) Other details
vi) Remote control for testing
The safety device
1.12.00 BRAKES
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
i) Manufacturer
ii) Types of brakes provided
iii) Method of operation
iv) Interlocking if any
v) Electromagnetic brake and external
Manual brake release
vi) Degree of protection
1.13.00 CENTRIFUGAL BRAKE
i) Make
ii) Details
iii) Remote control for testing
The safety device provided.
iv) Any other details of drive unit
Not covered above.
1.14.00 BUFFERS
i) No. and location of the buffers provided
ii) Type of buffers
iii) If the buffers are spring type
Furnish the following:
- Diameter of the spring in mm
- Max. Compression under extreme cond.
- No. of spring coil
- Sectional dimension
- Material of spring
- Compression /unit load
1.15.00 POWER CABLES Fixed Trailing
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
i) Manufacturer
ii) Type and material
iii) Rated voltage
iv) Rated current
v) Type of insulation
vi) No. of strands
vii) No. of cores
viii) Short circuit current rating
ix) Resistance per 1000 metres
x) Applicable standards
1.16.00 CONTROL CABLES
xi) Manufacturer
xii) Type and material
xiii) Rated voltage
xiv) Rated current
xv) Type of insulation
xvi) No. of strands
xvii) No. of cores
xviii) Short circuit current rating
xix) Resistance per 1000 metres
xx) Applicable standards
1.17.00 CONDUITS/ACCESSORIES AND FITTINGS
i) Material
ii) Manufacturer
iii) Applicable standard
1.18.00 CONTACTORS
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
i) Make
ii) Type
iii) Applicable standards
iv) No. of poles
v) Rated voltage
vi) Rated frequency
vii) Rated current
viii) Closing coil
- Rated voltage
- Current consumption
- Power consumption in KW
- Insulation class for electromagnet
ix)
Rated duty
ix)
- Rated insulation category
- No. of operations per hour
- Rated breaking capacity
- Rated making capacity
- Short time rating in sec
Limits of operation
- Supply voltage variations (%)
- Supply frequency variations (%)
- Drop out voltage (%)
- Min. pick up voltage (%)
x) Thermal overload relay setting range available
xi)
Auxiliary contacts
- Numbers
- Current rating (Make and break)
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
xi) Rated utilization category as per IS 2459
xii)
Max. recommended back up HRC fuse size
1.19.00 FUSES
i) Make
ii) Type
iii) Continuous current
iv) Rated voltage
v) Rated frequency
vi) Rupturing capacity
vii) Mounting details
viii) Fixing and removing arrangement
ix) Visual indication for fuses
x) Applicable standards
1.20.00 INDICATING LAMPS
i) Make
ii) Type
iii) Rated voltage
iv) Rated power consumption in Watt
v) Permissible voltage variation
vi) Series resistance provided
1.21.00 PUSH BUTTONS
i) Make
ii) Type
iii) Rating
- Voltage
- Continuous current
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
iv) No. of aux. Contacts
- Normally open
- Normally closed
v) Contact rating
vi) Colours
vii) Mounting arrangement
1.22.00 OVER TRAVEL LIMIT SWITCH
i) Make
ii) Type
iii) Material of contacts
iv) Contact rating
v) Numbers furnished
1.23.00 CONTROL TRANSFORMER
i) Make
ii) Type
iii) Output rating (VA)
iv) Ratio
v) Class of insulation
vi) Max. temp rise of winding over
Specified ambient temperature.
vii) One minute power frequency test voltage
viii) Applicable standards
1.24.00 CIRCUIT BREAKER AND ISOLATOR
i) Make
ii) Type
iii) Current rating in amps
iv) Interruption duty
v) Max. breaking capacity
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
vi)
vii)
Operating voltage of tripping and closing coils
Max. permissible variation of operating voltage
1.25.00 RACEWAY
i) Raceway as per specification
ii) Material of
- Indoor fittings
- Outdoor fittings
- Raceway support
- Junction boxes
1.26.0 EARTHING
i) Earthing conductor
- Size
- Material
ii)
iii)
Material of earthing cable
Clamps. Bolts, washers, nuts and another
Hardware of iron steel are galvanized.
1.27.00 MOTOR STARTER
i) Make & Size
ii) Rating]
iii) Mechanically latched type
iv) Single phase prevention feature provided
v) Degree of protection
1.28.00 DETAILS OF CONTROL PANELS
i) No. of panels
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

Title
Spec. No.: PE-TS-360-620-C001
STACK ELEVATOR Volume II B SUB SECTION III
DATA SHEET ‘B’ Sheet of
ii) Type of enclosures (Degree of protection)
iii) Thickness of sheet metal
iv) Painting
- Colour
- Finish
v) Cable entry
vi) Manufacturer
Name of Bidder / Vendor
Project
Revision No. 0 1 2 3 4 5
Signature of Bidder / Vendor /
Authorised Representative
Date

TITLE: 1X250 MW EXTENSION UNIT-8 AT
DURGAPUR PROJECTS POWER STATION
TECHNICAL SPECIFICATION
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - D SUB SECTION :I
REV.NO. 0
SHEET
OF
THE DURGAPUR PROJECTS
LIMITED
DURGAPUR PROJECTS POWER STATION
1 x 250 MW EXTENSION UNIT- 8
VOLUME – II B
SECTION – D
SUB SECTION I
TECHNICAL SPECIFICATION
CIVIL , STRUCTURAL & ARCHITECTURAL WORKS
Bharat Heavy Electricals Limited
Project Engineering Management
PPEI Building, Power Sector,
Plot No. 25, Sector 16A,
Noida (U.P.)-201301

DCPL-K4A02
THE DURGAPUR PROJECTS LIMITED
NEW ADMINISTRATIVE BUILDING
DURGAPUR – 713 201
WEST BENGAL
INDIA
MAIN PLANT PACKAGE
SPECIFICATION NO.: MP-1
O V E R A L L C O N T E N T S
VOLUME-I : CONDITIONS OF CONTRACT
VOLUME-II : TECHNICAL SPECIFICATIONS
VOLUME-III : BID PROPOSAL SHEETS (TECHNICAL PART)
VOLUME-IV : BID PROPOSAL SHEETS (PRICE PART)
(PCA.774.S034sca)

DCPL-K4A02
VOLUME : II
TECHNICAL SPECIFICATIONS
(PCA.774.S034sca)

DCPL-K4A02
CONTENTS
VOLUME : II
TECHNICAL SPECIFICATIONS
VOLUME II-A : GENERAL AND MECHANICAL
VOLUME II-B/1 & : SPECIFICATIONS FOR ELECTRICAL EQUIPMENT
VOLUME II-B/2
& ACCESSORIES (IN TWO VOLUMES)
VOLUME II-C : SPECIFICATIONS FOR CONTROLS & INSTRUMENTATION
VOLUME II-D/1 & : SPECIFICATIONS FOR CIVIL, STRUCTURAL
VOLUME-II-D/2
AND ARCHITECTURAL WORKS (IN TWO VOLUMES)
VOLUME II-E : TENDER DRAWINGS
(PCA.774.S034sca)

DCPL-K4A02
VOLUME : II-D/2
TECHNICAL SPECIFICATIONS
FOR
CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS
(PCA.774.S034sca)

DCPL-K4A02
CONTENTS
VOLUME : II-D/2
SECTIONS
SPECIFICATIONS FOR CIVIL, STRUCTURAL AND
ARCHITECTURAL WORKS
DESCRIPTION
SECTION-I : AREA GRADING
SECTION-II : EARTHWORK IN EXCAVATION AND BACKFILLING
SECTION-III : CEMENT CONCRETE (PLAIN & REINFORCED)
SECTION-IV : FABRICATION OF STRUCTURAL STEELWORK
SECTION-V : ERECTION OF STRUCTURAL STEELWORK
SECTION-VI : R. C. MULTIFLUE STACK ( REFER ANNEXURE A)
SECTION-VII : ROADS AND DRAINS
SECTION-VIII : MASONRY AND ALLIED WORKS
SECTION-IX : FINISH TO MASONRY AND CONCRETE
SECTION-X : FLOOR FINISH AND ALLIED WORKS
SECTION-XI : FALSE FLOORING
SECTION-XII : CARPENTERY AND JOINERY
SECTION-XIII : SUSPENDED CEILING
SECTION-XIV : METAL DOORS, WINDOWS, VENTILATORS, LOUVRES
ETC.
SECTION-XV : GLASS AND GLAZING
SECTION-XVI : ROLLING STEEL SHUTTERS AND GRILLS
SECTION-XVII : MISCELLANEOUS METAL
SECTION-XVIII : PAINTING, WHITEWASHING, POLISHING ETC.
SECTION-XIX : ROOF WATERPROOFING,INSULATION AND ALLIED WORKS
SECTION-XX : SHEETWORK IN ROOF AND SIDING
SECTION-XXI : WATER SUPPLY
SECTION-XXII : DRAINAGE AND SANITATION
SECTION-XXIII : ANTI-TERMITE TREATMENT
SECTION-XXIV : SANDWICH METAL CLADDING (REFER ANNEXURE B)
(PCA.774.S034sca)

DCPL-K4A02
VOLUME : II-D/2
SECTION-I
TECHNICAL SPECIFICATION
FOR
AREA GRADING
(PCA.774.S034sca)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D/2/S-I : 1
2.0.0 GENERAL V.II-D/2/S-I : 1
3.0.0 EXECUTION V.II-D/2/S-I : 4
4.0.0 TESTING AND ACCEPTANCE V.II-D/2/S-I : 18
CRITERIA
5.0.0 INFORMATION TO BE SUBMITTED V.II-D/2/S-I : 19
(PCA.774.S034sca)

DCPL-K4A02
VOLUME: II-D/2
SECTION-I
TECHNICAL SPECIFICATION
FOR
AREA GRADING
1.0.0 SCOPE
This specification shall govern all clearing, grubbing, excavating, area filling,
grading and compacting soils for areas designated on the drawings. The
work shall include clearing and grubbing, stripping and storage of top soil,
excavation, blasting (if required), hauling, dumping and spreading of soil,
undercutting to remove unstable soil areas, compacting existing soil
surfaces and bottom of excavated areas to receive fills, compacting
excavated areas for subgrade, placing and compacting soils in fills,
dealing with surface water, pumping to keep excavated areas and areas
to be filled dry, final grading of designated areas, disposing of unsuitable
and excess excavated materials and incidentals thereof.
2.0.0 GENERAL
2.1.0 Work to be provided for by the Contractor
The work to be provided for by the Contractor, unless specified otherwise,
shall include but not be limited to the following :
a) Furnish all labour, supervision, services, earth-moving
machineries and equipment, compaction plant and equipment,
tools and plants, survey instruments, transportation etc. required
for the work.
b) Prepare and submit working drawings showing the approaches,
slopes, berms, sumps for dewatering, space for temporary
stacking of spoils, disposal area, borrow pits, fencing etc. and all
other details as may be required by the Engineer.
c) To carry out and submit to the Engineer, results of soil
compaction tests whenever required by the Engineer to assess the
degree of compaction.
d) If blasting is resorted to, necessary licenses to be procured from the
proper authorities.
2.2.0 Work to be provided for by others
No work under this specification will be provided by any agency other than
the Contractor unless specifically mentioned elsewhere in the Contract.
2.3.0 Codes and Standards
(PCA.774.S034sca) V.II-D2/S-I : 1

DCPL-K4A02
All work under this specification, unless specified otherwise, shall
conform to the latest revision and/or replacements of the following or any
other relevant Indian Standard Specifications and Codes of Practice. In
case any particular aspect of work is not covered specifically by Indian
Standard Specification any other standard practice as may be specified by
the Engineer shall be followed :
IS : 1200 : Method of Measurement of Building and Civil
Engineering work, Part-I Earthwork
IS : 2720 : Determination of Moisture Content
(Part-II)
IS : 2720 : Grain Size Analysis
(Part-IV)
IS : 2720 : Determination of Moisture Content/Dry
(Part-VII)
IS : 2720 : Determination of Moisture Content/Dry
(Part-VIII)
IS : 2720 : Determination of Density Index (Relative
(Part-XIV)
IS : 2720 : Determination of Dry Density, in place,
(Part-XXIV)
IS : 2720 : Determination of Dry Density of Soils,
(Part-XXVIII)
IS : 3764 : Safety Code for Excavation Work
IS : 4081 : Blasting and related drilling operations
IRC : SP-11 : Hand book of quality control for construction of roads
and runways
IRC : 36 : Construction of Earth Embankments for Road Work
2.4.0 Conformity with Designs
The Contractor shall carry out the work as per the drawings issued to him
and/or Contractor's drawings which are approved by the Engineer and/or
the Engineer's instructions.
2.5.0 Materials to be used
(PCA.774.S034sca) V.II-D2/S-I : 2

DCPL-K4A02
2.5.1 General
All materials required for the work shall be of best commercial variety and
as approved by the Engineer.
2.5.2 Borrow Material
Borrow material required for area filling shall be excavated from approved
locations and levels, and shall consist of selected material, approved by
the Engineer, free from roots, vegetations, decayed organic matter, harmful
salts and chemicals, free from lumps and clods. Clean graded sand,
free from harmful and deleterious materials from approved quarries, shall be
used as fill material at places approved during detail engineering stage.
Necessary arrangement shall be done by the Contractor at his own cost for
locating and using the borrow areas as the source of supply of filling
material.
The depth of borrow pits should be so regulated that the borrow pits do
not cut an imaginary line having a slope of 1 vertical in 4 horizontal projected
from the edge of final section of the adjacent embankment of stack of
excavated soil.
2.6.0 Quality Control
The Contractor shall establish and maintain quality control for the various
aspects of the work, method, materials and equipment used. The quality
control operation shall include but not be limited to the following items of
work :
a) Lines, Levels and Grades : i) Periodic Surveys
ii)
Establishment of markers,
Boards etc.
iii) Checking levels and slopes
of the graded surface.
b) Area filling : i) Checking the quality of fill
material
ii) Checking moisture content
of the fill.
iii) Checking the degree of
compaction.
2.6.1 Any work which fails to conform to the specifications will be subject to the
issue of a Non-conformance Report in line with the Quality Control
Procedure to be implemented at site. Corrective or remedial action, design
modifications or product rejection will be reviewed in accordance with the site
(PCA.774.S034sca) V.II-D2/S-I : 3

DCPL-K4A02
Quality Plan.
2.7.0 Information regarding Site Conditions
Boring and sub-surface data regarding the nature of soil, rock, sub-soil
water etc. shown on drawings or otherwise furnished to the Contractor
shall be taken as a guidance only and variation therefrom shall not affect
the terms of the Contract. The Contractor must satisfy himself regarding
the character and volume of all work under this contract and expected
surface, sub-surface and/or sub-soil water to be encountered. He must
also satisfy himself about the general conditions of site and ascertain the
existing and future construction likely to come up during the execution of
the Contract so that he may evolve a realistic programme of execution.
3.0.0 EXECUTION
3.1.0 General
The work shall be undertaken in accordance with the lines,
levels,grades and details shown on the drawings, specification and the
approved method of work.
The works shall be carried out in a workman like manner without
endengering the safety of nearby structures, roads, railway tracks,
cable, pipelines, etc. and without causing hindrance to construction
activities.
Suitable approaches, fencing, area lighting and temporary works required
for the works shall be provided by the contractor. Sturdy and elegent
fencing is to be provided around the top edge of the exavation as well as
the bottom of the fill at the surplus disposal area where damping from a
high bench is in progress, if directed by the Engineer. Adequate area
lighting shall be provided by the contractor, if night work is undertaken.
The Contractor shall submit a proposal covering the proposed
excavation and placement of fill material for approval of the Engineer.
The proposal shall include but not be limited to the following.
a) Mobilisation and demobilisation of plant
b) Proposed plant and equipment, labour resources & supervision.
c) Details of proposed method of clearing and grubbing for each area of
cut and fill.
d) Drawings showing the areas for placement of material.
e) Management of excavation and filling works i.e., control of setting out,
testing procedures, handling, temporary stockpiles, etc.
f) Temporary works proposals
(PCA.774.S034sca) V.II-D2/S-I : 4

DCPL-K4A02
g) Excavation, filling and compaction by mechanical plant
h) Dealing with surface water
i) Dewatering
3.2.0 Setting Out
3.3.0 Initial Levels
j) Disposal of materials
k) Safety precautions, fencing and lighting
l) Calculations as appropriate to support work proposal
The Contractor will prepare and submit to the Engineer, detailed drawings
of the excavation and filling work necessary, as proposed to be executed
by him, showing the dimensions as per drawings and specification, adding
his proposals for slopes, approaches, dewatering sumps, berms etc. On
receiving the approval from the Engineer with modifications and corrections if
necessary, the Contractor will set out the work from the control points
furnished by the Engineer and fix permanent points and markers for future
checking. These permanent points and markers will be checked by the
Engineer and certified by him after which the Contractor will proceed with
the work. Engineer shall be provided with necessary men, material and
instruments for such checking. It should be noted that this checking by
the Engineer prior to start of the work will in no way absolve the Contractor of
his responsibility of carrying out the work to true lines, levels and grades as
per drawing and subsequent corrections, if any. In case any errors are
noticed in the Contractor's work at any stage, the same shall be remedied by
the Contractor.
Initial levels either in a definite grid pattern or as directed by the Engineer
will be taken by the Contractor jointly with the Engineer over the original
ground prior to starting actual excavation work and after setting out.
These initial levels will be used for preparing cross-sections for volume
measurement or for cross-checking the depths obtained from tape
measurements. These initial levels and cross-sections shall be jointly
signed by the Contractor and the Engineer before commencement of work.
(PCA.774.S034sca) V.II-D2/S-I : 5

DCPL-K4A02
3.4.0 Clearing and Grubbing etc.
3.5.0 Classification
The area to be excavated or filled shall be cleared out of fences, trees,
logs, stumps, bush, vegetation, rubbish, slush, etc. and levelled up. Trees
upto 300 mm girth shall be uprooted. Trees above 300mm girth which
are required to be cut, shall be got identified by the Engineer and then
marked.
Felling of trees shall include taking out roots upto 600 mm below ground
level. After the tree is cut and roots taken out, the pot- holes formed shall be
filled with good earth in 250 mm layers and compacted to acceptable
degree unless directed by the Engineer otherwise. The trees shall be cut in
suitable pieces as instructed by the Engineer and then shall be transported
to the Owner's store or any other space as directed by the Engineer.
Before earthwork is started, all the spoils and unserviceable materials
and rubbish shall be burnt or removed from the site to approved disposal
areas as may be specified. Ash shall be spread or removed as directed by
the Engineer. Useful materials, saleable timber, firewood, etc. shall be the
property of the Owner and shall be stacked properly at the worksite in a
manner as directed by the Engineer.
Materials involved in earthwork shall be classified under the following
categories. No distinction will be made whether the material is dry or wet.
The Engineer's decision in regard to such classification shall be final and
binding on the Contractor :
a) Ordinary and hard soil
This shall include clay, silt, sand, moorum, shingle, kankar, gravel,
loam, peat, ash and other similar materials in soft, hard or dense
state which can generally be excavated with ordinary spade, pick
axe, shovel etc. and does not require the use of wedges,
pneumatic breaking equipment and/or blasting for removal. It
shall also include loose rock boulders present in the soil, with
dimensions not exceeding 500 mm in any direction. Breaking of
consolidated brick ballast and mud concrete shall be considered
equivalent to excavation work under this type of soil.
b) Soft and Decomposed Rock
This shall include rocks like chalk, slate, mica schist, laterite and
other similar materials which in the opinion of the Engineer is
rock, but does not require blasting for removal and could be
removed with picks, hammers, crow bars, wedges, pneumatic
breaking equipment etc. It shall also include boulders with
dimensions greater than 500 mm but not exceeding 1000 mm in any
direction. The mere fact that the Contractor resorts to blasting for
his own convenience shall not mean that the rock will be classified
as hard rock.
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c) Hard Rock
3.6.0 Earthwork in Excavation
3.6.1 General
This shall include rocks occuring in large masses which cannot
be removed except by blasting. Harder varieties of rock such as
trap, with or without veins and secondary mineral which in the
opinion of the Engineer require blasting for removal shall also be
considered as hard rock. It shall also include boulders bigger than
1000 mm in any direction. Construction in concrete, both reinforced
and unreinforced, which is required to be dismantled during
earthwork.
Before commencement of excavation the existing ground surface shall be
cleared in accordance with Clause no. 3.4.0.
All excavation shall be done to the minimum dimensions as required for
safety and working facility. Prior approval of the Engineer shall be obtained
by the Contractor, in each individual case, for the method he proposes to
adopt for the excavation including dimension, side slopes, dewatering,
disposal, etc.
This approval, however, shall not in any way make the Engineer
responsible for any consequent loss or damage. The excavation must be
carried out in the most expeditious and efficient manner.
Prior to starting the excavation, the ground level at the location shall be
checked jointly with the Engineer.
The rough excavation may be carried upto a maximum depth of 150 mm
above the final level. The balance shall be excavated with special care.
If directed by the Engineer, soft and undesirable spots shall be removed
even below the final level.
3.6.2 Excavation in Ordinary Soil, Hard Soil
and Soft and Decomposed Rock
The excavation in ordinary soil, hard soil and soft and decomposed rock
shall be carried out as per the approved proposal, modified and corrected
where necessary by the Engineer. The work shall be carried out in a
workmanlike manner without endangering the safety of nearby structures or
roads, railway tracks, cables, pipelines etc. if any, and without causing
hindrance to other activities in the area. As the excavation reaches the
required dimensions, lines, levels and grades, the work will be checked by
the Engineer thoroughly and the balance work will be carried out carefully
to avoid any over-excavation.
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On completion, the work will be finally checked and approved by the
Engineer. In case where excavation in soil, soft and decomposed rock
and/or hard rock are involved, the soil or soft and decomposed rock layers,
shall be removed by turn and levels of the underlying rock surfaces observed
to enable measurements. Further work shall be resumed after getting
clearance from the Engineer.
3.6.3 Excavation in Hard Rock
3.6.4 Blasting
3.6.4.1 General
Overburden, if any, consisting of top soil, ordinary and hard soil, soft
and decomposed rock as per classification of soil, which do not require
blasting shall be completely stripped off and the levels of the hard rock
surface shall be taken to enable measurement. Further work in hard rock
shall be resumed after clearance from the Engineer.
Personnel deployed for rock excavations shall be protected from all
hazards such as loose rock/boulder rolling down and from general slips of
excavated surfaces. Where the excavated surface is such that it is not
stable against sliding, necessary supports, props, bracings or bulkheads
shall be provided and maintained during the period of construction. Where
danger exists of loose rock/boulder falling from the excavated surfaces
deeper than 2 metres, steel mesh anchored to the lower edge of
excavation and extending over and above the rock face, adequate to
retain the dislodged material shall be provided and maintained.
In case where blasting, though otherwise required, is prohibited for any
reasons, the excavation shall be carried out by chiselling, wedging or
any other approved method. All loose or loosened rock in the sides shall be
removed by barring, wedging, etc.
Excavation shall be continued in hard rock to such widths, lengths,
depths and profiles as are shown on the drawings or such other lines and
grades as may be specified by the Engineer. 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 for the excavation, in the soundest possible condition.
The quantity and strength of explosive used, shall be such as will neither
damage nor crack the rock outside the limits of excavation. All
precautions, as directed by Engineer, shall be taken during the blasting
operations and care shall be taken that no damage is caused to adjoining
buildings or structure as a result of blasting operations. In case of damage
to permanent or temporary structures, Contractor shall repair the same
to the satisfaction of Engineer. 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.
Unless otherwise stated herein, I.S. Specification IS:4081 "Safety Code for
Blasting & Related Drilling Operation" shall be followed.
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Specific permission of Engineer will have to be taken by Contractor
for blasting rock and he shall also obtain a valid Blasting licence from the
authorities concerned.
Contractor shall obtain necessary licence for storage of explosives,
fuses and detonators issued to him from owner's stores or from supplier
arranged by him, from the authorities dealing with explosives.
The fees, if any, required for obtaining such licence, shall be borne by
Contractor. Contractor shall have to make necessary storage facilities for
the explosives etc. as per rules of local, State and Central Govt.
authorities and statutory bodies/regulations.
In no case shall blasting be allowed closer than 30 metres 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.
Contractor shall employ a competent 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.
Before any blasting is carried out, Contractor shall intimate Engineer 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.
The blasting of rock near any existing buildings, equipments 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
M.S. plates with adequate dead weight over them. Blasting shall be done
with small charges and where directed by Engineer, a trench shall have to
be cut by chiselling prior to the blasting operation seperating the area under
blasting from the existing structures.
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 overbreak limit of 75 mm shall be filled up as
instructed by Engineer, with concrete of strength not less than M 10.
Stepping in rock excavation shall be done by hand trimming.
Contractor shall be responsible for any accident to workmen, public or
Owner'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.
Storage, handling and use of explosives shall be governed by the current
explosive rules laid down by the Central and the State Governments. The
Contractor shall ensure that these rules are strictly adhered to. The
following instruction, wherever found in variance with the above rules, shall
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3.6.4.2 Material
be considered as superceeded by the above rules.
No child under the age of 16 and no person who is in a State of
intoxication shall be allowed to enter the premises where explosives
are stored nor they shall be allowed to handle the explosives.
All materials such as explosives, detonators, fuses tamping materials
etc. are proposed to be used in the blasting operations shall have the prior
approval of the Engineer.
Only explosives of approved make and strength are to be used. The fuses
known as instantaneous fuse must not be used.
The issue of fuse with only one protective coat is prohibited. The fuse shall
be sufficiently water resistant as to be unaffected when immersed in water
for thirty minutes. The rate of burning of the fuse shall be uniform and not
less than 4 seconds or inch of length with 10% tolerance on either side.
Before use, the fuse shall be inspected and moist damaged or broken
ones discarded. The rate of burning of fuses or when they have been in
stock for long shall be tested before use.
The detonators used shall be capable of giving an effective blasting of
the explosives, moist; and damaged detonators shall be discarded.
3.6.4.3 Storage of Explosive
Storage of explosives shall be governed by the current Explosive Rules.
Explosives shall be stored in a clean, dry, well ventilated magazine to be
specially built for the purpose. Under no circumstances should a
magazine be erected within 400 m of the actual work site or any source of
fire. A space surrounding the magazine shall be fenced in. The ground
inside the fence shall be kept clear and free from trees, bushes etc. The
admission to this fenced space shall be by one gate only and no person
shall be allowed inside this fence without permission of the Officer-incharge.
The clear space between the fence and the magazine shall not be
less than 90m. The megazine shall be perfectly well drained.
Two lightning conductors shall be provided to the magazine, one at each
end. The lightning conductors shall be tested once in every year.
Fuses and detonators shall be stored in separate magazines. However,
detonators can be kept in an annexe adjoining the magazine provided
that their number does not exceed 25,000 and that the annexe is so
constructed that not less than 60 cm masonry and 100 cm of air space shall
intervene between any detonators in such annexe and the interior of the
main magazine. Cases containing explosives are not to be opened in
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a magazine.
Explosive in open cases are not to be received into a magazine.
Explosives which appear to be in a damaged or dangerous condition are
not to be kept in any magazine, but must be removed without delay to a
safe distance and destroyed.
Persons entering the magazine, must put on the magazine shoes which
shall be provided at the magazine for this purpose and should be careful :
Not to put their feet on the clean floor unless they have the magazine
shoes on.
Not to allow the magazine shoes to touch the ground outside the clean
floor.
Not to allow any dirty or grit to fall on the clean floor.
Persons with bare feet, shall before entering the magazine dip their feet
in water and then step direct from the tub over the barrier (if there be one)
on to the clean floor.
A brush broom shall be kept in the lobby of the magazine for cleaning
out the magazine, on each occasion if it is opened for the receipt, delivery
or inspection of explosives.
No matches or inflammable materials shall be allowed inside the
magazine. Illumination shall be obtained from an electric storage battery
lantern. No smoking shall be allowed within 100 m of a magazine.
No person having article of steel or iron on him shall be allowed to enter the
magazine.
Oily cotton, rag waste and articles liable to spontaneous ignition shall not be
allowed inside the magazine.
Workmen shall be examined before they enter the magazine to see that
they have none of the prohibited articles on their person.
The mallets, levers, wedges etc. for opening barrels or cases are to be of
wood. Inside a magazine the cases of explosives are to be carried by hand
and shall not be rolled or dragged. Explosives which have been issued
and returned to the magazine are to be issued first; otherwise those which
have been longest in store are to be issued first.
Cases of explosives must be kept clear of the walls and floors for free
circulation of air on all sides, special care is to be taken to keep the floor
free from grains of powder or portions of explosive matter fallen on the
floors due to leakage of cases etc.
The magazine shall not be opened during any duststorm or
thunderstorm nor any person shall be allowed in the vicinity of the
magazine.
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All magazines shall be officially inspected at definite intervals and a record
kept of the results of such inspections.
3.6.4.4 Carriage of Explosives
Detonators and explosives shall be transported separately to the blast site.
Explosives shall be kept dry and away from the direct rays of the sun, naked
lights, steam pipes or heated metal and other sources of heat. Before
explosives are removed, each cage or package is to be carefully examined
to ascertain that it is properly closed and shows no sign of leakage.
No person except the driver shall be allowed to travel on a vehicle
conveying explosives. No carriage or vessel shall be used for transporting
explosives unless all iron or steel therein with which a package containing
any explosive is likely to come in contact is effectually covered with lead,
leather, wood, cloth or other suitable material. No lights shall be carried
on the vehicle carrying explosives.
No operation connected with the loading, unloading and handling of
explosives shall be conducted after sunset.
3.6.4.5 Use of Explosives
The Contractor shall appoint an agent who shall personally superintend
the firing and all operations connected therewith.
The contractor shall satisfy himself that the person so appointed is fully
acquainted with the responsibilities imposed on him.
Holes for charging explosives shall be drilled with Pneumatic drills, the
drilling pattern being so planned that the rock pieces after blasting will be
suitable for handling.
The hole diameter shall be of such a size that cartridges can easily pass
down them and undue force is not required during charging. Charging
operations shall be carried out by or under the personal supervision of the
shotfirer. Wrappings shall never be removed from explosive cartridges.
Only wooden rods shall be used for loading and stemming shotholes. Only
one cartridge at a time shall be inserted and gently passed home with the
wooden tamping rod.
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Only such quantities of explosives as are required for the particular
amount of work to be done shall be brought to the works. Should any
surplus remain when all the holes have been charged, it shall be carefully
removed to a point at least 300 m from the firing point.
The explosives shall be fired by means of an electric detonator placed
inside the cartridge. For simultaneous firing of a number of charges the
electric detonators shall be connected with the exploder through the
shotfiring cable in a simple series circuit.
Due precautions shall be taken to keep the firing circuit insulated from
the ground, bare wires, rails, pipes or any other path of stray current and to
keep the lead wires short circuited until ready to fire. Any Kinks in detonator
leading wire shall be avoided.
For simultaneous firing of a large number of shotholes, use of cordtex
may be done. Cordtex shall be initiated by an electric detonator attached to
its side with adhesive tape, connecting wire or string.
All connections shall be made by the authorised shotfirer himself. The
shotfiring cable shall not be dragged along the ground to avoid possible
damage to the insulation. The shotfiring cable shall be tested for
continuity and possible short circuiting before it is used each time.
The shotfirer shall always carry the exploder handle on his person until he is
ready to fire shots. The number of shots fired at a time shall not exceed the
permissible limits.
Before any blasting is carried out, it shall be ensured that all workmen,
vehicles and equipment on the site are cleared from an area of minimum
300 metres radius from the firing point, or as required by statutory
regulations, at least ten minutes before the time of firing by sounding a
warning siren. The area shall be encircled by red flags.
At least five minutes after the blast has been fired in case of electric firing
or as stipulated in the regulations the authorised shotfirer shall return to the
blast area and inspect carefully and shall compare the number of blasts
planted/fired to the actual number of shorts heard and satisfy himself that
all blast have exploded. Withdrawl unexploded charges shall not be
permitted.
The unexploded charges shall be flooded with water and the hole shall be
marked distinguishable manner. Another hole shall be made by drilling a
parallel fresh hole not less than 450 mm from misfired hole and fired in
the usual way. The process shall be continued till the original blast is
exploded. The engineer shall also be informed by the Contractor of all
the cases of misfired/unexploded charges, their causes and steps taken.
The authorised shotfirer shall be present during removal of the debris liable
to contain unexploded explosives near the misfired hole. The workmen
shall not return to the site of firing until at least half an hour after firing.
Adequate safety precautions as per building bye-laws, safety code, statutory
regulations etc. shall be taken during blasting operations.
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3.6.5 Disposal
The excavated spoils will be disposed off within the specified lead in any
or a combination of some of the following manners, as directed by the
Engineer :
a) By stacking separately the materials suitable for area filling and
materials not suitable.
b) By stacking it temporarily for use in backfilling at a later date.
c) i) By either spreading, or
ii)
Spreading and compacting at designated filling areas and/or
disposal areas.
3.6.6 Dewatering
All areas shall be kept free of water. Grading in the vicinity of excavations
shall be controlled to prevent surface water running into excavated areas.
The Contractor shall remove by pumping or other means approved by the
Engineer, any water inclusive of rain water and subsoil water accumulated in
the area. Method of dewatering shall be got approved by the Engineer.
3.6.7 Dealing with Surface Water
All working areas shall be kept free of surface water as far as reasonably
practicable. Works in the vicinity of cut areas shall be controlled to
prevvent the ingress of surface water.
Working surfaces shall be formed to such falls to shed water and prevent
ponding.
No works shall commence until surface water streams have been
properly intercepted, redirected or otherwise dealt with.
Where works are undertaken in the monsoon period, the Contractor may
need to construct temporary drainage systems to drain surface water from
working areas.
3.7.0 Treatment of Slips
The Contractor will take all precautions to avoid high surcharges and
provide proper surface drainage to prevent flow of water over the sides.
These precautions along with proper slopes, berms, and control of ground
water should cause no slips to occur. If however slips do occur due to
causes beyond control of the Contractor, the same shall be removed by
him.
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3.8.0 Earthwork in Filling
3.8.1 Area Filling for Grading
The material to be used for area filling shall be selected material
capable of being compacted to the requirements stated herein below and
approved by the Engineer, obtained directly from excavation for area
grading, from nearby areas where excavation work by the same agency is
in progress, from temporary stacks of excavated spoils or from borrow
pits in selected areas designated/approved by the Engineer. The quality
of the material shall conform to that mentioned in clause 2.5.2 of this
specification.
Where excavated material is mostly rock, the boulders shall be broken
into pieces not longer than 150 mm size, mixed with properly graded
fine material consisting of murum or earth to fill up the voids and the
mixtures used for filling.
If any material is rejected by the Engineer, Contractor shall remove the
same forthwith from the site at no extra cost of the owner. Surplus fill
material shall be deposited/disposed of as directed by the Engineer after the
fill work is completed.
No earthfill shall commence until surface water discharges and streams
have been properly intercepted or otherwise dealt with as directed by the
Engineer.
Before commencement of area filling the existing top soil shall be removed
upto a minimum depth of 150 mm, or more, as directed by the Engineer
in order to clear the surface of undesirable materials. After this the
filling operation shall be performed with earth in layers not exceeding 250
mm, loose thickness. Successive layers shall not be placed until the
layer under construction has been thoroughly compacted to the
specified requirements as given below and got approved by the Engineer.
a) Each layer of earth of cohesive in nature shall be compacted to 90%
of proctors dry density unless otherwise permitted/directed by
the Engineer.
b) Each layer of earth of non-cohesive in nature shall be compacted
to minimum 75% relative density unless otherwise permitted/directed
by the Engineer. Each shall be compacted with approved machine
(mechanical plant) and usually manual compaction shall not be
allowed unless specifically permitted by the Engineer. The
original ground formation and each fill layer shall be compacted by
rollers as described below with a maximum of six posses of 8/10
tonne roller.
i) When the optimum moisture content of soil is relatively high, a
pneumatic tyred roller (type pressure 3.0 - 3.5 kg/sq.cm) shall
be considered to give better performance for mechanical
compaction.
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ii)
When the optimum moisture content of soil is relatively low, a
vibrating roller shall be considered to give better
performance for mechanical compaction.
Since the degree of compaction depends on the moisture content of the soil,
a close watch shall be kept on this aspect and corrections done to
optimise the moisture content. The adequacy of the compaction and
moisture content of the soil shall be determined by performing field density
tests and other tests as and when directed by the Engineer and shall
conform to the stipulations laid down in IS:4701.
The cohesionless soil to be used for area filling, should be placed in fully
saturated condition to obtain the maximum possible density. The saturation
moisture content shall be determined by laboratory tests prior to
commencement of work.
Field compaction test shall be carried out at different stages of filling and
also after the fill to the entire height has been completed.
When density measuements reveal soft areas in the construction, further
compaction shall be undertaken at the contractor's cost as directed by the
Engineer. If the required compaction is then not achieved the material in
the soft area shall be removed and replaced by approved material and
compacted in accordance with this specification all to the contractor's
account.
The fill shall be carried out to such dimensions and levels as indicated on
the drawings after the stipulated compaction. The fill will be considered as
incomplete if the desired compaction has not been obtained.
If so specified, the rock as obtained from excavation may be used for filling
and levelling to indicated grades without further breaking. In such an
event, filling shall be done in layers not exceeding 50 cms. 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 tonne roller. No less than 12 passes of the roller shall
be accepted before subsequent similar operations are taken up.
3.8.2 Filling in Disposal Areas
Excavated materials if not used in area filling, will be disposed of in
designated disposal areas as directed or as indicated in the drawings. The
earth shall not be dumped haphazardly but shall be spread in horizontal
layers not exceeding 500 mm in thickness and nominal compaction done to
the satisfaction of the Engineer.
All clods shall be broken before placing the fill. Earthmoving machinery
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including dumpers, dozers and trucks shall be allowed to ply over the fill to
permit compaction to take place.
In wide areas rollers may be employed and nominal compaction done to the
satisfaction of the Engineer.
3.9.0 Compaction Control
The density of each layer of compacted soil shall be ascertained by testing
a number of samples. For this purpose the necessary arrangements for
soil testing at the site shall be made by the Contractor in accordance
with these specifications and as directed by the Engineer.
The Contractor shall arrange the provision of the field laboratory including
the testing equipment and a suitable motor vehicle. He shall also supply
all consumable materials such as kerosene, spirit, gas and sample bags as
required.
All soil testing is to be carried out by a competent and suitable qualified
engineering testing firm. The Contractor is to obtain the Engineer's
approval for the firm to be used. The Contractor may undertake this work
with the Engineer's approval.
All density testing shall be carried out on a lot by lot basis. A lot shall be
considered to be a portion of work which is essentially homogeneous
with respect to material type general appearance response during
compaction, moisture condition during compaction, compaction process and
state of underlying material.
All fill testing shall be carried out in accordance with the recent editions
of relevant Indian Standards. The chainage and the off-set from the centre
line of the fill of each test sample shall be recorded and presented along with
the test results.
Each test lot shall be classified as cohesionless or cohesive. The
classification shall be determined by the Engineer based upon particle
size distribution. Cohesionless fill shall have 10% or less by mass of
particles finer than 0.075 mm. Otherwise fill shall be treated cohesive.
For cohesionless fill material, a representative laboratory sample obtained
from three field samples from each test lot shall be tested to determine
its maximum and minimum dry density. These reference values of dry
density shall be used to compute the density index (relative density) of
each of the field density test samples taken from the test lot.
For cohesive fill material, a representative laboratory sample obtained
from three field samples from each test lot shall be tested to determine its
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maximum dry density and optimum moisture content (OMC). These
reference values of dry density and moisture content shall be used to
compute the dry density ratio of each of the field density test samples taken
from that test lot.
The degree of compaction shall be determined by considering the mean
density of the samples in each test lot. The mean dry density shall be equal
to or exceed the minimum specified density. In no individual case shall
density be less than the minimum value specified by more than 2 percent,
otherwise further rolling shall be done at the appropriate locations.
The contractor shall lay a further layer or fill only after compaction or a
particular layer has been found and approved by the Engineer.
4.0.0 TESTING AND ACCEPTANCE CRITERIA
4.1.0 Soil Testing
The following tests shall be undertaken by the Contractor and results and
reports shall be submitted to the Engineer for approval. Test failures
are to be immediately notified to the Engineer, otherwise results to be
submitted within 24 hours of testing. Each layer of material shall be tested
for compaction.
Each layer is to be tested in a manner that is representative of its full
depth. The Engineer may at his discretion instruct the Contractor to
increase or decrease the frequency of testing.
a) Minimum one test per 500 cu.m. of soil coming out of the borrow
pits for determination of natural moisture contents in order to
evaluate how far the natural moisture content tallies with the
optimum value and whether further addition or reduction of water
content would be necessary. Test to be done in accordance with IS
: 2720 (Part-II).
b) Minimum two sets of laboratory tests per 8000 cu.m. of soil coming
out of the borrow pits for determination of dry density at optimum
moisture content. Test to be done in accordance with IS : 2720
(Part-VII, XIV, XXVIII, XXIV) as applicable.
c) Minimum two sets of test per 500 cu.m. of loose fill for
determination of moisture content just prior to compaction of area
filling. Test to be done in accordance with IS: 2720 (Part-II).
d) For each compacted layer, minimum one test per 2000 sq.m. of
compacted area for determination of moisture content and dry
density.
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e) Minimum two tests per 8000 cu.m. of soil for determination of soil
classification. Test to be done in accordance with IS: 2720 (Part-IV).
f) Minimum 10 (ten) density measurements shall be plotted to
establish moisture content-dry density relationship.
4.2.0 Acceptance Criteria
4.2.1 Excavation
4.2.2 Area-filling
On completion of excavation, the dimensions of the area will be checked
as per the drawings after the area is completely dewatered. The work will be
accepted after all undercuts have been set right and all over excavations
filled back to required lines, levels and grades by compacted earth. Over
excavation of the sides will be made good free of cost by the Contractor.
The excavation work will be accepted after the above requirements are
fulfilled & all temporary approaches encroaching inside the required
dimension of the excavation have been removed.
The degree of compaction required will be as per the stipulations laid down
in appropriate sections of this specification. The actual method for
measuring the compaction achieved will be as decided by the Engineer.
The work of area filling will be accepted after the Engineer is satisfied
with the degree of compaction achieved.
5.0.0 INFORMATION TO BE SUBMITTED
5.1.0 With Tender
Following details of Machineries, transport vehicles, equipment proposed
to be used for excavation, area-filling and compaction have to be submitted
along with the tender :
i) Equipment, machinery & earthmoving vehicles, available with the
Contractor and proposed to be used for excavation and haulage
giving details regarding make, model, capacity, year of manufacture,
numbers available for this contract and general condition.
ii)
iii)
Equipment proposed to be used for area filling and compaction giving
similar details as in item 5.1.0 (i) above.
Method of transportation.
5.2.0 After Award
After award of contract the successful tenderer shall submit the following for
approval and adoption:
a) Within 15 days of Award of the contract, the Contractor shall submit a
(PCA.774.S034sca) V.II-D2/S-I : 19

DCPL-K4A02
detailed programme of work as proposed to be executed giving
completion dates of excavation of the various areas and the time
required for area-filling and compaction. The programme should also
show how the excavation and area- filling quantities will be
balanced, minimising temporary stacking of spoils. It is to be noted
that the Engineer even after initial approval of the programme, may
instruct to enhance or retard the progress of work during the actual
execution, in order to match with overall construction schedule
without attracting any claims from the Contractor. The initial
programme being submitted by the Contractor should have
sufficient flexibility to take care of such reasonable variations.
b) Within 15 days of award, the Contractor shall submit drawings
showing details of slopes, approaches, sump pits, dewatering lines,
borrow pits, if any, fencing etc. for approval of the Engineer for
adoption.
(PCA.774.S034sca) V.II-D2/S-I : 20

DCPL-K4A02
VOLUME : II-D/2
SECTION-II
TECHNICAL SPECIFICATION
FOR
EARTHWORK IN EXCAVATION AND BACKFILLING
(PCA.774.S034sca1)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-II : 1
2.0.0 GENERAL V.II-D2/S-II : 1
3.0.0 EXECUTION V.II-D2/S-II : 3
4.0.0 TESTING AND ACCEPTANCE V.II-D2/S-II : 16
CRITERIA
5.0.0 INFORMATION TO BE V.II-D2/S-II : 17
SUBMITTED
(PCA.774.S034sca1)

DCPL-K4A02
VOLUME : II-D/2
SECTION-II
TECHNICAL SPECIFICATION
FOR
EARTHWORK IN EXCAVATION AND BACKFILLING
1.0.0 SCOPE
2.0.0 GENERAL
This specification covers excavation in all types of soil, soft and
decomposed rock not requiring blasting and rocks requiring blasting,
shoring, dewatering, filling around foundations and to grade, compaction of
fills and approaches, protective fencing, lighting, etc. relevant to structures
and locations covered under the scope of this contract.
2.1.0 Work to be provided for by the Contractor
The work to be provided for by the Contractor, unless specified
otherwise, shall include but not be limited to the following :
a) Furnish all labour, supervision, services including facilities as
required under statutory labour regulations, materials, scaffolds,
equipment, tools and plants, transportation, etc. required for the
work.
b) Prepare and submit working drawings showing the approaches,
slopes, berms, shoring, sumps for dewatering, including drains and
outfall for drainage, space for temporary stacking of spoils, disposal
area, fencing, etc. and all other details as may be required by the
Engineer.
c) To carry out sampling and testing and submit to the Engineer,
results of soil compaction tests whenever required by the Engineer
to assess the degree of compaction.
d) Construction, maintenance and removal after completion of magazine
of proper capacity as well as design for storing of explosives
required for blasting work to be carried out under the scope of this
tender including procurement of necessary licenses from proper
authorities.
2.2.0 Work to be provided for by others
No work under this specification will be provided by any agency other
than the Contractor unless specifically mentioned elsewhere in the
Contract.
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DCPL-K4A02
2.3.0 Codes and Standards
All works under this specification, unless specified otherwise, shall conform
to the latest revision and/or replacement of the following or any other Indian
Standard Specifications and Codes of Practice. In case any particular aspect
of work is not covered specifically by Indian Standard Specification any other
standard practice as may be specified by the Engineer shall be followed :-
IS:1200
(Part-I)
IS:2720
(Part-II)
IS:2720
(Part-VII)
IS:2720
(Part-xiv)
IS:2720
(Part-xxix)
IS:2720
(Part- xxviii)
IS:3764
IS:4081
IS:4701
Method of Measurement of Building and Civil
Engineering work; Part - I Earthwork.
Determination of Moisture Content
Determination of Moisture content / Dry Relation
using Light Compaction.
Determination of Density Index (Relative Density)
of cohesionless soils.
Determination of Dry Density , in place, by core
cutter method.
Determination of Dry Density of soils, in place,
by sand replacement methods.
Safety code for Excavation work.
Blasting and Related Drilling Operations
Earthwork on canals
2.4.0 Conformity with Designs
The Contractor is to carry out the work as per the drawings issued to him
and/or Contractor's drawings which are approved by the Engineer and/or the
Engineer's instructions.
2.5.0 Materials to be used
2.5.1 General
All materials required for the work shall be of best commercial variety
and approved by the Engineer.
2.5.2 Borrow Material
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DCPL-K4A02
Borrow material required for back-filling shall be excavated from approved
locations and levels, and shall consist of material, approved by the
Engineer, free from roots, vegetations, decayed organic matter, harmful salts
and chemicals, free from lumps and clods. If specified, clean graded sand
free from harmful and deleterious material from approved quarries, shall be
used as fill material.
2.6.0 Quality Control
The Contractor shall establish and maintain quality control for the various
aspects of the work, method, materials and equipment used. The quality
control operation shall include but not be limited to the following items of
work :
a) Lines, Levels and Grades : i) Periodic surveys
ii) Establishment of markers, boards etc.
b) Back-filling : i) Checking the quality of fill material
backfill
ii) Checking moisture content of the
2.7.0 Information regarding site conditions
iii) Checking the degree of compaction
Surface and Sub-surface data regarding the nature of soil, rock, sub-soil
water etc. shown on drawing or otherwise furnished to the Contractor
shall be taken as a guidance only and variation therefrom shall not affect
the terms of the contract. The Contractor must satisfy himself regarding
the character and volume of all work under this contract and expected
surface, sub-surface and / or sub-soil water to be encountered. He must also
satisfy himself about the general conditions of site and ascertain the existing
and future construction likely to come up during the execution of the
contract so that he may evolve a realistic programme of execution.
3.0.0 EXECUTION
3.1.0 Setting Out
The Contractor will prepare and submit to the Engineer, detailed drawings
of the excavation work as proposed to be executed by him showing the
dimensions as per drawings and specification adding his Proposals of slopes,
shorings, approaches, dewatering sumps, berms, etc. On receiving the
approval from the Engineer with modifications and corrections, if necessary,
the Contractor will set out the work from the control points furnished by the
Engineer and fix permanent points and markers for ease of future checking.
These permanent points and markers will be fixed at intervals prescribed by
the Engineer and checked by the Engineer and certified by him after which
the Contractor will proceed with the work. Engineer shall be provided with
(PCA.774.S034sca1) V.II-D2/S-II : 3

3.2.0 Initial Levels
DCPL-K4A02
necessary men, material and instructions for such checking. It should be
noted that this checking by the Engineer prior to start of the work will in no
way absolve the Contractor of his responsibility of carrying out the work to
true lines and levels and grades as per drawing and subsequent
corrections, if necessary, in case any errors are noticed in the Contractor's
work at any stage.
Initial levels of the ground either in a definite grid pattern or as directed
by the Engineer will be taken by the Contractor jointly with the Engineer over
the original ground prior to starting actual excavation work and after setting
out. These initial levels will be used for preparing cross-sections for volume
measurement or for cross-checking the depths obtained from tape
measurements.
All records of levels, measurements etc. and also any drawing, cross
section etc. made therefrom, shall be jointly signed by the authorised
representative of the contractor and the Engineer before the
commencement of work and they shall form the basis of all payments in
future.
3.3.0 Clearing and Grubbing, etc.
The area to be excavated or filled shall be cleared out of fences, trees,
logs, stumps, bush, vegetation, rubbish, slush, etc. and levelled up. Trees
upto 300mm girth shall be uprooted. Trees above 300 mm girth to be cut,
shall be approved by the Engineer and then marked. Felling of trees shall
include taking out roots upto 600 mm below ground level or 150 mm below
formation level whichever is lower. After the tree is cut and roots taken out
the pot-holes formed shall be filled with good earth in 250 mm layers and
consolidated unless directed by the Engineer otherwise. The trees shall be
cut in suitable pieces as instructed by the Engineer.
Before earthwork is started, all the spoils and unserviceable materials and
rubbish shall be burnt or removed from the site to approved disposal areas
as may be specified. Ash shall be spread or removed. Useful materials,
saleable timber, firewood, etc. shall be the property of the Owner and shall
be stacked properly at the worksite in a manner as directed by the
Engineer.
3.4.0 Classification
All earthwork shall be classified under the following categories :
No distinction will be made whether the material is dry or wet.
(PCA.774.S034sca1) V.II-D2/S-II : 4

DCPL-K4A02
a) Ordinary Soil
This shall comprise vegetable or organic soil, turf, sand, silt, loam,
clay, mud, peat, black cotton soil, soft shale or loose moorum, a
mixture of these and similar material which yields to the ordinary
application of pick and shovel, rake or other ordinary digging
implement. Removal of gravel or any other nodular material having
diameter in any one direction not exceeding 75 mm occurring in such
strata shall be deemed to be covered under this category.
b) Hard Soil
This shall include :
i) stiff heavy clay, hard shale, or compact moorum requiring
grafting tool or pick or both and shovel, closely applied ;
ii)
gravel and cobble stone having maximum diameter in any one
direction between 75 and 300 mm ;
iii) soling of roads, paths, etc., and hard core ;
iv)
macadam surfaces such as water bound, and bitumen/tar
bound;
v) lime concrete, stone masonry in lime mortar and brick work in
lime/cement mortar, below ground level ;
vi)
vii)
soft conglomerate, where the stones may be detached from the
matrix with picks ; and
generally any material which requires the close application of
picks, or scarifiers to loosen and not affording resistance to
digging greater than the hardest of any soil mentioned in (i)
and (vi) above.
c) Soft and Decomposed Rock
This shall include :
i) limestone, sandstone, laterite, hard conglomerate or other soft
or disintegrated rock which may be quarried or split with
crowbars ;
ii)
unreinforced cement concrete which may be broken up with
crowbars or picks and stone masonry in cement mortar below
ground level ;
iii)
boulders which do not require blasting having maximum
diameter in any direction of more than 300 mm, found lying
loose on the surface or embedded in river bed, soil, talus, slope
wash and terrace material of dissimilar origin ; and
(PCA.774.S034sca1) V.II-D2/S-II : 5

DCPL-K4A02
iv)
any rock which in dry state may be hard, requiring blasting, but
which when wet becomes soft and manageable by means
other than blasting.
d) Hard Rock (requiring blasting)
This shall include :
i) any rock or cement concrete for the excavation of which the
use of mechanical plant or blasting is required ;
ii)
iii)
reinforced cement concrete (reinforcement cut through but not
separated from the concrete) below ground level; and
boulders requiring blasting.
e) Hard Rock (blasting prohibited)
Hard rock requiring blasting as described under (d) but where blasting
is prohibited for any reason and excavation has to be carried out by
chiselling, wedging or any other agreed method.
In case of any dispute regarding classification, the decision of the
Engineer shall be final.
3.5.0 Excavation for Foundations and Trenches
3.5.1 General
All excavations shall be done to the minimum dimensions as required for
safety and working facility. Prior approval of the Engineer shall be obtained
by the Contractor, in each individual case, for the method he proposes to
adopt for the excavations including dimension, side slopes, shoring,
dewatering, disposal, etc. This approval, however, shall not in any way
make the Engineer responsible for any consequent loss or damage. The
excavation must be carried out in the most expeditious and efficient
manner.
All excavation in open cuts shall be made true to line, slopes and grades
shown on the drawing or directed by the Engineer. No material shall project
within the dimension of minimum excavation lines marked. Boulders
projecting out of the excavated surfaces shall be removed, if in the opinion of
the Engineer they are likely to be a hindrance to the workers.
Method of excavation shall be in every case subject to the approval of the
Engineer and the Contractor shall ensure the stability and safety of the
excavation, adjacent structures, services and works.
The Contractor shall have full responsibility of the stability of the
excavation and safety of the workmen. If any slip occurs, the Contractor
shall remove all slipped material from the excavated pit.
(PCA.774.S034sca1) V.II-D2/S-II : 6

DCPL-K4A02
All loose boulders, semi-detached rocks, not directly in excavation but so
close to the area to be excavated as to be liable, in the opinion of the
Engineer, to fall or otherwise endanger the workmen, equipment of the
work, etc., shall be stripped off and removed away from the areas of
excavation. The method used shall be such as not to shatter or render
unstable or unsafe the portion which was originally sound and safe. Any
materials not requiring removal as contemplated in the work, but which, in
the opinion of the Engineer, is later to become loose or unstable shall also
be promptly and satisfactorily removed as directed by the Engineer.
Prior to starting the excavation, the ground level at the location shall be
checked jointly with the Engineer.
The rough excavation may be carried upto a maximum depth of 150 mm
above the final level. The balance shall be excavated with special care. If
directed by the Engineer, soft and undesirable spots shall be removed even
below the final level. The extra excavation shall be filled up as instructed
by the Engineer.
If the excavation is done to a depth greater than that shown on the
drawing, or directed by the Engineer, due to the Contractor's fault, the
excess depth shall be filled up to the required level (with cement concrete
not leaner than 1:4:8 ordinary concrete or richer) as directed by the
Engineer in each individual case.
In formation of rock requiring blasting, those overcuts which are unavoidable
will be made up by ordinary cement concrete 1:2:4. All excavated materials
such as hard rock, boulders, bricks, dismantled concrete blocks, etc. shall be
stacked separately as directed by the Engineer and shall be the property of
the Owner.
3.5.2 Excavation in Ordinary Soil, Hard Soil
and Soft and Decomposed Rock
The excavation in ordinary soil, hard soil, soft and decomposed rock
will be carried out as per the approved proposal, modified and corrected
where necessary by the Engineer. The work will be carried out in a
workmanlike manner without endangering the safety of nearby
structures/services or works and without causing hindrance to other activities
in the area. As the excavation reaches the required dimensions, lines,
levels and grades, the work will be checked by the Engineer thoroughly and
the balance work will be carried out carefully to avoid any over-excavation.
On completion, the work will be finally checked and approved by the
Engineer. In certain cases, where deterioration of the ground, upheaval,
slips, etc. are expected, the Engineer may order to suspend the work at any
stage and instruct the Contractor to carry out the balance work just before
the foundation work of the structure can be started.
3.5.3 Excavation in Hard Rock
In case where excavation, both in ordinary soil and hard rock, are
involved, the ordinary soil comprising of soft, hard and dense soils (including
laterite formations) and rock including weathered rocks, lateritic rocks, etc.
(PCA.774.S034sca1) V.II-D2/S-II : 7

3.5.4 Blasting
3.5.4.1 General
DCPL-K4A02
which can be excavated without blasting, shall be completely stripped off.
Further work in hard rock shall be resumed after clearance from the
Engineer.
Personnel deployed for rock excavations shall be protected from all
hazards such as loose rock/boulder rolling down and from general slips of
excavated surfaces. Where the excavated surface is such that it is not
stable against sliding, necessary supports, props, bracings or bulkheads
shall be provided and maintained during the period of construction.
Where danger exists of loose rock/boulder falling from the excavated
surfaces deeper than 2 metres, steel mesh anchored to the lower edge
of excavation and extending over and above the rock face, adequate to
retain the dislodged material shall be provided and maintained.
In case where blasting, though otherwise required, is prohibited for any
reasons, the excavation shall be carried out by chiselling, wedging or any
other approved method.
Storage, handling and use of explosives shall be governed by the current
explosive rules laid down by the Central and the State Governments. The
Contractor shall ensure that these rules are strictly adhered to. The following
instruction, wherever found in variance with the above rules, shall be
considered as superseded by the above rules.
No child under the age of 16 and no person who is in a State of intoxication
shall be allowed to enter the premises where explosives are stored nor they
shall be allowed to handle the explosives.
3.5.4.2 Storage of Explosive
Storage of explosives shall be governed by the current Explosive Rules,
Explosives shall be stored in a clean, dry, well ventilated magazine to be
specially built for the purpose. Under no circumstances should a magazine
be erected within 400 m of the actual work site or any source of fire. A
space surrounding the magazine shall be fenced in. The ground inside the
fence shall be kept clear and free from trees, bushes etc. The admission to
this fenced space shall be by one gate only and no person shall be allowed
inside this fence without permission of the Officer-in-charge. The clear space
between the fence and the magazine shall not be less than 90m. The
mezzanine shall be perfectly well drained.
(PCA.774.S034sca1) V.II-D2/S-II : 8

DCPL-K4A02
Two lightning conductors shall be provided to the magazine, one at each
end. The lightning conductors shall be tested once in every year.
Fuses and detonators shall be stored in separate magazines. However,
detonators can be kept in an annexe adjoining the magazine provided that
their number does not exceed 25,000 and that the annexe is so
constructed that not less than 60 cm masonry and 100 cm of air space shall
intervene between any detonators in such annexe and the interior of the
main magazine. Cases containing explosives are not to be opened in a
magazine. Explosive in open cases are not to be received into a magazine.
Explosives which appear to be in a damaged or dangerous condition are not
to be kept in any magazine, but must be removed without delay to a safe
distance and destroyed.
Artificial light is not to be allowed in any magazine. No smoking shall be
allowed within 100 m of a magazine.
Magazine shoes without nails shall be used while entering the magazine.
The mallets, levers, wedges etc. for opening barrels or cases are to be of
wood. Inside a magazine the cases of explosives are to be carried by hand
and shall not be rolled or dragged. Explosives which have been issued
and returned to the magazine are to be issued first; otherwise those which
have been longest in store are to be issued first.
Cases of explosives must be kept clear of the walls and floors for free
circulation of air on all sides, special care is to be taken to keep the floor
free from grains of powder or portions of explosive matter fallen on the
floors due to leakage of cases etc.
The magazine shall not be opened during any duststorm or thunderstorm
nor any person shall be allowed in the vicinity of the magazine.
All magazines shall be officially inspected at definite intervals and a record
kept of the results of such inspections.
3.5.4.3 Carriage of Explosives
Detonators and explosives shall be transported separately to the blast site.
Explosives shall be kept dry and away from the direct rays of the sun,
naked lights, steam pipes or heated metal and other sources of heat. Before
explosives are removed, each cage or package is to be carefully examined to
ascertain that it is properly closed and shows no sign of leakage.
No person except the driver shall be allowed to travel on a vehicle conveying
explosives. No carriage or vessel shall be used for transporting explosives
unless all iron or steel therein with which a package containing any
explosive is likely to come in contact is effectually covered with lead,
leather, wood, cloth or other suitable material. No lights shall be carried on
the vehicle carrying explosives.
(PCA.774.S034sca1) V.II-D2/S-II : 9

DCPL-K4A02
No operation connected with the loading, unloading and handling of
explosives shall be conducted after sunset.
3.5.4.4 Use of Explosives
The Contractor shall appoint an agent who shall personally superintend
the firing and all operations connected therewith. The contractor shall satisfy
himself that the person so appointed is fully acquainted with the
responsibilities imposed on him.
Holes for charging explosives shall be drilled with Pneumatic drills, the
drilling pattern being so planned that the rock pieces after blasting will be
suitable for handling.
The hole diameter shall be of such a size that cartridges can easily pass
down them and undue force is not required during charging. Charging
operations shall be carried out by or under the personal supervision of the
shotfirer. Wrappings shall never be removed from explosive cartridges. Only
wooden rods shall be used for loading and stemming shotholes. Only one
cartridge at a time shall be inserted and gently passed home with the
wooden tamping rod.
Only such quantities of explosives as are required for the particular
amount of work to be done shall be brought to the works. Should any
surplus remain when all the holes have been charged, it shall be carefully
removed to a point at least 300 m from the firing point.
The explosives shall be fired by means of an electric detonator placed
inside the cartridge. For simultaneous firing of a number of charges the
electric detonators shall be connected with the exploder through the
shotfiring cable in a simple series circuit. Due precautions shall be taken
to keep the firing circuit insulated from the ground, bare wires, rails, pipes
or any other path of stray current and to keep the lead wires short circuited
until ready to fire. Any kinks in detonator leading wire shall be avoided.
For simultaneous firing of a large number of shotholes, use of cordtex may
be done. Cordtex shall be initiated by an electric detonator attached to its
side with adhesive tape, connecting wire or string.
All connections shall be made by the authorised shotfirer himself. The
shotfiring cable shall not be dragged along the ground to avoid possible
damage to the insulation. The shotfiring cable shall be tested for continuity
and possible short circuiting before it is used each time.
The shotfirer shall always carry the exploder handle on his person until he is
ready to fire shots. The number of shots fired at a time shall not exceed the
permissible limits.
Blasting shall only be carried out at certain specified times to be agreed
jointly by the contractor and the Engineer.
Before any blasting is carried out, it shall be ensured that all workmen,
vehicles and equipment on the site are cleared from an area of minimum
(PCA.774.S034sca1) V.II-D2/S-II : 10

3.5.5 Disposal
DCPL-K4A02
300 metres radius from the firing point, or as required by statutory
regulations, at least ten minutes before the time of firing by sounding a
warning siren. The area shall be encirled by red flags.
At least five minutes after the blast has been fired in case of electric firing or
as stipulated in the regulations the authorised shotfirer shall return to the
blast area and inspect carefully the work and satisfy himself that all
charged holes have exploded. Cases of misfired unexploded charges shall
be exploded by drilling a parallel fresh hole not less than 600 mm from the
misfired hole and by exploding a new charge. The authorised shotfirer shall
be present during removal of the debris liable to contain unexploded
explosives near the misfired hole. The workmen shall not return to the site
of firing until at least half an hour after firing.
When blasting is conducted in the neighbourhood of roads, structures,
buildings etc. controlled blasting has to be carried out by drilling shallow
shotholes and filling the same with light charge of explosives.
Adequate safety precautions as per building bye-laws, safety code, statutory
regulations etc. shall be taken during blasting operations.
The excavated spoils will be disposed of in any or all the following
manners :
a) By using it for backfilling straightway.
b) By stacking it temporarily for use in backfilling at a later date during
execution of the Contract.
c) i) By either spreading, Or
ii) spreading and compacting at designated
disposal areas.
filling areas and / or
d) By selecting the useful material and stacking it neatly in areas
designated by the Engineer for use in backfilling by some other
agency.
3.5.6 Disposal of Surplus
3.5.7 Protection
All surplus material from excavation shall be carried away from the
excavation site to designated disposal area selected by the Engineer.
All good and sound rock excavated from the pits and all assorted materials
of dismantled structures shall be the property of the Owner.
(PCA.774.S034sca1) V.II-D2/S-II : 11

DCPL-K4A02
The Engineer shall be notified by the Contractor as soon as the excavation
is expected to be completed within a day so that it may be inspected by him
at the earliest. Immediately after approval of the Engineer, the excavation
must be covered up in the shortest possible time. But, in no case the
excavation shall be covered up or worked on before approval and
measurement by the Engineer. Excavated material shall be placed beyond
1.5 metres from the edge of the pit or trench or half the depth of the pit or
trench whichever is more or further away if directed by the Engineer.
Excavation shall not be carried out below the foundation level of structure
close by until required precautions have been taken.
Adequate fencing is to be made enclosing the excavation.
The Contractor shall protect all under-ground services exposed by
excavation. The Contractor shall also divert all surface drains, etc. affected
by the excavation to maintain the working area neat and clean.
3.5.8 Dealing with Surface Water
All working areas shall be kept free of surface water as far as reasonably
praticable. Works in the vicinity of cut areas shall be controlled to prevent the
ingress of surface water.
No works shall commence until surface water streams have been properly
intercepted , redirected or otherwise dealt with.
Where works are undertaken in the monsoon period, the Contractor
may need to construct temporary drainage systems to drain surface water
from working areas.
3.5.9 Dewatering
All excavations shall be kept free of water and slush. Grading in the
vicinity of excavations shall be controlled to prevent surface water running
into excavated areas. The Contractor shall remove by pumping or other
means approved by the Engineer any water inclusive of rain water and
subsoil water accumulated in excavation and keep the trench dewatered until
the construction of foundation structure and backfilling are complete in all
respects. (except where such dewatering would need installation of well
points or deep wells for which separate payment will be made) Sumps made
for dewatering must be kept clear of the foundations. Method of pumping
shall be approved by the Engineer 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.
3.5.10 Timber Shoring
Timber Shoring made out of approved quality of timber shall be 'close' or
'open' type, depending on the nature of soil and the depth of pit or trench
and the type of timbering shall be determined by the Engineer. It shall be
(PCA.774.S034sca1) V.II-D2/S-II : 12

DCPL-K4A02
the responsibility of the Contractor to take all necessary steps to prevent
the sides of trenches and pits from collapsing.
3.5.10.1 Close Timbering
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 250 x 40 mm sections as directed by
the Engineer. The boards shall generally be placed in position vertically in
pairs, one board on each side of cutting, and shall be kept apart by
horizontal walers of strong wood at maximum 1.2 metres spacings,
cross strutted with ballies or as directed by the Engineer. The length of the
bally struts shall depend on the width of the trench or pit.
In case where the soil is very soft and loose, the boards shall be placed
horizontally against the sides of the excavation and supported by vertical
walers, which shall be strutted to similar timber pieces on the opposite face
of the trench or pit. The lowest board supporting the sides shall be taken
into the ground. No portion of the vertical side of the trench or pit shall
remain exposed, so that the earth is not liable to slip out.
The withdrawal of the timber shall be done very carefully to prevent the
collapse of the pit or trench. It shall be started at one end and proceeded
systematically to the other end. Concrete or masonry shall not be damaged
during the removal of the timber. No claim shall be entertained for any
timber which cannot be withdrawn and is lost or buried.
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3.5.10.2 Open Timbering
In the case of open timbering, the entire surface of the side of trench pit is
not required to be covered. The vertical board of minimum 250 mm width and
minimum 40 mm depth shall be spaced sufficiently apart to leave
unsupported strips of maximum 500 mm average width. The detailed
arrangement, sizes of the timber and the distances apart shall be subject to
the approval of the Engineer. In all other respects, specification for close
timbering shall apply to open timbering.
3.6.0 Treatment of Slips
3.7.0 Back-filling
3.7.1 General
The Contractor will take all precaution to avoid high surcharges and
provide proper surface drainage to prevent flow of water over the sides.
These precautions along with proper slopes, berms, shoring and control of
ground water should cause no slips to occur. If however slips do occur
due to causes beyond the control of the Contractor, the same shall be
removed by him. Slips caused due to negligence of the Contractor will be
cleared and back-filled later by him.
The material used for backfilling shall consist of material, approved by the
Engineer obtained directly from nearby areas where excavation work by the
same agency is in progress, from temporary stacks of excavated spoils or
from borrow pits from selected areas designated by the Engineer. The
material shall be free from lumps and clods, roots and vegetations, harmful
salts and chemicals, organic materials, etc.
In certain locations, the Engineer may direct sand fillings. The sand should
be clean, well graded and be of quality normally acceptable for use in
concrete.
3.7.2 Filling and Compaction in Pits and Trenches around Structures
As soon as the work in foundations has been accepted and measured,
the spaces around the foundation structures in pits and trenches shall be
cleared of all debris, brick bats, mortar droppings, etc., and filled with
earth in layers not exceeding 250 mm in loose thickness each layer being
watered, rammed and properly compacted to achieve a dry density of not
less that 90% of proctor's dry density at optimum moisture content as per
IS-2720 ( Part-VII) where backfilling with cohesive soil and sandy silt
containing high percentage of silt. For back filling with sand having little or
no silt, each layer shall be compacted to a relative density of 75% as per
IS-2720 part XIV. Earth shall be rammed with approved mechanised
compaction machine. Usually, no manual compaction shall be allowed unless
specifically permitted by the Engineer. The final surface shall be trimmed
and levelled to proper profile as shown in the drawing and as desired by the
Engineer.
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DCPL-K4A02
3.7.3 Plinth Filling
Since the degree of compaction depends on the moisture content of the
soil, a close watch should be kept on it and corrections done to optimise the
moisture content.
The plinth shall be filled with earth in layers not exceeding 250 mm in loose
thickness, watered and compacted as stated under clause no. 3.7.2 with
approved compaction machine or manually, if specifically permitted by the
Engineer. When the filling reaches the finished level, the surface shall be
flooded with water for at least 24 hours, allowed to dry and then rammed
and compacted, in order to avoid any settlement at a later stage. The
finished level of the filling shall be trimmed to the slope intended to be given
to the floor.
3.7.4 Filling in Trenches for Water Pipes and Drains
Earth used for filling shall be free from salts, organic or other foreign matter.
All clods of earth shall be broken or removed. Where excavated material
is mostly rock, the boulders shall be broken into pieces not bigger than 150
mm size in any direction, mixed with fine material consisting of disintegrated
rock, moorum or earth as available, so as to fill up the voids as far as
possible and then the mixture used for filling. The types of bedding &
pipe surround material shall be as specified in the drawings .
Filling in trenches for pipes and drains shall be commenced as soon as the
joints of pipes and drains have been tested and passed.
Where the trenches are excavated in soil, the filling shall be done with
earth on the sides and top of pipes in layers not exceeding 150 mm,
watered, rammed and compacted taking care that no damage is caused to
the pipe below. Filling of trenches shall be carried out simultaneously on
both sides of the pipe in such a manner that unequal pressures do not
occur.
In case of excavation of trenches in rock, the filling upto a depth of 300 mm
or the diamter of the pipe whichever is more, above the crown of pipe or
barrel shall be done with fine material such as earth, moorum, disintegrated
rock or ash according to the availability at site. The remaining filling
shall be done with rock filling of boulders of size not exceeding 150 mm
mixed with fine material as available to fill up the voids, watered, rammed
and compacted.
3.7.5 Filling in Disposal Area
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Surplus material from excavation which is not required for backfilling will be
disposed of in designated disposal areas. The spoils shall not be dumped
haphazardly but should be spread in layers approximately 250 mm thick
when loose and compacted with the help of compacting equipment. In
wide areas rollers will be employed and compaction done to the
satisfaction of the Engineer at the optimum moisture content which shall be
checked and controlled by the Contractor.
In certain cases the Engineer may direct disposal without compaction
which can be done by tipping the spoils from a high bench neatly
maintaining always a proper level and grade of the bench.
3.8.0 Approaches and Fencing
3.9.0 Lighting
The Contractor should provide and maintain proper approaches for
workmen and for inspection. The roads and approaches around the
excavated pits should be kept clear at all times so that there is no hindrance
to the movement of men, material and equipment of various agencies
connected with the Project. Sturdy and elegant fencing is to be provided
around the top edge of the excavation as well as the bottom of the fill at
the surplus disposal area where dumping from a high bench is in progress.
Full scale area lighting is to be provided if night work is permitted or
directed by the Engineer. If no night work is in progress, red warning lights
should be provided at the corners of the excavated pit and the edges of the
fill.
4.0.0 TESTING AND ACCEPTANCE CRITERIA
4.1.0 Excavation
On completion of excavation, the dimensions of the pits will be checked as
per the drawings after the pits are completely dewatered the work will be
accepted after all undercuts have been set right and all over excavations
filled back to required lines, levels and grades by placing ordinary
concrete of 1:4:8 proportion and/or richer and/or by compacted earth, as
directed by the Engineer. The choice of grade of concrete will be a matter
of unfettered discretion of the Engineer. Over excavation of the sides will
be made good by the Contractor while carrying out the back-filling. The
excavation work will be accepted after the above requirements are fulfilled
and all temporary approaches encroaching inside the required dimension of
the excavation have been removed.
4.2.0 Back-filling
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The degree of compaction shall be sufficient to achieve a dry density of not
less than 90% of proctor's dry density at optimum moisture content as
per IS-2720 (Part - VII) or a relative density of 75% as per IS-2720
(Part-XIV) as applicable depending on the nature of back filling material as
stated in clause no. 3.7.2 of this specification. The work of back-filling will
be accepted after the Engineer is satisfied with the degree of compaction
achieved.
5.0.0 INFORMATION TO BE SUBMITTED
5.1.0 With Tender
5.2.0 After Award
Details of Equipment proposed to be used for excavation, back-filling and
compaction have to be submitted along with the tender.
After award of the Contract the successful tenderer shall submit the
following for approval and adoption :
a) The Contractor shall submit a detailed programme of the work
as proposed to be executed giving completion dates of
excavation of the various foundations and the time required for
back-filling and compaction after completing the foundation for
structures.
The programme should show how the excavation and back-filling
quantities will be balanced, minimising temporary stacking of spoils.
It is to be noted that the Engineer even after initial approval of the
programme, may instruct to enhance or retard the progress of
work during the actual execution, in order to match with the
progress of foundations without attracting any claims from the
Contractor. The initial programme being submitted by the
Contractor should have sufficient flexibility to take care of such
reasonable variations.
b) The Contractor shall submit drawings showing details of slopes,
shorings, approaches, sump pits, dewatering lines, fencing etc. for
approval of the Engineer for adoption.
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DCPL-K4A02
VOLUME : II-D/2
SECTION-III
TECHNICAL SPECIFICATION
FOR
CEMENT CONCRETE (PLAIN & REINFORCED)
(PCA.774.S034sca2)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0 SCOPE V.II-D2/S-III : 1
2.0 GENERAL V.II-D2/S-III : 1
3.0 INSTALLATION V.II-D2/S-III : 11
4.0 SAMPLING AND TESTING V.II-D2/S-III : 45
5.0 ACCEPTANCE CRITERIA V.II-D2/S-III : 47
6.0 LIST OF I.S. CODES AND STANDARDS V.II-D2/S-III : 48
FOR REFERENCE
(PCA.774.S034sca2)

DCPL-K4A02
VOLUME : II-D/2
SECTION-III
TECHNICAL SPECIFICATION
FOR
CEMENT CONCRETE (PLAIN & REINFORCED)
1.0 SCOPE
1.1 General
This specification covers all the requirements, described hereinafter for
general use of Plain and Reinforced Cement Concrete work in Structures
and locations, cast-in-situ or precast, and shall include all incidental items of
work not shown or specified but reasonably implied or necessary for the
completion of the work.
1.2 This specification shall also apply to the extent it has been referred to or
applicable with the special requirements of structures covered in SCOPE of
IS:456.
1.3 IS:456 shall form a part of this specification and shall be complied with
unless permitted otherwise. For any particular aspect not covered by this
Code, appropriate IS Code, specifications and/or replacement by any
International Code of practice as may be specified by the Engineer shall
be followed. All codes and Standards shall conform to its latest revisions. A
list of IS codes and Standards is enclosed hereinafter for reference.
2.0 GENERAL
2.1 Work to be provided for by the Contractor
The work to be provided for by the Contractor, unless
specified shall include but not be limited to the following :-
otherwise
a) Furnish all labour, supervision, services including facilities as may
be required under statutory labour regulations, materials, forms,
templates, supports, scaffolds, approaches, aids, construction
equipment, tools and plants, transportations, etc. required for the
work.
b) Except where it is excluded from the Scope of Contract, Contractor
shall prepare progressively and submit for approval detailed
drawings and Bar Bending Schedules for reinforcement bars showing
the positions and details of spacers, supports, chairs, hangers etc.
c) Design and prepare working drawings of formworks, scaffolds,
supports, etc. and submit for approval.
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d) Submit for approval shop drawings for various inserts, anchors,
anchor bolts, pipe sleeves, embedments, hangers, openings,
frames etc.
e) Submit for approval detailed drawings of supports, templates,
hangers, etc. required for installation of various embedments
like inserts, anchor bolts, pipe sleeves, frames, joint seals, frames,
openings etc.
f) Submit for approval detailed schemes of all operations required for
executing the work, e.g. Material handling, Concrete mixing,
Placement of concrete, Compaction, curing, services, Approaches,
etc.
g) Design and submit for approval concrete mix designs required to
be adopted on the job.
h) Furnish samples and submit for approval results of tests of various
properties of the following :
i) The various ingredients of concrete
ii)
iii)
iv)
Concrete
Embedments
Joint seals
i) Provide all incidental items not shown or specified in particular but
reasonably implied or necessary for successful completion of the
work in accordance with the drawings and specifications.
j) For supply of certain materials normally manufactured by specialist
firms, the Contractor may have to produce, if directed by the
Engineer, a guarantee in approved proforma for satisfactory
performance for a reasonable period as may be specified,
binding both the manufacturers and the Contractor, jointly and
severally.
2.2 Work by Others
No work under this specification will be provided by any agency other
than the Contractor unless specifically mentioned elsewhere in the
contract.
2.3 Information to be submitted by the Tenderer
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2.3.1 With Tender
2.3.2 After Award
The following technical information are required with the tender :
a) Source and arrangement of processing of aggregates proposed to be
adopted.
b) Type of plant and equipment proposed to be used.
c) Names of firms, if any, with which association is sought for to
execute the special items of work in the contract.
d) Types of formwork proposed to be used.
The following information and data including samples where necessary,
shall be submitted by the Contractor progressively during the execution of the
contract.
a) Programme of Execution and Requirement of Materials
The Contractor will submit a Master Programme for completion of
the work giving monthwise requirements of materials for the
procurement.
This Master Programme may have to be reviewed and updated
by the Contractor, quarterly or at more frequent intervals as may be
directed by the Engineer depending on the exigencies of the work.
Detailed day to day programme of every month is to be submitted
by the Contractor before the end of the previous month.
b) Samples
Samples of the following materials and any other materials
proposed to be used, shall be submitted as directed by the
Engineer, in sufficient quantities for approval. Approved samples
will be preserved by the Engineer for future reference. The
approval of the Engineer shall not, in any way, relieve the
Contractor of his responsibility of supplying materials of specified
qualities :
i) Coarse and fine aggregates.
ii)
iii)
Admixtures.
Plywood for Formwork.
iv) Embedded and anchorage materials as may be desired by
the Engineer.
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v) Joint sealing strips and other waterproofing materials.
vi)
vii)
Joint filling compounds.
Foundation quality Rubber Pads.
c) Design Mix
Design mix as per Clauses 2.1 (g) & 3.4 of this specification
giving proportions of the ingredients, sources of aggregates
and cement, along with accompanying test results of trial mixes
as per relevant I.S., is to be submitted to the Engineer for his
approval before it can be used on the works.
d) Detail Drawings and Bar Bending Schedules
Detailed working drawings and Bar Bending Schedules in
accordance with Clause 2.1(b) and 3.16.1 of this specification.
e) Detailed Drawings and Designs of Formworks to be used
Detailed design data and drawings of standard formworks
used as per clause 2.1 (c).
to be
f) Detailed Drawings for Templates & Temporary Supports for
Embedments
As per Clause 2.1 (e).
g) Mill Test Reports for Cement & Reinforcing Steel
h) Inspection Reports
Inspection Reports in respect of Formwork and
Reinforcement and any other item of work as may be desired
by the Engineer in accordance with Clause 2.4 of this specification.
i) Test Reports
Reports of tests of various materials and concrete as required
under Clause 4.0 : SAMPLING & TESTING of this specification.
j) Any other data which may be required as per this
specification.
2.4 Conformity with Design
The Contractor will prepare check lists in approved proforma which will
be called 'Pour Cards'. These Pour Cards will list out all items of work
involved. The Contractor will inform the Engineer, sufficiently in
(PCA.774.S034sca2) V.II-D2/S-III : 4

DCPL-K4A02
advance, whenever any particular pour is ready for concreting. He shall
accord all necessary help and assistance to the Engineer for all
checking required in the pour. On satisfying himself that all details are
in accordance to the drawings and specifications, the Engineer will
give written permission on the same 'Pour Card' allowing the Contractor
to commence placement of concrete. Details of all instructions issued by
the Engineer and the records of compliance by the Contractor,
deviations allowed by the Engineer and any other relevant information will
be written on accompanying sheets attached to the Pour Cards. These
sheets, termed as 'Progress Cards', will be prepared by the Contractor
on approved proforma. The Pour Cards along with accompaniments will
be handed over to the Engineer before starting placement of concrete.
One of the mix designs developed by the Contractor as per the I.S.
Specifications and established to the satisfaction of the Engineer by trial
mixes shall be permitted to be used by the Engineer, the choice
being dictated by the requirements of designs and workability. The methods
of mixing, conveyance, placement, vibration, finishing, curing, protection
and testing of concrete will be as approved or directed by the Engineer.
2.5 Materials to be used
2.5.1 General Requirement
2.5.2 Cement
All materials whether to be incorporated in the work or used temporarily for
the construction shall conform to the relevant IS Specifications unless
stated otherwise and be of best approved quality.
Generally cement shall be 33 grade ordinary Portland Cement conforming
to IS-269 . In special cases any of the following type of cement may be
permitted or directed to be used with prior approval by the Engineer :
a) 43 Grade ordinary Portland Cement conforming to IS-8112
b) 53 Grade ordinary Portland Cement conforming to IS-12269
c) Rapid hardening Portland Cement conforming to IS-8041
d) Portland slag cement conforming to IS-455
e) Portland Pozzolona Cement (flyash based) Conforming to IS- 1489
(Part -1)
f) Portland pozzolona Cement (calcined clay based) conforming to IS-
1489 (Part-2)
g) Hydrophobic Cement conforming to IS-8043
h) Low heat Portland Cement conforming to IS : 12600
(PCA.774.S034sca2) V.II-D2/S-III : 5

2.5.3 Aggregates
i) Sulphate Resisting Portland Cement conforming to IS-12330
DCPL-K4A02
Aggregates shall be natural or crushed gravel or crushed rock and free from
deleterious material. It shall comply with the requirements of IS-383. All fine
and coarse aggregate shall be tested for susceptibility to Alkali Silicate
reaction in a laboratory approved by the Engineer.
a) Coarse Aggregate
Aggregate of sizes ranging between 4.75 mm and 150 mm will be
termed as Coarse Aggregate. Only Coarse Aggregate from
approved quarries and conforming to IS:383 will be allowed to be
used on the works. Aggregates shall be washed to make it free from
deleterious materials, if necessary.
The grading of coarse aggregates by seive analysis shall be as per
IS:383. If by the analysis the deficiency of a particular grain size is
found, which could affect the density of the concrete, the Engineer
may ask the contractor to avoid such quantities of aggregate of
the particular size or and such quantity of aggregate of any
particular size to achieve the required grading as per IS:383.
b) Fine Aggregate
Aggregate smaller than 4.75 mm and within the grading limits and
other requirements set in IS:383 is termed as Fine Aggregate or
Sand. Only Fine Aggregate from approved sources and conforming
to the above IS Specification will be allowed to be used on works.
In certain cases there may be two types of sand , one very fine
and the other very coarse. In such cases , the two types shall be
combined to meet the requirements of a particular zone of IS:383.
In all cases , the preferred zone is Zone - II.
In certain cases crushed stone sand may be added to natural
sand in order to achieve the required grading. Crushed stone sand
alone may be used only with the approval of the Engineer.
2.5.4 Water
Water for use in Concrete shall be clear and free from injurious oils,
acids, alkalis, organic matter, salt, silts or other impurities. Normally
potable water is found to be suitable. Generally, IS:3550 will be followed
for routine tests. Acceptance test for water shall be as per IS:3025, and
Table-1 of IS:456.
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2.5.5 Admixture
DCPL-K4A02
In case of doubt regarding development of strength , the suitability of
water for making concrete shall be ascertained by compressive strength and
initial setting time tests as per method of tests in accordance with the
requirements of IS-516 & IS- 4031 respectively. The PH value of water
shall generally be not less than 6.
Only admixture of approved quality will be used when directed or permitted
by the Engineer . The different types of admixtures which may be
necessary to satisfy the concrete mix and the design requirement shall be as
per the following I.S. Standards :
IS : 2645 - Integral cement water proofing compound
IS : 9103 - Indian standard specification for Admixtures for
Concrete or equivalent American Codes (ASTM C494
and ASTM C260 ) or British Codes ( BS 5075 , Part
1 to 3 ) and may be one of the following :
a) Accelerating admixtures :
- Set accelerating admixtures like "Sigunit Powder" or
"Sigunit LN10" .
b) Retarding admixtures :
- Modified ligno sulphonate based set retarding concrete
admixture like , "Plastiment R".
c) Water reducing admixtures :
- Modified sulphonated melamine formaldehyde based water
reducing concrete admixture like, "Sikament" .
d) Air entraining admixtures :
- Modified ligno sulphonate based air entraining concrete
admixture like "FLOMO AEP " or surface - active agents
like "Sika AER".
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e) Water proofing admixtures
- Modified ligno-sulphonate based waterproofing admixture
like "Plastocrete Super".
However, the Contractor shall furnish following technical
information about the admixtures (alongwith the manufacturer's
Catalogue) which he is planning to use in different areas within the
scope of work for the approval of the Engineer :
i) Type of admixture
ii)
Mix proportion & mode of application in concrete/mortar
2.5.6 Reinforcement
iii) Manufacturer's specification & necessary quality assurance
certificates ( mainly on chloride & suphate content , PH value
infra red analysis & solid content. )
Reinforcement shall be as per relevant IS Specification as mentioned in
the Contract/Drawing/Instructions. All bars shall be of tested quality.
2.6.0 Storage of Materials
2.6.1 General
2.6.2 Cement
All materials shall be so stored as to prevent deterioration or intrusion of
foreign matter and to ensure the preservation of their quality and fitness for
the work. Any material, which has deteriorated or has been damaged or is
otherwise considered defective by the Engineer, shall not be used for
concrete and shall be removed from site immediately, failing which, the
Engineer shall be at liberty to get the materials removed and Storage of
materials shall conform to IS:4082.
Sufficient space for storage, with open passages between stacks,
shall be arranged by the Contractor to the satisfaction of the Engineer.
Cement shall be stored off the ground in dry, leak proof, well-ventillated
ware-houses at the works in such a manner as to prevent deterioration due
to moisture or intrusion of foreign matter.
Cement shall be stored in easily countable stacks with consignment
identification marks. Consignments shall be used in the order of their
receipts at site. Sub-standard or partly set cement shall not be used and
shall be removed from the site, with the knowledge of the Engineer, as soon
as it is detected.
Different types of cement shall be clearly marked with the Type and
different types of cement shall not be intermixed.
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2.6.3 Aggregates
Aggregates shall be stored on planks or steel plates or on concrete or
masonry surface. Each size shall be kept separated with wooden or
steel or concrete or masonry bulk-heads or in separate stacks and
sufficient care shall be taken to prevent the material at the edges of the
stock piles from getting intermixed. Stacks of fine and coarse
aggregates shall be kept sufficiently apart with proper arrangement of
drainage. The aggregates shall be stored in easily measurable stacks of
suitable depths as may be directed by the Engineer.
2.6.4 Reinforcement
Reinforcing steel shall be stored consignment-wise and sizewise off the
ground and under cover, if desired by the Engineer. It shall be protected
from rusting, oil, grease and distortions. If necessary, the reinforcing steel
may be coated with cement wash before stacking to prevent scale and
rust. The stacks shall be easily measurable. Steel needed for immediate
use shall only be removed from storage.
2.7 Quality Control
Contractor shall establish and maintain quality control for different items of
work and materials as may be directed by the Engineer to assure
compliance with contract requirements and maintain and submit to the
Engineer records of the same.
The quality control operation shall include but not be limited to the
following items of work :
a) Admixture : Type, quantity, physical and chemical
properties that affect strength, workability
and durability of concrete.
For air entraining admixtures, dosage to be
adjusted to maintain air contents within
desirable limits
b) Aggregate : Physical, chemical and mineralogical
qualities. Grading, moisture content and
impurities.
c) Water : Impurities tests.
d) Cement : Tests to satisfy relevant IS Specifications
(only association with Owner's tests, if the
supply is made by Owner).
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e) Formwork : Material, shapes, dimensions, lines,
elevations, surface finish, adequacy of form,
ties, bracing and shoring and coating.
f) Reinforcement : Shapes, dimensions, length of plices,
clearances, ties and supports. Quality and
requirement of welded splices.
Material tests or certificates to satisfy
relevant IS Specification (If Contractor's
supply).
g) Grades of
concrete : Usage and mix design, testing of all
properties.
h) Batching &
Mixing : Types and capacity of plant, concrete
mixers and transportation equipment.
i) Joints : Locations of joints, water stops and filler
materials. Dimension of joints, quality and
shape of joint material and splices.
j) Embedded
and Anchorage
Items : Material, shape, location, setting.
k) Placing : Preparation, rate of pouring, weather
limitations, time intervals between mixing and
placing and between two successive lifts,
covering over dry or wet surfaces, cleaning
and preparation of surfaces on which
concrete is to be placed, application of
mortar/slurry for proper bond, prevention of
cold joint, types of chutes or conveyors.
l) Compaction : Number of vibrators, their prime mover,
frequency and amplitude of vibration,
diameter and weight of vibrators, duration of
vibration, hand-spreading, rodding and
tamping.
m) Setting of
base &
Beaming
plates : Lines, elevations and bedding mortar.
n) Concrete
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Finishes : Repairs of surface defects, screening,
floating, steel trowelling and brooming, special
finishes.
o) Curing : Methods and length of time.
Copies of records and tests for the items noted above, as well as,
records of corrective action taken shall be submitted to the Engineer for
approval as may be desired.
3.0 INSTALLATION
All installation requirements shall be in accordance with IS:456 and as
supplemented or modified herein or by other best possible standards
where the specific requirements mentioned in this section of the
specification do not cover all the aspects to the full satisfaction of the
Engineer.
3.1 Washing and Screening of Aggregates
3.2 Admixture
Washing and Screening of coarse aggregate shall be carried out to remove
fines , dirts or other deleterious materials.
Washing of fine aggregate shall not be allowed, Fine aggregates shall
be screened only to remove dirt or other deleterious materials.
However , all washing & screening of aggregates shall be carried out by
approved means to ensure compliance with the aggregate specification.
All concrete shall be designed for normal rate of setting and hardening at
normal temperature. Variations in temperature and humidity under different
climatic conditions will affect the rate of setting and hardening, which will,
in turn, affect the workability and quality of the concrete.
Admixtures may be permitted to be used in accordance with IS:456 to
modify the rate of hardening, to improve workability or as an aid to
control concrete quality. The Engineer reserves the right to require
laboratory test or use test data, or other satisfactory reference before
granting approval. The admixture shall be used strictly in accordance
with the manufacturer's directions and/or as directed by the Engineer.
3.3 Grades of Concrete
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Structural concrete shall be of M20/M25/M30 grade and for other part of the
work shall be as shown on the drawing as per grade classification of IS-456.
In case of liquid retaining structures, IS:3370 will be followed.
3.4 Proportioning and Works Control
3.4.1 General
Proportioning of ingredients of concrete shall be made by any of the two
following methods as directed by the Engineer.
a) With preliminary tests by designing the concrete mix. Such concrete
shall be called 'Design Mix Concrete'.
b) without preliminary tests adopting nominal concrete mix. Such
concrete shall be called 'Nominal Mix Concrete'.
As far as possible, design mix concrete shall be used on all concrete works.
Nominal mix concrete, in grades permitted in accordance with IS:456, may
be used if shown on drawings or approved by the Engineer. In all cases the
proportioning of ingredients and works control shall be in accordance with
IS:456 and shall be adopted for use after the Engineer is satisfied
regarding its adequacy and after obtaining his approval in writing.
3.4.2 Mix Design Criteria
Concrete mixes will be designed by the Contractor to achieve the strength,
durability and workability necessary for the job, by the most economical
use of the various ingredients. In general, the design will keep in view
the following considerations :
a) Consistent with the various other requirements of the mix, the
quantity of water should be kept at the lowest possible level.
b) The nominal maximum size of coarse aggregate shall be as large as
possible within the limits specified.
c) The various fractions of coarse and fine aggregates should be
mixed in such a proportion as to produce the best possible combined
internal grading giving the densest and most workable mix.
d) Chemical admixtures may be used to modify the rate of hardening, to
improve workability (maintaining low water - cement ratio) or as
an aid to control concrete quality.
e) The finished concrete should have adequate durability in all
conditions, to withstand satisfactorily the weather and other
destructive agencies which it is expected to be subjected to in actual
service.
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The requirement of adequate structural strength is catered for by
the choice of proper grade of concrete by the Engineer. The
Contractor will strictly abide by the same in his design of concrete mix
installation. Notwithstanding anything mentioned in various tables
given in IS:456 giving specific values and degrees of workability for
different condition of concrete placing, minimum cement content and
maximum water-cement ratio for concrete exposed to sulphate
attack and for concrete to ensure durability under different condition
of exposure, strength requirement for different grades of concrete,
proportion for nominal mix concrete, values given in the tables in
IS:456, shall be followed.
Various trials shall be given by the contractor with specific
cement content on each trial . In some cases, plasticizers and
other admixtures may be necessary to achieve the desired results.
TABLE - I
STRENGTH REQUIREMENT OF CONCRETE
Specified Characteristic Compressive
Grade of concrete
strength of 15 cm Cubes at 28
days conducted in accordance
with IS:516 (All values in
N/Sq.mm)
Note -1:
M - 10 10
M - 15 15
M - 20 20
M - 25 25
M - 30 30
M - 35 35
M - 40 40
Nominal mix concrete of proportions 1:4:8 or 1:3:6 may be used as lean
concrete for simple foundations for masonry walls , below the reinforced
concrete foundations and mass filling . These mixes need not be designed.
TABLE - II
MIX PROPORTIONS (BY WEIGHT) EXPECTED TO GIVE
DIFFERENT DEGREES OF WORKABILITY WITH DIFFERENT
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WORKABILITY
WATER/CEME
NT/RATIO
VALUES OF WATER - CEMENT RATIO
(FOR GUIDANCE)
CEMENT/TOTAL AGGREGATE RATIOS
RATIO BY WEIGHT OF
CEMENT OF GRAVEL
AGGREGATE
RATIO BY WEIGHT OF
CEMENT OF CRUSHED
STONE AGGREGATE
20 mm 38 mm 20 mm 38 mm
size size size size
Very low 0.4 01:04.8 01:05.3 01:04.5 01:05.0
Slump 0.5 01:07.2 01:07.7 01:06.5 01:07.4
0-25 mm 0.6 01:09.4 1:10 01:07.8 01:09.6
0.7 1:10 1:12 01:08.7 01:10.6
Low 0.4 01:03.9 01:04.5 01:03.5 01:04.0
Slump 0.5 01:05.5 01:06.7 01:05.0 01:05.5
25-50 mm 0.6 01:06.8 01:07.4 01:06.3 01:07.0
0.7 01:08.0 01:08.5 01:07.4 01:08.0
Medium 0.4 01:03.5 01:03.8 01:03.1 01:03.6
Slump 0.5 01:04.8 01:05.7 01:04.2 01:05.0
50-100 mm 0.6 01:06.0 01:07.3 01:05.2 01:06.2
High 0.4 01:03.2 01:03.5 01:02.9 01:03.3
Slump 0.5 01:04.4 01:05.2 01:03.9 01:04.6
100-175 mm 0.6 01:05.4 01:06.7 01:04.7 01:05.7
0.7 01:06.2 01:07.4 01:05.5 01:06.5
NOTE : 1 - Notwithstanding anything mentioned above, the cement/Total
aggregate ratio is not to be increased beyond 1:9.0 without specific
permission of the Engineer.
NOTE : 2 -
NOTE : 3 -
It should be noted that such high aggregate cement ratios will be required
for concretes of very low slump and high water- cement ratios which may
be required to be used in mass concrete work only.
The above figures are for guidance only, the actual cement/aggregate
ratios are to be worked out from the specific gravities of coarse
aggregates and sand being used and from trial mixes.
3.5 Strength Requirements
The strength requirements of both design mix and nominal mix concrete
where ordinary Portland Cement or Portland slag cement is used, shall be
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as per Table-2 of IS:456. All other relevant clauses of IS:456 shall also
apply.
3.6 Minimum Cement Content
The minimum cement content for each grade of concrete shall be as per
Table-5 of IS : 456.
3.7 Water-Cement Ratio
The choice of water-cement ratio in designing a concrete mix will depend on -
a) The requirement of strength.
b) The requirement of durability.
3.7.1 Strength Requirement
In case of 'Design Mix Concrete', the water-cement ratio of such value as to
give acceptable test results as per IS:456, will be selected by trial and error.
The values of water-cement ratios for different grade and mix designs will
have to be established after conducting sufficiently large number of
preliminary tests in the laboratory to the satisfaction of the Engineer.
Frequent checks on test will have to be carried out and the water-cement
ratios will be revised if the tests produce unsatisfactory results.
Notwithstanding anything stated above the Contractor's responsibility to
produce satisfactory test results and to bear all the consequences in
case of default remains unaltered.
In case of nominal mix concrete, proportions for different grades of
concrete is specified in Table-9 of IS:456 and no tests are necessary. The
acceptance test criteria for nominal mix concrete shall be as per IS:456.
3.7.2 Durability Requirement
Table-5 of IS:456 gives the maximum water-cement ratio permissible
from the point of view of durability of concrete subjected to adverse exposure
to weather, sulphate attacks, and contact with harmful chemicals.
Impermeability may also be an important consideration.
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3.8 Workability
DCPL-K4A02
Whenever the water-cement ratio dictated by durability consideration is
lower than that required from strength criterion, the former shall be
adopted.
In general the water cement ratio between 0.4 and 0.45 will be desirable to
satisfy the durability requirement and from the consideration of
impermeability of conrete. The contractor may propose lower water
cement ratio as mentioned above by addition of a suitable plasticizer /
super-plasticizer. However the contractor has to propose specifically
along with field trials in the event of lower cement content if found suitable
along with a plasticizer. It will be preferable to use Melamine based
plasticizer.
The degree of workability necessary to allow the concrete to be well
consolidated and to be worked into the corners of formwork and around
the reinforcement and embedments and to give the required surface finish
shall depend on the type and nature of structure and shall be based on
experience and tests. The usual limits of consistency for various types of
structures are given below :
TABLE - III
LIMITS OF CONSISTENCY
Degree of
workability
Slump in mm with
Standard Cone as
per IS:1199
Min. Max.
Use for which concrete
is suitable.
Very low 0 25 Large Mass concrete
structure with heavy
compaction equipment,
roads and like.
Low 25 50 Uncongested wide and
shallow R.C.C. structures.
Medium 50 100 Deep but wide R.C.C.
structures with congestion
or reinforcement and
inserts.
High 100 150 Very narrow and deep
R.C.C. structures with
congestion due to
reinforcement and inserts.
(NOTE : Notwithstanding anything mentioned above, the slump to
be obtained for work in progress shall be as per direction of
the Engineer)
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With the permission of the Engineer, for any grade of concrete, if the
water has to be increased in special cases, cement shall also be
increased proportionately to keep the ratio of water to cement same as
adopted in trial mix design for each grade of concrete. The workability of
concrete shall be checked at frequent intervals by slump tests.
Alternatively where facilities exist or if required by the Engineer, the
compacting factor test in accordance with IS:1199.
3.9 Size of Coarse Aggregates
The maximum size of coarse aggregates for different locations shall be as
follows unless otherwise directed by the Engineer :-
Very narrow space
Reinforced concrete except foundation
Ordinary Plain concrete and Reinforced concrete foundations
Mass concrete
Mass concrete in very large structure
- 12 mm
- 20 mm
- 40 mm
- 80 mm
- 150 mm
Grading of coarse aggregates for a particular size shall conform to relevant
I.S. Codes and shall also be such as to produce a dense concrete of
the specified proportions, strength and consistency that will work readily
into position without segregation.
Coarse aggregate will normally be separated into the following sizes and
stacked separately in properly designed stockpiles :
150 mm to 80 mm, 80 mm to 40 mm, 40 mm to 20 mm and 20 mm to 5
mm. In certain cases it may be necessary to further split the 20 mm to 5
mm fraction into 20 mm to 10 mm and 10 mm to 5 mm fractions.
This separation of aggregates in different size fractions is necessary
so that they may be remixed in the desired proportion to arrive at a correct
internal grading to produce the best mix.
3.10 Mixing of Concrete
Concrete shall always be mixed in mechanical mixer unless specifically
approved by the Engineer for concrete to be used in unimportant out
of the way locations in small quantities. Water shall not normally be
charged into the drum of the mixer until all the cement and aggregates
constituting the batch are already in the drum and mixed for at least one
minute. Mixing of each batch shall be continued until there is a uniform
distribution of the materials and the mass is uniform in colour and
consistency, but in no case shall mixing be done for less than 2 (two)
minutes and at least 40 (forty) revolutions after all the materials and water
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are in the drum. When absorbent aggregates are used or when the mix is
very dry, the mixing time shall be extended as may be directed by the
Engineer. Mixers shall not be loaded above their rated capacity as this
prevents thorough mixing.
The entire contents of the drum shall be discharged before the
ingredients for the next batch are fed into the drum. No partly set or
remixed or excessively wet concrete shall be used. Such concrete shall
be immediately removed from site. Each time the work stops, the mixer
shall be thoroughly cleaned & when the next mixing commences, the first
batch shall have 10% additional cement to allow for loss in the drum.
Regular checks on mixer efficiency shall be carried out as directed by the
Engineer as per IS:4634 on all mixers employed at site. Only those mixers
whose efficiencies are within the tolerances specified in IS:1791 will be
allowed to be employed.
Ingradients for design mix concrete shall be measured by wieght. For small
jobs portable swing weigh Bachers conforming to IS:2722 may be used.
Batching plant conforming to IS:4925 shall be used for large jobs. The
accuracy of the measuring equipment shall be within + 2% of the quantity
of Cement , water or total aggregates being measured and within + 5% of
the quantity of any admixture being used . The batching equipment shall be
fitted with an accurate mechanism for weighing separately the cement,
fine aggregate and coarse aggregate. Water may be measured by volume
or by weight. All measuring equipment should be maintained in a clean
serviceable condition, and their accuracy shall be checked periodically.
Mechanical / electrical control shall be provided on the mixing equipment
to ensure the batch cannot be discharged until approved mixing time has
elapsed and the entire batch shall be discharged before the mixer is
recharged.
Where admixtures are employed, separate containers & measuring
devices shall be used.
For minor concreting works, batching by volume according to specific
weight may be permitted by the Engineer. In that case the whole bags of
cement shall be used and gauge boxes used for measuring aggregates.
When hand mixing is permitted by the Engineer, it shall be carried out on a
water-tight platform and care shall be taken to ensure that mixing is
continued until the mass is uniform in colour and consistency. In case of
hand-mixing, 10% extra cement shall be added to each batch.
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3.11 Conveying Concrete
Concrete shall be handled and conveyed from the place of mixing to the
place of laying as rapidly as practicable by approved means and placed and
compacted in the final position before the initial setting of the cement
starts. Concrete should be conveyed in such a way as will prevent
segregation or loss of any of the ingre- dients. For long distance haulage,
agitator cars of approved design will be used. If, inspite of all
precautions, segregation does occur during transport, the concrete shall
be properly re-mixed before placement. During very hot or cold weather,
if directed by the Engineer, concrete shall be transported in deep
containers which will reduce the rate of loss of water by evaporation or
loss of heat. If necessary, the container may have to be covered and
insulated. Conveying equipments for concrete shall be well
maintained and thoroughly cleaned before commencement of concrete
mixing. Such equipments shall be kept free from set concrete.
3.12 Placing and Compacting Concrete
Where specifically covered, the relevant I.S. Code will be followed for the
procedure of surface preparation, placement, consolidation, curing,
finishes, repairs and maintenance of concrete. If, however, there is no
specific provision in the relevant I.S. Code for any particular aspect of
work, any other standard Code of practice, as may be specified by the
Engineer, will be adopted. Concrete may have to be placed against the
following types of surfaces :
a) Earth foundation
b) Rock foundation
c) Formwork
d) Construction joint in concrete or masonry
The surface on or against which concrete is to be placed has to be cleaned
thoroughly. Rock or old construction joint has to be roughened by wire
brushing, chipping, sand blasting or any other approved means for proper
bond. All cuttings, dirt, oil, foreign and deleterious material, laitance, etc.
are to be removed by air water jetting or water at high pressure. All
excavated areas for foundations, ring beams, plinths, pile caps etc. shall
be rammed & consolidated properly before blinding with nominal mix
plain concrete, as per drawing and / or direction of the Engineer and
shall be allowed to cure prior to setting out steel fixing, shuttering and
concrete pouring for the main structural element.
Formwork, reinforcement, preparation of surface, embedments, joint
seals etc., shall be approved in writing by the Engineer before concrete is
placed. As far as possible, concrete shall be placed in the formwork
by means approved by the Engineer and shall not be dropped from a height
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or handled in a manner which may cause segregation. Any drop over 1500
mm shall have to be approved by the Engineer.
Rock foundation or construction joint will be kept moist for at least 72 hours
prior to placement. Concrete will be placed always against moist surface
but never on pools of water. In case the foundation cannot be
dewatered completely, special procedure and precaution, as directed by the
Engineer will have to be adopted.
Formwork will be cleaned thoroughly and smeared lightly with form oil or
grease of approved quality just prior to placement.
A layer of mortar of thickness 12 mm of the same or less w/c ratio and the
same proportion as that of the concrete being placed and cement slurry
will be spread thoroughly on the rock foundation or construction joint just
prior to placement of concrete. The cost of application of such cement
slurry and mortar will be deemed to be included.
After concrete has been placed, it shall be spread, if necessary and
thoroughly compacted by approved mechanical vibration to maximum
subsidence without segregation and thoroughly worked around
shape. Vibrators shall not be used for pushing concrete into adjoining
areas. Vibrators must be operated by experienced workmen and the
work carried out as per relevant IS Code of Practice. In thin members
with heavy congestion of reinforcement or other embedments, where
effective use of internal vibrator is, in the opinion of the Engineer,
doubtful, in addition to immersion vibrators the contractor may have to
employ form vibrators conforming to IS:4656. For slabs and other
similar structures, the contractor will additionally employ screed
vibrator as per IS:2506. Hand tamping may be allowed in rare cases,
subject to the approval of the Engineer. Care must be taken to ensure
that the inserts, fixtures, reinforcement and formwork are not displaced or
distorted during placing and consolidation of concrete.
The rate of placement of concrete shall be such that no cold joint is formed
and fresh concrete is placed always against green concrete which is still
plastic and workable. No concrete shall be placed in open, during rains.
During rainy season, no placement in the open is to be attempted unless
sufficient tarpaulins or other similar protective arrangement for completely
covering the still green concrete from rain is kept at the site of placement.
If there has been any sign of washing of cement and sand, the entire
affected concrete shall be removed immediately. Suitable precautions
shall be taken in advance to guard against rains before leaving the fresh
concrete unattended. No accumulation of water shall be permitted on or
around freshly laid concrete.
The size of the concrete pours must be carefully considered prior to
commencement to ensure the structural elements are poured in on
contineous shift to avoid cold joints.
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Slabs, beams and similar members shall be poured in one operation, unless
otherwise instructed by the Engineer. Moulding, throating, drip course, etc.,
shall be poured as shown on the drawings or as directed by the Engineer.
Holes shall be provided and bolts, sleeves, anchors, fastenings or other
fixtures shall be embedded in concrete as shown on the drawings or as
directed by the Engineer. Any deviation therefrom shall be set right by the
Contractor as instructed by the Engineer.
In case the forms or supports get displaced during or immediately after
the placement and bring the concrete surface out of alignment beyond
tolerance limits, the Engineer may direct to remove the portion and
reconstruct or repair the same.
The Engineer shall decide upon the time interval between two placements of
concrete of different ages coming in contact with each other, taking in
consideration the degree of maturity of the older concrete, shrinkage,
heat dissipation and the ability of the older concrete to withstand the load
imposed upon it by the fresh placement.
Once the concrete is deposited, consolidated and finished in its final
position, it shall not be distributed.
3.13 Construction Joints and Cold Joints
3.13.1 Construction Joints
It is always desirable to complete any concrete structure by continuous
pouring in one operation. However, due to practical limitation of methods
and equipment and certain design considerations, construction joints
are formed by discontinuing concrete at certain predetermined stages. These
joints will be formed in a manner specified in the drawings/ Instruction.
Vertical construction joints will be made with rigid stop-board forms having
slots for allowing passage of reinforcement rods and any other
embedments and fixtures that may be shown. Next stage concrete shall be
placed against construction joint as per clause 3.12. For water retaining
structures and leak-proof buildings suitable approved water bars will be
installed at the construction joints.
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3.13.2 Cold Joint
Where the location of the joints are not specified, it will be in accordance
with the following :
a) In a column, the joint shall be formed 75 mm below the lowest soffit
of the beam framing into it.
b) Concrete in a beam shall preferably be placed without a joint, but
if provision of a joint is unavoidable, the joint shall be vertical and
within the middle third of the span.
c) A joint in a suspended floor slab shall be vertical and within the
middle third of the span and at right angles to the principal
reinforcement.
d) Feather-edges in concrete shall be avoided while forming a joint.
e) A construction joint should preferably be placed in a low-stress zone
and at right angles to the direction of the principal stress.
f) In case the Contractor proposes to have a construction joint
anywhere to facilitate his work, the proposal should be sub-mitted
well in advance to the Engineer for study and approval without
which no construction joint will be allowed.
An advancing face of a concrete pour, which could not be covered by fresh
concrete before expiry of initial setting time (due to an unscheduled stoppage
or delay on account of breakdown in plant, inclement weather, low rate of
placement or any other reason), is called a cold joint. The Contractor should
always remain vigilant to avoid cold joints.
If, however, a cold joint is formed due to unavoidable reasons, the
following procedure shall be adopted for treating it :
a) If the concrete is so green that it can be removed manually and if
vibrators can penetrate the surface without much effort, fresh
concrete can be placed directly against the old surface. The old
concrete should be covered by fresh concrete as quickly as
possible and the joint thoroughly and systemetically vibrated.
b) In case concrete has hardened a bit more than (a) but can still be
easily removed by a light hand pick, the surface will be raked
thoroughly and the loose concrete removed completely without
disturbing the rest of the concrete in depth. A rich mortar layer
12 mm in thickness, will be placed on the cold joint fresh concrete
shall be placed on the mortar layer and the joint will be thoroughly
and systematically vibrated penetrating the vibrator deep into the old
layer of concrete.
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c) In case the concrete at the joint has become so stiff that it cannot
be remoulded and mortar or slurry does not rise inspite of
extensive vibration, the joint will be left to harden for at least 12 - 24
hrs. It will then be treated as a regular construction joint, after
cutting the concrete to required shape and preparing the
surface as described under clause 3.12.
3.14 Repairs, Finishes and Treatment of Concrete surfaces
3.14.1 Adequate and sound concrete surfaces, whether formed or unformed, can
be obtained by employing a concrete mix of proper design, competent
formwork, appropriate methods of handling, placing and consolidation by
experienced workmen.
Unsound concrete resulting from improper mix design, incompetent
methods, equipment and formwork, poor workmanship and protection will
not be accepted and will have to be dismantled, removed and replaced by
sound concrete. The Engineer may, at his sole discretion, allow to retain
concrete with minor defects provided the Contractor is able to repair it by
approved methods. All concrete work shall be inspected by the
Contractor immediately after the forms are removed and he will promptly
report occurence of any defects to the Engineer. All repair works will be
carried out as per the instructions and in the presence of the Engineer or
his representative. Generally, repair work will consist of any or all of the
following operations :
a) Sack rubbing with mortar and stoning with carborundum stone.
b) Cutting away the defective concrete to the required depth and shape.
c) Cleaning of reinforcement and embedments. It may be necessary to
provide an anti-corrosive coating on the inforcement.
d) Roughening by sand blasting or chipping.
e) Installing additional reinforcement/welded mesh fabric.
f) Dry packing with stiff mortar.
g) Plastering, guniting, shotcreting etc.
h) Placing and compacting concrete in the void left bycutting out
defective concrete.
i) Groting with a cement sand slurry of 1:1 mix.
j) Repairing with a suitable mortar either cement or resin modified
mortar.
k) Polyer modified patching and adhesive repair mortar for beams &
columns.
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3.14.2 Finishing Unformed Surface
A few typical and common cases of treatment of concrete surface are cited
below :
a) Floor
Whenever a non-integral floor finish is indicated, the surface of
reinforcement concrete slab shall be struck off at the specified levels
and slopes and shall be finished with a wooden float fairly smooth
removing all laitance. No overtrowelling, to obtain a very smooth
surface, shall be done as it will prevent adequate bond with the
subsequent finish. If desired by the Engineer, the surface shall be
scored and marked to provide better bond.
Where monolithic finish is specified or required, concrete shall be
compacted and struck off at the specified levels and slopes with
a screed, preferably a vibrating type and then floated with a wooden
float. Steel trowelling by hand or by rotary power float is then
started after the moisture film and shine have disappeared from the
surface and after the concrete has hardened enough to prevent
excess of fines and water to rise to the surface but not hard enough
to prevent proper finishing of aberrations. Steel trowelling properly
done will flatten and smoothen sandy surface left by wooden floats
and produce a dense surface free from blemishes, ripples and trowel
marks. A fine textured surface that is not slick and can be used where
there is likelihood of spillage of oil or water can be obtained by
trowelling the surface lightly with a circular motion after initial
trowelling keeping the steel trowel flat on the surface.
To provide a better grip the Engineer may instruct marking the floor
in a regular geometric pattern after initial trowelling.
b) Beams, Columns & Walls
If on such or any other concrete structure it is intended to apply
plaster or such concrete surfaces against which brickwork or other
allied works are to be built, the Contractor shall hack the surface
adequately as soon as the form is stripped off so that proper bond
can develop. Pattern, adequacy and details of such hacking shall
meet with the approval of the Engineer, who shall be informed to
inspect such surfaces before they are covered up.
3.15 Protection and Curing of concrete
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Newly placed concrete shall be protected by approved means from rain,
sun and wind. Concrete placed below the ground level shall be protected
against contamination from falling earth during and after placing.
Concrete placed in ground containing deleterious substances, shall be
protected from contact with such ground, or with water draining from
such ground, during placing of concrete and for a period of at least three
days or as otherwise instructed by the Engineer. The ground water around
newly poured concrete shall be kept to an approved level by pumping out or
other adequate means of drainage to prevent floatation or flooding. Steps, as
approved by the Engineer, shall be taken to protect immature concrete from
damage by debris, excessive loadings, vibration, abrasion, mixing with earth
or other deleterious materials, etc. that may impair the strength and
durability of the concrete.
As soon as the concrete has hardened sufficiently, it shall be covered either
with sand, polythene sheet, hessian, canvas or similar materials and kept
continuously wet for at least 14 (fourteen) days after final setting. Curing by
continuous sprinkling of water will be allowed if the Engineer is satisfied
with the adequacy of the arrangements made by the Contractor.
If permitted by the Engineer, curing compound like "ANTISOLE (WP)"
may be used for prevention of premature water loss in concrete and
thereby effecting curing of concrete . This type of curing compound shall
be sprayed on newly laid concrete surfaces to form thin film barrier against
premature water loss without disturbances to normal setting action. The
curing compound shall comply with ASTM requirements for acceptance.
The curing compound shall be applied following the final finishing operation
and immediately after disappearance of water sheen from concrete
surface.
It is important not to apply the curing compound when standing water is still
present on concrete.
The contractor shall arrange for the manufacturer's supervision.
The Contractor shall remain extremely vigilant and employ proper equipment
and workmen under able supervision for curing. The Engineer's
decision regarding the adequacy of curing is final. In case any lapse on
the part of the Contractor is noticed by the Engineer, he will inform the
Contractor or his supervisor verbally or in writing to correct the
deficiency in curing. If no satisfactory action is taken by the Contractor
within 3 (three) hours of issuance of such instruction, the Engineer will be
at liberty either to employ sufficient means through any agency to make
good the deficiency and entirely at the discretion of the Engineer.
3.16 Reinforcement
Mild steel round bars, cold twisted and deformed bars as medium tensile
or high yield strength steel, plain hard drawn steel wire fabric etc., will be
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used as reinforcement as per drawings and directions. In an aggressive
environment an anti-corrosive coating on the reinforcement may be provided
as per IS:9077, as shown on the drawing or as directed by the Engineer.
3.16.1 Bar Bending Schedules
3.16.2 Cleaning
The Contractor shall submit to the Engineer for approval Bar Bending
Schedules with working drawings in triplicate, showing clearly the
arrangements proposed by the Contractor to match available stock of
reinforcing steel, within one month of receipt of the Letter of Intent or of
the receipt of the relevant design drawings, whichever is later. Upon
receipt of the Engineer's final approval of the Bar Bending Schedule
and drawings, the Contractor shall submit 6 (six) prints of the final drawings
with one reproducible print after incorporating necessary modifications or
corrections, for final record and distribution. Approval of such detailed
drawings by the Engineer shall not relieve the Contractor of his
responsibility for correctness nor of any of his obligations to meet the other
requirements of the Contract.
All steel for reinforcement shall be free from loose scales, oil, grease,
paint or other harmful matters immediately before placing the concrete.
3.16.3 Cutting & Bending of Reinforcement
Unless otherwise specified, reinforcing steel shall be bent in accordance
with the procedure specified in IS:2502 or as approved by the Engineer.
Bends and shapes shall comply strictly with the dimensions
corresponding to the approved Bar Bending Schedules. Bar Bending
Schedules shall be rechecked by the Contractor before any bending is
done.
No reinforcement shall be bent when already in position in the work, without
approval of the Engineer, whether or not it is partially embedded in
concrete. Bars shall not be straightened in a manner that will injure the
material. Rebending can be done only if approved by the Engineer.
Reinforcing bars above 16 mm diameter shall be bent by machine
producing a gradual and even motion. Bars of 16 mm or below may be
bent by hand. All the bars shall be cold bent unless otherwise
approved. Bending hot at a cherry-red heat(not exceeding 845C) may
be allowed under very exceptional circumstances except for bars whose
strength depends on cold working. Bars bent hot shall not be cooled by
quenching.
Reinforcing bars, whether high yield or mild steel shall be cut using either
hand held shears, guillotines or foot operated pneumatic cutters. Cutting
bars using cold chisels may be allowed by the Engineer at exceptional
cases.
3.16.4 Placing in Position
(PCA.774.S034sca2) V.II-D2/S-III : 26

DCPL-K4A02
3.16.5 Welding
3.16.6 Control
All reinforcements shall be accurately fixed and maintained in position
as shown on the drawings by such approved and adequate means like
mild steel chairs and/or concrete spacer blocks irrespective of whether
such supports are payable or not. Bars intended to be in contact at
crossing points, shall be securely tied together at all such points by No. 20
G annealed soft iron wire. Tack welding of bars should not be done
unless permitted by the Engineer. Binders shall tightly embrace the
bars with which they are intended to be in contact and shall be securely
held. The vertical distance between successive layers of bars shall be
maintained by provision of mild steel spacer bars. They should be spaced
such that the main bars do not sag perceptibly between adjacent spacers.
Before actual placing, the Contractor shall study the drawings thoroughly
and inform the Engineer in case he feels that placement of certain bars is
not possible due to congestion. In such cases he should not start placing
any bar before obtaining clearance from the Engineer.
Normal bond laps in reinforcement may be placed by lap or butt welding
reinforcement bars, if asked by the Engineer, under certain conditions.
The work should be done with suitable safeguards in accordance with
relevant Indian Standards for welding of mild steel bars used in
reinforced concrete construction as per IS:2751 and IS:456. Welded mesh
fabrics conforming to IS:1566 may also be used if specified in the
Schedule of Items and Drawings.
The placing of reinforcements shall be completed well in advance of
concrete pouring. Immediately before pouring, the reinforcement shall be
examined by the Engineer for accuracy of placement and cleanliness.
Necessary corrections as directed by him shall be carried out. Laps and
anchorage lengths of reinforcing bars shall be in accordance with
IS:456, unless otherwise specified. If the bars in a lap are not of the same
diameter, the smaller will guide the lap length. The laps shall be staggered
as far as practicable and as directed by the Engineer. Arrangements for
placing concrete shall be such that reinforcement in position do not have
to bear extra load and get disturbed.
The cover for concrete over the reinforcements shall be as shown on the
approved drawings unless otherwise directed by the Engineer. Where
concrete blocks are used for ensuring the cover and positioning
reinforcement, they shall be made of mortar not leaner than 1 (one) part
cement to 2 (two) parts sand by volume and cured in a pond for at least 14
(fourteen) days. The type, shape, size and location of the concrete blocks
shall be as approved by the Engineer.
(PCA.774.S034sca2) V.II-D2/S-III : 27

DCPL-K4A02
3.17 Cold Weather Concreting
When conditions are such that any operation of concreting may be
expected to be done at 5 Deg.C atmospheric temperature or below the
work shall conform to the requirement of Clause 14 of IS:456 and IS:7861.
(Part. II).
3.18 Hot Weather Concreting
When depositing concrete in very hot weather, the Contractor shall take
all precautions as per IS:7861 (Part-I) and stagger the work to the cooler
parts of the day to ensure that the temperature of wet concrete used in
massive structures does not exceed 40 Deg.C while placing. Positive
temperature control by precooling, postcooling or any other method, if
required, will be specified.
3.19 Concreting under water
3.20 Form Work
3.20.1 General
When it is necessary to deposit concrete under water it shall be done in
accordance with the requirements of clause 14 of IS:456.
Formwork shall conform to the shape, grade, lines, levels and dimension
as shown on the drawings. The contractor shall prepare design & working
drawings for formwork & temporary support system for important structures
and get them approved by the Engineer prior to commencement of actual
work.
Materials used for the formwork inclusive of the supports and centering shall
be capable of withstanding the working load and remain undistorted
throughout the period it is left in service. All supports and scaffolds should
be manufactured from structural or tubular steel except when specifically
permitted otherwise by the Engineer.
The centering shall be true to vertical, rigid and thoroughly braced both
horizontally and diagonally. Rekers are to be used where forms are to
support inclined members. The forms shall be sufficiently strong to
carry without undue deformation, the dead weight of the concrete as a
liquid as well as the working load, in case the Contractor wishes to adopt
any other design criteria, he has to convince the Engineer about its
acceptability before adopting it. Where the concrete is vibrated, the
formwork shall be strong enough to withstand the effects of vibration
without appreciable deflection, bulging, distortion or loosening of its
components. The joints in the formwork shall be sufficiently tight to prevent
any leakage of slurry or mortar.
To achieve the desired rigidity, tie bolts, spacer blocks, tie wires and
clamps as approved by the Engineer shall be used but they must in no way
(PCA.774.S034sca2) V.II-D2/S-III : 28

DCPL-K4A02
impair the strength of concrete or cause stains or marks on the finished
surface. Where there are chances of these fixtures being embedded, only
mild steel or concrete of adequate strength shall be used.
Alternatively, except in case of water retaining structures through rods
and the tie bolts shall be sleeved with PVC conduits to allow retraction of
the ties on removal of the shutters. Where required, the annulus of the
conduits will be filled with expanding mortar to seal the void. Bolts
passing completely through liquid retaining walls/slabs for the purpose of
securing and aligning the formwork shall not be used.
The formwork shall be such as to ensure a smooth uniform surface free
from honeycombs, air bubbles, bulges, fins and other blemishes. Any
blemish or defect found on the surface of the concrete must be brought to
the notice of the Engineer immediately and rectified as directed by him.
For exposed interior and exterior concrete surfaces of beams, columns and
wall, plywood or other approved form shall be thoroughly cleaned and tied
together with approved corrosion- resistant devices. Rigid care shall be
exercised in ensuring that all column forms are plumb and true and
thoroughly cross braced to keep them so. All floor and beam centering
shall be crowned not less than 8 mm in all directions for every 5 metres
span.Unless specifically described on the drawings or elsewhere to the
contrary, bevelled forms 25 mm by 25 mm shall be fixed in the form-work
at all corners to provide chamfering of the finished concrete edges. The
formwork should lap and be secured sufficiently at the lift joints to prevent
bulges and offsets.
Temporary openings for cleaning, inspection and for pouring concrete shall
be provided at the base of vertical forms and at other places, where they
are necessary and as may be directed by the Engineer. The temporary
openings shall be so formed that they can be conveniently closed when
required, during pouring operations without leaving any mark on the
concrete.
3.20.2 Cleaning and Treatment of Forms
All parts of the forms shall be thoroughly cleaned of old concrete, wood
shavings , saw dust, dirt and dust sticking to them before they are fixed in
position. All rubbish, loose concrete, chippings, shavings, saw dust etc.
shall be scrupulously removed from the interior of the forms before
concrete is poured. Compressed air jet and/or water jet along with wire
brushes, brooms etc. shall be used for cleaning. The inside surface of the
formwork shall be treated with approved non-staining oil based shutter
release agent like "Separol/Sika form oil/ Siparol Concentrate" before it is
placed in position. Care shall be taken that oil or other compound does
not come in contact with reinforcing steel or construction joint surfaces.
(PCA.774.S034sca2) V.II-D2/S-III : 29

3.20.3 Design
DCPL-K4A02
They shall not be allowed to accumulate at the bottom of the formwork.
The oiling of the formwork will be inspected just prior to placement of
concrete and redone wherever necessary.
The formwork shall be so designed and erected that the forms for slabs
and the sides of beams, columns and walls are independent of the
soffits of beams and can be removed without any strain to the concrete
already placed or affecting the remaining formwork. Removing any
props or repropping shall not be done except with the specific
approval of the Engineer. If formwork for column is erected for the full
height of the column, one side shall be left open and built up in sections,
as placing of concrete progress. Wedges, spacer bolts, clamps or other
suitable means shall be provided to allow accurate adjustment and
alignment of the formwork and to allow it to be removed gradually
without jarring the concrete.
The design of formwork shall take into account all vertical and lateral loads
that the forms will carry or be subjected to during the construction
process. Besides weight and pressures of reinforced concrete and
weight of the forms themselves, the design shall consider loading due
to unsymmetrical placement of concrete ; impact from dumping of concrete
; movement of men and construction equipment ; wind action and any other
imposed load during construction. The contractor shall assess the
magnitude of vertical live load to be taken for design of formwork duly
considering his method, sequence and rate of pouer of concrete.
However, minimum design vertical live load to be considered shall be 750
kg/sqm excluding weight of concrete.
3.20.4 Inspection of Forms
Casting of Concrete shall start only after the formwork has been inspected
and approved by the Engineer. The concreting shall start as early as
possible within 3 (three) days after the approval of the formwork and
during this period the formwork shall be kept under constant vigilance
against any interference. In case of delay beyond three days, a fresh
approval from the Engineer shall be obtained.
3.20.5 Removal of Forms
Before removing any formwork, the Contractor must notify the Engineer
well in advance to enable him to inspect the concrete if he so desires.
The Contractor shall record on the drawing or in any other approved
(PCA.774.S034sca2) V.II-D2/S-III : 30

DCPL-K4A02
manner, the date on which concrete is placed in each part of the work and
the date on which the formwork is removed therefrom and have this
record checked and countersigned by the Engineer regularly.
The Contractor shall be responsible for the safe removal of the formwork
and any work showing signs of damage through premature removal of
formwork or loading shall be rejected and entirely reconstructed by
him. The Engineer may, however, instruct to postpone the removal of
formwork if he considers it necessary.
Forms for various types of structural components shall not be removed
before the minimum periods specified herein and the removal after the
minimum periods shall also be subject to the approval of the Engineer in
each case.
(PCA.774.S034sca2) V.II-D2/S-III : 31

DCPL-K4A02
TABLE - IV
SCHEDULE OF REMOVAL OF FORM
________________________________________________________________________
Ordinary Portland
Rapid Hardening Portland
Cement Concrete
Cement Concrete
________________________________________________________________________
Part of Temperature Deg.C Temperature Deg.C
Structure
________________________________________________________________________
Above 40 Deg.- 20 Deg.-Below Above 40 Deg.- 20 Deg.- Below
40 Deg.C 20 Deg. 5 Deg. 5 Deg. 40 Deg. 20 Deg. 5 Deg. 5 Deg.
________________________________________________________________________
Days Days Days Days
Days Days Days Days
________________________________________________________________________
a) Columns 2 1 1 Do not 1 1 1 Do not
& Walls remove remove
forms until
forms
b) Beam sides 3 2 3 site cured 2 1 1 until
test speci-
site
c) Slabs, 10 7 8 men develop 7 4 5 cured
125 mm at least test
50% of the specimd)
Slabs over specified en dev-
125 mm 28 days elop at
thick and strength least
soffit of 18 14 16 12 8 9 50% of
minor beams
the specified
28
e) Soffit of 24 21 22 14 10 12 days
main beams
strength
________________________________________________________________________
Wherever exposed surfaces of concrete can be effectively sealed to prevent loss of
water, the periods specified for temperature above 40 Deg.C can be reduced to those of
the temperature range of 20 Deg.C to 40 Deg.C subject to approval of the Engineer.
Construction joints in beams, if required to be provided, will be located within the middle
third of span according to clause 3.13.1(b) of this specification. In such cases,
however, entire span of beam shall have to be kept supported by formwork till its removal
for the portion of beam, cast at a later date, is due and so approved by the Engineer.
If any type of cement other than ordinary portland cement and Rapid
hardening portland cement is used the time of removal or forms shall be
revised as approved by the Engineer such that the strength of this cement
(PCA.774.S034sca3) V.II-D2/S-III : 32

3.20.6 Tolerance
DCPL-K4A02
at the time of removal of forms match with strength of portland cement at
the time of removal of form as mentioned above . This has to be supported
by regular tests.
The formwork shall be so made as to produce a finished concrete, true
to shape, lines, levels, plumb and dimensions as shown on the drawings
subject to the following tolerances unless otherwise specified in this
Specification or drawings or directed by the Engineer :
For
a) Sectional dimension - + 5 mm
b) Plumb - 1 in 1000 of height
c) Levels - + 3 mm before any
deflection has taken place
The tolerance given above are specified for local aberrations in the finished
concrete surface and should not be taken as tolerances for the entire
structure taken as a whole or for the setting and alignment of formwork,
which should be as accurate as possible to the entire satisfaction of the
Engineer. Any error, within the above tolerance limits or any other as may
be specially set up by the Engineer, if noticed in any lift of the structure
after stripping of forms, shall be corrected in the subsequent work to
bring back the surface of the structure to its true alignment.
3.20.7 Re-use of Forms
3.20.8 Classification
Before re-use, all forms shall be thoroughly scraped, cleaned, joints
and planes examined and when necessary repaired, and inside
surface treated as specified hereinbefore. Formwork shall not be
used/re-used if declared unfit or unserviceable by the Engineer.
Generally, the 'ordinary' class formwork shall be used unless otherwise
directed by the Engineer :
a) Ordinary : These shall be used in places where ordinary
surface finish is required and shall be composed of
steel and/or approved good quality partially seasoned
timber.
b) Plywood : These shall be used in exposed surfaces, where
a specially good finish is required and shall be made
of approved brand of heavy quality plywood to
produce a perfectly uniform and smooth surface
conforming to the shape described in the drawing with
(PCA.774.S034sca3) V.II-D2/S-III : 33

DCPL-K4A02
required grain texture on the concrete. Re-use may
only be permitted after special inspection and approval
by the Engineer. He may also permit utilisation of
used plywood for the 'ordinary' class, if it is still in
good condition.
c) Ornamental: These shall be used where ornamental and curved
surface are required and shall be made of selected
best quality well seasoned timbers or of plywood,
which can be shaped correctly.
3.21 Opening, Chases, Grooves, Rebates, Blockouts etc.
The Contractor shall leave all openings, grooves, chases, etc. in
concrete work as shown on the drawings or as specified by the Engineer.
3.22 Anchor Bolts, Anchors, Sleeves, Inserts, Hangers/Conduits/Pipe and Other
misc. Embedded Fixtures. The Contractor shall build into concrete work all
the items noted below and shall embed them partly or fully as directed
and secure the same as may be required. The materials, if required to be
supplied by the Contractor, shall be as specified and be of best quality
available according to relevant Indian Standards of approved manufacture
and to the satisfaction of the Engineer. Exposed surfaces of embedded
materials are to be painted with one coat of approved anti-corrosive paint
and/or bituminous paint. If welding is to be done subsequently on the
exposed surface of embedded material the paint shall be cleaned off the
member to a minimum length of 50 mm beyond each side of the weld line.
Necessary templates, jigs, fixtures, supports etc. shall be used as may be
required or directed by the Engineer. Items to be embedded.
a) Inserts, hangers, anchors, frames around openings, manhole
covers, frames, floor clips, sleeves conduits and pipes.
b) Anchor bolts and plates for machinery, equipment and for structural
steel work.
c) Steel structurals to be left embedded for future extension, special
connection etc.
d) Lugs or plugs for door and window frames occurring in
concrete work.
e) Flashing and jointing in concrete work.
f) Any misc. embedments and fixture as may be required.
(PCA.774.S034sca3) V.II-D2/S-III : 34

DCPL-K4A02
Correct location and alignment, as per drawings/instruction of all these
embedded items shall be entirely the responsibility of the Contractor.
3.23 Expansion and Isolation Joints
3.23.1 General
Expansion and isolation joints in concrete structures shall be provided at
specific places as per details indicated on the drawings. The materials and
types of joints shall be as specified hereinafter. In case of liquid
retaining structures, additional precautions shall be taken to prevent
leakage of liquids as may be specified on the drawings or as directed by the
Engineer. All materials are to be procured from reliable manufacturers and
must have the approval of the Engineer. Where it is the responsibility of the
Contractor to supply the material, the Engineer may demand test
certificates for the materials and/or instruct the Contractor to get them tested
in an approved laboratory. Joints shall be formed true to line, level, shape,
dimension and quality as per drawings and specifications. Prior
approval of the method of forming the joints should be obtained from the
Engineer before starting the work.
3.23.2 Bitumen Board/Expanded Polystyrene Board
a) Bitumen Board
Bitumen impregnated fibre board of approved manufacturer as per
IS:1838 may be used as fillers for expansion joints. It must be
durable and waterproof. It shall be compressible and possess a
high degree of rebound. The dimensions of the board should be
equal to that of the joint being formed. It should, preferably be
manufactured in one piece, matching the dimension of the joint and
not prepared by cutting to size smaller pieces from larger boards at
site. At the exposed end, the joint shall be sealed with approved
sealing compound to a depth of at least 25 mm after application of
an approved primer. The sealing compound and the primer shall
be applied as specified by the manufacturer.
b) Expanded Polystyrene Boards
3.23.3 Joint Sealing Strips
If required, commercial quality\of expanded polystyrene
products commonly used for thermal insulations may also be used
as filler material in expansion joints. The thickness may vary from
12 mm to 50 mm. The material will have to be procured from
reliable manufacturers as approved by the Engineer. The method of
installations will be similar to that recommended by the
manufacturers for fixing on cold storage walls. A coat of Bitumen
paint may have to be applied on the board against which concrete will
be placed.
(PCA.774.S034sca3) V.II-D2/S-III : 35

DCPL-K4A02
Joint sealing strips may be provided at the construction, expansion and
isolation joints as a continuous diaphragm to contain the filler material
and/or to exclude passage of water or any other material into or out of the
structure.
The sealing strips will be non-metallic like rubber or P.V.C.
Sealing strips will not have any longitudinal joint and will be procured and
installed in largest practicable lengths having a minimum number of
transverse joints. The material is to be procured from reputed
manufacturers having proven records of satisfactory supply of joint strips
of similar make and shape for other jobs. The jointing procedure shall be
as per the manufacturer's recommendations, revised if necessary, by the
Engineer. The Contractor is to supply all labour and material for
installation including the material and tools required for jointing, testing,
protection, etc. If desired by the Engineer, joints in rubber seals may have
to be vulcanised.
Non - metallic sealing strips will be normally in Rubber or P.V.C. Rubber
or P.V.C. joint seals can be of shape having any combination of the
following features :
i) Plain
ii)
iii)
iv)
Central bulb
Dumb-bell or flattened ends
Ribbed and Corrugated Wings
v) V shaped
As these types of seals can be easily handled in very large lengths,
transverse joints will be allowed only under unavoidable circumstances
and with the specific approval of the Engineer.
The method of forming these joints, laps etc. shall be as specified by the
Manufacturer and/or as approved by the Engineer taking particular care
to match the central bulbs and the edges accurately.
a) Rubber Sealing Strips
The minimum thickness of Rubber sealing strips shall be 3 mm and
the minimum width 100 mm. The actual size and shape will be as
shown in drawings of items and/or as directed by the Engineer. The
material will be natural rubber and be resistant to corrosion,
abrasion and tear and also to attacks from the acids, alkalis and
(PCA.774.S034sca3) V.II-D2/S-III : 36

DCPL-K4A02
chemicals normally encountered in service. The physical properties
will be generally as follows. The actual requirements may be
slightly different as decided by the Engineer :
Specific Gravity : 1.1 to 1.15
Shore Hardness : 65A to 75A
Tensile Strength : 25 - 30 N/Sq.mm
Maximum Safe
Continuous
Temperature : 75 Deg.C
Ultimate Elongation : Not less than 350%
b) P.V.C. Sealing Strips
The minimum thickness of P.V.C. sealing strips will be 3 mm and
the minimum width 100 mm. The actual size and shape will be as
shown in drawings/schedule of items and/or as directed by the
Engineer. The material should be of good quality Polyvinyl
Chloride highly resistant to tearing, abrasion and corrosion as
well as to chemicals likely to come in contact with during use.
The physical properties will generally be as follows. The actual
requirements, which will be directed by the Engineer, may vary
slightly :
Specific Gravity : 1.3 to 1.35
Shore Hardness : 60A to 80A
Tensile Strength : 10 - 15 N/Sq.mm
Maximum Safe
Continuous
Temperature : 70 Deg.C
Ultimate Elongation : Not less than 275%
(PCA.774.S034sca3) V.II-D2/S-III : 37

DCPL-K4A02
3.23.4 Joint Sealing Compound
When directed, the gap in expansion joints shall be thoroughly cleaned
and bitumen compound laid as per manufacturer's specifications. The
compound to be used shall be of approved manufacture and shall conform
to the requirements of IS:1834.
Alternatively, when directed , the expansion Joints may be filled with joint
sealing compound like "Sikalastic" or approved equivalent and shall be
applied as per manufacturer's specification.
3.23.5 Isolation Joints
3.23.6 Rubber Pad
Strong and tough alkathene or PVC sheet about 1 mm in thickness and as
approved by the Engineer shall be used in isolation joints. It shall be fixed
by an approved adhesive compound on the cleaned surface of the already
set concrete, to cover it fully. Fresh concrete shall be laid against the
sheet, care being taken not to damage the sheet in any way.
Hard foundation quality rubber pads of required thickness and shapes shall
be put below machine or other foundations as shown on the drawings or as
directed by the Engineer. The rubber shall have a unit weight of 1500
Kg/Cu.m, a shore hardness - 65A to 70A and be of best quality of
approved manufacture, durable, capable of absorbing vibration and must be
chemically inert in contact with moist or dry earth or any other deleterious
material expected under normal conditions.
3.24 Grouting under Machinery or Structural Steel Bases
If required, grouting under base plates of machines or structural steel
etc. shall be carried out by the Contractor. In general, the mix shall be 1 (one)
part cement and 1 (one) part sand and just enough water to make it flow as
required. The areas to be grouted shall be cleaned thoroughly with
compressed air jet and/or with water in locations where accumulated
surplus water can be removed. Where directed by the Engineer, 6 mm
down stonechips may have to be used in the mix. Surface to be grouted
shall be kept moist for at least 24 hours in advance. The grout shall be
placed under expert supervision, so that there is no locked up air. Edges
shall be finished properly. If desired by the Engineer, admixtures like
Aluminium powder, 'Ironite' etc. may have to be added with the grout in
proportions to be decided by the Engineer. Admixture, if directed to be
added, will be measured and paid separately.
(PCA.774.S034sca3) V.II-D2/S-III : 38

DCPL-K4A02
Alternatively non-shink , free flow, cementious grout like "Sikagrout 214/
Ankor NSG" or approved equivalent specifically selected for the type
of equipment to be located (vibrating, static etc.) may also be used for
grouting as per manufacturer's specification with necessary approval of the
Engineer.
3.25 Precast Concrete
The Specification for precast concrete will be similar as for the cast-in-place
concrete described herein and as supplemented in this section. All
precast work shall be carried out in a yard made for the purpose.
This yard shall be dry, properly levelled and having a hard and even as well
as well drained surface to prevent excessive uneven settlement due to
softening of soil during casting & curing. If the ground is to be used as a
soffit former of the units, it shall be paved with concrete or masonry and
provided with a layer of plaster (1:2 proportion) with smooth neat cement
finish or a layer of M.S. sheeting. Where directed by the Engineer, casting
will have to be done on suitable vibrating table. The yard, lifting
equipment, curing tank, finished material storage space etc. shall be
designed such that the units are not lifted from the mould before 10 (Ten)
days of curing and can be removed for erection after 28 (twenty eight)
days of curing. The moulds shall preferably be of steel or of timber lined
with G.I. sheet metal and must be rigid enough to prevent distortion during
placing and compaction of the concrete.
Other than normal curing by applying water through spray nozzles or
perforated hose curing by high pressure steam, steam vapour or other
accepted processes may also be employed to accelerate the hardening of
the concrete and to reduce the curing time.
Lifting hooks, where necessary or as directed by the Engineer, shall be
embedded in correct position of the units to facilitate erection, even though
they may not be shown on the drawings, and shall be burnt off and
finished after erection.
All members shall be imdelibly marked with a unique identification
mark on a surface which will not be permanently exposed to show on
which production line they were manufactured , their type , the class of
concrete, the data of casting and if they are of a symmetrical section the
face which will be uppermost when the member is in its correct position
after erection.
Precast concrete units, when ready, shall be transported to site by suitable
means approved by the Engineer. Care shall be taken to ensure that no
damage occurs during transportation. All adjustments, levelling and
(PCA.774.S034sca3) V.II-D2/S-III : 39

DCPL-K4A02
plumbing shall be done as per instructions of the Engineer. The
Contractor shall render all help with instruments, materials and men to the
Engineer for checking the proper erection of the precast units.
After erection and alignment, the joints shall be filled with grout or concrete
as directed by the Engineer. If centerings have to be used for supporting the
precast units, they shall not be removed until the joints have attained
sufficient strength and in no case before 14 (fourteen) days. The joint
between precast roof planks shall be pointed with 1:2 cement : sand mortar
where called for in the drawings.
3.26 Waterproofing of Concrete Structure
3.26.1 General
Waterproofing of concrete structures shall be done by either suitable
extraneous treatments like applying waterproofing paints like "Sikatop Seal"
fixing bitumen felts etc. or internally by suitable design of the concrete
mix, addition of suitable admixtures conforming to IS:2645 and equivalent
American or British codes in the concrete or mortar at the time of mixing
and/or installing water bars at the joints.
The design, material and workmanship shall conform to the relevant I.S.
Codes where applicable. The Engineer's approval of the materials shall be
obtained by the Contractor before procurement. If desired by the
Engineer, test certificates for the materials and samples shall be submitted by
the Contractor. The materials shall be of best quality available indigenously,
fresh clean and suitable for the duties called upon.
3.26.2 Water Bar/Seal/Special Treatment of Construction Joint
Water bearing structures and underground structures may have water
bar/seals installed at the joints. They may be rubber or P.V.C. The
materials and installation will be as described under Clause 3.23.3.
Construction joint should be provided as per clause 3.13.1 with or without
water bar / Seal as shown on the drawing. In case of water bars being
used at the construction Joint, fixing of the same has to be done carefully so
that the water bar is not disturbed during concreting. The construction joint
shall also be treated by any one of the following methods :
Method 1 : A surface retarder in the form of a thixotropic gel shall be
applied on the joint surface of the previous pour in case of joint on the wall
and in case of floor the same shall be applied on the formwork against
which previous pour of concreting shall be done. The retarder may be liquid
or paste form depending on the type of formwork. The formwork shall
be removed within 24 hours after concreting. Within 2 hours of striking of the
formwork the retarder shall be washed off with strong water jet to make
surface rough and clean. Then a rich cement mortar using cement, sand
and aggregates (maximum size 8 mm) along with synthetic rubber
emulsion type water resistant bonding agent shall be applied for a depth of
50 mm just before pouring the next stage of concreting in case of walls.
(PCA.774.S034sca3) V.II-D2/S-III : 40

DCPL-K4A02
The above bonding agent will be mixed with water which will be used for
making the cement mortar. The proportion of mixing of this bonding agent
with water shall be as per manufacturer's specification. In case of floor
joint, however, after washing of retarder a solvent free two component
epoxy resin bonding agent will be used at the joint before the next pour of
concrete. The above bonding agent shall have the following properties
after 28 days :
Compressive strength - 55 to 60 N /Sq. mm
Flexural Strength - 25 to 30 N /Sq. mm.
Tensile strength - 15 N Sq. mm ( approx )
Bonding strength to concrete - 3 N / Sq. mm ( approx )
Bonding strength to steel - 20 N / Sq. mm ( approx)
The whole operation shall be done as per manufacturer's specification.
The contractor shall provide manufacturer's supervision.
Method 2 : One row of threaded nozzles at regular intervals not exceeding
1.5 m centre to centre shall be placed in concrete along the construction
joint during casting. Injection of cement water together with a suitable
waterproof expanding grouting admixture of approved quality shall be
done through the nozzles after the construction joint in walls and slabs.
The injection shall be done under pressure of approximately 2 to 4 Kg/Sq
cm . The nozzles shall be sealed off with suitable admixture after the
injection is over. The whole operation shall be carried out as per
manufacturer's specification and supervision.
3.26.3 Waterproofing Admixtures
The waterproofing admixture for concrete and cement mortar / plaster shall
conform to relevant IS code. The admixture shall not cause decrease of
strength of concrete / plaster at any stage and it is free from chlorides and
sulphates. The admixture shall not affect the setting time by more than 5 %
The maximum permissible dosage of admixture will be 3% (three
percent) by weight of cement but a lower dosage will always be preferred.
The product shall be stored in strong moisture proof packings.
However, in case of important structures where M25 or higher grade
concrete is specified, the use of melamine based, high range water
resistant concrete admixture shall be used to provide a waterproof
concrete around 410 Kg/ Cm.m a melamine based super plasiticizer will be
preferable.
a) In concrete : The approved admixture shall be based on
modified lignosulphonate like "Plastocrete -
(PCA.774.S034sca3) V.II-D2/S-III : 41

DCPL-K4A02
N/Super" or approved equivalent. The method
of application and other details shall conform to
the manufacturer's specification and/or as
instructed by the Engineer. The Contractor
shall have the services of the manufacturer's
supervisor to supervise the work, if desired by
the Engineer.
b) In Plaster : The concrete surface, to be plastered, shall
be hacked to Engineer's satisfaction,
cleaned thoroughly and kept wetted for 24
hours. The plaster shall be in cement sand
mortar mixed in proportion varying from 1:1 to
1:4 by volume along with the approved
waterproofing admixture like "Noleak CP/Sika
Latex" or approved equivalent and laid in
appropriate thickness and in layers not
exceeding 15 mm/layer or as per
manufacturer's specification. The additive shall
be of quality and type approved by the
Engineer. If desired by the Engineer, the
Contractor shall have the work supervised by
the manufacturer's supervisor. On completion,
the plastered surface shall be cured
continuously for a minimum period of 14 days
like concrete.
3.26.4 Bituminous or Tar Coating on External Surface
The surface to be waterproofed shall be rendered absolutely dry, clean and
dust free. The surface shall be sand papered, cleaned and completely coated
with hot coal tar pitch of approved manufacturer and quality as per IS:216
(not heated above 375 Deg.F) using not less than 2 Kg. per Sq.M. or with hot
asphalt i.e., bitumen according to IS:73 (not heated above 400 Deg.F) using
not less than 1.5 kg. per Sq.M. When the first coat has completely dried up
and approved by the Engineer, the second coat shall be applied in the same
manner using not less than 1.25 Kg. per Sq.M. in case of coal tar and 1 Kg.
per Sq.M. in case of asphalt. Immediately after application of the second coat
and before it is dried up, sand shall be spread on the surface to cover it
completely. Sufficient time shall be allowed after spreading of sand before
backfilling is done in order to allow the final coat to dry up completely. In
place of hot application by coal tar / asphalt the coating of the outside
surfaces of walls may be carried out using a ready to use liquid, bituminous
emulsion/rubber protective coating of approved manufacturer.
3.26.5 Protective Coating on Inside Surface
Two coats or cement based to components polymer modified flexible
protective and waterproofing slurry having 1 mm thick for each coat shall be
(PCA.774.S034sca3) V.II-D2/S-III : 42

DCPL-K4A02
applied on the walls/ floor after proper surface preparation as mentioned
above. The slurry shall be applied by brush.
3.26.6 Polyethelene Films : Application in Walls or base of Structures
Waterproof treatment shall be applied as outlined and as per sequence
given hereunder :
i) the concrete surface shall be made smooth with 12 mm cement
plaster 1:6
ii) apply hot bitumen 80/100 grade (IS:73-1961) at the rate of 1.0
Kg/Sq.m minimum
iii)
lay black polyethelene film 250 micron (IS:2508-1977) with cut
back bitumen adhesive in overlaps over hot bitumen surface,
gently pressed, taking care not to puncture the film.
(PCA.774.S034sca3) V.II-D2/S-III : 43

DCPL-K4A02
Alternatively, the overlaps shall be heat sealed by an electric iron
having three parallel sealing bars. A long piece of plywood is to be
placed below the polyethelene film to be heat sealed. On the
plywood a rubber gasket is to be laid to provide a cushion for better
welding of the film. On the rubber padding, a celophane tape is to
be spread and on this the LDPE film, with 100 mm overlap, is to
be stretched. On the overlapped film another celophane tape is to
be placed to prevent the heat sealer from sticking to the LDPE film.
After this, the electric iron is to be pressed on the overlap joint for
sufficient time so as to allow perfect welding. The operation is to be
repeated for subsequent lengths of joints. After heat sealing, the
celophane tape is to be removed and the joints are to be tested for
leaks.
iv)
Lay 100 gm brown craft paper laminated with a layer of straight run
bitumen.
v) Lay hot bitument 80/100 grade (IS:73-1961) at 1.0 Kg/Sq.m
minimum.
vi)
vii)
viii)
ix)
Lay 250 micron polyethelene film as second layer similar to (iii) above.
Lay second layer of 100 gm. brown craft paper laminated similar to
(iv) above.
Apply hot bitumen (straight run grade) to IS:73-1961 at 1.0 Kg/Sq.m
dusted with fine sand.
Protecting with a layer of 75 mm plain cement concrete M-100, or a
layer of brick laid in cement mortar 1:6. In case of wall apply a 12
mm thick plaster as shown on the drawing or a protective brick wall
in 1:6 cement mortar as shown on the drawing.
3.27 Protective coating on Concrete Surface
3.27.1 On Foundation
The outside faces of foundation of important structures will be protected from
adverse effect of soil/ underground water, if shown on drawing or instructed
by the Engineer , by using bitumen emulsion protective coating of
approved manufacturer.
3.28 Waterproofing by Pressure /Chemical Grouting
Where required, waterproofing for underground concrete structure shall
be done by injecting high polymer based non- shrink waterproof grouting
compound through nozzle under pressure as per manufacturer's
recommendation. The pressure during injection shall not be less than 2.5
kg/Sq.cum and the thickness of epoxy resinous emulsion waterproof paint
(to be applied on the external surface of walls/slabs) shall not be less than
700 microns.
(PCA.774.S034sca3) V.II-D2/S-III : 44

DCPL-K4A02
4.0 SAMPLING AND TESTING
4.1 General
4.2 Cement
4.3 Aggregates
4.4 Water
The Contractor shall carry out all sampling and testing in accordance with
the relevant Indian Standards and as supplemented herein for the
following items at his own cost unless otherwise specified in this
specification. The Contractor shall get the specimens tested in a laboratory
approved by the Engineer and submit to the Engineer the test results in
triplicate within 3 (three) days after completion of the test.
Representative samples will be taken from each consignment of cement
received from the manufacturer/supplier for carrying out the tests for
fineness (by hand sieving), setting time and compressive strengths.
Soundness Tests may also be required to be carried out if required by
the Engineer. The tests shall be carried out free of charge by the Owner if
cement is supplied by him. In case the Contractor is directed to arrange
for the supply of cement as per the terms and conditions of the Contract the
tests shall be carried out by him. In case due to any circumstances, the
agency of supply is changed in the middle of the Contract, the party who
bore the original contractual obligation will carry on with the test, free of
charge to the other, till the end of the job. No cement from a particular
consignment/batch will be used on the works unless satisfactory 3 (three)
days and 7 (seven) days test results for compressive strength are known.
The Owner, Engineer and Contractor will jointly associate themselves with
the tests irrespective of whether they are carried out by the Owner or the
Contractor. These tests are of great importance as their results will have a
bearing on the acceptance of concrete or otherwise as per the terms and
conditions of the Contract.
The Contractor shall carry out any or all the tests aggregates as may be
required by the Engineer in accordance with IS:2386 PARTS-I to VIII. The
acceptance criteria of the samples tested shall be in accordance with
the requirements of the relevant Indian Standards.
Sampling and Testing of water being used for concrete works as per
IS:3550 will be carried out by the Contractor at regular intervals and
whenever directed by the Engineer. The final acceptance criteria in case of
doubt will be as per IS:3025 & IS:456.
4.5 Admixture
(PCA.774.S034sca3) V.II-D2/S-III : 45

DCPL-K4A02
4.5.1 Air Entraining Agents (A.E.A)
Initially, before starting to use A.E.A., relationship between the
percentage of air entrained and the cube crushing strength vis-a-vis
quantity of A.E.A. used for all types of concrete will be established by the
Contractor by carrying out sufficiently large number of tests. After then, at
regular intervals and whenever directed by the Engineer, the Contractor will
check up the actual percentages of air entrained and corresponding
crushing strengths to correlate with the earlier test results.
4.5.2 Other Admixtures
4.6 Concrete
Tests for establishing the various properties of any other admixtures which
may be required to be added shall be carried out by the Contractor.
The sampling of concrete, making the test specimens, curing and testing
procedure etc. shall be in accordance with IS:516 and IS:1199 the size of
specimen being 15 cm cubes. Normally, only compression tests shall be
performed but under special circumstances the Engineer may require other
tests to be performed in accordance with IS:516.
Sampling procedure, frequency of sampling and test specimen shall conform
to Clause 14 of IS:456.
To control the consistency of concrete from every mixing plant, slump
tests and/or compacting factor tests in accordance with IS:1199 and as
mentioned in Clause 3.6 of this Specification shall be carried out by the
Contractor every two hours or as directed by the Engineer. Slumps
corresponding to the test specimens shall be recorded for reference.
The acceptance criteria of concrete shall be in accordance with Clause 15
of IS:456.
Concrete work found unsuitable for acceptance shall have to be dismantled
and replacement is to be done as per specification by the Contractor.
No payment for the dismantled concrete, the relevant formwork and
reinforcement, embedded fixtures, etc. wasted in the dismantled portion
shall be made. In the course of dismantling, if any damage is done to the
embedded items or adjacent structures, the same shall be made good to the
satisfaction of the Engineer.
5.0 ACCEPTANCE CRITERIA
5.1 Standard Deviation
(PCA.774.S034sca3) V.II-D2/S-III : 46

DCPL-K4A02
Standard deviation shall be based on test results and determination of
Standard deviation shall conform to clause 16 of IS:456.
5.2 Acceptance Criteria
The strength requirements and acceptance criteria shall conform to
Clause 16 of IS:456.
5.3 Inspection and Core Tests
5.4 Load Test
Inspection of concrete work immediately after stripping the formwork and
core test of structures shall conform to Clause 17 of IS:456.
Load tests of structural members may be required by the Engineer, when
the strength of test specimen results fall below the required strength, as per
'Load Test on Parts of Structures', Clause 17.6 of IS:456. If load testing
is decided by the Engineer, the member under consideration shall be
subjected to a test load equal to 1.25 (one and a quarter) times the
specified live load used for design and this load shall be maintained for a
period of 24 (twenty four) hours before removal. The detailed procedure of
the test is to be decided by the Engineer. Load tests shall not be made until
the structure is at least 56 days old.
If the member shows evident failure, such changes as are necessary to
make the structure adequately strong shall be made by the Contractor.
Alternatively, if permitted under Statutory Regulations and at the discretion of
the Engineer, the structure under test or a portion thereof may be retained
as such without any modification by derating its load bearing capacity,
provided the design criteria allows such derating.
A reinforced concrete beam, floor or roof shall be deemed to have passed
the test if the maximum deflection at the end of 24 hours does not exceed the
deflection given in Clause 17.6 of IS:456.
The entire cost of load testing shall be borne by the Contractor. If a
portion of the structure is found to be unacceptable, it shall be dismantled
and replaced by a new structure as per specification.
If, in the course of dismantling, any damage is done to the embedded items
and or other adjacent structures, the same will be made good by the
Contractor to the satisfaction of the Engineer.
6.0 LIST OF I.S. CODES AND STANDARDS FOR REFERENCE
All work under this specification shall, unless specified otherwise, conform
to the latest revisions and/or replacements of the following or any other
Indian Standard Specifications and Codes of Practice. In case any particular
aspect of work is not specifically covered by Indian Standard Specifications,
(PCA.774.S034sca3) V.II-D2/S-III : 47

DCPL-K4A02
any other standard practice, as may be specified by the Engineer, shall
be followed :-
IS : 73 - Indian Standard Specification for Paving Bitumen
IS : 216 - Indian Standard Specification for Coal Tar Pitch
IS : 269 - Indian Standard Specification for 33 grade Ordinary
Portland Cement
IS : 383 - Indian Standard Specification for Coarse and Fine
Aggregates from Natural Sources for Concrete
IS : 432 - Indian Standard Specification for Mild Steel and
Medium Tensile Steel Bars and Hard Drawn Steel
Wire for concrete Reinforcement - Part 1 & 2
IS : 455 - Indian Standard Specification for Portland Slag
Cement
IS : 456 - Indian Standard Code of Practice for Plain and
Reinforced Concrete
IS : 457 - Indian Standard Code of Practice for General
Construction of Plain and Reinforced Concrete for
Dams and other Massive Structures
IS : 516 - Indian Standard Specification for Methods of Test for
Strength of Concrete
IS : 737 - Indian standard specification for wrought Aluminium
and Aluminium Alloy sheet and strip for general
Engineering purpose. IS : 1199 - Indian Standard
Specification for Methods of Sampling and Analysis
of Concrete
IS : 1200 - Indian Standard Specification for Method of (Part-II)
Measurement Cement Concrete Works.
IS : 1200 - Indian Standard Specification for Method of (Part-V)
Measurement of Formwork
IS : 1322 - Indian Standard Specification for Bitumen Felts for
Waterproofing and Damp-proofing
IS : 1489 - Indian Standard Specification for Portland -
Pozzolona Cement - Part 1 & 2
IS : 1566 - Indian Standard Specification for hard drawn steel
wire fabric for concrete reinforcement.
IS : 1609 - Code of Practice for Laying Damp-proof Treatment
using Bitumen Felts
(PCA.774.S034sca3) V.II-D2/S-III : 48

DCPL-K4A02
IS : 1786 - Indian Standard Specification for high strength
deformed Bars & wires for Concrete Reinforcement
IS : 1791 - Indian Standard Specification for Batch Type
Concrete Mixers
IS : 1834 - Indian standard specification for hot applied sealing
compound for joint in concrete.
IS : 2062 - Steel for general structural purpose.
IS : 2185 - Indian Standard Specification for Hollow and solid /
solid light wt. Cement Concrete Blocks - Part - 1 & 2
IS : 2210 - Indian Standard Specification for Design of
Reinforced Concrete Shell Structures and Folded
Plates
IS : 2386 - Indian Standard Specification for Methods of Test for
Aggregates for Concrete - Part-I to VIII
IS : 2430 - Indian standard specification for method of sampling
of Aggregate for concrete.
IS : 2502 - Indian Standard Code of Practice for Bending and
Fixing of Bars for Concrete Reinforcement
IS : 2505 - Indian Standard Specification for Concrete Vibrators
Immersion Type
IS : 2506 - Indian Standard Specification for Screed Board
Concrete Vibrators
IS : 2514 - Indian Standard Specification for Concrete Vibrating
Tables
IS : 2645 - Integral Cement water proofing compound
IS : 2722 - Indian Standard Specification for Portable Swing
Weigh Batchers for Concrete (Single and Double
Bucket type)
IS : 2751 - Code of Practice for Welding of Mild Steel Bars used
for Reinforced Concrete Construction
IS : 2770 - Indian Standard Specification for Method of Testing
Bond in Reinforced Concrete. Part - 1 : Pull out Test
IS : 3025 - Indian Standard Specification for Methods of
Sampling and Test (Physical and Chemical) for
Water & waste water - art - 1 to 37
IS : 3201 - Indian Standard Specification for Design and
Construction of Precast Concrete Trusses and
purlins.
(PCA.774.S034sca3) V.II-D2/S-III : 49

DCPL-K4A02
IS : 3370 - Indian Standard Specification for Code of Practice for
Concrete Structures for Storage of Liquids Part 1 to 4
IS : 3384 - Indian standard specification for / Bitumen primer for
use in waterproofing and Danp proofing
IS : 3414 - Code of practice for Design and Installation of joints in
Buildings
IS : 3550 - Indian Standard Specification for Method of Test for
Routine Control for Water used in Industry
IS : 3558 - Code of Practice for use of Immersion Vibrators for
Consolidating Concrete
IS : 3696 - Safety Code for Part-1 : Scaffolding and Part 2:
Ladders
IS : 3812 - Indian Standard Specification for Fly Ash for Use as
Pozzolone & Admixture
IS : 4031 - Indian Standard Specification for Method of Tests for
Hydraulic Cement - Part - 1 to 14
IS : 4082 - Indian Standard Specification for Recommendation
on Stacking and Storage of Construction Materials at
site
IS : 4090 - Indian Standard Specification for Design of
Reinforced Concrete Archs
IS : 4634 - Indian Standard Specification for Method of Testing
Performance of Batch-type Concrete Mixers
IS : 4656 - Indian Standard Specification for Form Vibrators for
Concrete
IS : 4925 - Indian Standard Specification for Concrete Batching
and Mixing Plant
IS : 4926 - Indian Standard Specification for Ready Mixed
Concrete
IS : 4990 - Indian Standard Specification for Plywood for
Concrete Shuttering work
IS : 4991 - Indian Standard Specification for Blast Resistant
Design of Structure for Explosion above ground
IS : 4995 - Indian Standard Specification for Design (Part-I of
Reinforced Concrete Bins for the Storage & II) of
Granular and Powdery Materials
(PCA.774.S034sca3) V.II-D2/S-III : 50

DCPL-K4A02
IS : 4998 - Indian Standard Specification for Design of (Part - I)
Reinforced Concrete Chimneys
IS : 5512 - Indian Standard Specification for Flow Table for use
in Tests of Hydraulic Cement and Pozzolanic
Materials
IS : 5513 - Indian Standard Specification for Vicat Apparatus
IS : 5515 - Indian Standard Specification for Compaction Factor
Apparatus
IS : 5751 - Indian Standard Specification for Precast Concrete
Coping Blocks
IS : 5816 - Indian Standard Specification for Method of Test for
Splitting Tensile Strength of Concrete Cylinders
IS : 5891 - Indian Standard Specification for Hand Operated
Concrete Mixers
IS : 6452 - Indian Standard Specification for High Alumina
Cement for Structural Use
IS : 6909 - Indian Standard Specification for Supersulphated
Cement
IS : 6923 - Indian Standard Specification for Method of Test for
performance of Screed Board Concrete Vibrators
IS : 6925 - Indian Standard Specification for Method of Test for
Determination of Water Soluble Chloride in Concrete
Admixtures
IS : 7242 - Indian Standard Specification for Concrete Spreaders
IS : 7246 - Indian Standard Specification for Table Vibrators for
Consolidating Concrete
IS : 7251 - Indian Standard Specification for Concrete Finishers
IS : 7320 - Indian Standard Specification for Concrete Slump
Test Apparatus
IS : 7861 - Indian Standard Specification for (Part-I
Recommended Practice for hot and cold & II)
Weather Concreting
IS : 7969 - Safety Code for Storage and Handling of Building
Materials
IS : 8041 - Indian Standard Specification for Rapid Hardening
Portland cement
(PCA.774.S034sca3) V.II-D2/S-III : 51

DCPL-K4A02
IS : 8043 - Indian standard specification for hydrophobic cement
IS : 8112 - Indian Standard Specification for 43 grade Ordinary
Portland Cement
IS : 8142 - Indian Standard Specification for Determining
Setting time of Concrete by Penetration Resistance
IS : 8989 - Safety Code for Erection of Concrete Framed
Structures
IS : 9013 - Indian Standard Specification for Method of Making,
Curing and Determining Compressive Strength of
Accelerated - cured Concrete Test Specimens
IS : 9077 - Code of Practice for Corrosion Protection of Steel
Rails in RB and RCC Construction
IS : 9103 - Indian Standard Specification for Admixtures for
Concrete.
IS : 9417 - Recommendation for welding cold worked bars for
reinforced concrete construction
IS : 10262 - Recommended Guideline for concrete Mix Design
IS : 12269 - Indian standard specification for 53 gradeordinary
portland cement
IS : 12330 - Indian standard specification for sulplate resting
portland cement
IS : 12600 - Indian standard specification for low heat portland
cement
(PCA.774.S034sca3) V.II-D2/S-III : 52

DCPL-K4A02
VOLUME: II-D/2
SECTION-IV
TECHNICAL SPECIFICATION
FOR
FABRICATION OF STRUCTURAL STEELWORK
(PCA.774.S034sca4)

DCPL-K4A02
CONTENTS
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-IV : 1
2.0.0 GENERAL V.II-D2/S-IV : 1
3.0.0 WORKMANSHIP V.II-D2/S-IV : 11
4.0.0 INSPECTION, TESTING, ACCEPTANCE V.II-D2/S-IV : 19
CRITERIA AND DELIVERY
5.0.0 INFORMATION TO BE SUBMITTED V.II-D2/S-IV : 24
(PCA.774.S034sca4)

DCPL-K4A02
VOLUME: II-D/2
SECTION-IV
TECHNICAL SPECIFICATION
FOR
FABRICATION OF STRUCTURAL STEELWORK
1.00 SCOPE
2.00 GENERAL
This specification covers supply of all raw steel materials, fabrication, testing,
painting and delivery to site of structural steelwork including supply of all
consumable stores and bolts, nuts, washers, electrodes and other materials
required for fabrication and field connections of all structural steelwork in
general covered under the scope of the contract. However, for any
special structures such as rail & road bridges, steel chimney, tanks,
transmission towers, furnace structures, etc., the relevant Indian Standard
or IRC specification and Codes of Practices shall be given due
consideration over & above this specification.
2.1.0 Work to be provided for by the Contractor
The work to be provided for by the Contractor, unless otherwise
specified elsewhere in the contract, shall include, but not be limited to the
following :
a) Preparation of complete detailed fabrication drawings and erection
marking drawings required for all the structures covered under the
scope of the contract based on contractor’s design drawings
approved by the Owner / Consultants.
b) To submit revised design with calculations and detailed fabrication
drawings in case any substitution of the designed sections are to be
made.
c) To submit design calculations for joints and connections developed
by the contractor along with detailed fabrication drawings.
d) Furnish all materials, labour, tools and plant and all consumables
required for fabrication and supply, all necessary bolts, nuts, washers,
tie rods and welding electrodes for field connections. The field
connection materials supplied by the contractor shall be in
adequate quantity to avoid delay in erection.
e) Furnish shop painting of all fabricated steelwork as per requirements
of this Specification.
f) Suitably mark, bundle and pack for transport all fabricated
materials.
(PCA.774.S034sca4) V.II-D2/S-IV : 1

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g) Prepare and furnish detailed Bill of Materials, Drawing Office
Despatch lists, Bolt List and any other list of bought out items
required in connection with the fabrication and erection of the
structural steelwork.
h) Insure, load and transport all fabricated steelwork field connection
materials to site.
2.2.0 Work by others
No work under this specification will be provided for by any agency other
than the contractor, unless specifically mentioned otherwise elsewhere in
the contract.
2.3.0 Codes and standards
All work under this specification shall, unless otherwise specified in the
contract, conform to the requirements of the latest revision and/or
replacements of the following or any other relevant Indian Standard
specifications and codes of practice. In case any particular aspect of the
work is not specifically covered by any Indian Standard Specification, any
other standard practice, as may be specified by the Engineer shall be
followed:-
LIST OF I.S. CODES -
IS Codes
RELEVANT TO FABRICATION OF
STRUCTURAL STEEL WORK
Description
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 : 808 - Dimensions for rolled steel beams, channels and angle
sections.
IS : 812 - Glossary of terms relating to welding & cutting of
metals.
IS : 813 - Scheme of symbols for welding.
IS : 814 - Covered electrodes for metal arc welding of carbon and
carbon manganese steel.
IS : 815 - Classification coding of covered electrodes
for metal arc welding of mild steel and low
alloy high tensile steel.
(PCA.774.S034sca4) V.II-D2/S-IV : 2

DCPL-K4A02
IS : 816 - Code of practice for use of metal arc welding
for general construction in mild steel.
IS : 817 - Code of practice for training & testing metal
arc welders.
IS : 818 - Code of practice for safety and health
requirements in electric and gas welding and
cutting operations.
IS : 819 - Code of practice for resistance spot welding
for light assemblies in mild steel.
IS : 822 - Code of practice for inspection of welds.
IS : 919 - Recommendations for limits and fits for engineering.
(Part - 1&2)
IS : 1161 - Steel Tubes for structural purposes.
IS : 1182 - Recommended practice for Radiographic Examination
of fushion welded butt joints in steel plates.
IS : 1200 - Method of measurement of steel work and iron work
(Part - 8)
IS : 1239 - Mild steel tubes, tubulars and other wrought steel
(Part - 1&2) fittings
IS : 1363 - Hexagon head bolts, screws and nuts of product
(Part - 1 to 3) grade C.
IS : 1364 - Hexagon head bolts, screws and nuts of product
(Part - 1 to 5) grade A & B.
IS : 1365 - Slotted counter sunk head screws (dia. 1.6 to 20 mm)
IS : 1367 - Technical supply conditions for threaded steel
(Part - 1 to 18) fasteners.
IS : 1608 - Method for tensile testing of steel products.
IS : 1730 - Dimensions for steel plate, sheet and strip for structural
and general engineering purposes.
(PCA.774.S034sca4) V.II-D2/S-IV : 3

DCPL-K4A02
IS : 1852 - Rolling and cutting tolerances for hot-rolled steel
product.
IS : 1977 - Structural steel (Ordinary quality)
IS : 2016 - Plain washer
IS : 2062 - Steel for general structural purposes.
IS : 2629 - Recommended practice for hot-dip galvanising of
iron and steel.
IS : 2633 - Method for testing uniformity of coating on zinc coated
articles.
IS : 3644 - Code of practice for ultrasonic pulse echo testing by
contact and immersion method.
IS : 3757 - High Strength Structural Bolt
IS : 4000 - High strength bolts in steel structure
IS : 4759 - Specifications for hot-dip zinc coatings on structural
steel and other allied products.
IS : 4923 - Hollow steel sections for structural use.
IS : 5334 - Code of practice for magnetic particle flaw detection of
weld.
IS : 5369 - General requirements for plain washers and lock
washer.
IS : 6005 - Code of practice for phosphating of iron and steel.
IS : 6649 - Specification for hardened and tempered washers for
high strength structural bolts and nuts.
IS : 6623 - Specification for high strength structural nuts.
IS : 7215 - Tolerances for fabrication of steel structures.
IS : 7280 - Bare wire electrode for submerged arc welding.
IS : 8500 - Structural steel micro alloyed (medium & high strength
quality).
IS : 8629 - Code of practice for protection of iron and (Part - I to
III) steel structures from atmospheric corrosion.
IS : 9595 - Recommendation for metal arc welding of carbon
manganese steels.
(PCA.774.S034sca4) V.II-D2/S-IV : 4

DCPL-K4A02
PAINTING
IS : 117 - Specification for ready mixed paint, brushing, finishing,
exterior, semi-gloss, for general purposes.
IS : 128 - Specification for ready mixed paint, brushing, finishing,
semi-gloss for general purposes, black.
IS : 1477 - Code of practice for painting of ferrons metal
(Part - I & II) in building.
IS : 2074 - Ready mixed paint, air-drying red-oxide zinc chrome
priming.
IS : 2339 - Specification for aluminium paints for general purposes
in dual container.
IS : 2932 - Specification for enamel, synthetic exterior type - I.
IS : 2933 - Specification for enamel, synthetic exterior type - II.
2.4.0 Conformity with Designs
The contractor shall design all connections, supply and fabricate all
steelwork and furnish all connection materials in accordance with the
approved drawings and/or as instructed by the Engineer keeping in view
the maximum utilization of the available sizes and sections of steel
materials. The methods of painting, marking, packing and delivery of all
fabricated materials shall be in accordance with the provisions of the
contract and/or as approved by the Engineer. Provision of all relevant Indian
Standard Specifications and Codes of Practice shall be followed unless
otherwise specified in the contract.
2.5.0 Materials to be used
2.5.1 General
All steel materials shall be free from all imperfections, mill scales, slag
intrusions, laminations, pittings, rusts etc. that may impair their strength,
durability and appearance. All materials shall be of tested quality only unless
otherwise permitted by the Engineer and/or Consultant. If desired by the
Engineer, Test Certificates of materials supplied by the contractor in
respect of each consignment shall be submitted in triplicate. Whenever the
materials are required to be used from unidentified stocks, if permitted by
the Engineer, a random sample shall be tested at an approved laboratory
from each lot of 50 tonnes or less of any particular section.
(PCA.774.S034sca4) V.II-D2/S-IV : 5

2.5.2 Steel
2.5.3 Electrodes
DCPL-K4A02
The arc welding electrodes shall conform to the relevant Indian Standard
Codes of Practice and Specifications and shall be of heavily coated type and
the thickness of the coating shall be uniform and concentric. With each
container of electrodes, the manufacturer shall furnish instructions giving
recommended voltage and ampereage ( Polarity in case of D.C. supply ) for
which the electrodes are suitable.
All steel materials to be used in construction within the purview of this
specification shall comply with any of the following Indian Standard
Specifications as may be applicable :
1) IS : 801 - Cold formed light gauge steel structural member.
2) IS : 806 - Steel tubes in general building construction.
3) IS : 1161 - Steel tubes for structural purpose.
4) IS : 1977 - Structural steel (Ordinary quality)
St-42-0
5) IS : 2062 - Steel for general structural purpose
6) IS : 8500 - Structural steel-microalloyed (Ordinary & high strength
quality)
In case of imported steel materials being used, these shall conform to
specifications equivalent to any of the above as may be applicable.
All electrodes to be used under the Contract shall comply with any of the
following Indian Standard Specifications as may be applicable :
2.5.4 Bolts and Nuts
1) IS : 814 - Covered electrodes for metal arc welding structural
steel
2) IS : 815 - Classification and coding of covered electrodes for
metal arc welding of mild steel and low alloy high
tensile steel.
3) IS : 7280 - Base wire electrode for submerged arc welding.
All bolts and nuts shall conform to the requirements of Indian Standard
Specification IS:1367 - Technical Supply Conditions for Threaded
Fasteners.
Materials for Bolts and nuts under the purview of this contract shall
comply with any of the following Indian Standard Specifications as may
be applicable.
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2.5.5 Washers
2.5.6 Paints
DCPL-K4A02
a) Mild Steel : All mild steel for bolts and nuts when tested in
accordance with the following Indian Standard
Specification shall have a tensile strength of not less
than 44 Kg/mm 2 and a minimum elongation of 23 per
cent on a gauge length of 5.6 /A, where 'A' is the
cross sectional area of the test specimen : -
1) IS:1367 - Technical supply conditions for
threaded fasteners.
2) IS:1608 - Method for tensile testing of
steel other than sheet, strip, wire
and tube.
b) High
Tensile
Steel : The material used for the manufacture of high
tensile steel bolts and nuts shall have the mechanical
properties appropriate to the particular class of steel
as set out in IS:1367 or as approved by the Engineer.
Washers shall be made of steel conforming to any of the following Indian
Standard Specifications as may be applicable under the provisions of the
Contract :
1) IS : 1977 - Structural steel (Ordinary Quality) St-42-0
2) IS : 2062 - Steel for general structural purpose
3) IS : 8500 - Structural steel - microalloyed
(medium & high strength quality)
4) IS : 6623 - High Strength Structural Nuts
5) IS : 6649 - Hardened and tampered washers for high
strength structural bolts & nuts.
Paints to be used for shop coat of fabricated steel under the purview of this
contract shall conform to the Indian Standard Specification IS:2074 - Ready
mixed Paint, Air Drying, Red Oxide - Zinc Chromate Priming.
In highly corrosive environment other type of primer such as epoxy resin
based zinc rich primer (such as blast steel EZ1 of Shalimer Paints Ltd., may
be necessary.
2.6.0 Storage of Material
2.6.1 General
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2.6.2 Steel
2.6.3 Electrodes
DCPL-K4A02
All materials shall be so stored as to prevent deterioration and to ensure
the preservation of their quality and fitness for the work. Any material which
has deteriorated or has been damaged shall be removed from the
contractor's yard immediately, failing which, the Engineer shall be at
liberty to get the material removed. The Contractor shall maintain upto date
accounts in respect of receipt, use and balance of all sizes and sections
of steel and other materials. In case the fabrication is carried out in
contractor's fabrication shop outside the plant site where other fabrication
works are also carried out, all materials meant for use in this contract shall
be stacked separately with easily identifiable marks.
The steel to be used in fabrication and the resulting cut-pieces shall be
stored in separate stacks off the ground sectionwise and lengthwise so
that they can be easily inspected, measured and accounted for at any
time. If required by the Engineer, the materials may have to be stored
under cover and suitably painted for protection against weather.
The electrodes for electric are welding shall be stored in properly designed
racks, separating different types of electrodes in distinctly marked
compartments. The electrodes shall be kept in a dry and warm condition if
necessary by resorting to heating.
2.6.4 Bolts, Nuts and Washers
2.6.5 Paints
Bolts, nuts and washers and other fastening materials shall be stored on
racks off the ground with a coating of suitable protective oil. These shall
be stored in separate gunny bags or compartments according to diameter,
length and quality.
Paints shall be stored under cover in air tight containers. Paints supplied in
sealed containers shall be used up as soon as possible once the container
is opened.
2.7.0 Quality Control
The Contractor shall establish and maintain quality control procedures for
different items of work and materials to the extent he deems necessary to
ensure that all work is performed in accordance with this specification. In
addition to the Contractor's quality control procedures, materials and
workmanship at all times shall be subjected to inspection by the Engineer
or Engineer's representative. As far as possible, all inspection by the
Engineer or Engineer's representative shall be made at the Contractor's
fabrication shop whether located at Site or elsewhere. The Contractor shall
co-operate with the Engineer or Engineer's representative in permitting
access for inspection to all places where work is being done and in
providing all necessary help in respect of tools and plants, instrument, labour
and materials required to carry out the inspection. The inspection shall be so
scheduled as to provide the minimum interruption to the work of the
Contractor.
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DCPL-K4A02
Materials or workmanship not in reasonable conformance with the
provisions of this Specification may be rejected at any time during the
progress of the work.
The quality control procedure shall cover but not be limited to the following
items of work :
1) Steel : Quality, manufacturer's test certificates, test reports
of representative samples of materials from
unidentified stocks if permitted to be used.
2) Bolts, Nuts : Manufacturer's certificate, dimension
& Washers checks, material testing.
3) Electrodes : Manufacturer's certificate, thickness and quality of flux
coating.
4) Welders : Qualifying Tests
5) Welding sets : Performance Tests
6) Welds : Inspection, X-ray, Ultrasonic tests
7) Paints : Manufacturer's certificate, physical inspection reports
8) Galvanizing : Tests in accordance with IS : 2633 -
Method for testing uniformity of coating on Zinc
Coated Articles and IS : 4759 - Specification for Hot-
Dip Zinc coatings on Structural Steel and other
allied products.
2.8.0 Standard dimensions, forms and weights
The dimensions, forms, weights and tolerances of all rolled shapes bolts,
nuts, studs, washers etc. and other members used in the fabrication of
any structure shall, wherever applicable, conform to the requirements of
the latest relevant Indian Standards, wherever they exist, or, in the absence
of Indian Standards, to other equivalent standards.
2.9.0 Shop Drawings
The Contractor shall submit to the Engineer the Schedule of Fabrication
and delivery of structural steelwork for approval. He shall start to submit
progressively for approval the shop drawings based on the approved Design
Drawings and before proceeding with the fabrication work, shall get the
said shop drawings approved in accordance with the contract.
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DCPL-K4A02
The sequence of submission of shop drawings for approval shall match with
the approved fabrication and delivery schedule. The approval for the shop
drawings will be accorded only towards the general conformity with the
design requirements as well as specification and will ensure the correctness
of general arrangement for centreline dimensions and levels, Section
sizes, and adequacy of connections including splice joints as to the no. of
bolts, weld length, size of gusset/end plates.
The correctness of all other details like cutting lengths, matching of holes,
notch dimensions, match markings, bill of materials, bolt list etc. will be
entirely the contractor's responsibility. The approval of the drawing however
shall not relieve the contractor of his sole responsibility in carrying out the
work correctly and fulfilling the complete requirements of contract
documents.
The shop drawings shall include but not be limited to the following : -
a) Assembly drawings giving exact sizes of the sections to be used and
identification marks of the various sections.
b) Dimensional drawings of base plates, foundation bolt location etc.
c) Details of all connections with supporting calculations.
d) Comparison sheets to show that the proposed alternative section, if
any, are as strong as the original sections shown on the Design
Drawings.
e) Complete Bill of Materials and detailed drawings of all sections as
also their billing weights.
f) Any other drawings or calculations that may be required for the
clarification of the works or substituted parts thereof.
The shop drawings shall give all the necessary information for the
fabrication, erection and painting of the steelwork in accordance with the
provisions of this Specification. Shop drawings shall be made in
accordance with the best modern practice and with due regard to
sequence, speed and economy in fabrication and erection. Shop drawings
shall give complete information necessary for fabrication of various
components of the steelwork, including the location, type, size and extent of
welds. These shall also clearly distinguish between shop and field bolts and
welds and specify the class of bolts and nuts. The drawings shall be drawn
to a scale large enough to convey all the necessary information adequately.
Notes on the shop drawings shall indicate those joints or groups of joints in
which it is particularly important that the welding sequence and technique
of welding shall be carefully controlled to minimize the locked -up stresses
and distortion.
Welding symbols used shall be in accordance with the requirements
of the Indian Standard Specification --IS:813 - Scheme of symbols for
Welding, and shall be consistent throughout. Weld lengths called for on
the drawings shall mean the net effective length.
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DCPL-K4A02
The Contractor shall be responsible for and shall pay for any alterations of
the work due to any discrepancies, errors or omissions on the drawings or
other particulars supplied by him, whether such drawings or other particulars
have been duly approved or not in accordance with the Contract.
3.0.0 WORKMANSHIP
3.1.0 Fabrication
3.1.1 General
All workmanship shall be equal to the best practice in modern structural
shops, and shall conform to the provisions of the Indian Standard IS:800 -
Code of Practice for use of Structural Steel in General Building
Construction and other relevant Indian Standards.
3.1.2 Straightening Material
3.1.3 Cutting
Rolled materials before being laid off or worked, must be clean, free
from sharp kinks, bends or twists and straight within the tolerances
allowed by the Indian Standard Specification IS:1852 - Specification for
rolling and cutting tolerance for hot-rolled steel products. If straightening is
necessary, it may be done by mechanical means or by the application of
a limited amount of localized heat. The temperature of heated areas, as
measured by approved methods, shall not exceed 600 Deg. C.
Cutting shall be effected by shearing, cropping or sawing. Use of a
mechanically controlled gas cutting torch may be permitted for mild
steel only. Gas cutting of high tensile steel may also be permitted provided
special care is taken to leave sufficient metal to be removed by machining,
so that all metal that has been hardened by flame is removed. Gas cutting
without a mechanically controlled torch may be permitted if special care is
taken and done under expert hand, subject to the approval of the Engineer.
(PCA.774.S034sca4) V.II-D2/S-IV : 11

DCPL-K4A02
To determine the effective size of members cut by gas, 3 mm shall be
deducted from each cut edge. Gas cut edges, which will be subjected to
substantial stress or which are to have weld metal deposited on them, shall
be reasonably free from gouges. Occasional notches or gauges not more
than 4 mm deep will be permitted. Gouges greater than 4 mm, that remain
from cutting, shall be removed by grinding. All re-entrant corners shall be
shaped notch-free to a radius of at least 12 mm. Shearing, cropping and
gas cutting shall be clean, reasonably square and free from any distortion.
3.1.4 Planning of edges
3.1.5 Clearances
Planning or finishing of sheared or cropped edges of plates or shapes or of
edges gas-cut with a mechanically controlled torch shall not be required,
unless specifically required by design and called for on the drawings,
included in a stipulation for edge preparation for welding or as may be
required after the inspection of the cut surface. Surface cut with hand-flame
shall generally be ground, unless specifically instructed otherwise by the
Engineer.
The erection clearance for cleated ends of members connecting steel to
steel shall preferably be not greater than 2 mm at each end. The erection
clearance at ends of beams without web cleats shall be not more than 3 mm
at each end, but where, for practical reasons, greater clearance is
necessary, suitably designed cleatings shall be provided.
3.2.0 Bolted construction
3.2.1 Holes
Holes through more than one thickness of material for members, such as
compound stanchions and girder flanges, shall be drilled after the
members are assembled and tightly clamped or bolted together. Punching
may be permitted before assembly, if the thickness of the material is not
greater than the nominal diameter of bolt plus 3 mm subject to a maximum
thickness of 16 mm provided that the holes are punched 3 mm less in
diameter than the required size and reamed after assembly to the full
diameter.
Holes for rivets or black bolts shall be not more than 1.5 mm or 2.0
mm ( depending on whether the diameter of the bolt is less or more than or
equal to 25 mm ) larger in diameter than the nominal diameter of the black
bolt passing through them.
Holes for turned and fitted bolts shall be drilled to a diameter equal to the
nominal diameter of the shank or barrel subject to a tolerance grade of H8
as specified in IS:919. Parts to be connected shall be firmly held
together by tacking welds or clamps and the holes drilled through all the
thicknesses in one operation and subsequently reamed to size. Holes not
drilled through all thickness in one operation shall be drilled to a smaller size
and reamed out after assembly.
Holes for bolts shall not be formed by gas cutting process.3.2.2
Assembly
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DCPL-K4A02
Drifting to enlarge unmatching holes shall not generally be permitted. In
case drifting is permitted to a slight extent during assembly, it shall not
distort the metal or enlarge the holes. Holes that must be enlarged to admit
the bolts shall be reamed. Poor matching of holes shall be cause for
rejection. The component parts shall be so assembled that they are
neither twisted not otherwise damaged, and shall be so prepared that the
specified cambers, if any, are maintained.
Bolted construction shall be permitted only in case of field connections if
called for on the Drawings and is subjected to the limitation of particular
connections as may be specified. In special cases, however, shop bolt
connections may be allowed if directed by the Engineer.
Washers shall be tapered or otherwise suitably shaped, where necessary, to
give the heads and nuts of bolts a satisfactory bearing. The threaded
portion of each bolt shall project out through the nut at least one thread. In
all cases the bolt shall be provided with a washer of sufficient thickness
under the nut to avoid any threaded portion of the bolt being within the
thickness of the parts bolted together. In addition to the normal washer, one
spring washer or lock-nut shall be provided for each bolt for connections
subjected to vibrating forces or otherwise as may be specified on the
Drawings.
3.3.0 Welded Construction
3.3.1 General
Welding shall be in accordance with relevant Indian Standards and as
supplemented in the Specification. Welding shall be done by experienced
and good welders who have been qualified by tests in accordance with
IS:817.
3.3.2 Preparation of Material
3.3.3 Assembling
Surface to be welded shall be free from loose scale, slag, rust, grease,
paint and any other foreign material except that mill scale which withstands
vigorous wire brushing may remain. Joint surfaces shall be free from fins and
tears. Preparation of edges by gas-cutting shall, wherever practicable, be
done by a mechanically guided torch.
Parts to be fillet welded shall be brought in as close contact as practicable
and in no event shall be separated by more than 4 mm. If the separation is
1.5 mm or greater, the size of the fillet welds shall be increased by the
amount of the separation. The fit of joints at contact surfaces which are
not completely sealed by welds, shall be close enough to exclude water
after painting. Abutting parts to be butt-welded shall be carefully aligned.
Misalignments greater than 3 mm shall be corrected and in making the
correction the parts shall not be drawn into a sharper slope than two
degrees (2 Deg.).
The work shall be positioned for flat welding whenever practicable.
(PCA.774.S034sca4) V.II-D2/S-IV : 13

DCPL-K4A02
3.3.4 Welding Sequence
In assembling and joining parts of a structure or of built-up members, the
procedure and sequence of welding shall be such as will avoid needless
distortion and minimize shrinkage stresses. Where it is impossible to
avoid high residual stresses in the closing welds of a rigid assembly,
such closing welds shall be made in compression elements.
In the fabrication of cover-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 member. Long girders or girder sections may
be made by shop splicing not more than three sub-sections, each made in
accordance with this paragraph. When required by the Engineer, welded
assemblies shall be stress relieved by heat treating in accordance with
the provisions of the relevant Indian Standard or any other Standard
approved by the Engineer.
3.3.5 Welding technique
3.3.6 Temperature
All complete penetration groove welds made by manual welding, except when
produced with the aid of backing material not more than 8 mm thick with root
opening not less than one-half the thickness of the thinner part joined, shall
have the root of the initial layer gouged out on the back side before welding
is started from that side, and shall be so welded as to secure sound metal
and complete fusion throughout the entire cross-section. Groove welds
made with the use of the backing of the same material as the base metal
shall have the weld metal thoroughly fused with the backing material.
Backing strips need not be removed. If required, they may be removed by
gouging or gas cutting after welding is completed, provided no injury is done
to the base metal and weld metal and the weld metal surface is left flush
or slightly convex with full throat thickness.
Groove welds shall be terminated at the ends of a joint in a manner that will
ensure their soundness. Where possible, this should be done by use of
extension bars or run-off plates. Extension bars or run-off plates need not
be removed upon completion of the weld unless otherwise specified
elsewhere in the Contract.
To get the best and consistent quality of welding, automatic submerged arc
process shall be preferred. The technique of welding employed, the
appearance and quality of welds made, and the methods of correcting
defective work shall all conform to the relevant Indian Standards.
No welding shall normally be done on parent material at a temperature below (-)
5 Deg.C. However, if welding is to be undertaken at low temperature, adequate
precautions as recommended in relevant Indian Standard shall be taken. When the
parent material is less than 40 mm thick and the temperature is between (-) 5
Deg. C and 0 Deg. C, the surface around the joint to a distance of 100 mm or 4
times the thickness of the material, whichever is greater, shall be preheated till it is
handwarm. When the parent material is more than 40 mm thick, the temperature of
the area mentioned above shall be in no case be less than 20 Deg. C. All
requirements regarding preheating of the parent material shall be in accordance with
the relevant Indian Standard.
(PCA.774.S034sca4) V.II-D2/S-IV : 14

DCPL-K4A02
3.3.7 Peening
3.3.8 Equipment
3.4.0 Finish
Where required, intermediate layers of multiple-layer welds may be
peened with light blows from a power hammer, using a round-nose tool.
Peening shall be done after the weld has cooled to a temperature warm
to the hand. Care shall be exercised to prevent scaling or flaking of weld
and base metal from over peening.
These shall be capable of producing proper current so that the operator may
produce satisfactory welds. The welding machine shall be of a type and
capacity as recommended by the manufacturers of electrodes or as may
be approved by the engineer.
Column splices and butt joints of compression members depending on
contact for stress transmission shall be accurately machined and closebutted
over the whole section with a clearance not exceeding 0.2 mm locally
at any place. In column caps and bases, the ends of shafts together with
the attached gussets, angles, channels etc., after welding together,
should be accurately machined so that the parts connected butt over the
entire surfaces of contact. Care should be taken that those connecting
angles or channels are fixed with such accuracy that they are not
reduced in thickness by machining by more than 2.0 mm.
3.5.0 Slab bases and caps
3.6.0 Lacing bars
3.7.0 Separators
Bases and caps fabricated out of steel slabs, except when cut from material
with true surface, shall be accurately machined over the bearing surface
and shall be in effective contact with the end of the stanchion. A bearing
face which is to be grouted direct to a foundation need not be machined if
such face is true and parallel to the upper face. To facilitate grouting, holes
shall be provided, where necessary, in stanchion bases for the escape of
air.
The ends of lacing bars shall be neat and free from burrs.
Rolled section or built-up steel separators or diaphragms shall be required
for all double beams except where encased in concrete, in which case, pipe
separators shall be used.
(PCA.774.S034sca4) V.II-D2/S-IV : 15

DCPL-K4A02
3.8.0 Bearing Plates
Provision shall be made for all necessary steel bearing plates to take up
reaction of beams and columns and the required stiffeners and gussets
whether or not specified in Drawings.
3.9.0 Architectural Clearances
Bearing plates and stiffener connections shall not be permitted to
encroach on the designed architectural clearances.
3.10.0 Shop connections
3.11.0 Castings
3.12.0 Shop erection
3.13.0 Shop painting
3.13.1 General
a) All shop connections shall be welded as specified on the Drawings.
b) Certain connections, specified to be shop connections, may be
changed to field connections if desired by the Engineer for
convenience of erection and the Contractor will have to make the
desired changes.
Steel castings shall be annealed
The steelwork shall be temporarily shop-erected complete or as directed by
the Engineer so that accuracy of fit may be checked before despatch. The
parts shall be shop-erected with a sufficient number of parallel drifts to
bring and keep the parts in place. In case of parts drilled or punched
using steel jigs to make all similar parts interchangeable, the steelwork
shall be shop erected in such a way as will faciliate the check of
interchangeability.
Unless otherwise specified, steelwork which will be concealed by interior
building finish need not be painted; steelwork to be encased in concrete
shall not be painted. Unless specifically exempted, all other steelwork
shall be given one coat of shop paint, applied thoroughly and evenly to
dry surfaces which have been cleaned, in accordance with the following
paragraph, by brush, spray, roller coating, flow-coating or dipping as may be
approved by the Engineer.
After inspection and approval and before leaving the shop, all steelwork
specified to be painted shall be cleaned by hand-wire brushing or by other
mechanical cleaning methods to remove loose mill scale, loose rust,
weld slag or flux deposit, dirt and other foreign matter. Oil and grease
deposits shall be removed by solvent. Steelwork specified to have no shop
(PCA.774.S034sca4) V.II-D2/S-IV : 16

DCPL-K4A02
paint shall, after fabrication, be cleaned of oil or grease by solvent cleaners
and be cleaned of dirt and other foreign material by through sweeping with a
fibre brush.
After completion of the precleaning, the metal surface shall immediately
painted with red oxide zinc chromate primer conforming to IS : 2074.
In highly corrosive environment, all steelwork shall be given a coat of shop
paint, applied thoroughly and evenly to dry surfaces which have been
cleaned by sand blasting to SA 2/1/2 grade minimum. The shop paint shall
be epoxy rasin based zinc rich primer such as Blast Steel EZ1 of Shalimer
Paint Limited.
3.13.2 Inaccessible parts
Surfaces not in contact, but inaccessible after assembly, shall receive two
coats of shop paint, positively of different colours to prove application of two
coats before assembly. This does not apply to the interior of sealed hollow
sections.
3.13.3 Contact surfaces
Contact surface shall be cleaned in accordance with Sub-clause 3.13.1
before assembly.
3.13.4 Finished surfaces
Machine finished surfaces shall be protected against corrosion by a rust
inhibiting coating that can be easily removed prior to erection or which has
characteristics that make removal unnecessary prior to erection.
3.13.5 Surfaces adjacent to field welds
3.14.0 Galvanizing
3.14.1 General
Unless otherwise provided for, surfaces within 50 mm of any field weld
location shall be free of materials that would prevent proper welding or
produce objectionable fumes while welding is being done.
Structural steelwork for switchyard or other structures as may be specified in
the Contract shall be hot dip galvanized in accordance with the American
Society for Testing and Materials Specification ASTM-A 123 or IS : 2629 -
Recommended practice for Hot-Dip Galvanising of Iron and steel. Where
the steel structures are required to be galvanized the field connection
materials like bolts, nuts and washers shall also be galvanized.
3.14.2 Surface Preparation
(PCA.774.S034sca4) V.II-D2/S-IV : 17

3.14.3 Procedure
DCPL-K4A02
All members to be galvanized shall be cleaned, by the process of pickling of
rust, loose scale, dirt, oil, grease, slag and spatter of welded areas and other
foreign substances prior to galvanizing. Pickling shall be carried out by
immersing the steel in an acid bath containing either sulphuric or
hydrochloric acid at a suitable concentration and temperature. The
concentration of the acid and the temperature of the bath can be varied,
provided that the pickling time is adjusted accordingly.
The pickling process shall be completed by thoroughly rinsing with water,
which should preferably be warm, so as to remove the residual acid.
Galvanizing shall be carried out by hot dip process in a proper and uniformly
heated bath. It shall meet all the requirements when tested in accordance
with IS:2633 - Method for testing uniformity of coating on Zinc Coated
Articles and IS:4759 - Specification for Hot-dip zinc coatings on Structural
Steel & other allied products.
After finishing the threads of bolts, galvanizing shall be applied over the
entire surface uniformly. The threads of bolts shall not be machined after
galvanizing and shall not be clogged with zinc. The threads of nuts may be
tapped after galvanizing but care shall be taken to use oil in the threads of
nuts during erection.
The surface preparation for galvanizing and the process of galvanizing
itself, shall not adversely affect the mechanical properties of the materials to
be galvanized. Where members are of such lengths as to prevent
complete dipping in one operation, great care shall be taken to prevent
warping.
Materials on which galvanizing has been damaged shall be acid stripped
and re-galvanized unless otherwise directed, but if any member becomes
damaged after having been dipped twice, it shall be rejected. Special care
shall be taken not to injure the skin on galvanized surfaces during transport
and handling. Damages, if occur, shall be made good in accordance with
the provisions of this Specification or as directed by the Engineer.
4.0.0 INSPECTION, TESTING, ACCEPTANCE CRITERIA AND DELIVERY
4.1.0 Inspection
(PCA.774.S034sca4) V.II-D2/S-IV : 18

DCPL-K4A02
Unless specified otherwise, inspection to all work shall be made by the
Engineer or Engineer's representative at the place of manufacture prior to
delivery. The Engineer or his representative shall have free access at all
reasonable times to those parts of the manufacturer's works which are
concerned with the fabrication of the steelwork under this Contract and he
shall be afforded all reasonable facilities for satisfying himself that the
fabrication is being done in accordance with the provisions of this
Specification.
The Contractor shall provide such labour, materials, electricity, fuel, water,
stores, tools and plant, apparatus and instruments as may be required by
the Engineer to carry out inspection and/or tests in accordance with the
Contract.
The Contractor shall guarantee compliance with the
Specification.
provisions of this
4.2.0 Testing and Acceptance Criteria
4.2.1 General
4.2.2 Steel
The Contractor shall carry out sampling and testing in accordance with
the relevant Indian Standards and as supplemented herein for the
following items at his own cost, unless otherwise specified in the Contract.
The Contractor shall get the specimens tested in a laboratory approved by
the Engineer and submit to the Engineer the test results in triplicate
within 3 (three) days after completion of the test.
All steel supplied by the Contractor shall conform to the relevant Indian
Standards. Except otherwise mentioned in the Contract, only tested quality
steel having mill test reports shall be used. In case unidentified steel
materials are permitted to be used by the Engineer, random samples of
materials will be taken from each unidentified lot of 50 M.T. or less of any
particular section for tests to conform to relevant Indian Standards.
All material shall be free from all imperfections, mill scales, slag intrusions,
laminations, pittings, rusts etc. that may impair their strength, durability and
appearance.
4.2.3 Testing Criteria for checking Lamination in raw steel plates
All raw steel plate of thickness more than 20 mm supplied by the
contractor shall be checked against lamination before procurement & prior
(PCA.774.S034sca4) V.II-D2/S-IV : 19

4.2.4 Welding
DCPL-K4A02
to commencement of fabrication work in the following ways as directed by the
Engineer.
a) Ultrasonic testing along the edge of specified points of the plates shall
be carried out to delete lamination in the plates, if any.
b) If the results of the tests in (a) are not satisfactory, the whole area of
the plates shall be checked by ultrasonic testing at specified nodal
points formed at equidistant grid locations. The spacing of the grids
shall be determined from tests in (a) or as directed by the Engineer.
If the results of the above tests are not satisfactory, the plates shall not be
taken up for fabrication work. Even after fabrication at shop, if the Engineer
requires any ultrasonic testing to detect lamination of plates, the same
shall be carried out by the Contractor. If the plates in the fabricated item is
found to be laminated, the component will be rejected.
All electrodes shall be procured from reliable manufacturers with test
certificates. The correct grade and size of electrode which has not
deteriorated in storage shall be used. The inspection and testing of welding
shall be performed in accordance with the provisions of the relevant
Indian Standards or other equivalents. For every 50 tonnes of welded
fabrication, the Engineer may ask for at least 1 (one) test-destructive or
non-destructive including X-ray, ultrasonic test or similar. In the event of
further tests as may be desired by the Engineer, if the results are found to
be unsatisfactory; and if the test shows no defect. In cases of the test
results showing deficiency, the Engineer shall have option to reject or
instruct any remedial measures to be taken.
4.2.5 Bolts, nuts and washers
All bolts, nuts and washers shall be procured from reputed manufacturer
approved by the Engineer and shall conform to the relevant Indian
Standards. If desired by the Engineer, representative samples of these
materials may have to be tested in an approved laboratory and in
accordance with the procedures described in relevant Indian Standards.
4.2.6 Shop painting
All paints and primers shall be of standard quality and procured from
approved manufacturers and shall conform to the provisions of the relevant
Indian Standards.
(PCA.774.S034sca4) V.II-D2/S-IV : 20

DCPL-K4A02
4.2.7 Galvanizing
4.3.0 Tolerance
4.4.0 Acceptance
All galvanizing shall be uniform and of standard quality when tested in
accordance with IS:2633 - Method for testing uniformity of coating on
Zinc Coated Articles and IS:4759 - specification for Hot-Dip Zinc Coatings
on Structural Steel & other allied products.
The tolerances on the dimensions of individual rolled steel components
shall be as specified in IS:1852 - specification for rolling and Cutting
Tolerances for Hot-rolled Steel Products. The tolerances on straightness,
length etc. of various fabricated components (such as beams and girders,
columns, crane gantry girder etc.) of the steel structures other than steel
railway & road bridges, structures subjected to dynamic loading (like wind,
seismic etc.) and thin walled construction (like box girders) shall be as
specified in IS:7215 - Tolerances for Fabrication of Steel Structures.
Should any structure or part of a structure be found not to comply with any
of the provisions of this Specification, the same shall be liable to rejection.
No structure or part of the structure, once rejected, shall be offered again
for test, except in cases where the Engineer considers the defects
rectifiable. The Engineer may, at his discretion, check the test results
obtained at the Contractor's works by independent tests at an approved
laboratory and should the items, so tested, be found to be unsatisfactory.
When all tests to be performed in the Contractor's shop under the terms of
this contract have been successfully carried out, the steelwork will be
accepted forthwith and the Engineer will issue an acceptance certificate,
upon receipt of which, the items will be shop painted, packed and
despatched. No item to be delivered unless an acceptance certificate for the
same has been issued. The satisfactory completion of these tests or the
issue of the certificates shall not bind the Owner to accept the work,
should it, on further tests before or after erection, be found not in
compliance with the Contract.
4.5.0 Delivery of materials
4.5.1 General
The Contractor will deliver the fabricated structural steel materials to site
with all necessary field connection materials in such sequence as will
permit the most efficient and economical performance of the erection work.
(PCA.774.S034sca4) V.II-D2/S-IV : 21

4.5.2 Marking
DCPL-K4A02
the Owner may prescribe or control the sequence of delivery of materials, at
his own discretion.
Each separate piece of fabricated steelwork shall be distinctly marked
on all surfaces before delivery in accordance with the markings shown
on approved erection drawings and shall bear such other marks as will
further facilitate identification and erection.
4.5.3 Packing and Shipping
All projecting plates or edges and all ends of members of joints shall be
stiffened, all straight members and plates, shall be bundled, all screwed
ends and machined surfaces shall be suitably packed and all bolts, nuts,
washers, and small loose parts shall be packed separately in order to
prevent damage or distortion during shipping.
Shipping shall be strictly in accordance with the sequence stipulated in
the agreed programme. Payment may be held up for items sent in advance
of the sequence till they could be erected. The Contractor shall include
and provide for in his rates, the freight and other charges for
despatching the materials to the worksite and also for securely protecting
and packing the materials to avoid loss or damage during transport by rail,
road or water. All packings shall allow for easy removal and checking at
site. Special precautions shall be taken against rusting, corrosion, breakage
or damage otherwise of the materials. All parts shall be adequately braced
to prevent damage in transit.
Each bundle, bale or package delivered under this contract shall be
marked on as many sides as possible and such distinct marking (all previous
irrelevant markings being carefully obliterated) shall show the following : -
a) Name and address of the consignee
b) Name and address of the consignor
c) Gross weight of the package in tonnes and its dimensions
d) Identification marks and/or number of the package
e) Custom registration number, if required
All markings shall be carried out with such materials as would ensure quick
drying and indelibility.
Each component or part or piece of material when shipped, shall be
indelibly marked and/or tagged with reference to assembly drawings and
corresponding piece numbers.
(PCA.774.S034sca4) V.II-D2/S-IV : 22

DCPL-K4A02
Each packing case shall contain in duplicate in English a packing list
pasted on to the inside of the cover in a water-proof envelope, quoting
especially :
a) Name of the Contractor
b) Number and date of the Contract
c) Name of the office placing the contract
d) Nomenclature of stores
e) A schedule of parts or pieces, giving the parts or piece number with
reference to assembly drawings and the quantity of each.
The shipping dimensions of each package shall not exceed the maximum
dimensions permissible for transport over the Indian Railways/Roads.
After delivery of the materials at site, all packing materials shall automatically
become the property of the Owner.
Notwithstanding anything stated hereinbefore, any loss or damage
resulting from inadequate packing shall be made good by the Contractor
When facilities exist, all shipments shall be covered by approved Insurance
Policy for transit at the cost of the Contractor.
The contractor shall ship the complete materials or part on board a vessel
belonging to an agency approved by the Owner or on rail and/or road
transport as directed. The Contractor shall take all reasonable steps to
ensure correct appraisal of freight rates, weights and volumes and in no
case will the Owner be liable to pay any warehouse, wharfage, demurrage
and other charges.
If, however, the Owner has to make payment of any of the above mentioned
charges, the amount paid will be deducted from the progressive bills of the
Contractor.
Necessary advise regarding the shipment with relevant details shall reach
the Engineer at least a week in advance.
5.0.0 INFORMATION TO BE SUBMITTED
5.1.0 With Tender
The following information are required to be submitted with the Tender :
a) Progress Schedule
(PCA.774.S034sca4) V.II-D2/S-IV : 23

DCPL-K4A02
The Contractor shall quote in his Tender a detailed schedule of
progress of work and total time of completion, itemizing the time
required for each of the following aspects of work.
1) Preparation and approval of shop drawings
2) Procurement of materials
3) Fabrication and shipping of all anchor bolts
4) Fabrication and shipping of main steelwork
5) Fabrication and shipping of steelwork for bunkers. Tanks
and/ or silos as applicable.
6) Fabrication and shipping of all other remaining steel work
including miscellaneous steelwork
7) Final date of completion of all shipments
Time required for completion being one of the main criteria for selecting
the successful bidder, it is desired that the bidder quotes the minimum time
required by him for completing the work.
b) Shop
Location of the Tenderer's fabrication workshop giving details of
equipment, manpower, the total capacity and the capacity that will be
available exclusively for this contract shall be submitted.
c) Matching Steel
A rough indication of the quantities and details of matching steel
sections required to start the work shall be furnished.
5.2.0 After Award
After award of the Contract the successful Tenderer is to submit the
following :
a) Complete fabrication drawings, material lists, cutting lists, bolt lists,
field welding schedules based on the design drawings in accordance
with the approved schedule.
(PCA.774.S034sca4) V.II-D2/S-IV : 24

DCPL-K4A02
b) Monthly Progress Report with necessary photographs in six (6)
copies to reach the Engineer on or before the 7th day of each
month, giving the upto date status of preparation of detailed shop
drawings, bill of materials, procurement of materials, actual
fabrication done, shipping and all other relevant information.
c) Results of any test as and when conducted and as required by the
Engineer.
d) Manufacturer's mill test report in respect of steel materials, bolts,
nuts and electrodes as may be applicable.
(PCA.774.S034sca4) V.II-D2/S-IV : 25

DCPL-K4A02
VOLUME: II-D/2
SECTION-V
TECHNICAL SPECIFICATION
FOR
ERECTION OF STRUCTURAL STEELWORK
(PCA.775.S034sca5)

DCPL-K4A02
CONTENTS
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-V : 1
2.0.0 GENERAL V.II-D2/S-V : 1
3.0.0 WORKMANSHIP V.II-D2/S-V : 4
4.0.0 TESTING AND ACCEPTANCE CRITERIA V.II-D2/S-V : 10
5.0.0 INFORMATION TO BE SUBMITTED V.II-D2/S-V : 14
(PCA.775.S034sca5)

DCPL-K4A02
VOLUME: II-G/2
SECTION-V
TECHNICAL SPECIFICATION
FOR
ERECTION OF STRUCTURAL STEELWORK
1.0.0 SCOPE
This specification covers the erection of structural steelwork including
receiving and taking delivery of fabricated structural steel materials arriving
at Site and installing the same in position, painting and grouting the
stanchion bases all complete as per Drawings, this Specification and other
provision of the Contract.
2.0.0 GENERAL
2.1.0 Work to be provided for by the Contractor
The work to be provided for by the Contractor, unless otherwise
specified in the Contract, shall include but not be limited to the following:-
a) The Contractor shall provide all construction and transport
equipment, tools, tackle, consumables, materials, labour and
supervision required for the erection of the structural steelwork.
b) Receiving, unloading, checking and moving to storage yard at Site
including prompt attendance to all insurance matters as necessary for
all fabricated steel materials arriving at Site. The Contractor shall pay
all demurrage and/or wharfage charges etc. on account of default on
his part.
c) Transportation of all fabricated structural steel materials from Site
storage yard, handling, rigging, assembling, bolting, welding and
satisfactory installation of all fabricated structural steel materials in
proper location according to approved erection drawings and/or as
directed by the Engineer. If necessary suitable temporary approach
roads to be built for transportation of fabricated steel structures.
d) Checking center lines, levels of all foundation blocks including
checking line, level, position and plumb of all bolts and pockets. any
defect observed in the foundation shall be brought to the notice of
the Engineer. The Contractor shall fully satisfy himself regarding
the correctness of the foundations before installing the fabricated
steel structures on the foundation blocks.
e) Aligning, plumbing, levelling, bolting, welding and securely fixing the
fabricated steel structures in accordance with the Drawings or as
directed by the Engineer.
(PCA.775.S034sca5) V.II-D2/S-V : 1

DCPL-K4A02
f) Painting of the erected steel structures if required by the Contract.
g) All minor modifications of the fabricated steel structures as
directed by the Engineer including but not limited to the following :
i) Removal of bends, kinks, twists etc. for parts damaged during
transport and handling.
ii) Cutting, chipping, filling, grinding etc. if required for
preparation and finishing of site connections.
iii)
iv)
Reaming of holes for use of higher size bolt if required.
Welding of connections in place of bolting for which holes are
either not drilled at all or wrongly drilled during fabrication.
Welding in place of bolting will be permitted only at the
discretion of the Engineer.
v) Refabrication of parts damaged beyond repair during
transport and handling or Refabrication of parts which are
incorrectly fabricated.
vi)
vii)
Fabrication of parts omitted during fabrication by error, or
subsequently found necessary.
Drilling of holes which are either not drilled at all or are
drilled in incorrect location during fabrication.
2.2.0 Work by others
viii) Carry out tests in accordance with this Specification if
directed.
No work under this Specification will be provided for by any agency other
than the Contractor unless specifically mentioned elsewhere in the Contract.
2.3.0 Codes and Standards
All work under this Specification shall, unless specified otherwise, conform to the
latest revisions and/or replacements of the following or any other Indian Standard
Specification and codes of Practice of equivalent:-
IS-800
IS-456
IS-7205
: Code of Practice for general construction in steel
: Code of Practice for plain or reinforced concrete
: Safety Code for erection of Structural Steel work
IS-12843 : Tolerance for erection of Steel Structures
2.4.0 Conformity with designs
The Contractor will erect the entire fabricated steel structure, align all
the members, complete all field connections and grout the
(PCA.775.S034sca5) V.II-D2/S-V : 2

2.5.0 Material
2.5.1 General
DCPL-K4A02
foundations all as per the provisions of this specification and the
design criteria detailed in the approved erection drawings and/or other
stated document. All work shall conform to the provisions of the relevant
Indian Standard Specifications and/or the instructions of the engineer. The
testing and acceptance of the erected structures shall be in accordance
with the provisions of this Specification and/or the instructions of the
Engineer.
The Contractor will check the quantity, quality and the sizes of the fabricated
materials and verify the adequacy of the same in accordance with the
Drawings and Specifications. The Contractor shall make good any deficiency,
if detected, either by repair or with fresh material as may be directed by the
Engineer.
All consumables like oxygen and acetylene gas, paints, fuels, lubricants, oil,
grease, cement, sand, aggregates and any other material that may be
required for the execution of the works in accordance with the contract will
be supplied by the contractor for erection work and will be deemed to have
been included in this rates.
2.5.2 Materials to conform to Indian Standards
All materials required to be supplied by the Contractor under this Contract
shall conform to the relevant Indian Standard Specifications.
2.6.0 Storage of materials
2.6.1 General
2.6.2 Yard
All material shall be so stored as to prevent deterioration and to ensure the
preservation of their quality and fitness for use in the works. Any material
which has been deteriorated or damaged beyond repairs and has become
unfit for use shall be removed immediately from the site, failing which,
the Engineer shall be at liberty to get the materials removed by agency.
The Contractor will have to establish a suitable yard in an approved
location at site for storing the fabricated steel structures and other materials
which will be delivered to him by the Owner according to the Contract. The
yard shall have proper facilities like, drainage, lighting, suitable access for
large cranes, trailers and other heavy equipments. The yard shall be fenced
all around with security arrangement and shall be of sufficiently large area to
permit systematic storage of the fabricated steel structures without
overcrowding and with suitable access for cranes, trailers and other
equipment for use in erection work in proper sequence in accordance with
the approved programme of work. The Tenderer should visit the site prior to
submission of his Tender to acquaint himself with the availability of land
and the development necessary by way of filling, drainage, access roads,
(PCA.775.S034sca5) V.II-D2/S-V : 3

DCPL-K4A02
fences, sheds etc. all of which shall be carried out by the Contractor as
directed by the Engineer.
2.6.3 Covered Store
All field connection materials, paints, cement etc. shall be stored on well
designed racks and platforms off the ground in a properly covered store
building to be built.
2.7.0 Quality Control
The contractor shall establish and maintain quality control procedures for
different items of work and materials as may be directed by the Engineer to
assure compliance with the provisions of the Contract and shall submit the
records of the same to the Engineer. The quality control operation shall
include but not be limited to the following items of work:-
1) Erection : Lines, levels, grades, plumbs, joint characteristics including
tightness of bolts.
2) Grouting : Cleaning and roughness of foundation, quality of materials
used for grouting, admixtures, consistency and strength of grout.
3) Painting : Preparation of surface for painting, quality of primers and
paints, thinners, application and uniformity of coats.
The Contractor shall salvage, collect and deliver all the packing materials
to the Owner.
3.0.0 WORKMANSHIP
3.1.0 Erection
3.1.1 Plant and equipment
The suitability and adequacy of all erection tools and plant and equipment
proposed to be used shall be efficient, dependable, in good working
condition and shall have the approval of the Engineer.
3.1.2 Method and sequence of erection
The method and sequence of erection shall have the prior approval of the
Engineer. The Erection shall arrange for most economical method and
sequence available to him consistent with the Drawings and Specifications
and such information as may be furnished to him prior to the execution
of the Contract.
(PCA.775.S034sca5) V.II-D2/S-V : 4

DCPL-K4A02
3.1.3 Temporary bracing
Unless adequate bracing is included as a part of the permanent framing, the
erector during erection shall install temporary guys and bracings where
needed to secure the framing against loads such as wind or seismic forces
comparable in intensity to that for which the structure has been designed,
acting upon exposed framing as well as loads due to erection equipment and
erection operations.
If additional temporary guys are required to resist wind or seismic forces
acting upon components of the finished structure installed by others
during the course of the erection of the steel framing, arrangement for their
installation by the erector shall be made.
The responsibility of the Contractor in respect of temporary bracings and
guys shall cease when the structural steel is once located, plumbed,
levelled, aligned and grouted within the tolerances permitted under the
specification and guyed and braced to the satisfaction of the Engineer.
3.1.4 Temporary floors for buildings
3.1.5 Setting out
It shall be the responsibility of the Contractor to provide free of cost
planking and to cover such floors during the work in progress as may be
required by any Act of Parliament and/or by-laws of state, Municipal or other
local authorities.
Positioning and levelling of all steelwork, plumbing of stanchions and
placing of every part of the structure with accuracy shall be in accordance
with the approved Drawings and to the satisfaction of the Engineer. Concrete
foundations, where required, shall be made by other agencies. Anchor bolts
and other anchor steel shall be embedded by other agencies. The
Contractor shall check the positions and levels of the anchor bolts, etc.
before concreting and get them properly secured against disturbance
during pouring operations. He shall remain responsible for correct
positioning. For heavy columns, etc. the Contractor shall set proper screed
bars if desired by the Engineer, to maintain proper level.
Each tier of column shall be plumbed and maintained in a true vertical
position subject to the limits of tolerance allowable under this Specification.
No permanent field connections by bolting or welding shall be carried out
until proper alignment and plumbing has been attained.
3.1.6 Field bolting
All relevant portions in respect of bolted construction of the Specification for
Fabrication of Structural Steelwork applicable to the Project shall also be
applicable for field bolting in addition to the following :
Bolts shall be inserted in such a way so that they may remain in position
under gravity even before fixing the nut. Bolted parts shall fit solidly together
when assembled and shall not be separated by gaskets or any other
(PCA.775.S034sca5) V.II-D2/S-V : 5

DCPL-K4A02
interposed compressible materials. When assembled, all joint surfaces,
including those adjacent to the washers shall be free of scales except tight
mill scales. They shall be free of dirt, loose scales, burns, and other defects
that would prevent solid seating of the parts. Contact surfaces within
friction-type joints shall be free of oil, paint, lacquer, or galvanizing.
All high tensile bolts shall be tightened to provide, when all fasteners in the
joint are tight, the required minimum bolt tension by any of the following
methods.
a) Turn-of-nut method
When the turn-of-nut method is used to provide the bolt tension,
there shall first be enough bolts brought to a "snug tight" condition to
ensure that the parts of the joint are brought into good contact with
each other. "snug tight" is defined as the tightness attained by a
few impacts of an impact wrench or the full effort of a man using an
ordinary spud wrench. Following this initial operation, bolts shall be
placed in any remaining holes in the connection and brought to snug
tightness. All bolts in the joint shall then be tightened additionally by
the applicable amount of nut rotation specified in Table-1 with
tightening progressing systematically from the most rigid part of
the joint to its free edges. During this operation there shall be no
rotation of the part not turned by the wrench.
TABLE - I
------------------------------------------------------------------------------------------
Bolts length not Bolt length Remarks
exceeding 8 x dia.
exceeding 8xdia.
or 200 mm
or 200 mm
------------------------------------------------------------------------------------------
1/2 turn 2/3 turn Nut rotation is
relative to bolt
regardless of the
element (nut or
bolt) being turned.
Tolerance on
rotation - 30
over or under.
Bolts may be installed without hardened washers when tightening
is done by the turn-of-nut method. However, normal washers shall
be used.
Bolts tightened by the turn-of-nut method may have the outer face
of the nut match-marked with the protruding bolt point before final
tightening, thus affording the inspector visual means of noting the
actual nut rotation. Such marks can be made by the wrench operator
by suitable means after the bolts have been brought up snug tight.
b) Torque Wrench tightening
(PCA.775.S034sca5) V.II-D2/S-V : 6

NOTE :
DCPL-K4A02
When torque wrenches are used to provide the bolt tensions,
the bolts shall be tightened to the torques specified in TABLE - II.
Nuts shall be in tightening motion when torque is measured. When
using torque wrenches to install several bolts in a single joint, the
wrench shall be returned to touch up bolts previously tightened,
which may have been loosened by the tightening of subsequent
bolts, until all are tightened to the required tension.
TABLE - II
------------------------------------------------------------------------
Nominal Bolt
Torque to be applied
Diameter (mm) (Kg.M) for bolt class 8.8
of IS : 1367
------------------------------------------------------------------------
20 59.94
22 81.63
24 103.73
------------------------------------------------------------------------
The above torque values are approximate for providing tensions of 14.7
MT for 20 mm dia., 18.2 MT for 22 mm dia; and 21.2 MT for 24 mm dia.
bolts under moderately lubricated condition. The torque wrench shall be
calibrated at least once daily to find out the actual torque required to
produce the above required tension in the bolt by placing it in a tension
indicating device. These torques shall be applied for tightening the bolts on
that day with the particular torque wrench.
In either of the above two methods, if required, for bolt entering and
wrench operation clearances, tightening may be done by turning the bolt
while the nut is prevented from rotating.
Impact wrenches if used shall be of adequate capacity and sufficiently
supplied with air to perform the required tightening of each bolt in
approximately ten seconds.
3.1.7 Field Welding
Holes for turned bolts to be inserted in the field shall be reamed in the field.
All drilling and reaming for turned bolts shall be done only after the parts
to be connected are assembled. Tolerances applicable in the fit of the bolts
shall be in accordance with relevant Indian Standard Specifications. All other
requirements regarding assembly and bolt tightening shall be in accordance
with this sub clause.
(PCA.775.S034sca5) V.II-D2/S-V : 7

DCPL-K4A02
All field assembly and welding shall be carried out in accordance with
the requirements of the specification for fabrication work applicable to the
project, excepting such provisions therein which manifestly apply to shop
conditions only. Where the fabricated structural steel members have been
delivered painted, the paint shall be removed before field welding for a
distance of at least 50 mm on either side of the joints.
3.1.8 Holes, cutting and fitting
3.2.0 Drifting
No cutting of sections, flanges, webs, cleats, bolts, welds etc. shall be done
unless specifically approved and/or instructed by the Engineer.
The erector shall not cut, drill or otherwise alter the work of other trades, or
his own work to accommodate other trades, unless such work is clearly
specified in the Contract or directed by the Engineer. Wherever such work
is specified the Contractor shall obtain complete information as to size,
location and number of alterations prior to carrying out any work.
Correction of minor misfits and reasonable amount of reaming and cutting of
excess stock from rivets will be considered as permissible. For this, light
drifting may be used to draw holes together and drills shall be used to
enlarge holes as necessary to make connections. Reaming, that
weakens the member or makes it impossible to fill the holes properly or to
adjust accurately after reaming shall not be allowed.
Any error in shop work which prevents the proper assembling and fitting of
parts by moderate use of drift pins and reamers shall immediately be called
to the attention of the Engineer and approval of the method of correction
obtained. The use of gas cutting torches at erection site is prohibited.
3.3.0 Grouting of stanchion bases and bearings of beams and girders on stone,
brick or concrete (Plain or reinforced)
Grouting shall be carried out with Ordinary Cement grout as described
below :
The mix shall be one (1) part cement and one (1) part sand and just enough
water to make it workable. The positions to be grouted shall be cleaned
thoroughly with compressed air jet and wetted with water and any
accumulated water shall be removed. These shall be placed under expert
supervision, taking care to avoid air-locks. Edges shall be finished properly. If
the thickness of grout is 25 mm or more, two (2) parts of 6 mm down graded
stone chips may be added to the above noted cement-sand grout mix, if
required, by the Engineer or shown on the drawings.
Admixtures like aluminium powder, "ironite" may be required to be added to
the grout to enhance certain desirable properties of the grout.
Alternatively, the grouting may be done with non-shrink high strength free flow
cementious grout (ready mixed) like “Sika grout - 214", or "Anchor NSG" or
approved equivalent.
(PCA.775.S034sca5) V.II-D2/S-V : 8

DCPL-K4A02
No grouting shall be carried out until a sufficient number of bottom lengths of
stanchions have been properly lined, levelled and plumbed and sufficient floor
beams are tied in position.
Whatever method of grouting is employed, the operation shall not be carried
out until the steelwork has been finally levelled and plumbed, the stanchion
bases being supported meanwhile by steel wedges, and immediately before
grouting, the space under steel shall be thoroughly cleaned.
3.4.0 Painting after erection
Field painting, if required to be done by the erection Contractor, shall only
be done after the structure is erected, levelled, plumbed, aligned and grouted in
its final position, tested and accepted by the Engineer. However, touch up
paintings, making good any damaged shop painting and completing any
unfinished portion of the shop coat shall be carried out by the erection
Contractor to the Owner. The materials and specification for such painting in
the field shall be in accordance with the requirements of the specification for
fabrication of structural steelwork applicable for the project.
Painting shall not be done in rainy or foggy weather or when humidity is such
as to cause condensation on the surfaces to be painted. Before painting of steel,
which is delivered unpainted, is commenced, all surfaces to be painted shall
be dried and thoroughly cleaned from all loose scale and rust.
All field bolts, welds and abrasions to the shop coat shall be spot painted with
the same paint used for the shop coat. Where specified, surfaces which will be
in contact after site assembling shall receive a coat of paint (in addition to the
shop coat, if any) and shall be brought together while the paint is still wet.
Surface which will be inaccessible after field assembly shall receive the full
specified protective treatment before assembly. Bolts and fabricated steel
members which are galvanized or otherwise treated and steel members to
be encased in concrete shall not be painted.
The specification for paint and workmanship shall be in accordance with
the requirements of the specification for fabrication of structural steelwork
applicable to the project.
The number of coats and the shades to be used shall be as specified or as
directed by the Engineer.
3.5.0 Stainless Steel Plate Lining in Bunker Hopper
The hopper portion of the coal bunkers shall be lined with stainless steel
plates of 3 mm thickness. The stainless steel shall be of AISI-316 quality.
The work includes supply, fabrication, welding and fixing of stainless steel
lining plate to bunker M.S. plate as per drawing.
The stainless steel liner shall be fixed to the Bunker hopper by plug welding
using special electrodes (such as, Inox-CW coding AWS-310-16 ISMBOS-
311 or Inox-D2 coding AWSE-309-16, ISMB 04-311 manufactured by Advani
Oerlikon Ltd). Such plug welding shall be done by drilling 21.5 mm dia.
(PCA.775.S034sca5) V.II-D2/S-V : 9

DCPL-K4A02
holes at 300 mm centre to centre both ways. The plug welding shall be
ground flush with the lining plate.
3.6.0 Final cleaning up
Upon completion of erection and before final acceptance of the work by the
Engineer, the Contractor shall remove all falsework, rubbish and all
Temporary Works resulting in connection with the performance of his work.
3.7.0 Safety Measures during Erection
The safety measures to workmen and supervisors during all types of
erection work (e.g., use of lifting appliances, slingning, welding, gas
cutting, etc.) should be taken as per IS : 7205. When any statutory provisions
exist, the same shall be complied with in addition to the provisions contained
in the above code.
4.0.0 TESTING AND ACCEPTANCE CRITERIA
4.1.0 General
Loading tests shall be carried out on erected structures, if required by the
Engineer, to check adequacy of fabrication and/or erection. Any structure or
a part thereof found to be unsuitable for acceptance as a result of the test
shall have to be dismantled and replaced with suitable member. In course of
dismantling, if any damage is done to any other parts of the structure or to
any fixtures, the same shall be made good by the Contractor responsible, to
the satisfaction of the Engineer.
The structure or structural member under consideration shall be loaded
with its actual dead load for as long a time as possible before testing and
the tests shall be conducted as indicated in the following Sub-clauses 4.1.1,
4.1.2 and 4.1.3. The method of testing and application of loading shall be as
approved by the Engineer.
4.1.1 Stiffness Test
In this test, the structure or member shall be subjected, in addition to its
actual dead load, to a test load equal to1.5 times the specified superimposed
load, and this loading shall be maintained for 24 hours. The maximum
deflection attained during the test shall be within the permissible limit. If, after
removal of the test load, the member or structure does not show a recovery
of at least 80 per cent of the maximum strain or deflection shown during 24
hours under load, the test shall be repeated. The structure or member
shall be considered to have sufficient stiffness, provided that the recovery
after this second test is not less than 90 percent of the maximum increase in
strain or deflection recorded during the second test.
(PCA.775.S034sca5) V.II-D2/S-V : 10

DCPL-K4A02
4.1.2 Strength Test
The structure or structural member under consideration shall be subjected,
in addition to its actual dead load, to a test load equal to the sum of the
dead load and twice the specified superimposed load, and this load shall be
maintained for 24 hours.
In the case of wind load, a load corresponding to twice the specified wind
load shall be applied and maintained for 24 hours, either with or without the
vertical test load for more severe condition in the member under
consideration or the structure as a whole. Complete tests under both
conditions may be necessary to verify the strength of the structure. The
structure shall be deemed to have adequate strength if, during the test, no
part fails and if on removal of the test load, the structure shows a recovery
of at least 20 per cent of the maximum deflection or strain recorded during
the 24 hours under load.
4.1.3 Structure of same design
Where several structures are built to the same design and it is considered
unnecessary to test all of them, one structure, as a prototype, shall be fully
tested, as described in previous Sub-clauses, but in addition, during the
first application of the test load, particular note shall be taken of the strain or
deflection when the test load 1.5 times the specified superimposed load has
been maintained for 24 hours. This information is required as a basis of
comparison in any check test carried out on samples of the structure.
When a structure of the same type is selected for a check test, it shall be
subjected, in addition to its actual dead load, to a superimposed test load,
equal to 1.5 time the specified live load, in a manner and to an extent
prescribed by the Engineer. This load shall be maintained for 24 hours,
during which time, the maximum deflection shall be recorded. The check
test shall be considered satisfactory, provided that the maximum strain or
deflection recorded in the check test does not exceed by more than 20% of
the maximum strain or deflection recorded at similar load in the test on
the prototype.
4.1.4 Repair for subsequent test and use after strength tests
4.2.0 Tolerances
An actual structure which has passed the "Strength Test" as specified in
Sub-clause 4.1.2 hereinbefore and is subsequently to be erected for use,
shall be considered satisfactory for use after it has been strengthened by
replacing any distorted members and has subsequently satisfied the
'Stiffness Test' as specified in Sub-clause 4.1.1. hereinbefore.
Some variation is to be expected in the finished dimensions of structural steel
frames. Unless otherwise specified, such variations are deemed to be
within the limits of good practice when they are not in excess of the
cumulative effect of detailed erection clearances, fabricating tolerances for
the finished parts and the rolling tolerances for the profile dimensions
(PCA.775.S034sca5) V.II-D2/S-V : 11

DCPL-K4A02
permitted under the Specifications for fabrication of structural steelwork
applicable to this Project and as specified below :
I. For Buildings Containing Cranes
Component Description Variation
Allowed
Main columns a) Shifting of column axis
at foundation level with
respect to building line
i) In longitudinal i) 3.0 mm
direction
ii) In lateral direction
ii) 3.0 mm
b) Deviation of both major
column axis from vertical
between foundation and
other member connection
levels :
i) For a column upto i) 3.5 mm
and including 10M from true
height
vertical
ii) For a column greater ii) 3.5 mm from
than 10M but less true vertical for
than 40M height any 10M length
measured between
connection levels,
but not more than
7.0 mm per
30 m length.
Component Description Variation
Allowed
c) For adjacent pairs of
columns across the width
of the building prior to
placing of truss.
d) For any individual column
deviation of any bearing
or resting level from
levels shown on drawings.
9 mm on true
span.
3.0 mm
(PCA.775.S034sca5) V.II-D2/S-V : 12
e) For adjacent pairs of
columns either across the
width of building or
longitudinally level

DCPL-K4A02
difference allowed between
bearing or seating level
supposed to be at the
same level.
3 mm
Trusses a) Deviation at centre of 1/1500 of the
span of upper chord span or not
member from vertical greater than
plane running through 10 mm whichever
centre of bottom chord. is the least.
b) Lateral displacement of 1/250 of depth
top chord at centre of of truss or
span from vertical plane 20 mm whichever
running through centre is the least.
of supports.
Crane
a) Difference in levels of
Girders &
crane rail measured bet-
Tracks ween adjacent columns. 2.0 mm
b) Deviation to crane rail
gauge
c) Relative shifting of ends
of adjacent crane rail in
plan and elevation after
thermit welding.
d) Deviation of crane rail
axis from centre line of
web.
3.0 mm
1.0 mm
3.5 mm
Component Description Variation
Allowed
Setting of
Expansion
gaps
At the time of setting of
the expansion gaps, due
regard shall be taken of
the ambient temperature
above or below 30C.
The coefficient of expansion
or contraction shall
be taken as 0.000012 per
C per unit length.
II.
For Building without Cranes
The maximum tolerances for line and level of the steel work shall
be 3.0 mm on any part of the structure. The structure shall not be
(PCA.775.S034sca5) V.II-D2/S-V : 13

4.3.0 Acceptance
DCPL-K4A02
out of plumb more than 3.5 mm on each 10M section of height and
not more than 7.0 mm per 30 M section.
These tolerances shall apply to all parts of the structure unless the
drawings issued for erection purposes state otherwise.
Structures and members which have passed the tests and conform to all
requirements specified in the foregoing Sub-clause 4.1.0, 4.1.1, 4.1.2,
4.1.3 and 4.1.4 and other applicable provisions of this Specification and are
within the limits of tolerances specified in Sub-clause 4.2.0 and/or
otherwise approved by the Engineer shall be treated as approved and
accepted for the purpose of fulfilment of the provisions of this Contract.
5.0.0 INFORMATION TO BE SUBMITTED
5.1.0 Before Tender
Along with the Tenders the Tenderers will be required to submit the
following information :
5.1.1 Tentative Programme
The Tenderer shall submit a tentative programme based on the information
available in the Tender Document and visit to Site indicating the structurewise
erection schedule proposed to be maintained by the Contractor to
complete the job in time in accordance with the Contract.
5.1.2 Constructional Plant and Equipment, Tools,
Temporary Works & Manpower
5.1.3 Erection yard
A detailed list of all Constructional Plant & Equipment like cranes, derricks,
winches, welding sets, erection tools etc. along with their make, model,
present condition and location available with the Tenderer which he will be
able to employ on the job to maintain the progress of work in accordance
with the Contract shall be submitted along with the Tender. The total
number of each category of experienced personnel like fitters, welders,
riggers etc. that he will be able to employ on the job shall also be indicated.
A site plan showing the layout and location of the erection yard proposed
to be established by the Tenderer shall be attached with the Tender
indicating the storage space for fabricated steel materials, site-fabrication
and repair shop, covered stores, offices, locations of erection equipments
and other facilities. The Engineer shall have the right to modify the
(PCA.775.S034sca5) V.II-D2/S-V : 14

DCPL-K4A02
arrangement and location of the proposed yard to suit site conditions and
the Contractor shall comply with the same without any claim whatsoever.
5.2.0 After award of the Contract
After award of the contract, the Contractor shall submit the following :-
5.2.1 Detailed Programme
The Contractor shall submit a detailed erection programme for completion of
the work in time in accordance with the Contract. This will show the target
programme, with details of erection proposed to be carried out in each
fortnight, details of major equipment required and an assessment of
required strength of various categories of workers in a proforma approved
by the Engineer.
5.2.2 Fortnightly Progress Report
The Contractor shall submit fortnightly progress reports in triplicate to the
Engineer showing along with necessary photographs, 125 mm x 90 mm
size, and all details of actual achievements against the target programme
specified in Sub-clause 5.2.1 above. Any shortfall in the achievement in a
particular fortnight must be made up within the next fortnight. Along with
this report, the Contractor shall also furnish details of fabricated materials in
hand at site and the strength of his workers.
(PCA.775.S034sca5) V.II-D2/S-V : 15

DCPL-K4A02
VOLUME : II-D/2
SECTION-VII
TECHNICAL SPECIFICATION
FOR
ROADS AND DRAINAGE
(PCA.775.S034sca7)

DCPL-K4A02
CONTENTS
CLAUSE NO. DESCRIPTION PAGE NO.
1.0 SCOPE V.II-D2/S-VII : 1
2.0 GENERAL V.II-D2/S-VII : 1
3.0 EXECUTION V.II-D2/S-VII : 6
4.0 TESTING AND ACCEPTANCE V.II-D2/S-VII : 30
CRITERIA
(PCA.775.S034sca7)

VOLUME : II-D/2
SECTION-VII
TECHNICAL SPECIFICATION
FOR
ROADS AND DRAINAGE
1.0 SCOPE
This specification covers all work required for the construction of road
including box-cutting, edging, sub-base, water bound macadam, bituminous
macadam, wearing course etc. and shall include all incidental items of work
not shown or specified but reasonably implied or necessary for the
completion of the work.
This specification also includes all work required for drainage including
road side drain, R.C.C. culverts, pipe-culverts, drainage pipes, manholes
etc. and all other incidental items.
2.0 GENERAL
2.1 Work to be Provided for by the Contractor
The work to be provided for by the Contractor, unless specified otherwise,
shall include but not be limited to the following :
a) Furnish all labour, supervision, services, materials, equipment, tools
and plants, transportation etc. required for the work.
b) Submit for approval detailed schemes of all operations required for
executing the work e.g. material handling, placement, services,
approaches etc.
c) To carry out and submit to the Engineer results of tests whenever
required by the Engineer to assess the quality of work.
2.2 Work to be Provided for by Others
No work under this specification will be provided for by any agency other
than the Contractor unless specifically mentioned elsewhere in the
Contract.
2.3 Codes and Standards
(PCA.775.S034sca7) V.II-D2/S-VII : 1

DCPL-K4A02
All work under this specification, unless specified otherwise, shall conform
to the latest revision and/or replacements of the following or any other
relevant I.S. Specifications and Codes of Practice.
1. Specification for road and bridge works of Ministry of shipping &
Transport (Roads wing) Published by the IRC.
2. IRC-19 Standard specifications and Code of Practice for Water
Bound Macadam.
3. IRC:SP-11 Hand Book of Quality Control for Construction of Roads
and Runways.
4. IS:456 Indian Standard Code of Practice for Plain and
Reinforced Concrete.
5. IS:2212 Code of Practice for Brickwork.
6. IS:783 Code of Practice for Laying of Concrete Pipes.
7. Other specifications mentioned elsewhere in this specification.
In case any particular aspect of work is not covered specifically by Indian
Standard Specification, any other standard practice as may be specified by
the Engineer shall be followed.
2.4.0 Conformity with Designs
The contractor shall carryout the work as per the drawings issued to him
and/or contractor's drawings which are approved by the Engineer and/or
the Engineer's instructions.
2.5.0 Materials to be Used
2.5.1 General
All materials required for the work shall be of best commercial variety and
as approved by the Engineer.
2.6.0 Quality Control
The Contractor shall establish and maintain quality control for the various
aspects of the work, method, materials and equipment used. All works
performed shall conform to the lines, grades, cross sections and
dimensions shown on the drawings or as directed by the Engineer.
Permitted tolerances for roadworks are described hereinafter.
i) Horizontal Alignments
Horizontal alignments shall be reckoned with respect to the centre
line of the carriageway as shown on the drawings. The edges of the
(PCA.775.S034sca7) V.II-D2/S-VII : 2

DCPL-K4A02
carriageway as constructed shall be correct within a tolerance of
25 mm therefrom. The corresponding tolerance for edges of the
roadway and lower layers of pavement shall be 40 mm.
ii)
Longitudinal Profile
The levels of the subgrade and different pavement courses as
constructed, shall not vary from those calculated with reference to the
longitudinal and cross-profile of the road shown on the drawings or as
directed by the Engineer, beyond tolerances mentioned below :
Sub-grade
Sub-base
Base course
25 mm
20 mm
15 mm
Wearing course 10 mm
Tolerance in wearing course shall not be permitted in
conjunction with the positive tolerance for base course if the
thickness of the former is thereby reduced by more than 6 mm.
iii)
Surface Regularity of Subgrade and Pavement Courses
The surface regularity of completed sub-bases, base courses and
wearing surfaces in the longitudinal and transverse directions shall be
within the tolerances indicated in Table-I.
The longitudinal profile shall be checked with a 3 metre long straight
edge, at the middle of each traffic lane along a line parallel to the
centre of the road. The transverse profile shall be checked with a set
of three camber boards at intervals of 10 metres.
(PCA.775.S034sca7) V.II-D2/S-VII : 3

DCPL-K4A02
TABLE -I
PERMITTED TOLERANCES OF SURFACE REGULARITY
FOR PAVEMENT COURSES
____________________________________________________________________________________________________________________
Sl.
No. Type of Construction Longitudinal Profile with 3 metre straight edge Cross Profile
__________________________________________________________________________________________________________
Maximum Permi- Maximum number of undulations Maximum permissible variassible
undulation permitted in any 300 metres tion from specified profile
l ength exceeding : under camber template
mm mm mm
___________________________________
18 12 10 6
1 2 3 4 5 6 8
__________________________________________________________________________________________________________
1. Earthen subgrade 25 30 - - - 15
2. Granular subbase 15 - 30 - - 12
3. Water Bound Macadam with
oversize metal (40-90 mm size) 15 - 30 - - 12
4. Water Bound Macadam with normal
size metal (20-50 mm and 40-63mm
size), Bituminous Penetration
Macadam 12 - - 30 - 8
5. Surface dressing ** (two coat)
over WBM (20-50 mm or 40-63 mm
size metal), Bituminous penetration
macadam or built-up
spray grout 12 - - 20 - 8
____________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________
(PCA.775.S034sca7) V.II-D2/S-VII : 4

DCPL-K4A02
Sl.
No. Type of Construction Longitudinal Profile with 3 metre straight edge Cross Profile
_________________________________________________________________________________________________________________
Maximum Permi- Maximum number of undulations Maximum permissible variassible
undulation permitted in any 300 metres tion from specified profile
l ength exceeding : under camber template
mm mm mm
_____________________________________
18 12 10 6
1 2 3 4 5 6 8
_________________________________________________________________________________________________________________
6. Open graded premix carpet,
mixseal surfacing 10 - - - 30 6
7. Bituminous macadam 10 - - - 20 *** 6
8. Semi-dense carpet 10 - - - 20 *** 6
9. Asphaltic Concrete 8 - - - 10 *** 4
_________________________________________________________________________________________________________________
NOTES :
1. ** For surface dressing in all other cases, the standards of surface evenness will be the same as those for the surface
receiving the surface dressing.
2. *** These are for machine laid surfaces. If laid manually due to unavoidable reasons, tolerance upto 50 percent above
these values in this column may be permitted at the discretion of the Engineer. However, this relaxation does not apply to
the values of maximum undulation for longitudinal and cross profiles mentioned in columns 3 and 8 on the table.
3. Surface evenness requirements in respect of both the longitudinal and cross profiles should be simultaneously satisfied.
(PCA.775.S034sca7) V.II-D2/S-VII : 5

DCPL-K4A02
3.0 EXECUTION
3.1.0 Shoulder Construction
3.1.1 Description
3.1.2 Materials
This work shall consist of constructing shoulders on either side of the
pavement, in accordance with the requirements of this specification and in
conformity with the lines, grades and cross-sections shown on the drawings
or as directed by the Engineer.
Shoulder may be of selected earth or grannlar material conforming to the
requirements of embankment construction or granular sub-base construction
respectively.
3.1.3 Construction Operations
3.2.0 Kerb
3.2.1 Material
Except in the case of bituminous constructions, shoulders shall be
constructed in advance of the laying of pavement courses. The compacted
thickness of each layer of shoulder shall correspond to the compacted layer
of pavement course to be laid adjacent to it. After compaction, the inside
edges of shoulders shall be trimmed vertical and included area cleaned of all
spilled material before proceeding with the construction of the pavement
layer.
In the case of bituminous courses, shouldering operations shall start only
after the pavement course has been laid and compacted.
Regardless of the method of laying, all shoulder construction material
shall be placed directly on the shoulder. Any spilled material dragged on to
the pavement surface shall be immediately removed, without damage to the
pavement and the area so affected thoroughly cleaned.
During all stages of shoulder construction, the required cross-fall shall be
maintained to drain off surface water.
Kerb, if required for construction of footpath, shall consist of precast
concrete blocks with a concrete grade of M-15. The blocks shall be 100 mm
wide and of suitable length. The depth of blocks unless otherwise mentioned
elsewhere, shall be 375 mm considering 225 mm height of footpath from the
road level.
3.2.2 Laying
(PCA.775.S034sca7) V.II-D2/S-VII : 6

DCPL-K4A02
The Kerb shall be laid by cutting trenches 150 mm deep. The width of the trench shall
be minimum and just sufficient to insert the kerbs. The inside faces of the Kerbs
shall be in plumb and the gap between the block shall not be more than 10 mm.
The kerbs shall be thoroughly packed with a mixture of stone chips (50%) and
moorum (50%) at the outside face. The laying and packing shall be done in a proper
workmanlike manner acceptable to the Engineer.
3.3.0 Sub-base (Granular Sub-base)
3.3.1 Description
3.3.2 Materials
This work shall consist of laying and compacting well-graded material on prepared
subgrade in accordance with the requirements of these specifications. The material
shall be laid in one or more layers as shown on the drawings and according to lines,
grades and cross sections shown on the drawings or as directed by the Engineer.
The materials to be used for the work shall be natural sand, moorum, gravel,
crushed stone, crushed slag, crushed concrete, brick metal, laterite, kanker etc. or
combinations thereof depending upon the grading required. The mixed materials shall
be free from organic or other deleterious constituents and conform to one of the three
gradings given in Table-II below.
TABLE-II
Grading for Granular Sub-base Materials
__________________________________________________________________
Sieve designation
Percent by weight passing the seive
Grading 1 Grading 2 Grading 3
__________________________________________________________________
80 mm 100 100 100
63 mm 90-100 90-100 90-100
4.75 mm 35-70 40-90 50-100
75 micron 0-20 0-25 0-30
__________________________________________________________________
CBR Value (Minimum) :
for fraction of material
passing 20 mm sieve 30% 25% 20%
__________________________________________________________________
Note : The material passing 425 micron sieve for all the three gradings when
tested according to IS:2720 (Part V) shall have liquid limit and plasticity index
of not more than 25 percent and 6 percent respectively.
3.3.3 Physical Requirements
(PCA.775.S034sca7) V.II-D2/S-VII : 7

DCPL-K4A02
The fraction of material passing 20 mm sieve shall give a CBR value as
specified in Table-II when tested in accordance with IS:2720 (Part XVI)
after preparing the samples at maximum dry density and optimum moisture
content corresponding to IS:2720 (Part VII) and soaking the same in water
for 4 days.
3.3.4 Spreading and Compacting
Immediately prior to the laying of sub-base, the subgrade already finished
shall be prepared by removing all vegetation and other extraneous matter,
lightly sprinkled with water, if necessary, and rolled with one pass of 8-10
tonne smooth wheeled roller.
The sub-base material shall be spread on the subgrade with the help of a
drag spreader, motor grader or other approved means. The thickness of
loose layers shall be so regulated that the maximum thickness of the layer
after consolidation does not exceed 150 mm.
Moisture content of the loose material shall be checked in accordance with
IS:2720 (Part II) and suitably adjusted by sprinkling additional water from a
hose line, truck mounted water tank or other approved means so that at the
time of compaction it is from 1 percent above to 2 percent below the optimum
moisture content corresponding to IS:2720 (Part VIII). While adding water,
due allowance shall be made for evaporation losses. After water has been
added, the material shall be processed by mechanical or other approved
means if so directed by the Engineer until the layer is uniformly wet.
Immediately thereafter, rolling shall be started with 8 to 10 tonne smooth
wheeled rollers or other approved plant. Rolling shall commence at the
edges and progress towards the centre longitudinally except that on
superelevated portions it shall progress from the lower to the upper edge
parallel to the centre line of the pavement. Each pass of the roller shall
uniformly overlap not less than one third of the track made in the
preceding pass. During rolling, the grade and camber shall be checked and
any high spots or depressions which become apparent corrected by
removing or adding fresh material.
Rolling shall be continued till the density achieved is at least 100% of the
maximum dry density for the material determined as per IS:2720 (Part VII).
The surface of any layer of material on completion of compaction shall be
well closed, free from movement under compaction plant and from
compaction planes, ridges, cracks or loose material. All loose, segregated
or otherwise defective areas shall be made good to the full thickness of layer
and re-compacted.
3.4.0 Water Bound Macadam Sub-base/Base Course
3.4.1 Description
(PCA.775.S034sca7) V.II-D2/S-VII : 8

3.4.2 Materials
DCPL-K4A02
Water bound macadam shall consist of clean, crushed aggregates mechanically
interlocked by rolling and bonded together with screenings, binding material, where
necessary and water, laid on a prepared subgrade or sub-base, as the case may be,
and finished in accordance with the requirements of these Specifications and in
conformity with the lines, grades and cross-sections shown on the drawings or
otherwise directed by the Engineer.
3.4.2.1 Coarse Aggregates - General Requirements
Coarse aggregates shall be either crushed or broken stone. The aggregates shall
conform to the physical requirements set forth in Table-III.
TABLE-III
Physical Requirements of Coarse Aggregates
for Water Bound Macadam
____________________________________________________________
Sl. Type of Test Test method Requirements
No. Construction
___________________________________________________________
1. Sub-base Los Angeles IS:2386 50 percent
Abrasion Value* (Part IV) maximum.
or
Aggregate IS:2386 40 percent
Impact Value (Part IV) maximum.
or
IS:5640**
2. Base a) Loss Angeles IS:2386 50 percent
Abrasion Value* (Part IV) maximum.
or
Aggregate IS:2386 40 percent
Impact Value Part IV) maximum.
or
IS:5640**
b) Flakiness IS:2386 15 percent
Index*** (Part I) maximum.
__________________________________________________________
* Aggregate may satisfy requirements of either of the two tests.
** Aggregates like brick metal, kankar and laterite which get softened
in presence of water, shall be tested for impact value under
conditions in accordance with IS:5640.
*** The requirements of Flakiness Index shall be enforced only in case of
crushed or broken stone and crushed slag.
3.4.2.2 Crushed or Broken Stone
Crushed or broken stone shall be hard, durable and free from excess of
flat, elongated, soft and disintegrated particles, dirt and other objectionable
matter.
(PCA.775.S034sca7) V.II-D2/S-VII : 9

DCPL-K4A02
3.4.2.3 Grading Requirements of Coarse Aggregates
The coarse aggregates shall conform to one of the gradings given in Table-
IV, provided, however, the use of Grading No. 1 shall be restricted to subbase
courses only.
TABLE-IV
GRADING REQUIREMENTS OF COARSE AGGREGATES
__________________________________________________________________
Grading Size range Sieve Percent by weight
No. designation passing the sieve
__________________________________________________________________
1. 90 mm to 40 mm 100 mm 100
80 mm 65-85
63 mm 25-60
40 mm 0-15
20 mm 0-5
2. 63 mm to 40 mm 80 mm 100
63 mm 90-100
50 mm 35-70
40 mm 0-15
20 mm 0-5
3. 50 mm to 20 mm 63 mm 100
50 mm 95-100
40 mm 35-70
20 mm 0-10
10 mm 0-5
__________________________________________________________________
3.4.2.4 Screenings
Screenings to fill voids in the coarse aggregate shall generally consist of
the same material as the coarse aggregate. However, where permitted,
predominantly non-plastic material such as moorum or gravel (other than
rounded river borne material) may be used for this purpose provided liquid
limit and plasticity index of such material is below 20 and 6 respectively and
fraction passing 75 micron sieve does not exceed 10 percent.
As far as possible, screenings shall conform to the gradings set forth in
Table-V Screenings of Type A in Table shall be used with coarse
aggregates of grading 1 in Table IV. Screenings of Type A or B, shall be
used with coarse aggregates of grading 2. Type B screenings shall be used
with coarse aggregates of grading 3.
TABLE-V : GRADINGS FOR SCREENINGS
(PCA.775.S034sca7) V.II-D2/S-VII : 10

DCPL-K4A02
__________________________________________________________________
Grading Size of Sieve Percent by weight
Classi- screenings designation passing the sieve
fication
__________________________________________________________________
A 12.5 mm 12.5 mm 100
10.0 mm 90-100
4.75 mm 10-30
150 micron 0-8
B 10 mm 10 mm 100
4.75 mm 85-100
150 micron 10-30
__________________________________________________________________
3.4.2.5 Binding Material
Binding material to be used for water bound macadam construction shall
comprise of a suitable material approved by the Engineer having plasticity
index value of less than 6 as determined in accordance with IS:2720 (Part
V).
Application of binding material may not be necessary, when the
screenings used are of crushable type such as moorum or gravel.
3.4.3 Construction Operations
3.4.3.1 Preparation of Base
The subgrade/sub-base to receive the water bound macadam coarse shall
be prepared to the specified grade and camber and made free of dust and
other extraneous material. Any ruts or soft yielding places shall be corrected
in an approved manner and rolled until firm. Where water bound macadam
is to be laid over an existing black topped surface, 50 mm x 50 mm furrows
shall be cut at an angle of 45 degrees to the centre line of the road at 1
metre intervals in the latter before laying the coarse aggregate.
3.4.3.2 Inverted Choke
If the water bound macadam is to be laid directly over the sub-grade,
without any other intervening pavement course, a 25 mm course of
screenings (Grading B) shall be spread on the prepared subgrade before
application of the coarse aggregates is taken up.
3.4.3.3 Spreading Coarse Aggregate
(PCA.775.S034sca7) V.II-D2/S-VII : 11

3.4.3.4 Rolling
DCPL-K4A02
The coarse aggregates shall be spread uniformly upon the prepared surface
in such quantities that the thickness of the compacted layer is 100 mm for
grading 1 and 75-100 mm for gradings 2 and 3 for each layer.
The spreading shall be done from stockpiles along the side of the roadway or
directly from vehicles. In no case shall the aggregate be dumped in heaps
directly on the surface prepared to receive the aggregate nor shall hauling
over uncompacted or partially compacted base be permitted.
The surface of the aggregates spread shall be carefully checked with
templates and all high or low spots remedied by removing or adding
aggregate as may be required. No segregation of large or fine particles shall
be allowed and the coarse aggregate as spread shall be of uniform gradation
with no pockets of fine material.
The coarse aggregate shall not normally be spread more than 3 days in
advance of the subsequent construction operations.
Immediately following the spreading of the coarse aggregate, rolling
shall be started with three wheeled power rollers of 8 to 10 tonne capacity or
tandem or vibratory rollers of approved type. The weight of the roller shall
depend upon the type of the aggregate and be indicated by the Engineer.
Except on superelevated portions where the rolling shall proceed from inner
edge to the outer, rolling shall begin from the edges gradually progressing
towards the centre. First the edge/edges shall be compacted with roller
running forward and backward. The roller shall then move inwards parallel to
the centre line of the road, in successive passes uniformly lapping
preceding tracks by at least one half width.
Rolling shall continue until the aggregates are thoroughly keyed and the
creeping of aggregates ahead of the roller is no longer visible. During rolling
slight sprinkling of water may be done, if necessary. Rolling shall not be
done when the subgrade is soft or yielding or when it causes a wave-like
motion in the subgrade or sub-base course.
The rolled surface shall be checked transversely and longitudinally with
templates and any irregularities corrected by loosening the surface, adding or
removing necessary amounts of aggregate and re-rolling until the entire
surface conforms to desired camber and grade. In no case shall the use of
screenings be permitted to make up depressions.
3.4.3.5 Applications of Screenings
After the coarse aggregate has been rolled, screenings to completely
fill the interstices shall be applied gradually over the surface. These shall
not be damp or wet at the time of application. Dry rolling shall be done
(PCA.775.S034sca7) V.II-D2/S-VII : 12

DCPL-K4A02
while the screenings are being spread so that vibrations of the roller cause
them to settle into the voids of the coarse aggregate. The screenings shall
not be dumped in piles but be spread uniformly in successive thin layers
either by the spreading motion of hand shovels or by mechanical spreaders,
or directly from trucks. Trucks operating for spreading the screenings shall
be so driven as not to disturb the coarse aggregate.
The screenings shall be applied at a slow and uniform rate (in three or
more applications) so as to ensure filling of all voids. This shall be
accompanied by dry rolling and brooming with mechanical brooms, handbrooms
or both. In no case shall the screenings be applied so fast and thick
as to form cakes or ridges on the surface in such a manner as would
prevent filling of voids or prevent the direct bearing of the roller on the coarse
aggregate. These operations shall continue until no more screenings can
be forced into the voids of the coarse aggregate.
The spreading, rolling and brooming of screenings shall be carried out in
only such lengths of the road which could be completed within one day's
operation.
3.4.3.6 Sprinkling and Grouting
After the screenings have been applied, the surface shall be copiously
sprinkled with water, swept and rolled. Hand brooms shall be used to
sweep the wet screenings into voids and to distribute them evenly. The
sprinkling, sweeping and rolling operations shall be continued, with
additional screenings applied as necessary, until the coarse aggregate
has been thoroughly keyed, well-bonded and firmly set in its full depth and
a grout has been formed of screenings. Care shall be taken to see that the
base or subgrade does not get damaged due to the addition of excessive
quantities of water during construction.
3.4.3.7 Application of Binding Material
After the application of screenings, the binding material where it is required
to be used shall be applied successively in two or more thin layers at a slow
and uniform rate. After each application, the surface shall be copiously
sprinkled with water, the resulting slurry swept in with hand brooms, or
mechanical brooms to fill the voids properly, and rolled during which water
shall be applied to the wheels of the rollers if necessary to wash down the
binding material sticking to them. These operations shall continue until the
resulting slurry after filling of voids, forms a wave ahead of the wheels of
the moving roller.
3.4.3.8 Setting and Drying
After the final compaction of water bound macadam course, the road shall
be allowed to dry overnight. Next morning hungry spots shall be filled with
screenings or binding material as directed, lightly sprinkled with water if
necessary and rolled. No traffic shall be allowed on the road until the
macadam has set. The Engineer shall have the discretion to stop hauling
(PCA.775.S034sca7) V.II-D2/S-VII : 13

3.5.0 Tack Coat
3.5.1 Description
3.5.2 Materials
DCPL-K4A02
traffic from using the completed water bound macadam course if in his
opinion it would cause excessive damage to the surface.
The work shall consist of application of a single coat of low viscosity liquid
bituminous material to an existing road surface preparatory to another
bituminous construction.
Binder : The binder used for tack coat shall be bitumen of a suitable
grade as directed by the Engineer and conforming to IS:73, 217 or 454, as
applicable, or any other approved cutback.
3.5.3 Construction Operations
3.5.3.1 Preparation of Base
The surface on which the tack coat is to be applied shall be thoroughly
swept and scraped clean of dust and any other extraneous material before
the application of the binder.
3.5.3.2 Application of Binder
Binder shall be heated to the temperature appropriate to the grade of bitumen
used and approved by the Engineer and sprayed on the base at the rate
specified below. The rate of spread in terms of straight-run bitumen shall be
5 kg. per 10 square metre area for an existing bitumen treated surface and
10 kg per 10 square metre area for an untreated water bound macadam
surface. The binder shall be supplied uniformly with the aid of sprayers.
The tack coat shall be applied just ahead of the on-coming bituminous
construction.
3.6.0 Bituminous Macadam Binder Course
3.6.1 Description
3.6.2 Materials
3.6.2.1 Binder
This work shall consist of construction, in a single course, of 50 mm / 75 mm
thickness of compacted crushed aggregates premixed with a bituminous binder, laid
immediately after mixing, on a base prepared previously in accordance with the
requirements of these Specifications, and in conformity with the lines, grades and
cross sections shown on the drawings or directed by the Engineer.
(PCA.775.S034sca7) V.II-D2/S-VII : 14

3.6.2.2 Aggregates
DCPL-K4A02
The Binder shall be straight run bitumen of a suitable grade as directed by the
Engineer complying with IS:73.
The aggregates shall consist of crushed stone, crushed gravel (shingle) or other
stones. They shall be clean, strong, durable, of fairly cubical shape and free of
disintegrated pieces, organic and other deleterious matter, and adherent coats. The
aggregates shall preferably be hydrophobic and of low porosity.
The aggregates shall satisfy the physical requirements set forth in Table-VI.
TABLE-VI
PHYSICAL REQUIREMENTS OF AGGREGATES
FOR BITUMINOUS MACADAM
________________________________________________________________
Sl. No. Test Test method Requirements
__________________________________________________________________
1. Los Angeles Abrasion * IS:2386 35% Maximum
Value
(Part IV)
2. Aggregate Impact Value * -do- 30% "
3. Flakiness Index IS:2386 35% "
(Part I)
4. Stripping Value IS:6241 25% "
5. Water Absorption IS:2386 2% "
(Part III)
__________________________________________________________________
* Aggregates may satisfy requirements of either of the two tests.
The aggregates for bituminous macadam for different thicknesses shall conform to
the grading A or B given in Tables VII & VIII.
TABLE-VII
AGGREGATES GRADING FOR 75 MM COMPACTED
THICKNESS OF BITUMINOUS MACADAM
__________________________________________________________________
Sieve
Percent by weight passing the sieve
Designation ________________________________________
Grading A
Grading B
__________________________________________________________________
63 mm 100
50 mm 90-100
40 mm 35-65 100
25 mm 20-40 70-100
20 mm - 50-80
12.5 mm 5-20 -
(PCA.775.S034sca7) V.II-D2/S-VII : 15

DCPL-K4A02
4.75 mm - 10-30
2.36 mm - 5-20
75 micron 0-5 0-4
__________________________________________________________________
TABLE-VIII
AGGREGATE GRADING FOR 50 MM COMPACTED THICKNESS
OF BITUMINOUS MACADAM
____________________________________________________
Sieve
Percent by weight passing the sieve
Designation _________________________________
Grading A Grading B
____________________________________________________
50 mm 100
40 mm 90-100
25 mm 50-80 100
20 mm - 70-100
12.5 mm 10-30 -
10 mm - 35-60
4.75 mm - 15-35
2.36 mm - 5-20
75 micron 0-5 0-4
____________________________________________________
3.6.2.3 Proportioning of Materials
The binder content for premixing shall be 3.5 and 4.0 percent by weight of
the total mix for aggregate grading A and B respectively, except when
otherwise directed by the Engineer.
The quantities of aggregates to be used shall be sufficient to yield the
specified thickness after compaction.
3.6.2.4 Variation in Proportioning of Materials
The Contractor shall have the responsibility for ensuring proper proportioning
of materials and producing a uniform mix. A variation in binder content of
0.3 percent by weight of total mix shall, however, be permissible for
individual specimens taken for quality control tests.
3.6.3 Construction Operations
(PCA.775.S034sca7) V.II-D2/S-VII : 16

DCPL-K4A02
3.6.3.1 Weather and Seasonal Limitations
Bituminous macadam shall not be laid during rainy weather or when the
base course is damp or wet.
3.6.3.2 Preparation of Base
3.6.3.3 Tack Coat
The base on which bituminous macadam is to be laid shall be prepared,
shaped and conditioned to the specified lines, grade and cross sections as
directed by the Engineer. The surface shall be thoroughly swept and
scraped clean and free from dust and foreign matter.
A tack coat shall be applied over the base.
3.6.3.4 Preparation and Transport of Mix
3.6.3.5 Spreading
Hot mix plant of adequate capacity shall be used for preparing the mix.
The temperature of binder at the time of mixing shall be in the range 150
Deg.- 165 Deg.C and that of aggregates in the range 125 Deg. - 150 Deg.C,
provided that the difference in temperature between the binder and
aggregate at no time exceeds 25 Deg.C.
Mixing shall be thorough to ensure that a homogenous mixture is obtained
in which all particles of the aggregates are coated uniformly.
The mixture shall be transported from the mixing plant to the point of use in
suitable vehicles. The vehicles employed for transport shall be clean and be
covered over in transit if so directed by the Engineer.
The mix shall be spread immediately after mixing by means of a self
propelled mechanical paver with suitable screeds capable of spreading,
tamping and finishing the mix to the specified lines, grade and cross sections.
However, in restricted locations and in narrow widths, where the available
plants cannot operate in the opinion of the Engineer, he may permit manual
laying of the mix.
The temperature of mix at the time of laying shall be in the range 110 Deg. -
135 Deg.C.
In multilayer construction, the longitudinal joint in one layer shall offset that
in the layer below by about 150 mm. However, the joint in the topmost layer
shall be at the centre line of the pavement.
Longitudinal joints and edges shall be constructed true to the delineating
lines parallel to the centre line of the road. All joints shall be cut vertical to
(PCA.775.S034sca7) V.II-D2/S-VII : 17

3.6.3.6 Rolling
DCPL-K4A02
the full thickness of the previously laid mix and the surface painted with hot
bitumen before placing fresh material.
After the spreading of mix, rolling shall be done by 8 to 10 tonne power
rollers or other approved plant. Rolling should start as soon as possible
after the material has been spread. Rolling shall be done with care to keep
from unduly roughening the pavement surface.
Rolling of the longitudinal joint shall be done immediately behind the paving
operation. After this, the rolling shall commence at the edges and progress
towards the centre longitudinally except that on super-elevated portions it
shall progress from the lower to the upper edge parallel to the centre line of
the pavement.
The initial or breakdown rolling shall be done as soon as it is possible to
roll the mixture without cracking the surface or having the mix pick up on
the roller wheels. The second or inter mediate rolling shall follow the break
down rolling as closely as possible and be done while the paving mix is still
at a temperature that will result in maximum density. The final rolling shall
be done while the material is still workable enough for removal of roller
marks.
(PCA.775.S034sca7) V.II-D2/S-VII : 18

DCPL-K4A02
When the roller has passed over the whole area once, any high spots or depressions
which become apparent shall be corrected by removing or adding fresh material.
The rolling shall then be continued till the entire surface has been rolled to
compaction, there is no crushing of aggregate and all roller marks have been
eliminated. Each pass of the roller shall uniformly overlap not less than one third of
the track made in the preceeding pass. The roller wheels shall be kept damp if
necessary to avoid the bituminous material from sticking to the wheels and being
picked up. In no case shall fuel lubricating oil be used for this purpose.
Rolling operations shall be completed in every respect before the temperature of the
mix falls below 80 Deg.C.
Rollers shall not stand on newly laid material while there is a risk that it will be
deformed thereby. The edges along and transverse of the bituminous macadam laid
and compacted earlier shall be cut to their full depth so as to expose fresh surface
which shall be painted with a thin surface coat of appropriate binder before the new
mix is placed against it.
The bituminous macadam shall be provided with final surfacing without any delay.
If there is to be any delay, the course shall be covered by a seal coat before allowing
any traffic over it.
3.7.0 Open-Graded Premix Carpet
3.7.1 Description
3.7.2 Materials
3.7.2.1 Binder
3.7.2.2 Aggregates
This work shall consist of laying and compacting an open-graded carpet of 2 cm
thickness in a single course composed of suitable small sized aggregates premixed
with a bituminous binder on a previously prepared base, to form a wearing course, in
accordance with the requirements of these specifications.
The binder shall be bitumen of a suitable grade, as directed by the Engineer, and
satisfying the requirements of IS:73, 217, 454 or other approved cutback as
applicable.
The aggregates shall consist of angular fragments of clean, hard, tough and durable
rock of uniform quality throughout. They shall be obtained by crushing rock, gravel or
river shingle and be free of elongated and flaky pieces, soft and disintegrated
materials, and vegetable or other deleterious matter. They shall preferably be
hydrophobic type.
The aggregates shall satisfy the quality requirements set forth in Table VI except that
the Flakiness Index shall be limited to a maximum of 30.
3.7.2.3 Proportioning of Materials
The materials shall be proportioned as per quantities given in Table IX.
(PCA.775.S034sca7) V.II-D2/S-VII : 19

DCPL-K4A02
TABLE-IX : QUANTITIES OF MATERIALS REQUIRED FOR 10 SQ.M OF ROAD
SURFACE FOR 2 CM THICK OPEN-GRADED PREMIX CARPET
__________________________________________________________________
Aggregates of Carpet
a) Stone chippings - 12 mm size; passing
20 mm sieve and retained on 10 mm sieve 0.18 Cu.m
b) Stone chippings - 10 mm size; passing
12.5 mm sieve and retained on 6.3 mm sieve 0.09 Cu.m
_______________
Binder for premixing (quantities in terms of straight run bitumen)
Total : 0.27 Cu.m
_______________
a) For 0.18 Cu.m of 12 mm size stone
chippings at 52 kg per Cu.m
9.5 kg
b) For 0.09 Cu.m of 10 mm size stone
chippings at 56 kg per Cu.m
5.1 kg
______________
Total : 14.6 kg
______________
__________________________________________________________________
3.7.3 Construction Operation
3.7.3.1 Weather and Seasonal Limitations
Open-graded premix carpet shall not be laid during rainy weather or when
the base course is damp or wet or when the atmospheric temperature in
shade is 16 Deg.C or below.
3.7.3.2 Preparation of Base
The underlying base on which the bituminous carpet is to be laid shall be
prepared, shaped and conditioned to the specified lines, grade and cross
section in accordance with Table I as directed by the Engineer. The surface
shall be well cleaned by removing caked earth and other foreign matter with
wire brushes, sweeping with brooms and finally dusting with sacks as
necessary.
3.7.3.3 Tack Coat
A tack coat complying with clause 3.5 shall be applied over the base
preparatory to laying of the carpet. Application of tack coat shall, however,
(PCA.775.S034sca7) V.II-D2/S-VII : 20

DCPL-K4A02
not be necessary when the laying of carpet follows soon after the provision of
a bituminous course.
3.7.3.4 Preparation of Premix
Mixers of approved type shall be employed for mixing the aggregates with
the bituminous binder.
The binder shall be heated to the temperature appropriate to the grade of
bitumen approved by the Engineer, in boilers of suitable design avoiding
local overheating and ensuring a continuous supply.
The aggregates shall be dry and suitably heated to a temperature as
directed by the Engineer before these are placed in the mixer. After about 15
seconds of dry mixing, the heated binder shall be distributed over the
aggregates at the rate specified.
The mixing of binder with chippings shall be continued until the chippings are
thoroughly coated with the binder. The mix shall be immediately transported
from the mixer to the point of use in suitable vehicles or wheel barrows.
The vehicles employed for transport shall be clean and be covered over in
transit if so directed.
3.7.3.5 Spreading and Rolling
The premixed material shall be spread on the road surface with rakes to
the required thickness and camber or distributed evenly with the help of a
drag spreader, without any undue loss of time. The camber shall be
checked by means of camber boards and inequalities evened out. As
soon as sufficient length of bituminous material has been laid rolling shall
commence with 6 to 8 tonne power rollers, preferably of smooth wheel
tandem type, or other approved plant. Rolling shall begin at the edges and
progress toward the centre longitudinally, except that on the superelevated
portions it shall progress from the lower to upper edge parallel to the centre
line of the pavement.
When the roller has passed over the whole area once, any high spots or
depressions which become apparent shall be corrected by removing or
adding premixed materials. Rolling shall then be continued until the entire
surface has been rolled to compaction and all the roller marks eliminated.
In each pass of the roller, preceding track shall be overlapped uniformly by
at least 1/3 width. The roller wheels shall be kept damp to prevent the
premix from adhering to the wheels and being picked up. In no case shall
fuel/lubricating oil be used for this purpose.
Rollers shall not stand on newly laid material while there is a risk that it will be
deformed thereby.
The edges along and transverse of the carpet laid and compacted earlier shall be
cut to their full depth so as to expose fresh surface which shall be painted with a
thin surface coat of appropriate binder before the new mix is placed against it.
(PCA.775.S034sca7) V.II-D2/S-VII : 21

DCPL-K4A02
3.7.3.6 Seal Coat
3.8.0 Seal Coat
3.8.1 Description
3.8.2 Materials
3.8.2.1 Binder
A seal coat conforming to clause 3.8 shall be applied to the surface immediately
after laying the carpet. No traffic shall be allowed on the road till the seal coat has
been placed.
This work shall consist of application of a seal coat for sealing the voids in a
bituminous surface laid to the specified levels, grade and camber.
Seal coat shall be of either of the two types below, as specified:
Type A : Liquid seal coat comprising of an application of a layer of bituminous binder
followed by a cover of stonee chippings.
Type B : Premixed seal coat comprising of a thin application of fine aggregate
premixed with bituminous binder.
The binder shall be bitumen of a suitable grade as directed by the Engineer and
conforming to the requirements of IS:73, 217 or 454 as applicable or any other
approved cutback.
The quantity of binder to be utilised, in terms of straight run bitumen shall be 9.8
kg and 6.8 kg per 10 square metre area for Type A and Type B seal coat
respectively.
3.8.2.2 Stone Chippings for Type A Seal Coat
The stone chippings shall consist of angular fragments of clean, hard, tough and
durable rock of uniform quality throughout. They shall be free of elongated or flaky
pieces, soft or disintegrated stone, vegetable or other deleterious matter. Stone
chippings shall be of 6 mm size defined as 100 percent passing through 10 mm sieve
and retained on 2.36 mm sieve. The quantity used for spreading shall be 0.09 cubic
metre per 10 square metre area. The chippings shall satisfy the quality
requirements spelled out in Table VI except that the upper limit for flakiness Index
shall be 30.
3.8.2.3 Fine Aggregate for Type B Seal Coat
The fine aggregate shall be sand or fine grit and shall consist of clean, hard,
durable, uncoated dry particles and shall be free from dust, soft or flaky
material, organic matter or other deleterious substances. The aggregate
shall pass 1.7 mm sieve and be retained on 180 micron sieve. The quantity
used for premixing shall be 0.06 cubic metre per 10 square metre area.
(PCA.775.S034sca7) V.II-D2/S-VII : 22

DCPL-K4A02
3.8.3 Construction Operations
3.8.3.1 Preparation of Base
The seal cost shall be applied immediately after the laying of bituminous
course which is required to be sealed. Before application of seal coat
materials the surface shall be cleaned free of any dust or other extraneous
matter.
3.8.3.2 Construction of Type A Seal Coat
The binder shall be heated in boilers of suitable design, to the temperature
appropriate to the grade of bitumen approved by the Engineer and sprayed
on the dry surface in a uniform manner preferably with the help of mechanical
sprayers. Excessive deposits of binder caused by stopping or starting of the
sprayer or through leakage or any other reason shall be suitably corrected
before the stone chippings are spread.
Immediately after the application of binder, stone chippings in a dry and
clean state, shall be spread uniformly on the surface, preferably by means of
a mechanical gritter, otherwise manually so as to cover the surface
completely. If necessary, the surface shall be broomed to ensure uniform
spread of chippings.
Immediately after the application of the cover material, the entire surface
shall be rolled with a 8-10 tonne smooth wheeled roller. Rolling shall
commence at the edges and progress towards the centre except in
superelevated portions where it shall proceed from the inner edge to the
outer. Each pass of the roller shall uniformly overlap not less than one third of
the track made in the preceeding pass. While rolling is in progress additional
chippings shall be spread by hand in whatever quantities required to make
up irregularities. Rolling shall continue until all aggregate particles are
firmly bedded in the binder and present a uniform closed surface.
3.8.3.3 Construction of Type B Seal Coat
Mixers of approved type shall be employed for mixing the aggregates with
the bituminous binder.
The binder shall be heated in boilers of suitable design, to the temperature
appropriate to the grade of bitumen approved by the Engineer. Also the
aggregates shall be dry and suitably heated to a temperature directed by the
Engineer before the same are placed in the mixer. Mixing of binder with
aggregates to the specified proportions shall be continued till the latter are
thoroughly coated with the former.
The mix shall be immediately transported from the mixing plant to the point
of use and spread uniformly on the bituminous surface to be sealed.
(PCA.775.S034sca7) V.II-D2/S-VII : 23

DCPL-K4A02
As soon as sufficient length has been covered with the premixed material,
the surface shall be rolled with 6-8 tonne smooth wheeled power rollers.
Rolling shall be continued till the pre-mixed material completely seals the
voids in the bituminous course and a smooth uniform surface is obtained.
3.8.4 Opening to Traffic
In the case of Type B Seal coat, traffic may be allowed soon after final rolling
when the premixed material has cooled down to the surrounding
temperature. However, as regards Type A seal coat, traffic shall not be
permitted until the following day.
3.9.0 Repair of Existing Water Bound Macadam Surface
Pot holes or patches and ruts in water bound macadam base or surface
course, which is to be surface treated, shall be repaired by removal of all
loose material by cutting in rectangular patches and replacing with suitable
materials. The repair shall be done as under :
Pot holes, patches and ruts shall be drained of water and cut to regular
shape with vertical sides, and then be filled either with i) coarse aggregate
and screenings conforming to the specification for water bound macadam
and compacted with rollers or other approved rammer or ii) premixed material
conforming to the specification for open graded premix carpet and compacted
with rollers or other approved means after painting the sides and bottom of
the holes with a thin application of bitumen or a combination of both as
directed by the Engineer.
The above is only applicable in case of damage to the existing water
bound macadam surfaces. In case, however, it is found that there has been
damage to the granular sub-base as well, the area of the damaged surface
shall be repaired by removal of all loose materials, cut to regular shape with
vertical sides and relaid with graded material as per specification of granular
sub-base and then surfaced with water bound macadam as per specification
for the same.
3.10.0 Road Side Drains
3.10.1 Formation of Drains
The road side drains shall be made in sizes and slopes as shown on
drawings and/or as instructed by the Engineer. The minimum side slope
shall be as instructed by the Engineer. The sides and bottom shall be
neatly dressed after excavation. Proper connections shall be made to the
culverts, outside plant area, as per instructions of the Engineer.
The excavated spoils shall be transported and filled in low areas within the
plant area or in embankments as instructed by the Engineer. The lining
(PCA.775.S034sca7) V.II-D2/S-VII : 24

3.11.0 Culverts
DCPL-K4A02
for the drains shall be as per Dwg. and as mentioned in the Schedule of
items. Lining of drains may be of bricks or cement concrete blocks of M15
grade concrete as shown on drawing or as directed by the Engineer. If
instructed by the Engineer or shown on drawing, drains may be of R.C.C.
construction with necessary slopes.
Excavation in trenches for foundation of culverts and wing walls shall be
done with side slopes as per the instructions of Engineer after clearing the
site, etc. as per specifications of earthwork. Backfilling with ramming and
watering shall be done after construction of the foundations.
The construction of culverts shall be done true to lines and levels and as
shown on the drawing. The specification for Masonry and/or Plain and
Reinforced Cement concrete shall be followed, as applicable.
3.12.0 Pipe Culverts and Drainage Pipes
3.12.1 Materials
The drainage pipes unless otherwise shown on drawings or instructed by the
Engineer shall be made of R.C.C. and shall be either Class NP2 or NP3.
Pipe culverts shall be made of reinforced concrete pipe and shall be of class
NP3 or of RDSO class for railway as decided by the Engineer or shown in
the drawing. All pipes shall meet the requirements of IS:458- Latest edition
and shall be procured from approved manufacturers with collars as per
manufacturer's standard specifications. The tenderer shall specifically
mention the particular manufacturer's product he proposes to use. Cement
shall be ordinary Portland Cement as per IS:269 - Latest edition.
Aggregates shall be as per IS:383 - Latest edition - Maximum size shall not
exceed one third the thickness of the pipe or 20 mm whichever is smaller.
Fine aggregates for concrete shall be as per IS:383 - Latest edition.
3.12.2 Laying of Pipes
Laying of concrete pipes shall correspond to IS:783 - Latest edition - and
to specification given below :
a) The foundation bed for pipe shall be excavated true to lines and
grades shown on the drawings or as directed by the Engineer.
When trenching is involved its width on either side of the pipe shall
not be less than 150 mm nor more than one-third the diameter of pipe
unless otherwise instructed/permitted by the Engineer. The sides of the
trench shall be as nearly vertical as possible. Side slope, shoring,
bailing out water, etc. as required shall be done by the Contractor
without the Owner. Side slips, if there be any, shall be removed by the
(PCA.775.S034sca7) V.II-D2/S-VII : 25

DCPL-K4A02
Contractor. After laying of the pipes are completed, backfilling of the
trenches shall be done in 250 mm layers, measured loose, clods and
lumps broken, watered and compacted with iron rammers to the
satisfaction of the Engineer. The surplus spoils shall be transported
and filled in low areas within the plant area, as instructed by the
Engineer.
When bed-rock or boulder strata are encountered, excavation shall be
taken down to at least 200 mm below the bottom level of the pipe with
prior permission of the Engineer and all rock/boulders in the area shall
be removed and space filled with approved earth free from stone or
fragmented material, shaped to the requirements and thoroughly
compacted to provide adequate support for the pipe.
Filling of trench shall be carried out simultaneously on both sides of the
pipe in such a manner that unequal pressures do not occur.
When two or more pipes are to be laid adjacent to each other, they
shall be separated by a distance equal to at least half the diameter of
the pipe subject to a minimum of 450 mm.
Laying of pipes shall start from the outlet and proceed towards
inlet.
All pipes and fittings shall be gradually lowered into the trench or
placed on the supports by approved means taking due care not to
damage them. Under no circumstances the pipes shall be dropped
into the trench or on supports from a height.
b) Pipe bedding shall be first class projection bedding for positive projecting
pipes as per IS:783 - Latest edition - having a projection ratio of not greater
than 0.70, in which the pipe is carefully bedded on fine granular materials in an
earth foundation carefully shaped to fit the lower part of the pipe exterior for at
least ten percent of its overall height, and in which earthfilling material is
thoroughly rammed and tamped in layers not exceeding 15 cm in depth
around the pipe for the remainder of the lower 30 percent of its height.
If the pipe is laid in trench, pipe bedding shall be first class bedding
as per IS:783.
When indicated on the drawings or directed by the Engineer, the pipe
shall be bedded on a craddle constructed of concrete having a mix not
leaner than M15. The shape and dimension of the cradle shall be as
indicated on the drawing or directed by the Engineer. The pipe shall be
laid on the concrete bedding before the concrete has set.
c) The drop walls shall be made with first class brickwork in 1:4 cement
mortar.
(PCA.775.S034sca7) V.II-D2/S-VII : 26

DCPL-K4A02
d) The pipe culverts shall be made with proper care regarding the invert
of the pipe, gradient, if any, etc. as specified on drawings and/or as
instructed by the Engineer.
e) Where R.C.C. pipes are encased in concrete at road crossings or at
other places the pipes need be suitably supported avoiding
reinforcements of concrete blocks, joints properly done before
concreting is taken up. Concreting of total height of block may be
done in a single operation or may be done upto some height for
pipes to be properly laid in position and remaining height of block to
be concreted subsequently.
f) The R.C.C. pipes shall be joined with cement mortar. Cement mortar
shall consist of 1 part cement and 2 parts of clean sand with only
enough water for workability. Procedure of jointing shall be as per
IS:783 - latest edition.
3.12.3 Relation with Water Supply Pipeline
Unless specifically cleared by the Engineer, under no circumstances shall
drainage pipes be allowed to come close to water supply pipelines.
3.13.0 Manholes and Inspection Chambers
3.14.0 Masonry
3.14.1 Brick Masonry
The maximum distance between manholes shall be 30 meter unless
specifically permitted otherwise. In addition at every change of alignment,
gradient or diameter there shall be a manhole or inspection chamber. The
distance between manhole or inspection chamber and gully chamber shall
not exceed 6 meters unless permitted otherwise. Manhole shall be
constructed so as to be water-tight under test. The channel or drain at the
bottom of chamber shall be plastered with 1:2 cement sand mortar and
finished smooth to the grade. The channels and drains shall be shaped and
laid to provide smooth flow.
Connection to existing pipelines shall be through a manhole.
Manholes shall be provided with standard covers, usually C.I. or as directed
by the Engineer. The covers shall be close fitting so as to prevent gases
from coming out.
All bricks shall be of first class (Class A) quality, well burnt, of uniform size,
shape and colour free from cracks, flaws or nodules of free lime. Bricks
shall be soaked in water for at least two hours prior to use and shall be laid
truly horizontal and vertical in headers and stretchers with cement mortar
consisting of one part of cement and four parts of sand, unless otherwise
mentioned in the schedule of Items or directed by the Engineer, in
layers not exceeding 1.5 M in height. Each layer shall be allowed at least 24
(PCA.775.S034sca7) V.II-D2/S-VII : 27

3.14.2 Stone Masonry
DCPL-K4A02
hours to settle itself before another layer is placed on it and every layer
cured with water until the starting of next layer above it.
Materials for mortar such as sand and cement shall be of approved quality.
Mortar shall be well mixed, first dry mixed and then by adding water slowly to
have a thick workable consistency. Mortar shall be mixed in small batches
consistent with the rate of consumption so that no mortar is used after one
hour of mixing.
Mortar joints shall be kept uniformly 10 mm thick and all joints should be full
of mortar. Brickwork shall be carried up regularly in plumb every course being
horizontal. No vertical joints shall come directly over one another.
Joints of the brickwork shall be raked minimum 10 mm deep using raking
tool while mortar is still green to provide bond for plaster or pointing.
Where plaster or pointing is not provided, the joints shall be struck flush and
finished immediately. The brickwork shall be kept moist for 14 days.
All bricks which absorb water more than 20% of their own dry weight after
being immersed in water for 24 hours shall be rejected. Brick should be as
per IS:1077. Bricks shall have minimum crushing strength of 50 kg/Sq.cm.
All stones shall be from approved quarries, hard, tough, durable, compact grained,
uniform in texture and colour and free from decay, flaws, veins, cracks and sand
holes. A stone shall not absorb more than 5 percent of its weight of water after 24
hours immersion. Samples shall be submitted by the Contractor and approved
samples shall be retained by the Engineer for comparison of bulk supply.
Stone shall be thoroughly soaked before laying. Stones shall be laid on their natural
quarry beds. Individual stones shall be fitted with mallet and properly wedged to
reduce thickness of mortar joints. Thickness of joint shall not be less than 8 mm and
not greater than 25 mm. At least two stones shall run the full width of the wall for
every square meter of surface area.
3.14.3 Pointing to Masonry
After raking out of the joints, the brickwork shall be brushed down with a
stiff wire brush, so as to remove all loose dust from the joints and thoroughly
washed with water, mortar consisting of 1 part cement and 3 parts clean,
sharp, well graded sand by volume shall be pressed carefully into the joints
and finished with suitable tools to shape as shown on the drawings. Any
surplus mortar shall be scraped off the wall face leaving the surface clean.
The pointed surface shall be kept wet for at least three days for curing.
3.15.0 Plaster to Masonry and Concrete
Before application of plaster the surface shall be cleaned of all dirt, grease
or loose particles by hard brush and water. The surface shall be
thoroughly moist to prevent absorption of water from the base course. Any
excess water shall be mopped up.
(PCA.775.S034sca7) V.II-D2/S-VII : 28

DCPL-K4A02
3.15.1 Finish
Unless otherwise mentioned in the schedule of items plastering shall be
done with cement sand mortar - 1 part by volume of cement to 4 parts by
volume of clean, sharp, well graded sand. For sand cement plaster, sand
and cement in the specified proportion shall be mixed dry on a watertight
platform and minimum water added to achieve working consistency. For
lime gauge plaster, lime putty or hydrated lime and sand in the required
proportion shall be mixed on a watertight platform with necessary addition
of water and thoroughly ground in mortar mill. This mix shall than be
transferred to a mechanical mixer to which the required quantity of cement
is added and mixed for at least 3 minutes.
No mortar which has stood for more than half an hour shall be used.
Plaster, when more than 12 mm thick, shall be applied in two coats. All
plaster work shall correspond to IS:1661- latest edition.
Generally, all plastered surfaces shall have a standard finish unless
otherwise shown on the drawing or directed by the Engineer. The interior
plaster shall be finished to a smooth surface by steel trowelling. The
exterior surfaces shall be finished with a wooden float.
However, if shown on the drawing or directed by the Engineer the plastered
surface shall have a neat cement finish. Immediately after achieving a true
plastered surface with the help of a wooden straight edge, the entire area
shall be uniformly treated with a paste of neat and rubbed smooth with a
trowel.
3.16.0 Cement Concrete (Plain and Reinforced)
Shall be as laid down in “Techncial Specification for Cement Concrete (Plain
and Reinforced)” Section - III.
4.0 TESTING AND ACCEPTANCE CRITERIA
4.1 Roads
All testing, as mentioned in the body of the specification and as mentioned in
Clause No. 900 of Specification for Roads and Bridge Works, 1983 published
by IRC on behalf of Ministry of Shipping and Transport (Roads Wing) shall
be carried out by the Contractor as per direction of the Engineer. No extra
payment shall be made for such tests.
4.2 Masonry and Plastering
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DCPL-K4A02
Masonry and finish to masonry and concrete shall fully comply with the
drawings, approved samples and instructions of the Engineer with respect
to lines, levels, thickness and any other special criteria as mentioned in
the body of the specification or as shown on drawing.
4.3 Cement Concrete
The strength requirements and acceptance criteria shall conform to the
relevant clauses of IS:456.
(PCA.775.S034sca7) V.II-D2/S-VII : 30

DCPL-K4A02
VOLUME : II-D/2
SECTION-VIII
TECHNICAL SPECIFICATION
FOR
MASONRY & ALLIED WORKS
(PCA.775.S034sca8)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.00.00 SCOPE V.II-D2/S-VIII : 1
2.00.00 INSTALLATION V.II-D2/S-VIII : 1
3.00.00 I.S. CODES V.II-D2/S-VIII : 5
(PCA.775.S034sca8)

DCPL-K4A02
VOLUME : II-D/2
SECTION-VIII
TECHNICAL SPECIFICATION
FOR
MASONRY & ALLIED WORKS
1.0.0 SCOPE
This specification covers furnishing, installation, repairing, finishing,
curing, protection, maintenance and handing over of masonry and allied
works for use in structures and locations covered under the scope of the
Contract.
2.0.0 INSTALLATION
2.1.0 Soling
2.1.1 Brick Soling
2.1.2 Stone Soling
2.2.0 Brick Edging
The ground shall be dressed, consolidated by ramming or by light rolling
and a 12 mm thick cushion of sand laid. On the sand cushion the bricks
shall be laid with fine joints and placed firmly in position by hammering
with wooden mallet. The surface shall be free from undulations. The 'frog'
side shall be on the underside. The joints shall be broken the in all direction
and bricks cut as required. Orientation shall be as desired by the Engineer.
After laying of each layer of bricks sand shall be spread over and worked
into the joints to pack the bricks tight.
The stones for soling shall be selected on the basis of thickness of soling
as shown as the drawings. The larger stones shall be laid and the gaps
filled by smaller stones. The interstices shall then be firmly packed with
sand by flooding with water.
Excavation shall be done close to the brick dimensions and in perfect
alignment. Bricks shall be firmly placed by hammering with wooden mallets
and sides and joints packed firmly with earth so that the edging is not
disturbed easily. Alignment and level shall be acceptable to the Engineer.
(PCA.775.S034sca8) V.II-D2/S-VIII : 1

DCPL-K4A02
2.3.0 Masonry
2.3.1 General
2.3.2 Mortar
2.3.3 Brick Masonry
All masonry work shall be true to lines and levels as shown on drawings. All
masonry shall be tightly built against structural members and bonded with
dowels, inserts etc. as shown on drawings.
Mix for mortar shall be specified in the Schedule of Items.
When lime is used hydrated lime shall be mixed with water to form a putty
and stored with care to prevent evaporation for at least 24 hours before
use. Quick lime shall be slaked with enough water to make a cream,
passed through a No. 10 seive and stored avoiding evaporation for seven
days before use.
Lime putty and sand in proper proportion shall be mixed on a water-tight
platform with necessary addition of water and thoroughly ground in a
mortar mill. This mix shall be transferred to a mechanical mix, required
quantity of cement added and the content mixed for at least 3 minutes.
Mixtures of lime putty and sand may be stored avoiding drying out. For
cement sand mortar cement and sand in requisite proportions shall be
mixed dry in a mechanical mixer and then water added and mixed further.
Minimum quantity of water shall be added to achieve working consistency.
Surplus mortar droppings from masonry, if received on surface free from
dirt may be mixed with fresh mortar if permitted by the Engineer who
may direct addition of additional cement. No mortar which has stood for
more than half an hour shall be used.
Bricks shall be soaked by submergence in clean water for at least two hours
in approved vats before use. Bricks shall be laid in English bond unless
specified otherwise. Broken bricks shall not be used. Cut bricks shall be
used if necessary to complete bond or as closers. Bricks shall be laid with
frogs upwards over full mortar beds. Bricks shall be pressed into mortar
and tapped into final position so as to embed fully in mortar. Inside faces
shall be buttered with mortar before the next bricks is placed and
pressed against it. Thus all joints between bricks shall be fully filled with
mortar.
Mortar joints shall be kept uniformly 10 mm thick. All joints on face shall be
raked to minimum 10 mm depth using raking tool while the mortar is still
green to provide bond for plaster or pointing. Where plaster or pointing is
not provided, the joints shall be struck flush and finished immediately.
Brickworks two bricks thick or more shall have both faces in true plane.
Brickwork of lesser thickness shall have one selected face in true plane.
2.3.4 Exposed Brickwork
(PCA.775.S034sca8) V.II-D2/S-VIII : 2

DCPL-K4A02
Brickwork in superstructures which is not covered by plaster shall be as
shown on drawing and executed by specially skilled mason. Courses shall
be truly horizontal and vertical joints truly vertical. Wooden straight
edges with brick course graduations and position of window sills and lintels
shall be used to control uniformity of brick courses. Masons must check
workmanship frequently with plumb, spirit level, rule and string. All brickwork
shall be cleaned at the end of days work. If face bricks are specified
in the drawings, the brickwork shall be in composite bricks, with face bricks
on the exposed face and balance in routine bricks, but maintaining the
bond fully. Where face bricks are not specified, bricks for the exposed face
shall be specially selected from routine bricks. All exposed brickwork on
completion of work shall be rubbed down, washed clean and pointed as
specified. Where face bricks are used carborandum stone shall be used for
rubbing down.
2.3.5 Reinforced Brickworks
Reinforcements shall be as specified in the drawings. All reinforcements
shall be thoroughly cleaned and fully embeded in mortar. Where M.S. bars
are used as reinforcement, these shall be laped with dowels if left in R.C.
columns or welded to steel stanchions.
2.3.6 Stone Masonry
Stones shall be thoroughly soaked before laying. Stones shall be laid on
their natural quarry beds. Individual stones shall be fitted with mallet and
properly wedged to reduce thickness of mortar joints. Thickness of joint
shall be not less than 8 mm and not greater than 25 mm. Al least two
stones shall run the full width of the wall for every square meter of surface
area.
2.3.7 Exposed Stonework
Stonework which is to be kept exposed shall be as shown on drawing or
described in the Schedule of Items. It shall be executed by specially
skilled mason. Stones used for exposed face shall be specially selected.
All exposed stone faces shall be kept clean and free from mortar and
pointed up neatly as the work proceeds in a manner called for in the
drawings or instructions. A sample wall, 10 sq.m. in area shall be built and
approved by the Engineer and all works shall match with this sample.
2.3.8 Composite Masonry
Where stonework facing with brick masonry backing is specified the bond
between them shall be achieved by bond stones of dimensions and
frequency as desired by the Engineer.
2.3.9 Expansion & Separation Joints
(PCA.775.S034sca8) V.II-D2/S-VIII : 3

DCPL-K4A02
Location of joints shall strictly be as shown on drawings or as instructed by
the Engineer. Expansion joints shall be as shown on drawings. Expansion
joint filler boards and sealing strips shall have minimum transverse joints.
Transverse joints shall meet the approval of the Engineer.
Separation joints shall be with standard water proof paper or with alkathene
sheets about 1 mm in thickness. Length and sealing of laps shall be to the
satisfaction of the Engineer.
2.3.10 Mouldings, Cornices, Drip Course
2.3.11 Curing
These shall be made as shown in drawings. Bricks or stone shall be cut and
dressed as required. If no subsequent finish is envisaged, these shall be
rubbed to correct profile with carborandum stone.
Masonry shall be cured by keeping it wet for seven days from the date of
laying. In dry weather at the end of days work top surface of masonry shall
be kept wet by ponding.
2.3.12 Embedding of fixtures
All fixtures shall generally be embedded in mortar and masonry units shall
be cut as required.
2.3.13 Encasing of Structural Steel
This shall be done by building masonry work round flanges, webs etc. and
filling the gap between steel and masonry by minimum 12 mm thick mortar.
Encased members shall be wrapped with chicken wire mesh when shown
on drawings or instructed by the Engineer. The minimum lap in chicken
wire mesh shall be 50 mm.
2.4.0 Damp Proof Course
Unless otherwise specified Damp-proof course shall be 40 mm or as per
schedule thick 'artificial stone' in proportion 1:1-1/2:3 cement sand stonechips
(10 mm down) with admixture of a waterproofing compound as
approved by the Engineer. The percentage of admixture shall be as per
manufacturer's specifications but not less than 2% by weight of cement.
The top surface shall be double chequered and cured by ponding for seven
days.
2.5.0 Damp Proof Membrane
Damp proof treatment using fibre or hessian base bitumen felt shall be 6, 8
or 10 course treatment as specified in IS:1609. The number of courses
(PCA.775.S034sca8) V.II-D2/S-VIII : 4

DCPL-K4A02
shall be as mentioned. Sequence or work shall be as directed by the
Engineer. Extreme care shall be taken to prevent damage to felt during
and after laying. The Contractor shall be obliged to rectify any leakage
appearing within 5 years of installation by removing and renewing the coats
at the point of leakage.
Where shown on drawing, damp proof membrane with one layer bitumen
paper or one layer alkathene sheet shall be laid with minimum 150 mm
lap under slabs on grade.
3.0.0 I.S. CODES
Some of the important relevant codes for this section are :
IS:1127 : Recommendations for dimensions and workmanship
of natural building stones for masonry work.
IS:1597 : Code of Practice for Construction of stone Masonry.
IS:1609 : Code of Practice for laying Damp-proof treatment
using bitumen felts.
IS:2212 : Code of Practice for Brickwork.
IS:2250 : Code of Practice for preparation and use of Masonry
Mortar.
IS:5134 : Bitumen Impregnated Paper & Board.
(PCA.775.S034sca8) V.II-D2/S-VIII : 5

DCPL-K4A02
VOLUME : II-D /2
SECTION-IX
TECHNICAL SPECIFICATION
FOR
FINISH TO MASONRY & CONCRETE
(PCA.775.S034sca9)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-IX : 1
2.0.0 INSTALLATION V.II-D2/S-IX : 1
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-IX : 6
4.0.0 I.S. CODES V.II-D2/S-IX : 6
(PCA.775.S034sca9)

DCPL-K4A02
VOLUME : II-D/2
SECTION-IX
TECHNICAL SPECIFICATION
FOR
FINISH TO MASONRY & CONCRETE
1.0.0 SCOPE
This Specification covers furnishing, installation, repairing, finishing, curing,
testing, protection, maintenance till handing over of finishing items for
masonry and concrete. This shall also include the work to be done to make
the surface suitable for receiving the finishing treatment. Before commencing
finishing items the Contractor shall obtain the approval of the Engineer
regarding the scheduling of work to minimise damage by other trades. He
shall also undertake normal precaution to prevent damage or disfiguration to
work of other trades or other installation.
2.0.0 INSTALLATION
2.1.0 Preparation of Surface
2.2.0 Plastering
2.2.1 Mortar
All joints in masonry walls shall be raked out to a depth of at least 10 mm
with a hooked tool made for the purpose while the mortar is still green.
Walls shall be brushed down with stiff wire brush to remove all loose dust
from joints and thoroughly washed with water. All laitance shall be removed
from concrete to be plastered.
For all types of flooring, skirting and dado work, the base cement
concrete slab or masonry surface shall be roughened by chipping and
cleaned of all dirt, grease or loose particles by hard brush and water. The
surface shall be thoroughly moist to prevent absorption of water from the
base course. Any excess of water shall be mopped up.
At any point, the level of base shall be lower than the theoretical finished
floor level by the thickness of floor finish. Any chipping or filling to be done
to bring the base in the required level shall be brought to the notice of the
Engineer and his approval shall be taken regarding the method and
extent of rectification work required.
Prior to commencement of actual finishing work, the approval or the
Engineer shall be taken as to the acceptability of the base.
Mortar for plastering shall be as specified in the drawings.
(PCA.775.S034sca9) V.II-D2/S-IX : 1

DCPL-K4A02
For sand cement plaster, sand and cement in the specified
proportion shall be mixed dry on a watertight platform and minimum
water added to achieve working consistency.
For lime gauged plaster, lime putty or hydrated lime and sand in the
required proportion shall be mixed on a watertight platform with necessary
addition of water and thoroughly ground in mortar mill. This mix shall then be
transferred to a mechanical mixer to which the required quantity of cement is
added and mixed for at least 3 minutes.
No plaster which has stood for more than half an hour shall be used;
plaster that shows tendency to become dry before this time, shall have water
added to it.
2.2.2 Application of Plaster
2.2.3 Finish
Plaster, when more than 12 mm thick, shall be applied in two coats - a base
coat followed by the finishing coat. Thickness of the base coat shall be
sufficient to fill up all unevenness in the surface; no single coat, however,
shall exceed 12 mm in thickness. The lower coat shall be thicker than the
upper coat, the overall thickness of the coats shall not be less than the
minimum thick-ness shown on the drawings. The undercoat shall be allowed
to dry and shrink before applying the second coat of plaster. The undercoat
shall be scratched or roughened before it is fully hardened to form a
mechanical key. The method of application shall be 'thrown on' rather than
'applied by trowel'.
To ensure even thickness and true surface, patches of plaster about 100
mm to 150 mm square or wooden screed 75 mm wide and of the thickness
of the plaster, shall be fixed vertically about 2000 mm to 3000 mm apart,
to act as gauges. The finished wall surface shall be true to plumb, and the
Contractor shall make up any irregularity in the brickwork with plaster.
All vertical edges of brick pillars, doorjambs etc. shall be chamfered or
rounded off as directed by the Engineer. All drips, grooves, mouldings and
cornices as shown on drawing or instructed by the Engineer shall be done
with special care to maintain true lines, levels and profiles. After the
plastering work is completed, all debris shall be removed and the area
left clean. Any plastering that is damaged shall be repaired and left in
good condition at the completion of the job.
Generally, the standard finish shall be used unless otherwise shown on
drawing or directed by the Engineer. Wherever any special treatment to
the plastered surface is indicated, the work shall be done exactly as shown
on the drawings, to the entire satisfaction of the Engineer regarding the
texture, colour and finish.
a) Standard Finish
(PCA.775.S034sca9) V.II-D2/S-IX : 2

DCPL-K4A02
Wherever punning is indicated, the interior plaster shall be
finished rough. Otherwise the interior plaster shall generally be
finished to a smooth surface. The exterior surface shall generally be
finished with a wooden float.
b) Neat Cement Finish
Immediately after achieving a true plastered surface with the
help of a wooden straight edge, the entire area shall be uniformly
treated with a paste of neat cement at the rate of one (1) kg. per
Sq.M. and rubbed smooth with a trowel.
c) Coloured Plaster Finish
This shall be done in the same way as specified in Clause
2.2.2 but using coloured cement in place of ordinary cement. When
coloured plastering is specified in more than one coat, the top coat
only shall be made with coloured cement.
Coloured cement shall be either ready mixed material or may
be obtained by mixing pigments and cement at site, as approved by
the Engineer. The pigments to be mixed with cement shall conform
to Appendix-A of IS:2114 latest edition. Samples of colouring
material shall be submitted to the Engineer for approval and
material procured, shall conform in all respects to the approved
samples, which shall remain with the Engineer. All coloured cement
and/or pigments shall be stored in an approved manner in order to
prevent deteriorations.
d) Pebble-dash Finish
Mortar of required thickness consisting of 1 part cement and
4 parts sand by volume shall be applied in the usual manner as
described under plastering Clause 2.2.2. While the mortar is still
plastic small pebbles or crushed stone of size generally from 10
mm to 20 mm as approved by the Engineer shall be thrown on the
plastered surface. The aggregate shall be lightly tapped into the
mortar with a wood float or the flat end of a trowel, in order to
ensure satisfactory bond between the dashing and the mortar.
e) Rough-Cast Finish
A wet plastic mix of 3 parts coloured cement 6 parts sand and
4 parts aggregate by volume (gravel or crushed stone of size from 6
mm to 12 mm as approved by the Engineer) shall be thrown on to
the wall by means of a plaster's trowel and left in the rough condition.
f) Scraped Finish
Ordinary plaster as described under Clause 2.2.2 after being
levelled and allowed to stiffen for a few hours, shall be scraped
(PCA.775.S034sca9) V.II-D2/S-IX : 3

2.2.4 Curing
DCPL-K4A02
with a steel straight edge to remove the surface skin. The pattern
shall be as approved by the Engineer.
g) Textured Finish
Mortar consisting of 1 part cement and 3 parts sand by volume
shall be applied in a manner as specified under "Plastering" Clause
2.2.2. Ornamental treatments in the form of horizontal or vertical rib
texture fan texture etc. shall be applied by means of suitable tools to
the freshly applied plastered surface, as approved by the Engineer.
All plastered surfaces after laying, shall be watered, for a minimum period
of seven days, by an approved method, and shall be protected from
excessive heat and sunlight by suitable approved means. Moistening shall
commence, as soon as the plaster has hardened sufficiently and not
susceptible to damage. Each individual coat of plaster shall be kept damp
continuously, for at least two days, and then dried thoroughly, before applying
the next coat.
2.3.0 Pointing to Masonry
All joints of brickwork shall be raked out to a depth of 10 mm with a
hooked tool made for the purpose while the mortar is still green. The
brickwork shall then be brushed down with a stiff wire brush, so as to
remove all loose dust from the joints and thoroughly washed with water.
Mortar consisting of 1 part cement and 3 parts clean, sharp, well graded
sand by volume shall be pressed carefully into the joints and finished with
suitably tools to shape as shown on the drawings. Any surplus mortar shall
be scraped off the wall face leaving the surface clean.
The pointed surface shall be kept wet for at least three days for curing.
2.4.0 Plaster with Metal Lath
The supports, hangers, brackets, cleats etc. shall be as shown on
drawings and/or as approved by the Engineer. These shall have a
coat of prime paint before and another coat of approved paint after
erection.
The metal lath shall be expanded metal, with 12 mm x 38 mm mesh,
16 BG thick and 3 mm wide strands. Side laps shall be minimum 12
mm and end laps 25 mm minimum. The plastering shall be minimum 20
mm thick measured from the back of lath and applied in two layers.
The mortar for plastering shall consist of 1 part cement, 1/2 part lime and 4
parts sand by volume, or 1 part cement and 4 parts sand by volume mixed
as specified in plastering, Clause 2.2.1. The application, finish etc. shall
be as specified under relevant clause above. A 2 mm Plaster of Paris
punning shall be applied over plaster as a finishing coat to give perfectly
smooth and even finish.
(PCA.775.S034sca9) V.II-D2/S-IX : 4

DCPL-K4A02
2.5.0 Lime Punning
For plastered surfaces, where an even smooth surface is specified, lime
punning with 5 parts of shell lime properly slaked, strained and aged, mixed
with 1 part clean, washed, sieved, fine sand by volume shall be done. The
thickness of lime punning shall be not less than 2 mm and more than 3 mm.
The plastered surface shall be saturated with water before application of the
lime punning. The punning shall be applied by skilled workman and given a
smooth and even finish free from undulations, cracks etc. and to the
satisfaction of the Engineer.
2.6.0 Plaster of Paris Punning
2.7.0 Stone Facing
Plastered surfaces, where specified shall be finished with Plaster-of-
Paris punning. The material shall be from approved manufacturers and
approved by the Engineer. The thickness of the punning shall be 2 mm
and shall be applied by skilled workmen. The finish shall be smooth, even
and free from undulation, cracks etc.
Before bulk work is taken in hand, a sample of punning shall be done on
roughly 10 Sq.M. area and approval of the Engineer taken. The work shall
then be taken in hand as per approved sample.
Stone facing where specified shall be done as shown on design
drawings and approved shop drawings. The stone shall be as
specified on drawings. Samples of stone shall be submitted to the
Engineer for approval and then bulk purchase made. The Contractor shall
submit three copies of shop drawing for the Engineer's approval before
commencing the work.
The thickness of facing stone shall be not less than 25 mm
otherwise specified on drawings.
unless
The stone slabs shall be cut and finished to sizes as per pattern shown on
drawings. They shall be fastened to wall with suitable noncorrodable
anchorage as approved by the Engineer. Where mild steel clamps, stays
etc. are used for anchorage, they shall be galvanised (weight of zinc
coating shall not be less than 700 gms per square meter of surface) to
prevent rust stains developing on the finished surface. There shall be at
least 12 mm gap between the stone and masonry, which shall be filled up
and packed by a mortar of 1 part cement and 3 parts of sand by volume.
After the mortar is set and cured for at least four days, the exposed
surface shall be rubbed and polished as approved by the Engineer.
The completed surface shall be neat, or uniform texture and
acceptable to the Engineer.
Where pointing is specified on drawings it shall be done by mortar as
specified on drawings.
3.0.0 ACCEPTANCE CRITERIA
(PCA.775.S034sca9) V.II-D2/S-IX : 5

DCPL-K4A02
Finish to masonry and concrete shall fully comply instructions of the
Engineer with respect to lines, levels, thickness, colour, texture, pattern and
any other special criteria as shown on drawings.
4.0.0 I.S. CODES
Important relevant code for this Section :
a) IS:1661 : Code of practice for cement and cement-lime
plaster finish on walls & ceilings.
b) IS:4101 : Code of practice for external facings and
veneers.
(PCA.775.S034sca9) V.II-D2/S-IX : 6

DCPL-K4A02
VOLUME : II-D/2
SECTION-X
TECHNICAL SPECIFICATION
FOR
FLOOR FINISHES AND ALLIED WORKS
(PCA.775.S034sc10)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-X : 1
2.0.0 INSTALLATION V.II-D2/S-X : 2
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-X : 20
4.0.0 I.S. CODES V.II-D2/S-X : 21
(PCA.775.S034sc10)

DCPL-K4A02
VOLUME : II-D/2
SECTION-X
TECHNICAL SPECIFICATION
FOR
FLOOR FINISHES AND ALLIED WORKS
1.0.0 SCOPE
This specification covers furnishing, installation, finishing, curing, testing,
protection, maintenance till handing over various types of floor finishes and
allied items of work as listed below :
a) In Situ Finishes
i) Integral finish to concrete base
ii)
iii)
iv)
Red Oxide of Iron finish
Terrazzo finish
Granolithic finish
v) Patent Stone
vi)
vii)
viii)
Metallic Hardener like "Ironite" finish
Mastic Asphalt finish
Chemical Resistant finish
b) Tiled Finishes
i) Terrazzo tile
ii)
iii)
iv)
Chequered tile
Glazed tile
Tesse rae (Mosaic etc.)
v) Chemical Resistant
vi)
vii)
Rubber, Vinyl etc.
Stone Slab
(PCA.775.S034sc10) V.II-D2/S-X : 1

DCPL-K4A02
1.0.1 Base
1.0.2 Sequence
The base to receive the finish is covered under other relevant
specifications.
Commencement, scheduling and sequence of the finishing works shall
be planned in detail and must be specifically approved by the
Engineer in view the activities of other agencies working in that area.
However, the Contractor for the finishing items shall remain fully responsible
for all normal precautions and vigilance to prevent any damage whatsoever
till handing over.
2.0.0 INSTALLATION
2.0.1 Special Materials
2.0.2 Workmanship
Basic materials are covered under Specification "Properties Storage and
Handling of Common Building Materials". Special materials required for
individual finishing items are specified under respective items. In general, all
such materials shall be as per relevant I.S. Codes where available. In all
cases these materials shall be of the best quality available indigenously,
unless specified otherwise.
The materials for finishing items must be procured from well-reputed
specialised manufacturers and on the basis of approval of samples by the
Engineer. The materials shall be ordered, procured and stored well in
advance to avoid compulsion to use substandard items to maintain in the
construction schedule.
Only workers specially experienced in particular items of finishing work
shall be engaged, where such workers are not readily available, with the
Engineer's permission, experienced supervisors recommended by the
manufacturer shall be engaged. In particular cases where the Engineer so
desires the Contractor shall get the finishing items installed by the
manufacturer.
2.0.3 Preparation of the Base Surface
The surface to be treated shall be thoroughly examined by the
Contractor. Any rectification necessary shall be brought to the notice of the
Engineer and his approval shall be taken regarding method and extent of
such rectification work.
For all types of flooring, skirting, dado and similar locations, the base to receive the
finish shall be adequately roughened by chipping, raking out joints and cleaning
thoroughly all dirts, grease etc. with water and hard brush and detergent if required,
(PCA.775.S034sc10) V.II-D2/S-X : 2

2.1.0 In Situ Finishes
DCPL-K4A02
unless otherwise directed by the manufacturer of any special finishing materials
or specifically indicated in this specification under individual item.
To prevent of water from the finishing treatment the base shall be thoroughly soaked
with water and all excess water mopped up.
The surface shall be done dry where adhesives are used for fixing the finishes.
Prior to commencement of actual finishing work the approval of the Engineer shall be
taken as per the acceptability of the surface.
2.1.1 Integral Finish To Concrete Base
While the surface of the concrete laid as per specification for 'Cement Concrete'
has been fully compacted and levelled but the concrete is still 'green' a thick slurry
made with neat cement shall be applied evenly and worked in with iron floats.
When the slurry starts to set it shall be pressed with iron floats to have a firm
compact smooth surface without trowel mark or undulations.
This finish shall be as thin as possible by using 2.2 kg. of cement per Sq. M. of
area.
The surface shall be kept in shade for 24 hours and then cured for at least 7 days
continuously by flooding with water. The surface shall not be subjected to any load
or abrasion till 21 days after laying.
As desired by the Engineer the surface, while still 'green' shall be indented by
pressing strings. the marking shall be of even depth, in straight lines and the
panels shall be of uniform and symmetrical patterns.
2.1.2 Red Oxide of iron Finish
It shall consist of an underbed and a topping over already laid and matured concrete
base.
a) Thickness
Unless otherwise specified the total thickness of the finish shall be minimum
40 mm for horizontal and 25 mm for vertical surface of which the topping
shall (not less than 10 mm) while the topping shall be of uniform thickness
the underbed may vary in thickness to provide necessary slopes. The vertical
surface shall project out 6 mm from the adjacent plaster or other finishes.
Necessary cutting into the surface receiving the finish shall be done to
accommodate the specified thickness.
All junctions of vertical with horizontal shall be rounded neatly to uniform
radius of 25 mm.
b) Mix
i) Underbed
(PCA.775.S034sc10) V.II-D2/S-X : 3

DCPL-K4A02
The underbed for floors and similar horizontal surfaces
shall consist of a mix of 1 part cement, 2 parts coarse sand
and 4 parts 10 mm down graded stone chips by volume.
For vertical and similar surfaces the mix shall consist of 1
part cement to 3 parts coarse sand by volume.
ii)
Topping
For the topping cement, screened through a fine mesh and
red oxide of iron pigment powder similarly screened shall
be dry mixed thoroughly in right proportions to produce the
desired colour when laid. The mix shall then be prepared with
1 part cement (mixed with pigment) and 3 parts coarse sand
volume. The whole quantity required for each visible area
shall be prepared in one batch to ensure uniform colour.
c) Laying
The underbed shall be laid in panels of mixing area 5 Sq.M.
each and no side shall be more than 2.5 along. For outdoor
locations the maximum area shall be 2.0 Sq.M. The forms for the
panels shall have perfectly aligned edges to the full depth of the
total thickness of finish. If specified aluminium or glass dividing strips
shall be used.
The panels shall be laid in alternate bays or in chequered
board pattern. No panel shall be cast in contact with another already
laid until the contraction of the latter has taken place. The underbed
shall be laid, compacted, levelled and brought to proper grade with a
screed or float. The topping shall be placed after about 24 hours
while the underbed is still somewhat 'green' but firm enough to
receive the topping. The surface of the underbed shall be
roughened for better bonding. The topping shall be rolled for
horizontal areas and thrown and pressed for vertical areas to extract
all superfluous cement and water to achieve a compact dense mass
fully bonded with the underbed. The topping shall then be levelled
up by trowelling and finished smooth with a slurry made with
already prepared cement and pigment mixture. About 2.0 Kg. of the
mixture shall be consumed/per Sq.M. for horizontal surface, and 1.0
Kg. for vertical surface. The surface shall be cured for seven days
by keeping it moist.
d) Polishing
About 36 hours after laying when the surface has hardened
sufficiently it shall be polished with polishing stone till a smooth shiny
surface to the satisfaction of the Engineer, is achieved. The finish
shall be washed and cleaned just before handing over.
(PCA.775.S034sc10) V.II-D2/S-X : 4

DCPL-K4A02
2.1.3 Terrazo Finish : In Situ
It shall consist of an underbed and a topping laid over an already laid and
matured concrete base.
a) Thickness
b) Mix
Unless otherwise specified the total thickness of the finish
shall be minimum 40 mm for horizontal and 25 mm for vertical
surface of which the topping shall be not less than 10 mm. While
the topping shall be of uniform thickness the underbed may very in
thickness to provide necessary slopes. The vertical surface shall
project cut 6 mm from the adjacent plaster or other finish.
Necessary cutting into the surface receiving the finish shall be
done to accommodate the specified thickness.
All junctions of vertical with horizontal shall be rounded
neatly to uniform radius of 25 mm.
i) Underbed
The underbed for floors and similar horizontal surfaces
shall consist of a mix of 1 part cement, 1.1/2 parts sand
and 3 parts stone chips by volume. For vertical surfaces the
mix shall consist of 1 part cement to 3 parts sand by volume.
The sand shall be coarse. The stone chips shall be 10 mm
down well graded. Only sufficient water to be added to
give a workable consistency.
ii)
Topping
The mix for the topping shall be composed of cement,
colour pigment, marble dust and marble chips.
Proportions of the ingredients shall be such as to produce
the terrazzo of colour texture and pattern approved by the
Engineer. The cement shall be white or grey or a mixture of
the two to which pigment shall be added to achieve the
desired colour. To 3 parts of this mixture 1 part marble
powder by volume shall be added and thoroughly mixed dry.
To 1 part of this mix 1 to 1.1/2 parts of marble chips by
volume shall be added and thoroughly mixed dry again.
The pigment must be stable and nonfading. It must be
very finely ground. The marble powder shall be from white
marble and shall be finer than IS Sieve No. : 30. The size of
marble chips may be between 1 mm to 20 mm.
Sufficient quantity to cover each visible area shall be
prepared in one lot to ensure uniform colour. Water to make
(PCA.775.S034sc10) V.II-D2/S-X : 5

DCPL-K4A02
it just workable shall be added to a quantity that can be used
up immediately before it starts to set.
c) Laying
The underbed shall be laid in panels. The panels shall not be
more than 5 sq.m in area of which no side shall be more than 2.5 M
long. For exposed locations the maximum area of a panel shall be 2.0
Sq.M. The panel shall be laid in alternate bays or chequered board
pattern. No panel shall be cast in contact with another already laid
until the latter has contracted to the full extent.
Dividing strips made of aluminium or glass shall be used for
forming the panels. The strips shall exactly match the total depth of
underbed plus topping.
d) Curing
After laying, the underbed shall be levelled compacted and brought
to proper grade with a screed or float. The topping shall be laid
after about 24 hours while the underbed is still somewhat "green"
but firm enough to receive the topping. A slurry of the mixture of
cement and pigment already made shall be spread evenly and
brushed in just before laying the topping. The topping shall be
rolled for horizontal areas and thrown and pressed for vertical areas
to extract all superfluous cement and water and to achieve a
compact dense mass fully bonded with the underbed. The
surface of the topping shall be trowelled over, pressed and brought
to a smooth dense surface showing a minimum 75% area covered by
marble chips in a even pattern of distribution.
The surface shall be left for curing for about 12 to 18 hours
and then cured by allowing water to stand on the surface or by
covering with wet sack for four days.
e) Grinding and Polishing
When the surface has sufficiently hardened it shall be watered and
ground evenly with rapid cutting coarse grade (no.60) grit blocks, till
the marble chips are exposed and the surface is smooth. Then the
surface shall be thoroughly washed and cleaned. A grout with already
prepared mixture of cement and pigment shall be applied to fill up all
pinholes. The surface shall be cured for 7 days by keeping it moist
and then ground with fine grit blocks (no.: 120). It shall again be
cleaned with water, the slurry applied again to fill up any pinholes that
might have appeared and allowed to be cured again for 5 days.
Finally, the surface is ground a third time with very fine grit blocks
(no.: 320) to get smooth surface without any pinhole. The grinding
shall be done by a suitable machine. Where grinding machine can not
be used hand grin- ding may be allowed when the first rubbing shall
be with carborundum stone of coarse grade (no.60), second rubbing
with medium grade (no.: 80) and final rubbing and polishing with fine
grade (no.: 120). The surface shall be cleaned with water, dried and
(PCA.775.S034sc10) V.II-D2/S-X : 6

2.1.4 Granolithic Finish
DCPL-K4A02
covered with soil free, clean sawdust if directed by the Engineer. The
final polishing shall be positioned till before handing over if desired by
the Engineer. Just before handing over the surface shall be dusted
with oxalic acid at the rate of 0.33 gm. per. Sq.M, water sprin- kled on
to it and finished by buffing with felt or hessian bobs. The floor shall
be cleaned with soft moist rag and dried. However, all excess wax
polish to be wiped off and the surface to be left glossy but not
slippery.
Granolithic finish shall either be laid monolithically over base concrete or
separately over hardened base concrete.
a) Thickness
b) Mix
The finish shall be average 20 mm and minimum 12 mm thick,
unless specified otherwise.
The mix shall consist of 1 part cement : 1 part coarse sand : 2 parts
coarse aggregate by volume. The coarse aggregate shall be very
hard like granite and well graded between 6 mm and 12 mm.
Minimum quantity of water to get workability shall be added.
c) Laying of Monolithic Topping
The concrete base shall be laid as per specification "Cement
Concrete" and levelled upto the required grade. The form shall
remain sufficiently protruding to take the finish.
Within about 3 hours of laying the base while it is still fully "green"
the topping shall be laid evenly to proper thickness and grade. If
considered necessary the surface of the base shall roughened by
wire brushing. Unless manual operation is permitted by the
Engineer, mechanical vibrators of suitable design shall be used to
press the topping firmly and work vigorously and quickly to secure
full bond with concrete base.
The laitance brought to the surface during compression shall
be removed carefully without disturbing the stone chips. The surface
shall then the lightly trowelled to remove all marks. When sufficiently
set, hand trowelling shall be done to secure a smooth surface
without disturbing the stonechips.
For large areas the laying shall be in panels of maximum 25
Sq.M area. The panels shall be laid in chequered board pattern.
d) Laying of Topping Separately on Hardened Base
(PCA.775.S034sc10) V.II-D2/S-X : 7

e) Curing
DCPL-K4A02
The base concrete shall be prepared as stated in clause 2.0.3 and a
slurry of neat cement applied just prior to laying the granolithic
concrete mix (1:1:2). The method of compaction etc. shall be same
as for monolithic topping.
Immediately after laying, the finish shall be protected against rapid
drying. As soon as the surface had hardened sufficiently, it shall be
kept continuously moist for at least 10 days by means of wet gunny
bags or pounding of water on the surface. The floor shall not be
exposed to heavy traffic during this period.
f) Grinding
If grinding is specified, it shall start only after the finish has fully
set. Clause 2.1.3 (c) shall be followed. However, the ultimate polish
required shall be decided upon by the Engineer.
g) Finishing
2.1.5 Patent Stone
Where specified, sodium silicate or magnesium or zinc silico
fluoride treatment shall be done. The number of coats to be applied
shall be as specified. The concentration and method of application
of the solutions shall be as specified in IS : 5491.
It shall consist of an underbed and a topping laid on an already laid and
matured concrete base.
a) Thickness
The patent stone finish shall have thickness as stipulated
under clause 2.1.2 (a) except that the topping shall be 6 mm thick.
b) Mix
i) Underbed
The mix shall be as stipulated under clause 2.1.3(b).
ii)
Topping
The mix for the topping shall consist of 1 part cement
and 1 part fine sand by volume.
c) Laying
(PCA.775.S034sc10) V.II-D2/S-X : 8

DCPL-K4A02
The Patent Stone finish, including the underbed shall be laid
in alternate bays or in chequered board pattern. No panel shall be
cast in contact with another already laid till the contraction of the
latter has already taken place.
The maximum area of each panel shall be 3 Sq.M of which no
side shall be more than 2 M long.
A cement grout shall be applied and worked into the surface
to receive the finish, the underbed then laid, compacted and levelled
to proper grade with a screed or float. The topping shall be applied
evenly on the underbed while it is not fully set but firm enough and
rolled and pressed to get full bond.
The topping shall trowelled to a dense finish to the
satisfaction of the Engineer. All trowel marks shall be mopped out
with a soft cloth to give a clean smooth surface.
After the surface is sufficiently set, the finished floor shall be kept
moist for 7 days for curing. If desired the finish shall be polished as
directed by the Engineer.
2.1.6 Metallic Hardener Like "Ironite" Finish
This will consist of a topping (incorporating iron particles) to bond with
concrete base while the latter is "Green".
a) Thickness
Unless otherwise specified the metallic hardener finish shall
be of 12 mm depth.
b) Material
c) Mix
The hardening compound shall be uniformly graded iron particles free
from non-ferrous metal impurities, oil, grease, sand soluble alkaline
compounds or other injurious materials. When desired by the
engineer, actual samples shall be tested.
Proportion of the metallic hardener shall be as specified or
as indicated by the manufacturer. However, in absence of any such
direction 1 part metallic hardener shall be mixed dry with 4 parts
cement, by weight. To this mixture 6 mm nominal size stone chips
shall be added in proportion of 1 part cement (mixed with
(PCA.775.S034sc10) V.II-D2/S-X : 9

d) Laying
2.1.7 Mastic Asphalt Finish
DCPL-K4A02
hardener) to 2 parts of stone chips by volume and uniformly mixed.
Minimum quantity of water shall be added to make it workable.
The concrete floor shall be laid as per specification "Cement
Concrete" an levelled upto the required grade. The forms, if any shall
remain sufficiently projecting to take the finish.
The surface shall be roughened by wire brush as soon as
possible.
The finish shall be laid while the concrete underbed is still
very "green" within about 3 hours of laying of the latter. The finish
shall be of uniform thickness and even dense surface without
trowel marks, pin holes etc. This topping layer shall be pressed
firmly and worked vigorously and quickly to secure full bond with the
concrete base. Just when the initial set starts the surface shall be
finished \smoothened with steel trowel.
The finished floor shall be cured for 7 days by keeping it wet.
This is a one layer treatment on concrete or brick base.
a) Thickness
The thickness shall be as specified in the drawing
b) Materials
Bitumen shall be industrial bitumen of the grades 90/15 and
75/15 conforming to IS: 702.
Mineral filler shall be dry stone dust passing through 75-micron IS
Sieve.
Fine aggregate shall be crushed and graded natural lime stone
or other hard-work.
Coarse aggregate shall be crushed siliceous stone or other
approved aggregate 6 mm stone chips shall be used for finish upto
20 mm thick & 10 mm chips for thicker finish.
c) Composition
(PCA.775.S034sc10) V.II-D2/S-X : 10

DCPL-K4A02
Bitumen mastic shall conform to IS: 1195 and shall be either
brought to site in blocks weighing about 25Kg. or prepared at site. If
brought in blocks, these shall be remelted in mechanically agitated
mastic cookers and coarse aggregate, preferably preheated fed in
successive portions until the complete change is thoroughly
incorporated. At no stage during the remelting and mixing
process, shall the temperature exceed 205°C.
d) Laying
The hot mastic shall be laid on dry base surface cleaned
thoroughly by wire brushing and sweeping. The mastic shall be
levelled and when cooled to some extent shall be finished with a
wooden float with addition of small quantity of fine sand if required.
No load shall be allowed till the finish has cooled to normal
temperature.
The mastic shall be laid in suitable panels of about 15 Sq.M
in area each formed by formers. Succeeding panels shall be laid
overlapping the finish panel so as to melt its edges and form a
continuous finish without joint.
2.1.8 Chemical Resistant in Situ Finish
2.2.0 Tiled Finish
Chemical resistant in situ finish shall be as epoxy resin with suitable filler
material over a primer or called for in the Schedule of Items. The
minimum thickness shall be 6 mm. About its performance the Engineer shall
have to be fully satisfied by test results and examination of similar treatment
already in existence.
The Contractor shall get it done by a specialised manufacturer, get
guarantee of performance from the organisation and pass it on to the Owner
in addition to his own guarantee.
These shall include finish tiles, stone slabs and similar manufactured or
natural items over already laid and matured base of concrete or masonry by
means of an underbed or an adhesive layer.
2.2.1 Terrazzo Tile Finish
The finish will consist of manufacture terrazo tile and an underbed.
a) Thickness
The total thickness including the underbed shall be minimum
40 mm for floors 30 mm for walls unless otherwise specified.
The skirting, dado and similar vertical surfaces shall
project out 6 mm uniformly from the adjacent plaster or other wall
finishes. The necessary cutting into the surface receiving the
tiled finish, to accommodate the specified thickness shall be done.
(PCA.775.S034sc10) V.II-D2/S-X : 11

DCPL-K4A02
b) Tiles : Terrazzo
The tiles shall, unless specifically permitted in special cases be
machine made under quality control in a shop. The tile shall be
pressed hydraulically to a minimum of 140 Kg. per Sq.cm.
Each tile shall bear on its back permanent and legible trade
mark of the manufacturer. All angles of the tiles shall be right angles
all arises sharp and true, colour and texture of the wearing face
uniform throughout. Maximum tolerance allowance length and
breadth shall be + 1 mm and the thickness + 3 mm. Face of the tile
shall be plane, free from pin holes and other blemishes.
The tiles shall be composed of a backing and topping. The
topping shall be of uniform thickness not less than 10 mm.
The total thickness including the topping shall be as
specified but not less than 20 mm in any case.
The backing shall be composed of 1 part ordinary grey cement
and 3 parts of stone chips by weight mixed with water.
The topping shall be as specified under clause 2.1.3 (b).
The tile shall be cured at the shop for at least 14 days
before delivery to the site. First grinding shall be given to the tiles at
the shop before delivery. Tiles shall be packed properly to prevent
damage during transit and storage. The tiles must be carefully
stored to prevent staining by damp, rust, oil, and grease or other
chemicals.
Tiles made in each batch shall be kept and used separately so
that colour of each area of the floor may remain uniform.
The manufacturer shall supply along with the tiles the grout mix
containing cement and pigment in exact proportions as used in
topping of the tiles. The containers for the grout mix shall be suitably
marked to relate it to the particular type and batch of tiles.
c) Mix : Underbed
d) Laying
The underbed for floor and similar horizontal surfaces shall be 1 part
lime putty : 1 part surkhi : 2 parts coarse sand by weight mixed with
sufficient water to form a stiff workable mass. For skirting and dado
and all vertical surfaces it shall be about 12 mm thick and composed
of 1 part cement and 3 parts coarse sand by weight.
The underbed mortar shall be evenly spread and brought to
proper grade and consolidated to a smooth surface. The surface
shall be roughened for better bond. Before the underbed had time to
set and while it is still fairly moist but firm, cement shall be hand
(PCA.775.S034sc10) V.II-D2/S-X : 12

DCPL-K4A02
dusted over it or a cement slurry applied and the tiles shall
immediately be placed upon and firmly pressed by wooden mallet
on to the underbed until it achieves the desired level. The tiles shall
be kept soaked for about 10 minutes just before laying. The joints
between tiles shall be as close as possible and not more than 1.5 mm
wide.
Special care shall be taken to check the level of the surface
and the lines of the joints frequently so that they are perfect.
When tiles are required to be cut to match the dimensions these
shall be sawn and edges rubbed smooth. The location of cut tiles
shall be planned in advance and approval of the Engineer taken.
At the junction of horizontal surface with vertical surface the tiles on
the former shall enter at least 12 mm under the latter.
After fixing, the floor shall be kept moist and allowed to
mature undisturbed for 7 days. Heavy traffic shall not be allowed.
If desired dividing strips as specified under Clause 2.1.3 (c) may be
used for dividing the work into suitable panels.
e) Grinding and Polishing
Procedure shall be same as Clause 2.1.3 (c) 2. Grinding shall
not commence earlier than 14 days after laying of tiles.
2.2.2 Chequered Tile Finish
The finish shall consist of manufactured grey or coloured cement tiles or
terrazzo tiles with chequered face and an underbed laid over concrete or
brick surface.
a) Thickness
Thickness shall be same as in clause 2.2.1 (a).
b) Tiles : Chequered
The tiles shall have chequers not less than 2.5 cm. c/c and
not more than 5 cm c/c, Depth of grooves shall be not less than 5
mm. The grooves shall be uniform and straight.
The tiles shall conform to clause 2.2.1 (b) except that these
may have the topping in terrazzo or plain grey cement or colour
pigment added to cement as specified.
c) Underbed
As per clause 2.2.1 (c).
(PCA.775.S034sc10) V.II-D2/S-X : 13

DCPL-K4A02
d) Laying
As per clause 2.2.1 (d).
e) Grinding and Polishing
2.2.3 Glazed Tiles Finish
As per clause 2.2.1 (e) except that the tiles shall be ground
and polished by hand after laying taking special care in polishing
the grooves properly and uniformly.
This finish shall be composed of glazed earthenware tiles with an
underbed laid over a concrete or masonry base.
a) Thickness
The total thickness shall be between 20 mm and 25 mm
including the underbed. The tile finish on vertical surface shall
project out 6 mm uniformly from the adjacent plaster or other wall
finishes. The necessary cutting into the surface receiving the finish,
to accommodate the specified thickness shall be done.
b) Tiles : Glazed
The tiles shall be of earthenware, covered with glaze white
or coloured, plain or with designs, of 150 mm x 150 mm nominal
sizes and 10 mm thick unless otherwise specified. The tolerance
shall be + 1.5 mm for length and breadth and + 0.5 mm for thickness
specials like internal and external angles, beads, covers, cornices,
corner pieces etc. shall match. The top surface of the tiles shall be
glazed with a gloss or matt unfading stable finish as desired by the
Engineer. The tiles shall be flat and true to shape. The colour shall
be uniform and fractured section shall be fine grained in extures,
dense and homogeneous. The tiles shall be strong and free
from flaws like cracks, craze, specks, crawlings, etc. and other
imperfections. The edge and the underside of the tiles shall be
completely free from glaze and the underside shall have ribs or
indentations for better anchorage with the fixing mortar.
The coloured tiles, when supplied, shall preferably come from
one batch to avoid difference in colour.
c) Mix : Underbed
The mix for the underbed shall consist of 1 part cement and 3
parts coarse sand by weight mixed with sufficient water or any other
mix if specified.
(PCA.775.S034sc10) V.II-D2/S-X : 14

DCPL-K4A02
d) Laying
Same as clause 2.2.1 (d).
e) Finishing
The joints shall be cleaned and flush pointed with white
cement and cured for 7 days by keeping it wet. The surface shall
be cleaned with soap or suitable detergent, washed fully and wiped
with soft cloth to prevent scratching before handing over.
2.2.4 Tesserae Finish (Mosaic etc.)
This finish consists of manufactured vitreous, glass, ceramic or similar hard
small pieces set in an underbed over a concrete or masonry surface, already
laid.
a) Thickness
The total thickness including the underbed shall be between
16 mm and 25 mm.
b) Tesserae Finish
These shall usually be 6 mm thick small piece of ceramic
vitreous china, tinted glass or similar hard wearing, strong and
durable material in desired shapes and sizes and patterns.
The supply shall come in the desired pattern in full or
sections conveniently for handling, stuck to pieces of strong thick
paper on the surface to be exposed. The gum used for this purpose
must be water soluble and non-staining. The sections shall be
properly marked to avoid mistakes and master drawing shall be
available at the site for guidance.
c) Mix : Underbed
d) Laying
Same as clause 2.2.3 (c)
The specification for laying if given by the manufacturer of
the item shall be followed provided it is approved by the Engineer.
Otherwise clause 2.2.3 (d) shall generally be followed. However,
instead of grey cement the slurry shall be made with white cement to
fix the panels. The paper mounted patterns in sections shall be
carefully placed and pressed in position true to lines and levels.
Earliest possible the paper shall be peeled off and surface
(PCA.775.S034sc10) V.II-D2/S-X : 15

DCPL-K4A02
examined and cleaned, joints flush pointed with white cement
and cured for 7 days by keeping it wet.
2.2.5 Chemical Resistant Tiled Finish
This shall include all varieties of special tiles used for specific chemical
resistance function and an underbed over already laid concrete or masonry.
a) Tiles
The chemical resistant tiles as detailed in the Schedule of items shall
be of the best indigenous manufacture unless otherwise specified
and shall be resistant to the chemical described in the Schedule of
Items. The tiles shall have straight edges, uniform thickness, plain
surface, uniform non-fading colour and textures.
Glazed tiles if permitted to act as chemical resistant finish
shall be considered under clause 2.2.3.
Usually the chemical resistant tiles shall not absorb water more than
2% by weight. The tiles shall have at least compression strength of
700 Kg/cm2. The surface shall be abrasion resistant and durable.
b) Laying
The mortar used for setting or for underbed the tiles shall be durable
and strong. The grout which shall be to the full depth of tile shall have
equal chemical resistant properties. Joints shall be pointed if so
desired. The setting and fixing shall be according to the
manufacturer's specification approved by the Engineer.
2.2.6 Rubber, Vinyl or Vinyl Asbestos Tiles Finish
This shall include various types of tiles manufactured from rubber, vinyl,
etc. set with a adhesive on concrete or masonry base. An underbed may be
required to secure desirable surface and grade.
a) Thickness
b) Tiles
The thickness of the tiles shall be mentioned in the Schedule
or in drawing.
Unless otherwise desired the tiles shall be squares of
approved dimensions.The tolerance in dimensions shall be 1.5mm.
The face of the tiles shall be free from porosity, blisters,
cracks, embedded foreign matters or either physical defects which
affect appearance or serviceability. All edges shall be cut true and
square. The colour shall be nonfading and uniform in appearance,
(PCA.775.S034sc10) V.II-D2/S-X : 16

DCPL-K4A02
insoluble in water and resistant to alkalies, cleaning agents and usual
floor polishes.
Each tile shall be marked on the back legibly and indelibly
with manufacturer’s trade mark, the thickness, sizes, batch number
and date of manufacturer.
Tiles shall be delivered securely packed and stored in clean, dry
well ventilated place at a temperature near about to that the tiles shall
be called upon to stand ultimately.
Adhesive to be used for sticking the tiles shall be approved by the
tile manufacturer. The adhesive shall have a short drying time and
long life in addition to toughness.
c) Mix : Underbed
The underbed where required to make up the specified
thickness or to give the required grade or to get the right type of
surface shall be composed of 1 part like putty : 1 part cement : 4
parts coarse sand mixed with just sufficient water to make it workable.
d) Laying
The tiles shall be kept in the room to be tiled for at least 24 hours to
bring them to the same temperature as the room. For air
conditioned space, the air-conditioning shall be completed before
tiling is taken up.
The surface to receive this finish shall be firm even
textured but not too smooth, without undulations and other
deficiencies. If an underbed is laid the same shall be cured
for at least 7 days by keeping it moist and then fully dried.
The surface shall be thoroughly cleaned. All loose dust
particles shall be removed. Oil and grease if any shall be
completely cleaned by use of detergent.
The adhesive shall be applied to fully dry surface in desired
thickness uniformly. The adhesive shall also be applied to the backs
and edges of the tiles and allowed to surface dry. The tiles shall be
placed neatly on the surface exactly to the approved pattern and set
with a suitable tool. If the edges tend to curl, weights are to be used
to keep the edges down. Special care shall be taken to avoid
formation of air pockets under the tiles. The joints shall be very fine.
Any adhesive squeezed out through the joints shall be removed
immediately.
e) Finishing
If any adhesive mark is there on the surface a soft cloth
soaked in solvent shall be used to wipe it off. The surface shall be
(PCA.775.S034sc10) V.II-D2/S-X : 17

DCPL-K4A02
cleaned with soft soap, dried and polished with an approved type of
polish just before handing over.
2.2.7 Stone Slab Finish : Marble, Stone and Similar Fine Grained Stone
a) Thickness
The underbed shall be minimum 12 mm and average 20 mm thick.
The slabs may be 25 mm, 30 mm or 40 mm thick as specified.
b) Stone Slab
The stone slabs shall be made from selected stock which are
hard, sound, homogeneous and dense in texture and free from
flaws. Angles and edges shall be true, square, free from chipping
and surface shall be plane. The slabs shall preferably be
machine cut to the required dimensions.
Tolerance of 5 mm in dimensions and 2 mm in thickness
will be allowed. Unless specified the slabs shall be minimum 300 mm
x 300 mm.
The stone slabs shall come from specific regions and in
specified quality with top surface fine chisel dressed. All sides shall
also be fine chisel dressed to the full depth to allow finest possible
joints.
The slabs shall be delivered to the site well protected
against damages and stored in dry place under cover.
c) Mix : Underbed
d) Laying
Same as clause 2.2.1 (c).
The sides and top surface of the slabs shall be machine rubbed
or table rubbed with coarse sand stone and washed clean before
laying.
The underbed mortar shall be evenly spread and brought to
proper level on the area under each slab. The slab shall be laid over
the underbed, pressed and tapped down with wooden mallet to the
proper level. The slab shall then be lifted and the underbed corrected
as necessary and allowed to stiffen a little. Next, a thick cement slurry
shall be spread over the surface. The edges of the slab shall be
buttered with slurry of cement, grey/white/mixed with pigment
matching the colour of the stone slabs. The slab shall be gently laid
and tapped with wooden mallet to bed properly to a very fine joint
and to the required level. All surplus cement slurry shall be
removed and the surface mopped clean with wet soft cloth. The
laid finish shall be cured for 7 days by keeping it wet.
(PCA.775.S034sc10) V.II-D2/S-X : 18

DCPL-K4A02
e) Polishing, Finishing
Fine chiselling shall be done to remove the slight undulations that
usually exist at the joints. The polishing and finishing shall be done
as specified under clause 2.2.1 (e). However, the joints shall be so
fine in the case of stone slabs that grouting shall not be called for.
2.2.8 Stone Slab Finish : Sand Stone and
Similar Coarse Grained Stone Finish
Generally clause 2.2.7 shall be followed except that the workmanship and
finish shall not be fine as which are explained hereunder.
The slabs shall be rough chiseled or fine chiseled as specified. Tolerance
may be allowed upto + 6 mm for rough finish, but no sharp unevenness
and shall be allowed. For fine chiseling the unevenness shall be limited to
2 mm. The sides shall be chisel dressed at least to half slab depth so that
the maximum deviation from straight line shall be within 25 mm. Beyond this
depth the edge may be slightly splayed.
The joint thickness shall be kept limited to 5 mm in case of rough finish
and 3 mm in case of fine finish unless wider joints are specified. The joints
shall be grouted with white or coloured cement.
3.0.0 ACCEPTANCE CRITERIA
The finish shall be checked specially for :
a) Level, Slope, Plumb as the case may be
b) Pattern and Symmetry
c) Alignment of joints, dividing strip etc.
d) Colour, texture
e) Surface finish
f) Thickness of joints
g) Details at edges, junctions etc.
(PCA.775.S034sc10) V.II-D2/S-X : 19

DCPL-K4A02
h) Performance
i) Precautions specified for durability
4.0.0 I.S. CODES
Important relevant codes for this section :
IS : 777 : Glazed earthenware tiles
IS : 1196 : Code of practice for laying bitumen mastic
flooring
IS : 1197 : Code of practice for laying of rubber floors
IS : 1237 : Cement concrete flooring tiles
IS : 1443 : Code of practice for laying and finishing of
cement concrete flooring tiles
IS : 2114 : Code of practice for laying in situ terrazzo floor
IS : 3461 : PVC asbestos floor tiles
IS : 4860 : Specification for acid resistant bricks
IS : 5518 : Code of practice for laying of flexible PVC Sheet
and tile flooring.
IS : 5491 : Code of practice for laying in situ granolithic
floor topping.
(PCA.775.S034sc10) V.II-D2/S-X : 20

DCPL-K4A02
VOLUME : II-D/2
SECTION-XI
TECHNICAL SPECIFICATION
FOR
FALSE FLOORING
(PCA.775.S034sc11)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.00.00 SCOPE V.II-D2/S-XI : 1
2.00.00 FALSE FLOORING SYSTEM V.II-D2/S-XI : 1
3.00.00 ACCEPTANCE CRITERIA V.II-D2/S-XI : 2
(PCA.775.S034sc11)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XI
TECHNICAL SPECIFICATION
FOR
FALSE FLOORING
1.0.0 SCOPE
This specification covers supplying, installation, repairing, finishing, testing,
protection and maintenance till handing over of removable free access false
flooring systems consisting of an assembly of panels mounted on adjustable
pedestal and supporting steel grid system to provide an under floor space.
2.0.0 FALSE FLOORING SYSTEM
2.1.0 Base
The system shall be placed over a base of R.C.C. floor slab and with
necessary grouting etc. to fix the supporting structure.
2.2.0 Supporting Structure
2.3.0 Floor Panel
The supporting structure shall comprise of fabricated jacks made out of 25
mm. dia. MS rounds having 150 mm. threads at top. This jack shall be
welded to 100 mm x 100 mm x 6 mm thick MS base plate pedestal.
Pedestals shall be vertically true and located at 600 mm centre to centre to
conform to the size of the floor panels and shall be fixed to the RCC floor slab
with ARALDITE. The jack shall be equipped with locking device to prevent
loss of finished elevation. Adjustment shall be provided by the threaded rod
member and elevating nut. The capital shall be of aluminium alloy die cast
and shall receive cold rolled MS floor supporting channels of size 40 mm x 40
mm x 3.15 mm thickness as per drawings, both for main and cross runners.
The pedestal shall be equipped with conducting grounding pad. All MS
members shall be treated with steel protective paint as per drawing.
2.3.1 The floor panels shall be made of phenol for maldehyde bonded particle
board treated with fire resistant paint as per schedule items. Size of each
panel shall be 600 mm x 600 mm with all panel edges finished to a tolerance
of + 0.25 mm on the diagonals. The edges of the floor panels shall be
covered by 4 mm. thick rigid PVC edging. The underside of the panel shall
have 0.05 mm. thick Aluminium foil which shall be fixed to the particle board
with resin-based adhesive.
(PCA.775.S034sc11) V.II-D2/S-XI : 1

DCPL-K4A02
2.4.0 Strength
2.5.0 Surface Finish
2.6.0 Skirting
2.7.0 Installation
Each 600 mm x 600 mm floor panel must be capable of supporting an
uniform minimum live load of 1220 Kg/Sq.M or a concentrated minimum load
of 450 Kg. applied through a phenolic caster 75 mm in diameter and 45 mm
wide, or a rolling minimum load of 450 Kg. at any point with a maximum
deflection of 2 mm. The ultimate strength shall be capable of carrying a 2300
Kg. axial load without deformation of any part.
All removable panels shall have the top surface finished with 2 mm thick
Antiatatic Vinyl Flooring bonded to the surface with adhesive as per
manufacturer’s specification.
Skirting shall be of the same Anstistatic Vinyltiles, 150 mm. high and 2 mm.
thick, completely matching with the false flooring surface and shall be fixed
with the plastered wall surface as per manufacturer’s specification.
All steel surface are to be protected by pointing over a primer as per
schedule of items and any damage to the paint during installation shall be
made good. Finished floor surface, when specified by the Engineer-in-
Charge shall be protected by the Contractor with kraft paper taped and
sealed at edges to prevent tearing.
Any damage to the sub floor during installation of the false flooring system
shall be made good by the Contractor without to the owner.
3.0.0 ACCEPTANCE CRITERIA
The false flooring system shall be checked specially for :
a) Level
b) Alignment of joints
c) Thickness of joints
d) Surface finish
e) Colour and texture
(PCA.775.S034sc11) V.II-D2/S-XI : 2

DCPL-K4A02
VOLUME : II-D /2
SECTION-XII
TECHNICAL SPECIFICATION
FOR
CARPENTRY & JOINERY
(PCA.775.S034sc12)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0 SCOPE V.II-D2/S-XII : 1
2.0 INSTALLATION V.II-D2/S-XII : 1
3.0 ACCEPTANCE CRITERIA V.II-D2/S-XII : 3
4.0 I.S. CODES V.II-D2/S-XII : 4
(PCA.775.S034sc12)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XII
TECHNICAL SPECIFICATION
FOR
CARPENTRY & JOINERY
1.0 SCOPE
This shall include supply, fitting and fixing of timber frames to doors and
windows with M S holdfasts, paneled or flush doors, windows, shutters,
partitions, wall paneling, pelmets, shelves, furniture, etc. as shown in drawings,
including a prime coat of approved paint, varnish, or fixing of decorative plastic
laminate. This shall also include the supply and fixing of all hardware and
fixtures shown in drawing.
2.0 INSTALLATION
2.1 Materials
a) Timber
Unless otherwise specified, all timber shall be best quality well
seasoned C P teakwood free from large or loose, knots cracks or other
defects. Where specified, timber shall be treated with approved wood
preservative before use. Before starting the carpenters work, the
Tenderer shall have the rough timber approved by the Engineer.
b) Plywood
Plywood shall be commercial quality with decorative surface veneer.
Unless specifically permitted otherwise, the adhesive used in plywood
shall be phenol-formaldehyde resin of B W R grade conforming to
IS:848.
c) Decorative Laminated Plastic Sheets
The colour, pattern, finish and texture shall be approved by the
Engineer and the bulk supply procured in sheet sizes which will ensure
the least number or joints in one surface.
d) Flush Doors
(PCA.775.S034sc12) V.II-D2/S-XII : 1

DCPL-K4A02
Flush doors shall be hollow or solid core doors with commercial or
decorative faces and hardwood edges. The core for solid core doors
shall be of block board or wood particle board. Manufacturer's literature
and test certificates shall be submitted for the approval of the Engineer.
The Contractor shall give a guarantee that the adhesive used is phenol
formaldehyde of B W R grade, conforming to IS:848. The thickness
shall be as specified in the drawing.
e) Panel Doors
Panel door shall be of teakwood shutter frame and panels of teakwood.
Other considerations shall be as mentioned in item (d) above.
f) Fixtures
2.2 Workmanship
2.2.1 General
Fixtures for doors, windows, furniture, etc. shall be as shown on
drawing.
The work shall be done by skilled carpenters as per details shown on drawing
or instructed by the Engineer.
Framing timber and other work shall be close-fitting with proper wood joinery,
accurately set to required lines or levels and rigidly secured in place. The
surface of frames etc. which will come in contact with masonry after fixing, shall
be given two coats of approved paint before fixing. Mastic caulking shall be
done after fixing external door and window frames. Special care shall be taken
to match the grain of timber or plywood which will be subsequently polished.
Screwing or nailing will not be permitted to the edge of plywood and particle
board. The edge of all plywood, blockboard and particle board shall be finished
with teakwood lipping unless otherwise shown on drawings.
Fixing for frames and partitions shall generally be with 40 mm x 6 mm x 300
mm long M S holdfasts bifurcated at end and grouted with 1:2:4 cement
concrete. The gap between masonry and external door and window frame
shall be caulked with polysulphide mastic. M S grills or guard bars shall be
provided to windows where called for in the drawings.
2.2.2 Finish
(PCA.775.S034sc12) V.II-D2/S-XII : 2

DCPL-K4A02
All carpentry work after finishing shall be sand papered smooth. A prime coat
paint shall be given after inspection of the Engineer to all surfaces other than
those which shall be subsequently polished or covered with laminated plastic
sheet.
2.2.3 Surface Treatment
When shown on drawings decorative ply or laminated plastic sheets shall be
bonded under pressure to the surface to be finished. The adhesive used shall
be of approved brand and brought to site in sealed containers. The rate of
application and the length of time for which the pressure is to be applied shall
be as per the manufacturer's instructions. The edge of sheets shall be
protected by teak lipping or beveled as shown on drawings.
3.0 ACCEPTANCE CRITERIA
3.1 Door and Window Frames
All frames shall be square and flat at the time of delivery and shall be checked
for dimensions and corner angles. After fixing they shall be on a fine vertical
plane. All external door and window frames shall be caulked with mastic.
3.2 Door and Window Shutters
Shall be of proper size, shape and design and free of warp. When fixed to
frames, these shall operate smoothly without jamming and all latching or
locking devices shall engage properly without undue pressure.
3.3 Partitions, Paneling, Pelmets, Furniture, etc.
3.3.1 General
These shall conform to drawings in all details. No unsightly nailmarks etc. shall
be permitted. Plywood grains shall be matched to give a uniform and pleasing
appearance.
3.3.2 Partition
3.3.3 Pelmets
Shall be checked for rigidity of fixing, plumb and horizontal as well as vertical
alignment.
Shall be checked for rigidity of fixing and adequate clearance of fixture.
3.3.4 Cupboard Shutters
Shall operate smoothly without jamming and locks, bolts and double ball
catches shall engage securely. Single ball catches shall not be used.
(PCA.775.S034sc12) V.II-D2/S-XII : 3

DCPL-K4A02
3.3.5 Drawers
Shall operate smoothly and have back stops to prevent them from being
pushed too far. Locks shall engage securely.
3.3.6 Loose Furniture
When placed on a level surface tables tops etc. shall be horizontal and the
pieces stand stably on legs or supports.
4.0 I.S. CODES
Some of the important relevant Codes for the Section are:
IS:4021 - Timber door, window and ventilator frames.
IS: 1003 - Timber paneled and glazed shutters.
IS:2191 - Wooden flush door shutter (Cellular and hollow core type).
IS:2202 - Wooden flush door shutters (solid core type).
(PCA.775.S034sc12) V.II-D2/S-XII : 4

DCPL-K4A02
VOLUME : II-D/2
SECTION-XIII
TECHNICAL SPECIFICATION
FOR
SUSPENDED CEILING
(PCA.775.S034sc13)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XIII : 1
2.0.0 MATERIAL V.II-D2/S-XIII : 1
3.0.0 INSTALLATION V.II-D2/S-XIII : 2
4.0.0 SHOP DRAWINGS V.II-D2/S-XIII : 2
5.0.0 WORKMANSHIP V.II-D2/S-XIII : 2
6.0.0 SAMPLES V.II-D2/S-XIII : 2
7.0.0 ACCEPTANCE CRITERIA V.II-D2/S-XIII : 2
8.0.0 I.S. CODES V.II-D2/S-XIII : 2
(PCA.775.S034sc13)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XIII
TECHNICAL SPECIFICATION
FOR
SUSPENDED CEILING
1.0.0 SCOPE
2.0.0 MATERIAL
This specification covers the furnishing of all materials, labour, tools,
equipment, supervision and services necessary for incidental to the
supply, installation, finishing and completion of suspended ceiling work
of various profiles and at all elevations as per drawing, specification and
instruction of Architect/Owner. The work shall also include providing
openings in the ceiling for lighting fixtures, air conditioning diffusers
etc. as shown in drawing and instruction of Architect/Engineer.
2.1.0 Aluminium Grid suspension system
a) Suspender : shall be fabricated from 10 dia. M.S. rod angle, flast or
as required to suit ceiling profile and suspension system with
turnbuckle for adjustment of levels. All M.S. works shall have one
coat of synthetic enamel paint over a coat of red lead primer.
b) Frame work/grid : shall be of aluminium sections as follows :
Wall angle - 25 x 25 x 1.6 mm. thick.
Main Tee
- 35 x 25 x 1.6 mm. thick
2.2.0 Ceiling Panel
Cross Tee - 25 x 25 x 1.6 mm. thick
Tees shall be jointed with adequate cleats etc.
Ceiling Panels shall be best quality both side laminated rigid phenolic foam
insulation board similar to "PHENOTHERM" as manufactured by
`Bakelite Hylam'. The thickness, size and finish shall be as per drawing.
(PCA.775.S034sc13) V.II-D2/S-XIII : 1

DCPL-K4A02
3.0.0 INSTALLATION
3.1.0 The ceiling grid shall be suspended from structural walls slabs, beams
truss structural steel etc. with suspender fabricated from M.S.rod/
angles/flasts etc. to the required level. The entire suspension system shall
be of sufficient strength and rigidity to allow placing of planks over the grid
for movement of maintenance personnel to attend various electrical and air
conditioning installation over the ceiling and to carry ceiling panels in true
level and plane without exceeding a deflecting of 1/360th of their span. All
ceiling panels shall be secured in position using hold down clips of sufficient
number. All joints in ceiling panels shall run straight.
The installation of ceiling system shall be strictly as per drawing.
4.0.0 SHOP DRAWINGS
4.1.0 Contractor shall prepare complete working details layout based on the
conceptual layout and design of suspended ceiling and illumination and air
conditioning layout shown on the drawings and obtain approval from
the Architect/Owner before installation.
5.0.0 WORKMANSHIP
5.1.0 Shall be done in the best workmanlike manner by the manufacturer
authorised agency in accordance with manufacturer standards and
recommendations.
6.0.0 SAMPLES
6.1.0 3 (three) mock-up samples of reasonable size showing standard grid with
panels and suspender etc. having desired finish, colour etc. shall be
submitted to the Architect/Owner for approval before materials are
Delivered at site. Installed material shall match approved samples.
7.0.0 ACCEPTANCE CRITERIA
Finished ceiling shall be at the correct plane and present a pleasing and
uniform appearance, free from sags, warps, figures or damaged boards.
Joints, exposed grids etc. shall be in true lines and symmetrically
placed in manner shown on drawings. Cutouts for light fixtures, diffusers
etc. shall be of exact dimensions and in exact locations.
8.0.0 I.S. CODES
IS:2441 : Code of Practice for fixing ceiling coverings.
(PCA.775.S034sc13) V.II-D2/S-XIII : 2

DCPL-K4A02
VOLUME : II-D/2
SECTION-XIV
TECHNICAL SPECIFICATION
FOR
METAL DOORS, WINDOWS, VENTILATORS, LOUVRES, ETC.
(PCA.775.S034sc14)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XIV : 1
2.0.0 INSTALLATION V.II-D2/S-XIV : 1
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-XIV : 7
4.0.0 INFORMATION TO BE SUBMITTED V.II-D2/S-XIV : 9
5.0.0 RATES V.II-D2/S-XIV : 9
6.0.0 METHOD OF MEASUREMENT V.II-D2/S-XIV : 9
7.0.0 I.S.CODES V.II-D2/S-XIV : 10
(PCA.775.S034sc14)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XIV
TECHNICAL SPECIFICATION
FOR
METAL DOORS, WINDOWS, VENTILATORS, LOUVRES, ETC.
1.0.0 SCOPE
The work in general shall consist of supplying and/or erecting and installing of
all metal doors, windows, ventilators, louvers, glazed partitions, etc. as shown
on drawings with all materials complete excluding supply of glass and glazing.
The scope of work shall also include the assembly and the Owner from the
store at site shall supply erection of all doors, windows, louvres, glazed partitions,
etc. for which fabricated materials. Supplying and/or fixing of all door and window
accessories and hardware is also included in the scope.
2.0.0 INSTALLATION
2.1.0 Materials
Steel sections used for fabrication of doors, windows etc. shall be standard
rolled steel sections specified in IS:1038 and IS:1361 or as specified in drawing
and schedules.
Steel sheets for frames, shutters, louvre blades etc. shall be of gauge
mentioned in drawings.
Aluminium sections for fabricating doors, windows, partitions etc. shall be
extruded sections conforming to IS:1948 and 1949 or as manufactured by
Indian Aluminium Company Limited or approved equivalent. The alloy used
shall conform to IS Designation HE 9-WP of IS:733.
Hardware and fixtures shall be as specified in "Schedule of Fixtures" and the
best quality from approved manufacturers shall only be used. The Tenderer
shall specifically state the particular manufacturer's materials he proposes to
use. "Schedule of Fixtures" is for the purpose of stating the minimum
requirement and improper alignment or faulty operation due to inadequate
strength of hardware or fixture shall entirely be the Contractor's responsibility.
All hardware and fixtures shall be able to withstand repeated use. Door
closures shall conform to IS:3564 and shall be suitable for doors weighing
61-80 Kg. unless otherwise stated in schedule. Each closer shall be
guaranteed against manufacturing defect for one year and any defect found
within this period shall be rectified or the closer replaced free of .
(PCA.775.S034sc14) V.II-D2/S-XIV : 1

2.2.0 Fabrication
DCPL-K4A02
Concealed door closers shall be either floor mounted or transom mounted,
suitable for installation with metal doors. It shall conform to the performance
requirements and endurance test stated in IS:3564 - Appendix A.
The Contractor shall submit samples of each type of hardware to the Engineer.
The approved samples shall be retained by the Engineer for comparison of
bulk supply. The samples shall be returned to the Contractor towards the end
for incorporation in the job.
The mastic for caulking shall be of best quality from a manufacturer approved
by the Engineer. In general, the mastic for fixing of metal frames shall be as
per IS:1081 and/or as approved by the Engineer.
2.2.1 Steel Doors, Windows, Ventilators, Louvres etc.
a) Door Frames
Frames shall be fabricated from 16 G sheets. They shall be mortised,
reinforced, drilled and tapped for hinges and lock and bolt strikes.
Where necessary, frames shall be reinforced for door closers.
Welded construction with mitred corners shall be used. Rubber door
silencers shall be furnished for the striking jamb. Loose "T" masonry
anchors shall be provided. Frames shall finish flush with floor and
adjustable floor anchors shall be supplied. Frames shall be brought to
site with floor ties/weather bars installed in place.
b) Double Plate Flush Door Shutters
Door shutters shall be 45 mm. thick, completely flush design and shall
comprise of two outer sheets or 18 G steel sheets, rigidly connected
and reinforced inside with continuous vertical 20 G stiffeners, spot
welded in position at not more than 150 mm on centres.
Both edges of doors shall be joined and reinforced full height by steel
channels placed immediately inside and welded to the door faces. Top
and bottom of doors shall be reinforced horizontally as shown on
drawing by steel channels running full width of door. Doors shall not
have more than 2.5 mm clearance at jambs and heads, shall have
proper level on lock stiles and rails to operate without binding, and shall
be reinforced at corners to prevent sagging or twisting. Pairs or double
doors shall have meeting-stile edges bevelled or rebated. Where
shown on drawing or called for in the schedule of items the doors shall
be sound-deadened by filling the inside voids with mineral wool or other
suitable approved materials.
(PCA.775.S034sc14) V.II-D2/S-XIV : 2

Doors shall be mortised, reinforced, drilled and tapped in shop for
hinges, locks and bolts. They shall also be reinforced for closers,
push-plates and other surface hardwares where necessary. Any
drilling and tapping required for surface hardware shall be done at site.
Where shown on drawing, provision shall be made for fixing glazing,
vision panels, louvres etc. glazing moldings shall be of 18 G steel or
extruded aluminium sections with profiles shown on drawing and
suitable for fixing 6 mm. glass. Louvres blades shall be V or Z shaped
and made out of 16 G sheets.
c) Single Sheet Door Shutters
Single sheet doors shall be made from best quality 18 G mild steel
sheets, and shall present a flush surface on the outside. The inside
shall be stiffened with semi tubular edge and central stiffening rail,
which shall convey the lock and other furniture. The frames shall be
made from best quality 16 G mild steel sheets.
Wherever required as shown on drawings, provisions for fixing glass
panes, louvres etc. shall be made.
The manufacturing shall be done as specified in 2.2.1.b. "Double Plate
Flush Door Shutters".
d) Sliding Doors
DCPL-K4A02
Sliding doors shall be either double plate or single plate construction as
called for in drawings made out of 18 gauge steel sheets with adequate
stiffeners. The Contractor shall specify the weight of the door in his
shop and submit the manufacturer's catalogue of the sliding gear he
proposes to use. Where shown on drawings or call for in the Schedule
of Items, the Contractor shall make provision for openings to the door
for mono-rail beams. Doors shall close positively to exclude rain water
from seeping in. When called for in schedule, sliding doors shall
withstand specified wind loads without buckling or jamming. The door
shall slide freely under all ambient conditions.
(PCA.775.S034sc14) V.II-D2/S-XIV : 3

DCPL-K4A02
e) Door Threshold
Door threshold shall be provided as shown on drawing. Doors without
threshold shall have bottom tie of approved type.
f) Steel Windows, Sashes, Ventilators etc.
These shall conform in all respects to IS:1038 and IS:1361 latest
editions and as shown on drawings. The details as called for in the
above codes shall be applicable for coupling mullions, transoms,
weather bars, pivot arrangements for ventilators, etc. or as shown on
drawings or called for in the Schedule of Items.
All welds shall be dressed flush on all exposed and contact surfaces.
Where composite unit openings are shown on drawings, the individual
window units shall be joined together with requisite transoms and
mullions as shown on drawings. All windows shall be outside glazed,
fixed with putty or metal glazing beads as shown on the drawings
and/or specified under Schedule of Items. Where aluminium glazing
beads are specified, they shall be extruded aluminium channel 9.5 mm
x 9.5 mm x 1.6 mm (Indal Section No. 2209) unless otherwise shown on
drawings. Aluminium beads shall be given one coat of zinc chromate
primer before fixing to windows.
2.2.2 Aluminium Door, Windows and Frames
Extruded sections shall have a minimum 3 mm wall thickness unless otherwise
approved in samples by the architect/engineer. All sections shall be approved
by the Architect/Engineer before fabrication is taken up. Doors, frames,
mullions, transom etc. shall be anodized in a bath of sulphuric acid to provide a
clear coating of minimum 0.6 mm thickness. The anodized materials shall then
be sealed by immersing in bailing water for 15 minutes. A protective
transparent coating shall be applied to the sections before shipment from the
factory.
All work shall be fitted and shop assembled to a first class job, and ready for
erection. Shop joints shall be made to hair lines and then welded or braced by
such method as will produce an uniform colour throughout the work. Work on
the above, other than described, shall be carefully fitted and assembled with
neat joints with concealed fasteners. Wherever possible, joints shall be made
in concealed locations and on edges of doors. Field connections of all work
may be made with concealed screws or other approved type of fasteners.
Glazing beads shall be snap fit type without visible screws and shall be of sizes
to accommodate 6 mm thick glazing or as specified in schedule of items. All
work shall be adequately braced and reinforced as necessary for strength and
rigidity.
(PCA.775.S034sc14) V.II-D2/S-XIV : 4

DCPL-K4A02
2.2.3 Aluminium Structural Glazing
Providing and fixing of barriered semi unitised structural glazing system at
all levels through designing and selection of mullion and transoms profiles
anodised (15 to 20 micron) or powder coated (50 to 70 micron), selected for
their fixing on the structure depending on the structural conditions, functional,
statistical requirement and should withstand the wind load criteria as per IS-875
(part - III) 1987. System should provide proper rebate areas for air pressure
compensation / water drainage at required stages. Double insulated hard
coated toughened glass consist of 6mm outer single safety glass, 12mm inter
space and 6mm inner clear glass panel glued onto the glass glazing frame
profile selected according to the vision / spandrel panel (Aluminium Composite
Panels) requirement with DC 995 structural sealant. Proper supporting element
should be provided for taking care of the respective infill load and reliving in
case of the glass bonding failure. ( The profile sections shall be Hindalco -
Alupuram unit, HYDRO product or equivalent). Floor to floor height would be
4.2m approx and width of glazing supporting frame would be 1.0m approx.
2.3.0 Shop Coat or Paint
The shop paint for steel doors, windows etc. shall be best lead or zinc
chromate primer paint from approved manufacturer. All surfaces shall be
thoroughly cleaned of rust, grease, loose mill scales etc. and given one coat of
shop paint. Portions like mullions, transoms etc. which will be inaccessible
after assembly of units shall be given an extra coat of paint before assembly.
All steel doors, windows, etc. shall be hot dip galvanised to give a coating
weight of 1-1/2 - 2 oz. per sft. One coat zinc chromate primer coat shall then
be applied as shop paint.
Portions of aluminium frame which come in contact with masonry construction,
shall, before shipment from workshop, be protected with a heavy coat of alkali
paint. Aluminium coming in contact with other incompatible metals shall be
coated with zinc chromate primer.
2.4.0 Handling & Storage of Fabricated Material
All metal doors, windows, etc. shall be packed and crated properly before
despatch, to ensure that there will be no damage to the fabricated materials.
Loading into wagons and trucks shall be done with all care to ensure safe
arrival of materials at site in undamaged condition.
When taking delivery of items supplied by Owner, the Contractor shall satisfy
himself that the items supplied are upto the specified standard. Any defect
detected shall promptly be brought to the notice of the Engineer.
All metal doors, windows etc. shall be stored under cover in a way to prevent
damage or distortion. Special care shall be taken to prevent staining of
aluminium products by rust, mortar etc.
(PCA.775.S034sc14) V.II-D2/S-XIV : 5

2.5.0 Assembly & Erection at Site
DCPL-K4A02
In general, the fixing of steel doors, windows, ventilators, louvres, etc. shall
conform to IS:1081 and as shown on drawings. The Contractor shall assemble
and install all steel doors, windows, sashes, fixed metal louvres, etc. including
transoms and mullions for composite units in respective places as shown on
drawing, keeping proper lines and levels, and in approved workmanlike
manner, to give trouble free and leak-proof installations.The installation shall be
done according to the instructions of the manufacturer, and/or as approved by
the Engineer. If required by the Engineer, the installation shall have to be
carried out under the supervision of the manufacturer's staff. The Contractor
shall take every precaution against damage of the components during
installation. Necessary holes, chases, etc. required for fixing shall be made by
the Contractor and made good again as per original, after installation.
After installation of steel doors, windows, etc. all abrasions to shop-coat of paint
shall be retouched and made good with the same quality of paint used in shopcoat.
All coupling mullions, transoms, frames, etc. in contact with adjacent steel and
other members, shall be well bedded in mastic. The Contractor shall bring to
the site the mastic cement in original sealed containers of manufacturer and
shall apply it as per the instructions. For all frames supplied by either the
Owner or the Contractor, mastic shall be supplied by the Contractor and
caulking done properly as per drawings, specifications and as per instructions
of the Engineer.
Door shutters, partitions hardware fixtures etc. shall be fixed only after major
equipments have been installed in rooms.
Wherever required, nylon cords of approved quality shall be supplied along with
pivoted sashes and shall be of adequate length to terminate one metres from
the floor. Loose ends of cords shall end in metal or plastic pull as approved by
the Engineer.
(PCA.775.S034sc14) V.II-D2/S-XIV : 6

DCPL-K4A02
3.0.0 ACCEPTANCE CRITERIA
3.1.0 For Fabricated Items
a) Overall dimensions shall be within +1.5 mm of the size shown on
drawings.
b) Mullions, transoms etc. shall be in one length and permissible
deviations from straightness shall be limited to + 1.5 mm from the axis
of the member.
c) Door and window shutters shall operate without jamming. The
clearance at head and jamb for door shutters shall not exceed 1.5 mm.
For double leaf doors, the gap at the meeting stiles shall not be more
than 1.5 mm.
d) Door leaves shall be undercut where shown on drawings.
e) Doors, windows, frames, etc. shall be on a true planes, free from warp
or buckle.
f) All welds shall be dressed flush on exposed and contact surfaces.
g) Correctness of location and smoothness of operations of all shop
installed hardware and fixtures.
h) Provision for hardware and fixtures to be installed at site.
i) Glazing beads shall be cut with mitred corners.
j) Glazing clips, fixing devices etc. shall be supplied in adequate numbers.
k) Shop coats shall be properly applied.
l) Exposed aluminium surfaces shall be free from scratches, stains and
discolouration. Anodised surfaces shall present a uniform and pleasing
look.
(PCA.775.S034sc14) V.II-D2/S-XIV : 7

DCPL-K4A02
3.2.0 For Installed Items
a) Installations shall be at correct location, elevation and in general, on a
true vertical plane.
b) Fixing details shall be strictly as shown on drawings.
c) Assembly of composite units shall be strictly as per drawings with
mastic caulking of transoms and mullions, gaskets, weather strips etc.
complete.
d) All frames on external walls shall be mastic caulked to prevent leakage
through joint between frames and masonry.
e) All openable section shall operate smoothly without jamming.
f) Locks, fasteners etc. shall engage positively. Keys shall be
non-interchangeable.
g) Cutting to concrete or masonry shall be made good and all abrasions to
shop paint shall be touched up with paint of same quality as shop paint.
h) Aluminium doors, windows, etc. shall be free from scratches stain or
discolouration.
(PCA.775.S034sc14) V.II-D2/S-XIV : 8

4.0.0 INFORMATION TO BE SUBMITTED
DCPL-K4A02
4.1.0 With Tender
a) Names of manufacturers for doors, windows, etc.
b) Manufacturer’s catalogue for all hardware and fixtures proposed to be used.
4.2.0 After Award
a) Before starting fabrication of all metal doors, windows, etc. the Contractor shall
submit detailed fabrication drawings to the Engineer for approval. The
fabrication shall be started only after approval of drawings.
b) He shall submit a programme of work to be done for the approval of the
Engineer.
c) Before bulk supply, he shall submit for the approval of the Engineer samples of
all bought out items and samples of each type of fabricated items. The samples
shall be retained by the Engineer for comparison of bulk supply and returned to
the Contractor towards the end for final incorporation in the job.
5.0.0 RATES
[This clause may be ignored in view of EPC mode of execution]
Rates shall be unit rates for items described in the schedule.
6.0.0 METHOD OF MEASUREMENT
[This clause may be ignored in view of EPC mode of execution]
a) Supply and installation of doors shall be measured in number of each type used.
The types shall be as shown on drawings and described in Schedule of Items.
b) Supply of windows shall be measured in number of each type of unit used either
single or in combination.
c) Installation including assembly and erection of windows shall be measured in
number of types of combinations mentioned in the Schedule of Items.
d) Supply and installation of louvers shall be measured for area of opening in which
the louvre is to be installed.
e) Supply of mullions and transoms shall be measured for net length of different
types shown on drawings and described in Schedule. In computing the length, the
length required for embedding in concrete or masonry shall not be considered. No
extra payment shall be made for end or cover plates.
f) Vision panels, louvers to doors and insulation between door faces shall be
measured for actual area and paid separately over the basic rate doors.
(PCA.775.S034sc14) V.II-D2/S-XIV : 9

DCPL-K4A02
g) Glazed beads, weather stripping, fixing devices etc. shall not be measured
separately but shall be included in the supply rate of respective items.
h) And cutting or grouting to concrete and masonry or welding and drilling to steel
required for installation shall be included in the installation rate. No separate
payment shall be made for cauking and jamming or frames or making good to
concrete or masonry.
i) Glass and glazing shall be measured and paid under relevant items.
j) Door and window fixtures, locks, door closures etc. shall be measured in actual
number use.
7.0.0 I.S. CODES
Following are some of the important I.S. Codes as relevant to this section :
Steel doors, windows and ventilators - IS:1038
Steel windows for industrial buildings - IS:1361
Aluminium doors windows and ventilators - IS:1948
Aluminium windows for industrial buildings - IS:1949
Steel door frames - IS:4351
Code of practice for fixing and glazing of
metal (steel and aluminium) doors,
windows, and ventilators - IS:1081
(PCA.775.S034sc14) V.II-D2/S-XIV : 10

DCPL-K4A02
VOLUME : II-D/2
SECTION-XV
TECHNICAL SPECIFICATION
FOR
GLASS AND GLAZING
(PCA.775.S034sc15)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XV : 1
2.0.0 INSTALLATION V.II-D2/S-XV : 1
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-XV : 3
4.0.0 I.S. CODES V.II-D2/S-XV : 3
(PCA.775.S034sc15)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XV
TECHNICAL SPECIFICATION
FOR
GLASS AND GLAZING
1.0.0 SCOPE
The work in general shall consist of supplying and fixing all glass and glazing
including all clips, putty, mastic cement etc. wherever required as shown on
drawings and specifications, supply of metal glazing beads and neoprene
gaskets shall not be included in this scope.
This shall also include the fixing of all glass and glazing supplied by the Owner
at his site stores.
2.0.0 INSTALLATION
2.1.0 General
2.2.0 Materials
The Contractor shall supply and install all glass and glazing as required for
various doors, windows, sashes, ventilators and fixed louvres, miscellaneous
glazing and partitions, unless otherwise stated from approved manufactur
having uniform refractive index and free from flaws, specks and bubbles. The
glass shall be brought to site in the original packing from the manufacturer and
cut to size at site.
a) Glare reducing or heat absorbing glass shall be of approved
manufacturer and special care shall be taken to grind smooth and
round off the edges before fixing.
b) Glass shall be float glass of required thickness and shall be clear or
tinted as indicated.
c) Wired glass shall be thick rolled glass with centrally embedded 42g.
wire mesh of Georgian type. This may be of clear or coloured glass, as
shown on drawings.
(PCA.775.S034sc15) V.II-D2/S-XV : 1

DCPL-K4A02
d) Obscure glass shall have a cast surface in one side.
e) Coloured and figured glass shall be as per approved sample.
f) In general, the putty shall conform to IS : 400 and be of best quality
from approved manufacturer. It shall be brought to site in the
manufacturer's original packing. Quick setting putty glass is used where
it shall be non-setting type.
g) EPDM gaskets with snap-fit glazing beads shall be fixed as per
manufacturer's instructions and shall sit snugly against glass to give a
leakproof installation.
h) Float glass
i) Double glazing
2.3.0 Glazing, Setting and Finish
All glazing clips, bolts, nuts, putty, mastic cement etc. as required shall be
supplied by the Contractor.
All glass shall be thoroughly cleaned before putting in position. Each glass
pane shall be held in place by special glazing clips of approved type. As
specified in relevant I.S. Codes, four glazing chips shall be provided per
glasspane, except for large panes were six or more clips shall be used as per
Engineer's instructions. All holes that may be necessary for holding the clips
glazing heads and all other attachments shall be drilled by the Contractor.
Glass panes shall be set without springing, and shall be bedded in putty and
back puttied, except where moulding or gasket are specified, putty, mastic
cement etc. shall be smoothly finished to the even line and figured glass shall
be set with smooth side out.
After completion of glazing work, the Contractor shall remove all dirt stains,
excess putty etc. clean the glass panes and leave the work in perfectly
acceptable condition. All broken cracked or damaged glass shall be replaced
by new ones.
(PCA.775.S034sc15) V.II-D2/S-XV : 2

DCPL-K4A02
3.0.0 ACCEPTANCE CRITERIA
a) All installation shall be free from cracked, broken or damaged glass.
Edges of large panes of thicker glass and heat absorbing glass shall be
inspected carefully for chipped, cracked or underground edges.
b) Glazing shall be carefully done to avoid direct contact with metal
frames.
c) All glass shall be embedded in mastic or fixed by neoprene gaskets to
give a leakproof installation.
d) At completion, the panes shall be free from dirt, stains, excess putty etc.
to the complete satisfaction of the Engineer.
4.0.0 I.S. CODES
Following are some of the important I.S.Codes relevant to this Section :
IS : 3548 - Code of practice for glazing in building.
IS : 1083 - Code of practice for fixing and glazing metal doors, windows &
ventilators.
(PCA.775.S034sc15) V.II-D2/S-XV : 3

DCPL-K4A02
VOLUME : II-D/2
SECTION-XVI
TECHNICAL SPECIFICATION
FOR
ROLLING STEEL SHUTTERS/GRILLS
(PCA.775.S034sc16)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XVI : 1
2.0.0 INSTALLATION V.II-D2/S-XVI : 1
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-XVI : 3
4.0.0 I.S. CODES V.II-D2/S-XVI : 3
(PCA.775.S034sc16)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XVI
TECHNICAL SPECIFICATION
FOR
ROLLING STEEL SHUTTERS/GRILLS
1.0.0 SCOPE
This specification covers the design, supply of materials, fabrication, delivery
and erection of Rolling Shutters/Grills with motor drive and/or manual operation
including all accessories as hereinafter specified.
2.0.0 INSTALLATION
2.1.0 Components
a) Slats for rolling shutters shall be made from tested bright cold rolled,
annealed M.S. strips, not less than 0.9 mm thick for shutters upto 4.5 M
wide and not less than 2.25 mm thick for shutters 5.5 M wide and
above, machine rolled at 75 mm rolling centres, interlocking with each
other. The profile will be such as to prevent excessive deflection under
specified wind load.
b) Rolling grills shall be constructed out of 6 mm dia. rods at 35 mm on
centres running horizontally flexible connected with vertical links spaced
not more than 200 mm centres. Alternatively, rolling grills shall be made
from perforated slats of approved design reinforced with 6 mm dia rods.
c) End locks shall be heavy type M.C.I./C.I. and shall be provided at each
end of alternate slats unless specified otherwise in the Schedule.
d) Bottom bars shall be finished with two angles not less than 6 mm thick
for external shutters. When shown on drawings, a flexible weather strip
shall be applied to make tight contact with the floor.
e) Guides shall be of such depth as to retain the shutter under a wind
pressure of 100 Kg/Sq.M or as specified in Schedule.
f) Shafts shall be of steel pipe of sufficient size to carry the torsion load
with a maximum deflection of 1/360th of span.
Grease packed ball bearings or bushings shall be provided for smooth
trouble free operation.
g) Hoods shall be formed of not less than 20 gauge steel, suitable
(PCA.775.S034sc16) V.II-D2/S-XVI : 1

DCPL-K4A02
reinforced to prevent sag.
h) Locks shall be slide bolt and hasp, or cylinder lock operable from one or
both sides. Provision securing hand chain with pad-lock, provision for
removable handle for hand cranks etc. shall be made as described in
Schedule or as described by the Engineer.
i) Power unit shall be suitable for 3 phase, 50 cycle, 400 volt A.C. power
supply and shall be either floor or wall mounted unit. The motor shall be
of sufficient capacity to move the shutter in either direction at a speed of
0.3 metres per second. In addition to the gear motor each standard
power unit shall include a magnetic brake, a reversing starter with
built-in overload protection, a geared limit switch and one push button
station located inside the building unless otherwise stated drawing.
It is desirable that the bottom bar of motor operated doors shall be
provided with a sensitive edge, electrically connected to stop the travel
of the door on meeting an obstruction.
j) Operating chains shall be of tested quality, heavily galvanised and with
all ends rounded to assure smooth operation and hand protection.
k) Reduction gears shall be high strength gray cast iron, machine moulded
from machine out patterns.
2.2.0 Manually Operated Shutters/Grills
Manually operated shutters shall be easily operable by one person. The speed
of operation shall be about 1.3 metres per second. In general, manually
operated shutters shall be push pull type for openings upto 9 Sq.metre in area.
Larger shutters shall be either chain and gear operated or crank and gear
operated. The crank handle shall be removable. All shutters shall be lockable
from one or both sides as described as desired by the Engineer.
2.3.0 Power Operated Shutters/Grills
2.4.0 Shop Coat
2.5.0 Erection
These shall be operable from a push button station conveniently located beside
the door or as shown on drawings. One emergency hand chain/crank operation
shall also be provided for use in case of failure of the electric system. Where
called for in Schedule, externally mounted shutters shall be operated by control
mechanism located inside the building.
Shutters shall be painted with one coat of red lead or zinc chromate primer.
Where specified, doors shall be galvanized and subsequently painted one coat
of zinc chromate for adhesion of field coat.
Door shall be installed by the manufacturer or his authorised representative and
(PCA.775.S034sc16) V.II-D2/S-XVI : 2

DCPL-K4A02
all work shall be as per manufacturer's instructions. Any drilling or cutting to
concrete, masonry etc. shall be made good after erection of shutters and all
abrasion to shop coat shall be touched up. All electrical work shall be in strict
accordance with the latest Indian Electricity Rules.
3.0.0 ACCEPTANCE CRITERIA
3.1.0 Shop Inspection
After completing the manufacture of the different components of the rolling
shutter, an arrangement for shop inspection by the Engineer shall be made to
check the conformity with approved shop drawings.
3.2.0 Field Inspection
3.3.0 Guarantee
After installing the shutters, the Contractor shall test the performance of the
shutter in the presence of the Engineer. The doors shall be smoothly operable
under all ambient conditions. All control and locking devices shall give fault-free
performance.
The Contractor shall give one year's guarantee for the successful operation of
the shutters. This shall be supported by a separate and unilateral guarantee
from the manufacturer of the shutters.
4.0.0 I.S. CODE
IS : 6248 - Metal rolling shutters and rolling grills.
(PCA.775.S034sc16) V.II-D2/S-XVI : 3

DCPL-K4A02
VOLUME : II-D/2
SECTION-XVII
TECHNICAL SPECIFICATION
FOR
MISCELLANEOUS METAL
(PCA.775.S034sc17)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XVII : 1
2.0.0 INSTALLATION V.II-D2/S-XVII : 1
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-XVII : 4
4.0.0 I.S. CODES V.II-D2/S-XVII : 4
(PCA.775.S034sc17)

DCPL-K4A02
VOLUME : II-G/2
SECTION-XVII
TECHNICAL SPECIFICATION
FOR
MISCELLANEOUS METAL
1.0.0 SCOPE
This specification shall generally be read in conjunction with item nos. 6.01 &
6.03.
This shall include supply, fabrication and erection of miscellaneous metal items
of light nature in gates, grills, balcony and stair handrails particulars, structural
mullions and transoms, ladders hangers masonry anchors, shelf angles,
anchor bolts, fasteners, etc. as shown on drawing or as instructed by the
Engineer. The above items shall be of fabricated or cast M.S/Aluminium/Brass,
cast iron, M.S. and galvanised M.S. Sheets, aluminium sheets, expanded
metal, wire mesh etc. as shown on drawings and/or described.
2.0.0 INSTALLATION
2.1.0 Fabrication/Casting
2.1.1 General
All work shall be done according to approved shop drawings. All workmanship
shall be equal to the best practice in modern structural or foundry shop.
2.1.2 Shop Connections
a) All shop connections shall be riveted or welded except when noted
otherwise on drawings.
b) Welding of steel shall be done in accordance with the IS : 816. Use of
metal arc welding for general construction in Mild Steel.
c) Welding of aluminium shall be done in accordance with IS: 2812, Arc
welding of Aluminium and Alloys, Special care shall be taken to grind
smooth all welded surface that shall remain exposed to view. Welds
shall be electrically continuous if so required by the Engineer.
2.1.3 Shop Coat
(PCA.775.S034sc17) V.II-D2/S-XVII : 1

DCPL-K4A02
2.2.0 Erection
2.2.1 Bracing
Before leaving the shop, all metal work shall be thoroughly cleaned by effective
means of all loose mill/ scale, rust and foreign matter. Except where encased in
concrete, all steelwork shall be given one coat of approved metal protective
paint, applied by brush thoroughly and evenly, well worked into joints and other
open spaces. All paint shall be applied to dry surfaces. Steel work shall be
galvanised or galvanized and painted with a coat of zinc chromate primer.
Aluminium surfaces which shall come in contact with masonry shall be given
one coat of zinc chromate primer.
The Contractor shall provide all necessary temporary guys and braces to
ensure alignment and stability of the members and to take care of all loads to
which the structure may be subjected including erection of equipment and
operation of the same.
2.2.2 Temporary Bolting-Up
2.2.3 Turned Bolt
2.2.4 Welding
As erection proceeds the Contractor shall plumb up and level all members and
shall securely bolt up to take care of all dead load, wind load and erection
stresses. Wherever piles of materials, erection equipment or other loads are
carried during erection, proper provision shall be made to take care of the
stresses resulting from the same.
For field connections where bolting is specified, holes for the turned bolts may
be reamed in the field, if required. All drilling or reaming for turned bolts shall be
done after the parts to be connected are assembled.
Where specified on drawings, welding shall be done in accordance with IS :
816 for steel and IS: 2812 for Aluminium and Alloys.
2.2.5 Cutting and Fitting
No cutting of sections, flanges, webs of angles shall be done without the
approval of the Engineer. Where indicated on the drawings, holes, cuttings, etc.
shall be provided as required for installation, to the work by the other
Contractors. No additional holes or cuttings, than those shown on drawings,
shall be made without the approval of the Engineer.
(PCA.775.S034sc17) V.II-D2/S-XVII : 2

DCPL-K4A02
2.2.6 Drifting
2.2.7 Grouting
Correction of minor misfits and a reasonable amount of reaming and cutting of
excess stock from rivets may be permitted. For this, light drifting may be
allowed to draw holes together. Twist drills shall be used to enlarge as
necessary to make connections. Reaming that weakens the members or make
it impossible to fill the holes properly or to adjust accurately after reaming shall
not be allowed.
Any error in shop work which prevents the proper assembling and fitting of
parts by moderate use of drift pins or a moderate amount or reaming and slight
chipping and cutting shall immediately be called to the attention of the Engineer
and approval of the method of correction obtained. The use of cutting torches
to enlarge or alter rivet holes shall not be permitted.
All bearing plates, loose lintels and beams, etc. shall be set to proper grade
and level by the Contractor and the Engineer's approval obtained before
proceeding with the grouting. Grouting shall be done in 1:1.5:3 or 1:1- 1/2:3
concrete with 6 mm down stone chips.
2.2.8 Anchor Bolting
2.2.9 Pipe Joints
2.2.10 Spot Painting
2.2.11 Making Good
When shown on drawings, the miscellaneous metal items shall be fixed to
concrete by case hardened and drawn carbonizing steel expander nut and bolt.
The Contractor shall submit the manufacturer's literature showing the average
pull out and average shear values for bolts of various sizes. The bolts shall be
fixed strictly as per the manufacturer's instructions.
M.S. Pipes shall be joined by threaded sockets or by welding. Cast iron pipes
shall be socket and spigot jointed and caulked with hemp and molten lead.
All field rivets and bolts and also any serious abrasion to shop paint shall be
spot painted with the same materials as used for the shop paint.
All cutting to concrete or masonry shall be made good to the satisfaction of the
Engineer.
(PCA.775.S034sc17) V.II-D2/S-XVII : 3

DCPL-K4A02
3.0.0 ACCEPTANCE CRITERIA
a) All items shall be of correct shape, size, weight etc. shown on drawings.
b) For installed items, the tolerances shall be follows :
i) Permissible deviation from straightness - 1 in 1000.
ii)
Seats, stiffener connections etc. shall be as per approved
drawings and shall not interfere with architectural clearances.
c) All castings shall be free from blow holes, cracks and other blemishes.
4.0.0 I.S. CODES
IS : 226 - Structural Steel (Standard Quality)
IS:800 - Code of practice for use of structural steel in general
building construction.
IS : 816 - Use of metal arc welding for general construction in mild
steel.
IS : 2812 - Arc welding of Aluminium and Alloys
IS : 3150 - Hexagonal Wire Netting
IS : 4948 -
Welded steel wire fabric for general use.
(PCA.775.S034sc17) V.II-D2/S-XVII : 4

DCPL-K4A02
VOLUME : II-D/2
SECTION-XVIII
TECHNICAL SPECIFICATION
FOR
PAINTING, WHITE WASHING AND POLISHING ETC.
(PCA.775.S034sc18)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XVIII : 1
2.0.0 INSTALLATION V.II-D2/S-XVIII : 1
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-XVIII : 8
4.0.0 I.S. CODES V.II-D2/S-XVIII : 9
(PCA.775.S034sc18)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XVIII
TECHNICAL SPECIFICATION
FOR
PAINTING, WHITE WASHING AND POLISHING ETC.
1.0.0 SCOPE
This specification covers painting, white washing, varnishing, polishing etc. of
both interior and exterior surfaces of wood work, masonry, concrete plastering,
plaster or paris,Punning false ceiling, structural and other miscellaneous steel
items, rain water down comer, floor and roof drains, soil, waste and service
water pipes, and other ferrous and non-ferrous metal items as shown on
drawings, or as directed by the Engineer.
Copper, bronze, chromium plate, nickel, stainless steel, aluminium and monel
metal shall generally not be painted or finished except if otherwise specified.
The painting Contractor shall inspect the work of others prior to the application
of paint. If surface to be finished cannot be put in suitable condition for painting
by customary preparatory methods, the painting contractor shall notify the
Engineer in writing or assume responsibility for and rectify unsatisfactory
finishing that results.
Before commencing painting, the painting Contractor shall obtain the approval
of the Engineer in writing regarding the schedule of work to minimize damage,
disfiguration or staining by other trades. He shall also undertake normal
precautions to prevent damage, disfiguration or staining to work of other trades
or other installations.
2.0.0 INSTALLATION
2.0.1 Materials
Materials shall be highest grade products or well-known approved manufacture
and shall be delivered to the site in original sealed containers, bearing brand
name, manufacturer's name and colour shade, with labels intact and seals
unbroken. All materials shall be subject to inspection, analysis and approved
by the Engineer. It is desired that materials of one manufacturer only shall be
used as far as possible & paint or one shade is obtained the same
manufacturing batch. All paint shall be subject to analysis from random
samples taken at site from painters bucket, if so desired by the Engineer.
All prime coats shall be compatible to the material of the surface to be finished
as well as to the finishing coats to be applied.
All unspecified materials such as shellac, turpentine or linseed oil shall be of
the highest quality available and shall conform to the latest IS standards. All
(PCA.775.S034sc18) V.II-D2/S-XVIII: 1

DCPL-K4A02
such materials shall be made by reputable recognised manufacturers and shall
be approved by the Engineer.
All colours shall be as per painting schedule and tinting and matching shall be
done to the satisfaction of the Engineer. In such cases, where samples are
required, they shall be executed in advance with the specified materials for the
approval of the Engineer.
a) White Washing
Shall be done from pure shell lime or fat lime, or a mixture of both as
instructed by the Engineer; and shall conform to IS:712 latest edition.
Samples of lime shall be submitted to the Engineer for approval, and
lime as per approved sample shall be brought to site in unslaked
condition. After slaking, it shall be allowed to remain in a tank of water
for two days and then stirred up with a pole, until it attains the
consistency of thin cream. 100 grams of gum to 6 litres of white wash
water and a little quantity of indigo or synthetic ultramarine blue shall be
added to the lime.
b) Dry distemper
Shall be made from suitable pigments, extenders, lime proof tinters,
water soluble binders etc. and shall conform to IS:427.
c) Oil Bound Washable Distemper
Shall be of oil emulsion type, containing suitable preservatives and shall
conform to IS:428.
d) Waterproof Cement Paint
Shall be made from best quality white cement and lime resistant colours
with accelerators, waterproofing agents and fungicides. The paint shall
conform to IS:5410.
e) Acrylic Emulsion Paint
Shall be water-based acrylic copolymer emulsion with retile titanium
dioxide and other selected pigments and fungicide. It shall exhibit
excellent adhesion to plaster and cement surface and shall resist
deterioration by alkali salts. The paint film shall allow the moisture in
wall to escape without peeling or blistering. The paint, after it is dried,
shall be able to withstand washing with mild and water without any
deterioration in colour, or without showing flaking, blistering or peeling.
f) Synthetic Enamel Paint
(PCA.775.S034sc18) V.II-D2/S-XVIII: 2

2.0.2 Storage
DCPL-K4A02
Shall be made from synthetic resins and drying oil with rutile titanium
dioxide and other selected pigments to give a smooth, hard, durable
and glossy finish to all exterior and interior surfaces. White and pastel
shades shall resist yellowing and darkening with aging. The paint shall
conform to IS:2932 and IS:2933.
g) Aluminium Paint
Shall be in two pack containers and shall resist weathering. The paint
shall conform to IS:2339.
h) Shall be best quality alkyd varnish suitable for brushing over the tint of
paint or light natural wood and shall not darken or yellow with age.
i) French Polish
Shall be made from best quality shellac, denatured spirit and other
suitable alcohol soluble ingredients and made by a well known
approved manufacturer. The material shall conform to IS:348.
French polish shall not be used on bare wood. It shall only be used as
finishing coat on wood after the wood is pretreated with a liquid wood
filler conforming to IS:345 is applied and rubbed out.
The Contractor shall arrange for safe and proper storage of all materials and
tools. The storage space if allotted within the building shall be adequately
protected from damage, disfigurement & stains. Paint shall be kept covered at
all times and mixing shall be done in suitable containers. All necessary
precautions shall be taken by the Contractor to prevent fire.
2.1.0 Preparation of surface
2.1.1 Wood
Before starting the work the Contractor shall obtain the approval of the
Engineer regarding the soundness & readiness of the surface to be painted on.
All surfaces shall be free from dirt and loose or peeling paints. The surface
shall be rubbed down smooth. All nails & screws shall be sunk below the
surface and filled with putty after applying an under coat. Small knots that do
not justify cutting and sap streaks shall be covered with minimum 2 coats of
pure shellac coating applied thinly & extended 25 mm beyond the area. All
large, loose or resinous knots shall be removed and filled with sound wood. All
work shall be done as per IS:2338.
2.1.2 Masonry, Concrete and Plastered Surface
Surface shall be free from all oil, grease, efflorescence, mildew, loose paint or
other foreign and loose materials. Masonry cracks shall be cleaned out and
(PCA.775.S034sc18) V.II-D2/S-XVIII: 3

2.1.3 Metal
DCPL-K4A02
patch filled with mortar similar to the original surface and uniformly textured.
Where this type of re- surfacing may lead to the finishing paint being different in
shade from the original surfaces, the resurfaces area shall be treated with
minimum one coat of cement primer, which should be continued to the
surrounding area for a distance of minimum 100 mm.
Surface with mildew or efflorescence shall be treated as below :
a) Mildew
2.2.0 Application
2.2.1 General
All mildewed surfaces shall be treated with an approved fungicide such
as ammonia cal wash consisting of 7g of copper carbonate dissolved in
80 ml. liquor ammonia and diluted to 1 litre with water, or 2.5 percent
magnesium silicofluoride solution and allowed to dry thoroughly before
paint is applied.
All metal surfaces shall be absolutely clean, dry and free from wax, grease or
dried soap films. In addition, all steel and iron surfaces shall be free from rust,
surfaces shall be cleaned by mechanical power tools to remove mill scales
unless otherwise approved by the Engineer for exposed chemical resistant
paints, surfaces shall be blast cleaned to near white metal. All galvanised iron
surfaces shall be pretreated with a compatible primer according to the
manufacturer's direction. Any abrasion in shop coat shall be touched up with
the same quality of paint as the original coat.
The method of application shall be as recommended by the manufacturer. In
case of selection of special shades and colour (not available in standard
shades) the Contractor shall mix different shades and prepare test panels of
minimum size 1 meter square as per instruction of the Engineer and obtain his
approval prior of application of finishing paints.
Proper tools and implements shall be used. Scaffoldings if used shall be
independent of the surface to be painted to avoid shade differences of the
freshly repaired anchor holes.
Painting shall be done by skilled labours in a workmanlike manner. All
materials shall be evenly applied so as to be free of sags, runs, crawls or other
defects. All coats shall be of proper consistency. In case of application by
brush, no brush marks shall be visible. The brushes shall be clean and in good
condition before application of paint.
All priming undercoats for painting shall be applied by brush only, and rollers
spray equipments etc. shall not be used.
No work shall be done under conditions that are unsuitable for production of
good results. No painting shall be done when plastering is in progress or is
(PCA.775.S034sc18) V.II-D2/S-XVIII: 4

DCPL-K4A02
drying. Application of paint, which seals the surfaces to moisture, shall only be
done after the moisture on and below the surface has dried out.
All coats shall be thoroughly dry before succeeding coat is applied. Coats of
painting as specified are intended to cover surfaces perfectly. In case the
surface is not covered properly by applying the specified number of coats,
further coats shall be applied by the Contractor when so desired by the
Engineer.
All primers and undercoats shall be tinted to approximate the colour of the
finishing coats. Finished coats shall be of exact colour and shade as per
approved samples and all finish shall be uniform in colour and texture. All parts
of mouldings and ornaments shall be left clean and true to finish.
Painting on ferrous metal surface shall be done as per IS:1477 (Part 1 & 2).
The total dry thickness of the film should not be less than 120 micron.
2.2.2 White Washing
The surface where white washing is to be applied shall be cleared of all loose
materials and dirt. All holes and irregularities of the surface shall be filled up
with lime putty and shall be allowed to dry up before application of the lime
solution.
One coat of whitewash shall consist of one stroke from top downwards, another
from bottom upwards over the first stroke and another from left to right before
the previous one dries up. Second coat shall be applied and in case the
Engineer feels that one or more coats are required. No brush marks shall show
on the finished surface.
2.2.3 Dry Distemper
New plastered surface shall be allowed to dry for at least two months. New
lime or lime cement plastered surface shall be washed with a solution of 1 part
Vinegar to 12 parts water or 1:50 sulphuric acid solution and for 24 hours after
which the wall shall be thoroughly washed with clean water. For cement
plastered surface, the surface shall be washed with a solution of 100 gms. of
zinc sulphate to 1 litre of water and then allowed to dry.
Dry distempering shall be done as per manufacturer's instruction. In applying
the distempers the brush should first be applied horizontally and immediately
crossed off perpendicularly. Brushing shall not be continued too long as
otherwise brush marks may result.
2.2.4 Oil bound washable distemper
The distemper shall be applied after surface is primed with an alkali resistant
primer, and followed by minimum two coats of oil bound washable distemper all
as per manufacturer's instruction.
2.2.5 Waterproof Cement Paint
(PCA.775.S034sc18) V.II-D2/S-XVIII: 5

DCPL-K4A02
Surface to be coated with cement paint shall be washed and brushed down.
As soon as the moisture has disappeared, the surface shall be given one coat
of paint. Care shall be taken so that the paint does not dry out too rapidly.
After 4 to 6 hours, the water shall be sprinkled over the surface to assist curing
and prevent cracking. After the first coat has dried (24 to 48 hours) the second
coat shall be applied in a similar manner. The finished surface shall be kept
moist by occasional sprinkling with water for seven days after painting.
2.2.6 Acrylic Emulsion Paint
Lime gauged cement plastered surfaces shall not be painted for at least one
month after plastering. A sample patch shall be painted to check alkali reaction
if so desired by the Engineer. Painting shall be strictly as per manufacturer's
specification.
2.2.7 Synthetic Enamel Paint
Shall be applied on properly prime red surface. Subsequential coat shall not be
applied till the previous coat is dry. The previous shall be lightly sand papered
for better adhesion of subsequent coats.
2.2.8 Aluminium Paint
The paint, supplied in two pack containers shall be mixed and applied strictly as
per manufacturer's direction. When more than one coat of paint is required or
indicated, the next coat shall only be applied after the previous coat become
hard dry.
2.2.9 Clear Synthetic Varnish
The Varnish shall be applied on wood surface after (a) filling, (b) staining & (c)
sealing operations are carried out. The application of a combination of filler
and stain shall not be permitted.
For the finishing coats of varnish, the surface shall be allowed to dry and be
rubbed down lightly, wiped off and allowed to dry. Careful attention to
cleanliness is required for varnishing. All dust and dirt shall be removed from
the surface as well as from the neighbourhood. Damp atmosphere and
draughts shall be avoided, and exposure to extreme heat or cold & dampness
shall not be allowed.
The varnish shall be applied liberally with a brush and spread evenly over a
portion of the surface with light strokes to avoid frothing. It shall be allowed to
flow on while the next section is being laid on excess varnish shall then be
scrapped off the brush and the first section be crossed, recrossed and then laid
off lightly. The varnish once it has began to set, shall not be retouched. In
case of any mistake in application, the varnish shall be removed and the work
started afresh.
The varnish shall be minimum of two coats, with the first coat being a flatting
varnish. This shall be allowed to dry hard and be flatted down, before applying
(PCA.775.S034sc18) V.II-D2/S-XVIII: 6

2.2.10 French Polish
DCPL-K4A02
the next coat. Sufficient time must be allowed between coats to get a hard dry
surface before next coat is applied. All work shall be as per relevant IS Code.
All unevenness of the surface shall be rubbed down to smoothness with sand
paper and the surface shall well dusted. The pores in the wood shall be filled
up with a paste of whitening in water or methylated spirit with a suitable
pigment like burnt siemma or umber.
After application of the filler paste, the french polish shall be applied with 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 so that the
polish is sparingly but uniformly applied over the entire area to give an even
surface. A trace of linseed oil may be used on the pad for case of application.
The surface shall be allowed to dry before further coats are applied in the same
manner. To finish off, the pad shall be covered with a fresh piece of clean fine
cloth, slightly damped with methylated spirit and rubbed lightly and quickly with
circular motions to leave the finished surface with a uniform texture and high
gloss.
2.2.11 Chemical Resistant Paint
For chemical resistant paints, epoxy, chlorinated rubber or vinyl butyl paint
system shall be used manufacturer's recommendation regarding the paint
system exposed to moderately severe corrosive condition and subject to
acid/alkali spillage and fumes, shall be followed.
2.2.12 Epoxy coating/painting
On the clean surface of concrete after properly drying of the following system is
to be adopted as per manufacturers specification :
One coat of primer of following proportion to be applied over clean and dried
concrete surface by brush application.
ARALDITE GY 250 - 100 Parts by weight
HARDENER HY 840 - 50 Parts by weight
Over the primer, the uneven surface of concrete should be filled with leveling
putty as mentioned above. The cost of putty is included in the item rate without
fixing prior limit to consumption of putty. Two top coats of the protective
treatment to be applied over the prepared smooth surface in the following
proportion.
ARALDITE GY 250
HARDENER HY 830
HARDENER BY 850
- 100 Parts by weight
- 45 Parts by weight
- 15 Parts by weight
(PCA.775.S034sc18) V.II-D2/S-XVIII: 7

DCPL-K4A02
SILICA FLOUR
FLOW CONTROL
AGENT
- 20 Parts by weight
- 2 Parts by weight
2.3.0 Protection
2.4.0 Cleaning up
Pigment may be added if desired by Engineer. The first top coat is applied
over the primer and is left to reach a tack free state. At this stage, the final top
coat is applied.
Furniture and other movable objects, equipments, fittings and accessories shall
be moved, protected and replaced upon completion of work. All stationary
equipments shall be well covered so that no paint can fall on them. Work
finished by other agencies shall be well protected. All protections shall be done
as per instructions of the Engineer.
In addition to provisions in general conditions the Contractor shall, upon
completion of painting etc. remove all marks and make good surfaces, where
paint has been spilled, splashed or splattered, including all equipments,
fixtures, glass, furniture, fittings etc. to the satisfaction of the Engineer.
3.0.0 ACCEPTANCE CRITERIA
a) All painted surfaces shall be uniform and pleasing in appearance.
b) All varnished surfaces shall be of uniform texture and high glossy finish.
c) The colour, texture etc. shall match exactly with those of approved
samples.
d) All stains, splashes and splatters of paints and varnishes shall be
removed from surrounding surfaces.
4.0.0 I.S. CODE
Important relevant IS Codes for this Sections are listed below :
IS:348 : Specification for French Polish
IS:427 : Specification for Distemper, dry colour as required.
IS:428 : Specification for Distemper oil emulsion, colour as
required.
(PCA.775.S034sc18) V.II-D2/S-XVIII: 8

DCPL-K4A02
IS:1477 : Code of Practice for painting of ferrous (I&II)metal in
buildings.
IS:2338 : Code of Practice for finishing of wood (I&II)and wood
based materials.
IS:2339 : Specification for Aluminium Paints for general purposes
in dual containers.
IS:2395 : Code of Practice for painting concrete, masonry and
plaster surface.
IS:2932 : Specification for enamel, synthetic, exterior, type-I.
IS:5410 : Specification for cement paint, colour as required.
(PCA.775.S034sc18) V.II-D2/S-XVIII: 9

DCPL-K4A02
VOLUME : II-D/2
SECTION-XIX
TECHNICAL SPECIFICATION
FOR
ROOF WATER PROOFING, INSULATION
AND ALLIED WORKS
(PCA.775.S034sc19)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XIX : 1
2.0.0 INSTALLATION V.II-D2/S-XIX : 1
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-XIX : 5
4.0.0 I.S. CODES & STANDARDS V.II-D2/S-XIX : 5
(PCA.775.S034sc19)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XIX
TECHNICAL SPECIFICATION
FOR
ROOF WATER PROOFING, INSULATION
AND ALLIED WORKS
1.0.0 SCOPE
This specification covers furnishing, installation, repairing, finishing, curing,
testing,, protection, maintenance till handing over of roof water-proofing,
insulation and allied work for buildings and at locations covered under the
scope of the Contract.
2.0.0 INSTALLATION
2.1.0 Grading Underbed
The surface to receive the underbed shall be roughened and thoroughly
cleaned with wire brush and water. Oil patches if any shall be removed with
detergent. The surface shall be soaked with water and all excess water
removed just before laying of the underbed.
The underbed shall not be laid under direct hot sun and shall be kept in shade
immediately after laying so as to avoid quick loss of water from the mix and
separation from the roof surface. The underbed shall be cured under water for
at least 7 days.
The underbed shall be laid to provide an ultimate run off gradient not less than
1 in 120 and as directed by the Engineer. Upto an average thickness of 25 mm
the underbed shall usually be composed of cement and sand plaster. For
higher thickness the underbed shall be made with cement concrete.
The underbed shall be finished to receive the waterproofing treatment direct
or insulation as the case may be.
2.1.1 The grading plaster shall be average 25mm thick maximum. It shall consist
of cement and coarse sand in the ratio 1:4 nominal by volume. The same
and cement shall be throughly mixed dry and them water added. Each batch
of mix shall be consumed before the initial set starts.
The plaster shall be fully compacted to the desired grade in continuous
operation. The surface shall be even and reasonably smooth.
2.2.0 Concrete
(PCA.775.S034sc19) V.II-D2/S-XIX : 1

DCPL-K4A02
2.3.0 Insulation
The concrete shall be used where the subgrade is more than average 25mm
thick. It shall consist of cement concrete 1:2:4 nominal mix by volume with
12mm down stone chips and coarse sand. The aggregate shall be mixed
dry and minimum quantity of water shall be added to make the mix workable.
The mix shall be laid to proper grade, fully consolidated and surface shall be
smooth and even.
The Tenderer shall along with the tender send specification of insulating
materials he proposes to use and the proposed method of laying. Before
bulk supply, the contractor shall send samples of insulating material to the
Engineer, and after approval of the samples, the Contractor shall procure and
transport the bulk material to the site. Whenever asked by the Engineer, the
Contractor shall furnish test certificates from testing laboratory on the
insulating and other properties of the materials.
After laying the insulation the surface shall be made ready as required to
receive the waterproofing treatment. If any plastering is used it shall be not
leaner than 1:4 cement sand by volume and not thiner than 12mm and it shall
be cured for seven days.
2.3.1 Foam Concrete
This shall be of light weight foam concrete of average 50 mm thickness or as
specified or as shown on drawings. This may be laid in situ in suitable panels
or in precast blocks. The insulating properties shall be such that the thermal
conductivity shall not exceed 0.125 Kcl m/m degree C. The weight of the
insulating material shall be from 0.3 to 0.5 gm/cm.
Before starting the laying of foam concrete samples shall be prepared at site
and got tested for approval of the Engineer.
The foam concrete laid shall be sufficiently strong to make the usual work
load and standard loads expected on the roof. Any damaged portion shall be
removed and replaced forthwith. Approval of the Engineer shall be taken
before laying the waterproofing over the insulation.
While laying the foam concrete, samples from each batch of the mix shall be
kept for test if so desired by the Engineer.
2.3.2 Expanded Polystyrene Blocks
The expanded polystyrene block insulation shall be fire retardant quality and
shall have a maximum thermal conductivity of 0.026 KCl m/m degree C. It
must be strong enough to withstand without deformation the workload and
standard loads expected on the roof.
The Contractor shall lay the expanded polystyrene block as per
manufacturer’s approved specification. Only specifically experienced workers
shall be used for this work. If the Engineer is not satisfied about the
(PCA.775.S034sc19) V.II-D2/S-XIX : 2

2. 4.0 Fillets
DCPL-K4A02
efficiency of the workers the Contractor shall have to secure manufacturer’s
supervision.
Either of above items (cl. No. 2.03.01 or 2.03.02) can be adopted subject to
approval of engineer.
Fillets at junction of roofs and vertical walls shall be provided with the same
insulating material as provided for the main roof insulation. The fillets shall
be 150 mm x 150 mm in size unless otherwise shown on drawings or
instructed by the Engineer.
Where there is no insulation over roof slab, fillets shall be cast-in-situ cement
concrete (1:2:4) nominal mix by volume.
2.5.0 Water proofing by epoxy resin based application
2.6.0 Flashing
Exposed surfaces of cement concrete, lime concrete or brickwork to be
treated for waterproofing by the resin based application shall be throughly
cleaned and the epoxy resin based material to be applied as directed by the
manufacturer. The material shall not have any adverse effect on the surface
on which it is applied and must stick to it uniformly to make a strong durable
bond. It shall not be affected by short duration from fire, sun, light traffic.
The application shall be resistant to growth of fungus and proof against
saltpetre action. If desired by the Engineer, a sample shall be prepared in
advance and tested for waterproofness for 48 hours under 300 mm depth of
standing water. The Contractor shall arrange the demonstration by providing
free the materials and labours for the application.
Unless otherwise stated flashing shall be done in the same way as the
waterproofing except that the last layer, instead of being finished with peasized
gravel, shall be finished with two coats of bituminous primer. The
flashing shall be extended up the vertical surfaces as shown on drawing. The
flashing shall end in grooves in vertical walls. The grooves shall be at least
65 mm deep and caulked with waterproof mastic cement. The minimum
overlap with horizontal roofing felt shall be 100 mm.
Where specified on drawings or directed by the Engineer, metal flashing shall
be provided. The metal flashing shall be done as shown on the drawings.
The materials shall be 18g or 22g G.I. sheets, as specified on the drawings
and/or as directed by the Engineer.
2.7.0 Elastromeric Membrane
2.7.1 Primer Coat
(PCA.775.S034sc19) V.II-D2/S-XIX : 3

DCPL-K4A02
It shall consist of polyurethane (P.U.) or any other equivalent material.
Primer coat shall be a special blend of moisture curing urethane pre-polymers
in solvent. A single coat of this primer shall be applied by brush /spray with
airless spray equipment over the prepared bed as an adhesion coat with an
application rate of 6-8 sq.m per litre depending on the surface porosity.
The primer shall be allowed to dry for a minimum period of 2 to 4 hours time
before the successive finishing coats of P.U. liquid membrane are applied. In
any case successive finishing coat shall be applied within 24 hours.
The substrate shall be properly prepared by removing all loose materials by
vigourous brushings, fungal growth with proprietary fungitide as
recommended. Priming coat shall not be applied to damp substrate.
2.7.2 Finishing Coats
2.7.3 Surface Finish
The finishing coats shall consist of two successive liquid coatings of high
solid content urethane pre-polymers material to form an elastomeric
membrane. Application shall be with brush or spray to form an uniform
jointless elastomeric membrane. The overall dry film thickness shall be 1.5
mm subject to minimum 750 gm per sq.m per coat application rate.
Each coat shall be allowed to dry for minimum 12 hours before applying the
next coat. The surface should be dry and smooth before application.
The coating shall be continued up the parapets/walls for minimum of 150 mm
over the finished roof surface or fillet with suitable tucking into the vertical
wall surface. It shall be continued into rain water pipes by atleast 100 mm.
The final coat of PU liquid when tacky shall be sprinkled with the sand.
For edges, expansion joints and any vulnerable points a layer of polyscrim
cloth/fabric are to be embedded between 2 finishing coats.
The entire work shall be carried out under the supervision of approved
authorized agency.
Areas of roof treatment shall be provided with wearing course consisting of
minimum 25 mm thick PCC 1:11/2:3(using 12.5 mm size aggregate) cast in
panel of maximum size of 1.20 m x 1.20 m and reinforced with 0.56 mm
diameter galvanized chicken wire mesh and sealing of joints using sealant or
elastomeric compound.
When the roof surface is subjected to foot traffic or used as a working area, a
cement mortar (1:4) shall be applied over the top most layer of roofing
treatment. Over this, a layer of chequered cement concrete flooring tiles
conforming to IS:13801 shall be provided. The tiles shall be laid as per IS
1443.
(PCA.775.S034sc19) V.II-D2/S-XIX : 4

DCPL-K4A02
3.0.0 ACCEPTANCE CRITERIA
The surface level shall be such as to allow quick draining of rains without
leaving any pool anywhere. The finishing course shall be fully secured and
shall have an even density. There shall not be any bubble formation or
crushed or squeezed insulation or underbed.
The Contractor shall give a guarantee in writing for all work executed under
this specification supplemented by a separate and unilateral guarantee from
the specified agency for the roof water-proofing treatment work. The
guarantee shall be for materials and workmanship for a period of minimum
10 years. The mode of execution of the guarantee shall be acceptable to the
Owner.
4.0.0 I.S. CODES AND STANDARDS
a) IS:73 : Paving Bitumen
b) IS:702 : Industrial Bitumen
c) IS:1203 : Methods of testing tar and bitumen
d) IS:1322 : Bitumen felts for waterproofing and damp proofing
e) IS:1346 : Code of Practice for waterproofing of roofs with
bitumen felts
f) IS:3384 : Bitumen primer for use in waterproofing and damp
proofing.
(PCA.775.S034sc19) V.II-D2/S-XIX : 5

DCPL-K4A02
VOLUME : II-D/2
SECTION-XX
TECHNICAL SPECIFICATION
FOR
SHEETING WORK IN ROOF AND SIDING
(PCA.775.S034sc20)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XX : 1
2.0.0 INSTALLATION V.II-D2/S-XX : 1
3.0.0 ACCEPTANCE CRITERIA V.II-D2/S-XX : 2
4.0.0 I.S. CODES V.II-D2/S-XX : 2
(PCA.775.S034sc20)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XX
TECHNICAL SPECIFICATION
FOR
SHEETING WORK IN ROOF AND SIDING
1.0.0 SCOPE
This specification covers the erection of asbestos, C.G.I., aluminium or other
sheet covering to roof and side walls at various elevations and the fabrication
and/or installation of asbestos, C.G.I or aluminium gutters, flashings etc., as
shown on drawings.
2.0.0 INSTALLATION
2.1.0 Storage of Materials
2.2.0 Workmanship
All materials shall be stored by the Contractor in proper way to prevent all
damage. If the materials are issued at site by the Owner, the Contractor shall at
the time of issue, satisfy himself about the condition of issued sheets, gutters,
etc. and no complaints shall be entertained later.
The workmanship shall be according to best construction practice to give a
water tight finish to the satisfaction of the Engineer fixing of gutters and down
pipes shall be according to IS:2527.
2.2.1 Asbestos Sheeting
Asbestos sheets of profiles as stated in the Schedule of Items, shall be fixed
with minimum 150 mm end lap and side laps as per manufacturer's
specification Hook bolts or J-bolts shall be 8 mm dia. at 305 centres 6 mm dia
galvanised iron seam bolt and nut with G.I. flat washers and bitumen washers
shall be used for stitching ridge capping, corner pieces, ventilators, north light
curves etc.
2.2.2 C.G.I. Sheeting and Aluminium Sheeting
Side laps shall be 2 corrugations for roof and one corrugation for side sheeting.
End laps shall be minimum 150 mm for roof and 100 mm for side sheeting. In
ridges and hips where plain sheets are used the end laps shall be minimum
100 mm. Holes in C.G.I sheets shall prefer.h1 Sheeting work in ably be made
on the ground the sheets should be placed on trestles and holes punched in
the ridge of the corrugation from the outside inward for obtaining proper seating
of limpet washes. Sheets shall be secured to sheet framing by 8 mm dia.
galvanised iron hooks or J-bolts and maximum 305 mm apart. The length of the
(PCA.775.S034sc20) V.II-D2/S-XX : 1

DCPL-K4A02
hook or J- bolts shall be to suit the sections of the bearers. Sheets shall also be
bolted at the ends at every third corrugation with 6 mm dia. galvanised iron
seam bolts and G.I. flat washers and bituminous washers.
2.2.3 Firbre Glass Reinforced Plastic Sheeting
This shall be of thickness and profile as mentioned in the drawing. Colour
and light transmittance shall be as mentioned in drawings and or schedules.
Where used in conjunction with C.G.I. or asbestos sheeting the end and side
laps and fixing device shall be same as used for general sheeting. Where
used in lieu of glass, the fixing shall be by means of timber or metal glazing
beads as mentioned in drawing. In all cases, the installation shall be
completely watertight and able to withstand the designed wind-pressure.
3.0.0 ACCEPTANCE CRITERIA
The installations shall present a neat appearance and shall be checked for
water tightness. The following shall be checked :
a) Side and end laps
b) Absence of cracks, holes or damages in sheet
c) Spacing of bolts
d) Provision of double washers (G.I. and asbestos or bituminous washers)
e) Proper installation of flashing
4.0.0 IS CODES
The following are some of the important IS Codes relevant to this sections :
IS : 3007
IS : 2527
IS : 1626
IS : 277
: Code of practice for laying of asbestos cement sheets.
: Code of practice for fixing rain water gutters and down pipes
for roof drainage.
: Specification for asbestos cement building pipes gutters and
fittings.
: Specification for galvanised steel sheets (plain and corrugated).
(PCA.775.S034sc20) V.II-D2/S-XX : 2

DCPL-K4A02
VOLUME : II-D/2
SECTION-XXI
TECHNICAL SPECIFICATION
FOR
WATER SUPPLY
(PCA.775.S034sc21)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XXI : 1
2.0.0 INSTALLATION V.II-D2/S-XXI : 2
3.0.0 TESTING AND ACCEPTANCE V.II-D2/S-XXI : 7
4.0.0 I.S. CODES V.II-D2/S-XXI : 8
(PCA.775.S034sc21)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XXI
TECHNICAL SPECIFICATION
FOR
WATER SUPPLY
1.0.0 SCOPE
1.0.1 Materials
This section includes supply of all materials, labour and incidentals for water
supply for residential, business and industrial and other types of buildings.
The water supply system of a building or premises covers service pipes and
the necessary connecting pipes, fittings, control valves and all
appurtenances in or adjacent to the building or premises.
All materials, fittings, fixtures and appliances shall be of the best quality
conforming to relevant Indian Standard and shall be procured from
approved manufacturers. Unless specifically allowed by the Engineer, the
Contractor shall submit samples of fittings and fixtures which will be
retained by him for comparison when bulk supplies are received at the site.
Ultimate choice of type, model and manufacturer lies completely with the
Engineer.
It shall be the responsibility of the Contractor to procure the materials
selected by the Engineer. Hence order are to be placed with the
manufacturers in time, so that the materials are available at the site well
ahead of their requirement.
The materials brought to the site, shall be stored in a separate secured
enclosure away from the building materials. Pipe threads, sockets and
similar items shall be specially protected till final installation. Brass and
other expensive items shall be kept under lock and key. Fragile items shall
be checked thoroughly when received at the site and items found damaged
shall not be retained at the site.
1.0.2 Pipes and Pipe Fittings
Under scope of this specification, pipes and pipe fittings may be any or a
combination of the following types :
a) Cast Iron
b) Steel : lined, coated with bituminous composition, out coated with
cement concrete or mortar or galvanised.
c) Reinforced Concrete
d) Prestressed Concrete
(PCA.775.S034sc21) V.II-D2/S-XXI : 1

DCPL-K4A02
e) Lead (Not to be used for potable water)
f) P. V. C.
g) Copper
h) Brass
i) Wrought iron
1.0.3 Water Reservoirs
Water reservoirs like pressed steel tanks and G.I. tanks shall come under
scope of this specification. Reservoirs made of concrete masonry or
fabricated steel shall be covered by respective work specifications.
1.0.4 Related Works
1.0.5 Regulation
All works, like earthwork, masonry, concrete, steelwork, cutting holes,
chases, repairs and rectification associated directly with installation of water
supply systems shall come under scope of the Contractor unless specifically
excluded.
The work which is required to be carried out under the scope of this section,
shall be executed by a licensed plumber only (engaged by the Contractor)
and he shall obtain all necessary sanctions, permissions, certificates etc.
from Municipal and/or other Local Authorities and shall abide by all the
rules of such Authorities.
2.0.0 INSTALLATION
While basic layouts may be available in the drawings provided by the
Owner, the details might have to be supplemented by the Contractor for
approval of the Engineer.
Special attention shall be given by the Contractor to economy. Symmetry
of layout is very important. Fittings meant for operation shall be located and
oriented to allow easy reach and operation. Maintenance, repairs and
replacements of pipes, fittings and fixtures must be conveniently possible.
2.1.0 Pipe Lines
2.1.1 Laying
(PCA.775.S034sc21) V.II-D2/S-XXI : 2

DCPL-K4A02
2.1.2 Back Flow
In addition to fulfilling the functional requirements all pipelines shall be laid
true to line, plumb and level. Any deviation shall need approval of the
Engineer. Meticulous care shall be taken to avoid chances of airlock and
water hammer.
Pipes shall be laid on continuous unyielding surface or on reliable supports
at least one near each joint and spacings as directed by the Engineer. The
support must be strong, neat and shall have provisions for securing the
pipes in every direction and easy maintenance. Pipes shall be encased or
concealed in masonry or concrete if shown on drawing or directed by the
Engineer.
The layout of pipe work shall be such that there is no possibility of back
flow towards the source of supply from any cistern or appliances, whether
by siphonage or otherwise. All pipe works shall be so laid or fixed and
maintained as to be and to remain completely water-tight, thereby avoiding
waste of water, damage of property and the risk of contamination of the
water conveyed.
2.1.3 Contamination
There shall be no cross connection whatsoever between a pipe or fitting for
conveying or containing wholesome water and a pipe or fitting for containing
impure water or water liable to contamination or of uncertain quality of water
which has been used for any purpose.
No piping shall be laid or fixed so as to pass into or through any sewer,
scour outlet or drain or any manhole connected therewith.
2.1.4 Underground Pipings
Underground piping shall be laid at such a depth that it is not likely to be
damaged by traffic and other loads and frost, where applicable.
The size and depth of the trench shall be as approved by the Engineer.
Back-filling shall be done with selected fine earth, unless otherwise
permitted in 150 mm layers and carefully consolidated. Special care shall
be taken while filling in the vicinity of the pipe to avoid damage. Before
backfilling the laid pipe shall be fully tested and approved.
Where the pipe rests on rock it may be bedded on a layer of fine selected
material or concrete to avoid local point support.
The trench shall be so treated by gradient and filling in the area that it does
not act as a drainage channel.
2.1.5 Concealed Piping
Where desired by the Engineer or shown on the drawings the pipes shall be
concealed in masonry or concrete of the structure. The Contractor may co-
(PCA.775.S034sc21) V.II-D2/S-XXI : 3

DCPL-K4A02
ordinate with the building Contractor for leaving the chases, openings,
conduits as necessary. However, the Contractor will rectify if required the
chases, openings and conduits, supplement and make good after laying
and testing of the concealed pipelines.
2.1.6 Jointing of Pipes
Jointing of pipes shall be completely leakproof and durable. Instruction of
the manufacturer shall be followed unless desired otherwise by the
Engineer. However, usually recommended practices are stated below for
guidance :
a) Cast Iron
i) Spigot and Socket Joints
Lead joint : The joint is made by first caulking in clean spun
yarn upto half depth and filling the reminder by running in
molten lead taking care that no dross enters the joint and
then thoroughly caulking the lead. The lead need not extend
into the joint further than the back of the groove formed in the
socket. After completing the joint it shall not be allowed to
move. For rectification the joint shall be completely redone.
ii)
Flanged Joints : Flanged joints shall be made by jointing
rings of good quality, smooth and hard compressed fibre
board of thickness not less than 1.5 mm and of such width as
to fit inside the circle of bolt. Diagonally opposite bolts shall
be tightened in pairs and in stages so that degree of all bolts
in a joint are similar. Damaged gaskets shall be replaced.
b) Steel
Plain ended steel pipes may be jointed by welding. Screwed and
socketed joints shall be carefully tightened. Care shall be taken to
remove any burr from the ends of the pipes. Jointing compound, if
used, shall be lead free and approved by the Engineer. Once a
joint has been screwed up it shall not be backed off unless threads
are recleaned and new compound applied.
c) GI Pipes
Threads shall be cut with sharp tools, and before jointing all scales
shall be removed from pipes by suitable means. The screw / threads
of the pipe shall be cleaned out and the joint made by screwing the
fittings after treating the threads with approved pipe jointing
(PCA.775.S034sc21) V.II-D2/S-XXI : 4

DCPL-K4A02
d) Lead
2.1.7 Painting
compound. Once a joint has been screwed up it shall not be backed
off unless threads are recleaned and new compound applied.
Lead and lead alloy pipes shall be jointed with wiped solder joints.
e) Concrete
Concrete pipes may be socket and spigot ended collar or band
jointed. Joints shall be effected by caulking with 1:3 cement sand
mortar.
f) P. V. C.
Manufacturer’s instruction shall be followed. For heating approved
equipment with adequate control shall be used.
g) Tyton Joint
The manufacturer’s instruction shall be strictly followed in making
such joints. Tyton joints shall be made by push-on type specification
stipulated by the pipe manufacturer. The tools specified by the pipe
manufacturer shall be used to secure the joint fully.
Where mentioned in the Schedule, underground steel and cast iron pipes shall be
given 2 coats of bituminous paint on the outside after laying, when painting is to be
done above ground G.I. pipes shall be given a coat of zinc chromate primer, C.I. and
M.S. pipes shall be given one coat of red lead or zinc chromate primer. Top coats
shall be minimum 2 coats of best quality paint.
2.2.0 Storage Tank - Pressed Steel Tank
Unless otherwise mentioned, water storage tanks shall be pressed steel tanks of
nominal size and capacity as mentioned in the Schedule and fabricated with all
flanges external, all flanges internal, or bottom flange internal and side flanges
external, as shown on drawings or schedule of items. The fabricator shall supply 6
prints of fabrication drawings to the Engineer for prior approval showing thickness of
plates, method of jointing the plates, all supports, stays, gussets etc. Pads, cleats
etc. required for supporting the tanks shall be supplied by the manufacturer. Inlet,
overflow vent pipes, manholes etc. shall be arranged and provided as shown on
drawing or mentioned in the schedule. Unless otherwise specified, the outlet pipe
shall be 50 mm above the bottom of the tank and there shall be a 150 mm free
board at the top of the tank.
All tanks shall be supplied with mosquito-proof covered top with manhole
not less than 450 mm diameter. Tanks deeper than 1.00 Metre shall be
provided with m.s. internal access ladder adjacent to the manhole. Water
level indicator shall be provided if asked for. Two coats of anti-corrosive
paint over a suitable primer shall be applied to both internal and external
surface of tanks. Such paint if used shall not impart any taste or odour to
water and be of lead free composition..
(PCA.775.S034sc21) V.II-D2/S-XXI : 5

DCPL-K4A02
Erection of tanks shall be in accordance with detailed drawings and
manufacturer’s instructions. The two finishing coats of paint shall be
applied to outside after erecting is complete.
2.2.1 G. I. Water Tank
G. I. water tanks shall be procured from a reputed manufacturer. The
design shall be good enough to withstand the loads safely. Galvanised iron
water storage tank shall be made of minimum 2 mm thick galvanised iron
sheet. Plain sheets shall be fixed at the corner to angle iron frames by
means 6 mm rivets at 40 mm pitch for tanks upto 1000 litres capacity and 8
mm rivets at 35 mm pitch for tanks above 1000 litres capacity. Tanks
above 1000 litres shall have 20 mm dia. galvanised / iron stay rods, one
fixed to angle framing at top and two in the body of the tank for extra
strength. Holes for rivetting shall be drilled and not punched. White lead
shall be applied to the joints before rivetting.
In case it is desired by the Engineer that corners of tank should be welded
instead of rivetted then the sheets shall be welded to form a tank will not
have angle iron frame.
Tanks shall have 400 mm dia. holes at the top with hinged covers. The
covers shall be made of galvanised iron sheet with angle iron frame. The
cover shall be just loose but close fitting to keep out dust and mosquito and
will not be airtight. It shall be complete with lockable arrangement.
Tanks shall be provided with rising main inlets of 40 mm dia. galvanised iron
pipe or as shown on Drawing and 25 mm dia. G.I. overflow pipe. The
rising main shall be connected to the tank with a ball valve near the top
which disconnects the supply when tank is full up to the point of overflowing.
The ball valve permits the entry of water when the tank is empty and disconnects the
supply when the tank is full. It consists of a hollow floating ball made of copper,
plastic or hand Tubber, 110 mm in diameter, attached to an arm which is so pivoted
that the end near the pivot closes the orifice of the main when the ball is raised to
the required height of water in the tank and opens the main as soon as the ball
drops with the fall of water level as it is drawn off through the distribution pipes. The
ball valve shall be fixed to the tank independent of the inlet pipe and set in such a
position that the body of the ball valve cannot submerge when the tank is full upto
the water line. The ball valve shall be so adjusted as to limit the level of the water
line. The level of the water in the tank to 75 mm below the lip of the overflow pipe.
Free surface shall be about 150 mm above the maximum water filled level.
2.3.0 Valve, Cocks, Taps
2.4.0 Protection
All valves, stop cocks, taps etc. shall conform to relevant Indian Standard
Specification and shall be of best quality from approved manufacturers.
These shall be suitable for working pressures mentioned in the Schedule.
Nominal size and material shall be as per schedule.
(PCA.775.S034sc21) V.II-D2/S-XXI : 6

DCPL-K4A02
Open end of each pipe shall be protected during installation by suitable
covers or plugs so that the ends, threads, sockets or spigot are not
damaged and no foreign material can find its way into the pipe line.
Fittings and fixtures liable to be misused or stolen during the construction
phase shall be fitted only before testing and handing over.
3.0.0 TESTING AND ACCEPTANCE
3.1.0 Inspection Before Installation
All pipes, fittings and appliance shall be inspected, before delivery at the
site to see whether they conform to accepted standards. The pipes and
fittings shall be inspected on site before laying and shall be sounded to
disclose cracks. Any defective items shall be clearly marked as rejected
and forthwith removed from the site.
3.2.0 Testing of Mains After Laying
After laying and jointing, the main shall be slowly and carefully charged with water,
so that all air is expelled from the main by providing a 25 mm inlet with a stop cock,
allowed to stand full of water for a few days if time permits, and then tested under
pressure. The test pressure shall be 5 Kg/CM 2 or double the maximum working
pressure, whichever is greater. The pressure shall be applied by means of a
manually operated test pump, or in the case of long mains or mains of a large
diameter, by a power driven test pump, provided that the pump is not left
unattached. In either case due precaution shall be taken to ensure that the required
test pressure is not exceeded. Pressure gauges shall be accurate and shall
preferably have been recalibrated before the test. The pump having been stopped,
the test pressure shall maintain itself without measurable less for at least five
minutes. The end of the main shall be closed by fitting a water-tight expanding plug
and the plug shall be secured by struts to resist the end thrust of the water pressure
in the mains.
3.3.0 Testing of Service Pipes and Fittings
The service pipes shall be slowly and carefully charged with water allowing all air to
escape avoiding all shock or water hammer. The service pipe shall then be
inspected under working conditions of pressure and flow. When all draw-off taps
are closed, the service pipes shall be absolutely water-tight. All pipings, fittings and
appliances shall be checked for satisfactory support and protection from damage,
corrosion and frost.
4.0.0 I.S. CODES
Important relevant IS Codes for this Specification are listed below :
Latest editions shall always be consulted.
IS:2065 : Code for Practice for water supply in buildings
IS:1172 : Code of basic requirements for water supply, drainage
and sanitation
IS:1200
(Pt. XVI)
: Laying of water and sewer lines including appcurtnant
items.
(PCA.775.S034sc21) V.II-D2/S-XXI : 7

DCPL-K4A02
IS:1239
(Pt. I & II)
: Specification for Mild Steel Tubes and Mild Steel Tubulars
and other wrought steel pipe fittings (10 mm to 15 mm
nominal diameter)
IS:1536 : Specification for Centrifugally cast (Spun) iron pressure
pipes for water gas and sewage
IS:1537 : Specification for vertically cast iron pressure pipes for
water, gas and sewage.
IS:3486 : Specification for Cast iron spigot and socket drain pipes
(80 mm to 250 nominal diameter)
IS:3589 : Specification for Electrically welded steel pipe for water,
gas and sewage (200 mm to 2000 mm nominal diameter)
IS:784 : Prestressed concrete pipes
IS:458 : Concrete pipes (with or without reinforcement)
IS:783 : Code of Practice for laying of concrete pipes
IS:1592 : Asbestos cement pressure pipes
IS:1626 : Asbestos cement pressure pipes, gutters and fittings
(Spigot and Socket types)
IS:404 : Lead pipes
IS:3076 : Low density polyethylene pipes for potable water supplies
IS:4984 : High density polyethylene pipes for potable water supplies
IS:2501 : Copper tubes for general engineering purposes
IS:407 : Brass tubes for general purposes
IS:1230 : Cast iron rain water pipes and fittings
IS:804 : Rectangular pressed steel tanks
(PCA.775.S034sc21) V.II-D2/S-XXI : 8

DCPL-K4A02
VOLUME : II-D/2
SECTION-XXII
TECHNICAL SPECIFICATION
FOR
DRAINAGE AND SANITATION
(PCA.775.S034sc22)

DCPL-K4A02
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D2/S-XXII : 1
2.0.0 INSTALLATION V.II-D2/S-XXII : 1
3.0.0 TESTING AND ACCEPTANCE V.II-D2/S-XXII : 9
4.0.0 CODES AND STANDARDS V.II-D2/S-XXII : 11
(PCA.775.S034sc22)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XXII
TECHNICAL SPECIFICATION
FOR
DRAINAGE AND SANITATION
1.0.0 SCOPE
1.1.0 This section covers the layout and construction of drains for roof water, surface
water and sewage together with all fittings and fixtures and inclusive of ancillary
works, such as connections, manholes and inspection chambers used within the
building and from the building to the connection to a public sewer or to treatment
work, septic tank and soak pit dispersion trenches.
2.0.0 INSTALLATION
2.0.1 General
All pipe lines, locations of fittings and fixtures, etc. shall be as per drawings or as
directed by the Engineer. Correctness of lines, plumb, orientation, symmetry and
levels shall be strictly ensured. All items shall be fully secured against movement in
any direction and so located as to allow easy maintenance.
All pipe lines, fittings and fixtures shall be installed leakproof. When the works under
scope of this specification linked up with works executed by others, the
connections shall be such as to prevent any splashing or spilling or emission of
foul odour and gases.
2.1.0 Rainwater Downcomers
2.2.0 Gutters
Rainwater downcomers shall be standard Cast Iron Pipes. In case where
specifically desired, M.S. pipes may also be used. M.S. pipes shall be painted
outside with two coats of anticorrosive paints under a coat of primer.
Rainwater downcomers shall run along and be secured to walls, columns etc. where
desired by the Engineer these may have to be installed in chases cut in the structure.
All pipes shall be well secured and supported by adequately strong brackets.
The brackets may be wrought iron clevis type, split ring type or perforated strap
iron type as approved by the Engineer. For vertical runs each pipe shall hang
freely on its brackets fixed just below the socket. Suitable spacer blocks shall be
provided against the vertical surface to which the pipe is fixed.
All bends and junctions shall be supplied with watertight cleanouts.
Roof and floor drains and yard gullies shall be installed, if required, by cutting
into the structure and grouted with 1:2:4 cement concrete. All gutters shall be
provided with removable gratings.
All horizontal pipes shall have a minimum fall of 1 in 100.
(PCA.775.S034sc22) V.II-D2/S-XXII : 1

DCPL-K4A02
The gutters shall be made of G.I. All gutters shall be supplied by reputable
specialised firms. Each section shall be sufficiently rigid, edges and
corners straight and the slopes perfectly uniform. G.I. gutters shall have the
edges strengthened by suitable means.
Unless noted otherwise the gutters shall have a minimum fall of 1 in 120.
Adequate number of string supports shall be provided so that there is no
reflection even when the gutter is full. Each joint must have a support.
Unless otherwise specified the supports shall be fabricated M.S. brackets.
All junctions shall be thoroughly watertight. The joints may be made by
rivetting, bolting or soldering. All joints between successive lengths of
gutters shall have on overlap of at least 5 cm. The drop in the overlap shall
always be in the direction of the fall of the gutter. Ends of gutters shall
be closed watertight. Junction with rainwater down comers shall be made
fully watertight and secured.
2.3.0 Soil and Drainage Pipes
2.3.1 Gradients
If not specified the minimum gradients of soil and drainage pipe line shall
be as follows :
100 mm nominal dia : 1 in 35
150 mm nominal dia : 1 in 65
230 mm nominal dia : 1 in 120
300 mm nominal dia : 1 in 200
2.3.2 Relation with water supply pipe lines
2.3.3 Laying
Unless specifically cleared by the Engineer, under no circumstances shall
special drainage and soil pipes be allowed to come close to water supply
pipelines.
Each separate pipe shall be individually set for line and for level. Where
lengths of sewer or drain pipes are laid in trench, properly painted sight
rails shall be fixed across the trench at a height, equal to length of the
boning rod to be used, above the required invert level of the drain or sewer
at the point where the sight is fixed. More sight rails shall be required at
manholes, change of gradient and intermediate positions if the distance for
sighting is more than 50 ft. apart. The excavation shall be boned in at least
once in every 6 ft. The foot of the boning rod shall be set on a block of
wood of the exact, thickness of the wall of the pipe. Each pipe shall be
separately and accurately boned between sight rails.
2.3.4 Support and Protection on Pipelines
(PCA.775.S034sc22) V.II-D2/S-XXII : 2

DCPL-K4A02
All pipes shall be laid with sockets leading uphill. Preferably the pipe shall
rest on solid and even foundations for the full length of the barrel. However,
the pipe manufacturer's instruction as approved by the Engineer shall be
followed in the matter of support and jointing.
To achieve full and continuous support, concrete for bedding and packing
is the best. Where pipes are not bedded on concrete, the floor shall be
left slightly high and carefully placed so that the pipe barrels rest on
undisturbed ground. If anywhere the excavation has been carried too low
packing shall be done in concrete. Where laid on rock or very hard ground
which cannot be easily excavated to a smooth surface, the pipes shall be
laid on a cradle of fine concrete floor of gravel and crushed stone over
laid with concrete or on a well consolidated gravel and crushed stone bed as
desired by the Engineer. PVC or similar pipes shall be laid directly on
stable soil and packed with selected soil.
The minimum support and protection for glazed stoneware pipes shall be as
follows :
a) When cover is less than 2 metre below ground level and where
pipes are unavoidably exposed above ground surface, the pipes
shall be completely encased or surrounded with concrete.
b) Where pipes are laid on soft soil with the maximum water table
laying at the invert of the pipe, the sewer shall be bedded on
concrete.
c) Where the pipes have to be laid on soft soil with the maximum water
table rising above the invert of the pipe, but below the top of the
barrel, the pipe sewer shall be haunched.
d) Where maximum water table is likely to rise above the top of the
barrel or wherever the pipe is laid on soft soil the pipe sewers shall
be completely encased or surrounded with concrete.
Cast iron pipes and concrete pipes may be supported on suitable
concrete or brick support, where specified. The supports shall be
unyielding and strong enough. At least one support shall be located
close to ends. Spacing of intermediate supports shall be as decided
by the Engineer. Pipes shall be secured to the supports by approved
means.
Anchoring of pipes where necessary shall be achieved by suitable
concrete encasing designed for the expected thrust.
2.3.5 Entry into structures
For entry of the pipe lines into any building of structure suitable conduits
under the structure or sleeves shall be used. The conduits and sleeves shall
(PCA.775.S034sc22) V.II-D2/S-XXII : 3

2.3.6 Ducts
DCPL-K4A02
be such as to allow easy repairs and replacement of the pipes. When
openings or chases are required to be made in the structure for entry of pipe
lines, locations and sizes shall be marked and checked by the Engineer.
After laying of the pipeline the openings and chases shall be mended.
Where solid, waste and ventilating pipes are accommodated in ducts,
access to cleaning areas shall be provided. Connection to drain shall be
through a gully with sealed cover to guard against ingress of sewer gas,
vermin or backflow.
2.3.7 Traps and Ventilating Pipes
Pipes are carrying off the waste from water closets and waste water and
overflow water from baths, wash basins, sinks to drains shall be trapped
immediately beneath such fixtures. Traps shall have minimum water seal of
50 mm and shall be ventilated whenever such ventilation is necessary to
maintain water seal of the trap.
Ventilating pipes shall be carried up vertically from the drain to a height of
at least 600 mm above the outer covering of the roof of the building or as
shown on drawings. All vertical ventilating, anti-syphonage and similar pipe
shall be covered on top with a cowl. The cowl shall be made of C.I. unless
desired otherwise by the Engineer.
2.3.8 Manhole and Inspection Chambers
The maximum distance between manholes shall be 30 meter unless
specially permitted otherwise. In addition, at every change of alignment
gradient or diameter there shall be a manhole or inspection chamber. The
distance between manhole or inspection chamber and gully chamber shall
not exceed 6 metres unless desired otherwise.
Manhole shall be constructed so as to be watertight under test. The bending
at the sides shall be carried out in such a manner as to provide no
lodgement for any splashings in case of accidental flashing of the chamber.
The channel or drain at the bottom of chamber shall be plastered with 1:2
cement, sand mortar and finished smooth to the grade. The channels and
drains shall be shaped and laid to provide smooth flow.
Connecting to existing sewer lines shall be through a manhole.
Manholes shall be provided with standard C.I. covers. The covers shall
be close fittings so as to prevent gases from coming out. Suitable heavy
duty covers shall be used where necessary as decided by the Engineer.
2.3.9 Cutting of Pipes
Manufacturer's instructions shall be followed for cutting of pipes where
necessary. Suitable and approved tools shall be used for the cutting so as
to leave surface clean and square to the axis of the pipe.
(PCA.775.S034sc22) V.II-D2/S-XXII : 4

DCPL-K4A02
2.3.10 Jointing
Jointing of laid pipes shall be so planned as to avoid completely any
movement or strain to the joints already made. If any joint is suspected to be
damaged it shall be opened out and redone.
All joints between pipes, pipes and fittings and manholes shall be gas-tight
when above ground and water-tight when underground. Method of jointing
shall be as per instructions of the pipe and fittings manufacturer and as
approved by the Engineer. However, in the absence of any instruction
available from the manufacturer the methods as detailed hereunder shall be
used.
a) Cast Iron Pipes
Socket and spigot pipes shall be jointed by the cast lead joints. The
spigot shall be centered in the socket of the next pipe by tightly
caulking in sufficient turns of tarred gasket or hemp yarn to have
unfilled half the depth of socket. When the gasket or hemp yarn
has been caulked tightly a jointing shall be placed round the barrel
and tightened against the face of the socket to prevent airlock.
Molten lead shall then be poured in to fill the remainder of the socket
and caulked with suitable tools right round the joint to make up for
shrinkage of the molten metal on cooling and shall be finished 3 mm
behind the socket face.
Joints in cast iron pipes with special jointing arrangements like 'Tyton'
joints etc. shall follow the instructions of the manufactures.
In special cases if flanged joints are accepted by the Engineer the
joints shall be made leakproof by inserting approved type of rubber
gaskets. The bolts shall be secured in stages to avoid uneven strain.
b) Concrete Pipes
Care shall be taken to place the collar centrally over the joint.
(PCA.775.S034sc22) V.II-D2/S-XXII : 5

DCPL-K4A02
2.4.0 Trenches and other excavations
2.5.0 Fixtures
Width of the trench at the bottom shall be such as to provide 200 mm
clearance on either side of the pipe for facility of laying and jointing.
Excavated material shall be stacked sufficiently away from the edge of the
trench and the side of the spoil bank shall not be allowed to endanger the
stability of the excavation. Spoil may be carted away and used for filling the
trench behind the work.
Turf, top soil or other surface material shall be set aside, turf being carefully
rolled and stacked for use in reinstatement.
All excavation shall be properly timbered, where necessary.
Efficient arrangements for dewatering during excavation and keeping it dry
till backfilling shall be made to the satisfaction of the Engineer. Sumps for
dewatering shall be located away from the pipe layout.
Where the excavation proceeds through roads necessary permissions shall
be secured by the Contractors from the appropriate authorities.
Special care shall be taken not to damage underground services, cables
etc. These when exposed shall be kept adequately supported till the trench
is backfilled.
The backfilling shall be done only after the pipeline has been tested and
approved by the Engineer. Special care shall be taken under and sides of
the pipe during handpacking with selected material. At least 300 mm over
the pipe shall also be filled with soft earth or sand. Consolidation shall be
done in 150 mm layers. The surface water shall be prevented from getting
into the filled up trench. Traffic shall not be inconvenienced by heaping up
unduly the backfilling material to compensate future settlement. All future
settlements shall be made good regularly to minimise inconvenience of traffic
where applicable.
The Tenderer shall mention in his bid the type and make of the fixtures he
intends to use enclosing manufacturer's current catalogues. In the absence
of any such agreement, the Engineer shall be at liberty to choose any type
and make.
All fixtures and fittings shall be of approved quality and type manufactured by
well known manufacturers. All items brought to the site must bear
identification marks of the type of the manufacturer. Procurements shall
be made well in advance and inspected and approved immediately by the
Engineer. All fixtures shall be adequately protected, covered and plugged
till handed over.
All fittings, gratings, fasteners, unless specified otherwise, shall be chromium
plated. The connecting lead pipes and bends shall weigh at least 3 kg. per
(PCA.775.S034sc22) V.II-D2/S-XXII : 6

2.5.1 Water closet
2.5.2 Urinals
DCPL-K4A02
25 mm dia per meter length. Where PVC or similar pipes are allowed the
Contractor shall produce the test reports and convince the Engineer about
their durability.
Unless specified in the contract the fixtures shall be as specified hereinafter.
a) Raised type
It shall include glazed vitreous china basin with siphon, open front
solid plastic seat and plastic cover, low level glazed stoneware
flushing cistern with valveless fittings, supply connections and
necessary fittings. All fittings shall be chromium plated. Colour of
basin, cistern, seat and cover shall be as desired by the Engineer.
b) Squatting type
2.5.3 Wash basin
2.5.4 Sink
It shall include glazed vitreous china pan with foot rests and high
level cast iron flushing cistern with valveless fittings, supply
connections and necessary fittings. All fittings shall be chromium
plated. The foot rests shall be made of white glazed vitreous china
with chequered surface. The flushing cistern shall be painted as
desired by the Engineer.
It shall consist of wall type glazed vitreous china urinals, cast iron automatic
flushing cistern complete with supply connections, flush pipe, lead
pipes, gratings, traps and all other necessary fittings. Automatic flushing
shall be approximately once every five minutes. For a number of urinals
located together may be served by one cistern of adequate capacity. All
fittings shall be chrome plated. In Technical Building automatic flushing
cistern based on photo electric effect should be installed.
It shall be made of glazed vitreous china. The basin shall be flat back, wall
hung by painted cast iron brackets and complete with pattern with hot and
cold brass faucets with nylon washers, waste chain, waste washers, lead
waste pipes with traps, perforated waste complete with necessary fittings.
All fittings including faucets shall be chromium plated.
It shall be made of Marble or Granite . It shall be wall hung by painted cast
iron brackets and complete with one brass faucet with nylon washers,
waste chain, waste washers, lead waste pipes with traps, perforated waste
with necessary fittings. All fittings including faucets shall be chromium
plated.
2.5.5 Bathroom mirror
(PCA.775.S034sc22) V.II-D2/S-XXII : 7

2.5.6 Glass shelves
2.5.7 Towel rail
2.5.8 Soap holder
DCPL-K4A02
It shall be made of the best quality 6 mm thick glass and produced by a reputed
mirror manufacturer. It shall be wall mounted with adjustable revolving brackets. The
brackets, screws and other fittings shall be chromium plated.
Glass shelves shall consist of 6 mm thick clear glass with guard rails and shall
be wall mounted with brackets. All brackets, guard rails and screws shall be
chromium plated.
Towel rails shall be 20 mm dia chromium plated MS pipes wall mounted with steel
brackets. The brackets, screws etc. shall also be chromium plated.
It shall be made of chromium plated strong members. The holders shall be wall
mounted with chromium plated screws.
2.5.9 Liquid soap dispenser
It shall be round and easily revolving with removable threaded nozzle. The body,
bracket for wall mounting and screws shall be chromium plated.
2.5.10 Toilet roll holder
It shall be made of glazed vitreous china with suitable cover cum cutter.
mounting screws shall be chromium plated.
Wall
2.5.11 Installation
All plumbing fittings and fixtures shall be installed in most workmanlike manner by
skilled workers. These shall be perfect in level, plumb, plane, location and
symmetry. All items shall be securely anchored to walls and floors. All cuttings in
walls and floors shall be made good by the Contractor.
2.6.0 Septic tank & effluent disposal
2.6.1 Septic tank
Septic tank shall consist of the tank itself with inlet and outlets therefrom complete
with all necessary earthwork and backfilling. The details of septic tank shall be as
shown on drawings. This item shall also include ventilating pipe of at least 100 mm
dia whose top shall be provided with a suitable mosquito proof wiremesh and
cowl. Ventilating pipe shall extend to a height of about 2 meter when the septic tank is
at least 15 meter away from the nearest building and to a height of 2 meter above
the top of building when it is located closer than 15 meter. Ventilating pipes can be
connected to the normal soil ventilating system of the building where allowed.
2.6.2 Effluent Disposal
The effluent from the septic tank shall be disposed by allowing it into an
open channel or a body of water if the concerned authority approves or into
(PCA.775.S034sc22) V.II-D2/S-XXII : 8

DCPL-K4A02
a soak pit for absorption by soil or shall be allowed to be absorbed by soil
through open jointed CI pipes laid in a trench filled with broken bricks.
2.6.3 Soak pit / Chlorination Chamber
The soak pit shall be complete as shown on drawing. It shall consist of a
900 mm dia pit 1000 mm in depth below the invert level of the inlet pipe. The
pit shall be lined with stone, brick or concrete blocks set in cement mortar
(1:6) and filled with brick bats. Inlet pipe shall be taken down to a depth of
900 mm from the top as an anti-mosquito measure.
2.6.4 Joining C.I. Pipes / dispersion trenches
Minimum dia of the CI pipe shall be 150 mm nominal. The trench for
laying the pipes shall be minimum 600 x 600 mm pipes. The joints of the
pipes shall be made with lead. The entire length of the pipe within the
trench shall be buried in a 250 mm layer gravel or crushed stone of
uniform size. On top of gravel/crushed stone layer is a 150 mm bed of
well graded coarse aggregate. Ordinary soil is used for filling the top of
trench.
2.6.5 Commissioning septic tank and Soak pit/Chlorination Chamber
After the septic tank has been proved watertight and the sewage system is
checked the tank shall be filled with water to its outlet level before the
sewage is let into the tank. It shall be seeded with well digested sludge
obtained from septic tank or sludge digestion tank. In the absence of
digested sludge a small quantity of decaying organic matter such as digested
cow-dung may be introduced.
3.0.0 TESTING AND ACCEPTANCE
3.1.0 Inspection before installation
All pipes, fittings and fixtures shall be inspected, before delivery at the site
to see whether they conform to accepted standards. The pipes shall again
be inspected on site before laying by sounding to disclose cracks. All
defective items shall be clearly marked and forthwith removed from the site.
3.2.0 Testing of Pipelines
Comprehensive tests of all pipe lines shall be made by simulating conditions
of use. The method of actual tests shall be decided by the Engineer. All
test data shall be recorded and submitted to the Engineer for review and
instruction. The Engineer's discretion regarding tolerance shall be final.
General guidance for the tests are given below :
a) Smoke test
(PCA.775.S034sc22) V.II-D2/S-XXII : 9

DCPL-K4A02
All soil pipes, waste pipes and vent pipes and all other pipes when
above ground shall be approved gastight by a smoke test conducted
under a pressure of 25 mm of water and maintained for 15 minutes
after all trap seals have been filled with water. The smoke is produced
by burning oily waste or tar paper or similar material in the
combustion chamber of a smoke machine. Chemical smokes are not
satisfactory.
b) Water test
For pipes other than Cast Iron
Glazed ware and concrete pipes shall be subjected to a test pressure
of at least 1.5 m head of water at the highest point of the section
under tests. The tolerance figure of two litres per centimeter of
diameter per kilometer may be allowed during a period of 10 (ten)
minutes. 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 in at
the top end and a sufficient length of the 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.
Subsidence of test water may due to one or more of the following
cases :
a) Absorption by pipes and joints
b) Sweating of pipes or joints
c) Leakage at joints or from defective pipes
d) Trapped air.
Allowance shall be made for (a) by adding water until absorption
has ceased and after which the test proper should commence. Any
leakage and the defective part of the work shall be cut out and
made good.
For cast iron pipes
Cast iron sewers and drains shall be tested as for glazedware and
concrete pipes. The drain plug shall be suitably strutted to prevent
their being forced out of the pipe during the test.
c) For straightness
i) By inserting at the high end of the sewer or drain a smooth
ball of a diameter 13 mm less than the pipe bore. In the
absence of obstruction, such as yarn or mortar projecting
(PCA.775.S034sc22) V.II-D2/S-XXII : 10

DCPL-K4A02
through the joints, the ball with roll down the invert of the
pipe end emerge at the lower end; and
ii)
By means of a mirror at one end of the line and lamp at the
other. If the pipe line is straight, the full circle of light may
be observed. The mirror will also indicate obstruction in
the barrel if the pipe line is not straight.
3.3.0 Testing Septic Tank
3.4.0 Fixtures etc.
The septic tank shall be tested for watertightness. It shall be filled up with
water and allowed to soak for 24 hours. Then, it shall be topped up and
allowed to stand again for 24 hours and loss of level recorded. The fall shall
not be more than 15 mm.
All fixtures and fittings shall be connected by watertight joints. No dripping
shall be accepted.
4.0.0 CODES AND STANDARDS
Some of the important Codes and Standards relevant to this specification
shall be followed : Latest editions shall always be consulted.
IS:1172 -
IS:1200 -
(Pt. XVI)
IS:1239 -
(Pt. I & II)
IS:1536 -
IS:1537 -
IS:3486 -
IS:1742 -
Code of basic requirements for water supply drainage and
sanitation.
Laying of water and sewer lines including appurtenant items.
Mild Steel Tubes and Mild Steel Tubulars and other
wrought steel pipe fittings.
Centrifugally cast (Spun) iron pressure pipes for
water gas and sewage.
Vertically cast iron pressure pipe for water, gas & sewage.
Cast Iron spigot & socket drain pipes.
Code of Practice for building drainage.
IS:5329 - Code of Practice for sanitary pipe work above ground for
buildings.
IS:2470 - Code of Practice for designs and construction of septic tank
for small and large installations.
IS:3076 -
IS:4984 -
Low density polythelene pipes for potable water supplies.
High density polythelene pipes for potable water supplies.
IS:1537 - Vertically cast iron pressure pipes for water, gas and sewage.
(PCA.775.S034sc22) V.II-D2/S-XXII : 11

DCPL-K4A02
IS:1538 -
IS:1230 -
IS:3889 -
IS:1729 -
IS:1626 -
Cast Iron fittings for pressure pipes for water, gas & sewage.
Cast Iron rain water pipes and fittings.
Centrifugally cast (spun) iron spigot & socket soil waste and
ventilating pipes, fittings and accessories.
Sand cast iron spigot & socket soil, waste and ventilating
pipes and accessories.
Asbestos cement building pipes, gutters and fittings (spigot
& socket types).
IS:458 - Concrete pipes (with and without reinforcement)
IS:783 - Code of Practice for laying of concrete pipes.
IS:784 - Prestressed concrete pipes.
IS:651 - Salt glazed stoneware pipes & fittings.
IS:4127 -
Code of practice for laying of glazed stoneware pipes.
IS:1726 - Cast Iron manhole covers and frames intended for use in
drainage works.
IS:5961 -
Cast Iron gratings for drainage purposes.
IS:5219 - 'P' & 'S' traps.
(Part-I)
IS:771 - Glazed earthen-ware sanitary appliance.
IS:772 - General requirements of enamelled cast iron sanitary appliances.
IS:774 - Flushing cistern for water closets & urinals (valveless
siphonic type).
IS:775 - Cast Iron brackets & supports for wash basins and sinks.
IS:2548 -
IS:2527 -
Plastic water closet seats & covers.
Code of Practice for fixing rain water gutters and down-pipes
for roof drainage.
(PCA.775.S034sc22) V.II-D2/S-XXII : 12

DCPL-K4A02
VOLUME : II-D/2
SECTION-XXIII
TECHNICAL SPECIFICATION
FOR
ANTI-TERMITE TREATMENT
(PCA.775.S034sc23)

DCPL-K4A02
CONTENTS
CLAUSE NO. DESCRIPTION PAGE NO.
1.00.00 SCOPE V.II-D2/S-XXIII: 1
2.00.00 EXECUTION V.II-D2/S-XXIII : 1
3.00.00 ACCEPTANCE CRITERIA V.II-D2/S-XXIII : 3
4.00.00 RATES V.II-D2/S-XXIII : 3
5.00.00 METHOD OF MEASUREMENT V.II-D2/S-XXIII : 3
6.00.00 I.S. CODES V.II-D2/S-XXIII : 3
(PCA.775.S034sc23)

DCPL-K4A02
VOLUME : II-D/2
SECTION-XXIII
TECHNICAL SPECIFICATION
FOR
ANTI-TERMITE TREATMENT
1.00.00 SCOPE
The scope of work is to set up a chemical barrier against attack by
subterranean termites while the building is under construction.
2.00.00 EXECUTION
2.01.00 General
All work shall in general be executed as specified in IS: 6313 Part II-1981 and
as per approved specification of the agency having special know-how for the
job.
All necessary work to ensure uniform distribution and proper penetration of
treatment of treating solution shall be done according to the instruction of the
Engineer.
Soil treatment shall not be done when it is raining or when the soil is wet with
rain or subsoil water. Once formed, the treated soil barrier shall not be
disturbed.
2.02.00 Chemicals and Rate of Application
Any of the following chemicals (conforming to relevant Indian Standards) in
water emulsion shall be applied by pressure pumps, uniformly over the area
treated.
Chemicals
Concentration by Weight,
Percentage
Chlorpyrifos Emulsifiable
(IS 8944 - 1978) : 1.0
Heptachlor Emulsifiable
Concentrate (IS: 6439 - 1978) : 0.5
Chlordane Emulsifiable
Concentrate (IS: 2682 - 1984) : 1.0
(PCA.775.S034sc23) V.II-D2/S-XXIII : 1

2.02.01 Treatment of Column Pits, Wall Trenches and Basement Excavations
DCPL-K4A02
Foundations, basements etc. may either be fully enveloped by the chemical
barrier or the treatment may start 500 mm below ground level. The bottom
surface and sides of excavation (upto a height of about 300 mm) for column
pits, walls trenches and basements shall be treated with chemicals at the rate
of 5 litres / M 2 of surface area. Backfills around columns, walls etc. shall be
treated at the rate of 7.5 litres / M 2 of the vertical surface. Chemical
treatment shall be done in stages following the compaction of earth in layers.
The treatment shall be carried out after the ramming operation is done by
rodding the earth at 150 mm centres close to the wall surface and spraying
the chemicals in the specified dose.
2.02.02 Treatment of Top Surface of Plinth Filling
Holes 50 mm to 75 mm deep at 150 mm centres both ways shall be made
with crowbars on the surface of compacted plinth fill. Chemical emulsion at
the rate of 5 litres / M 2 of surface shall be applied prior to laying soling or subgrade.
Special care shall be taken to maintain continuity of the chemical
barrier at the junction of vertical and horizontal surfaces.
2.02.03 Treatment of Soil Surrounding Pipes, Wastes and Conduits
Special care shall be taken at the points where pipes and conduits enter the
building and the soil shall be treated for a distance of 150 mm and a depth of
75 mm at the point where they enter the building.
2.02.04 Treatment of Expansion Joints
These shall receive special attention and shall be treated in a manner
approved by the Engineer.
2.02.05 Treatment at Junction of the Wall and the Floor
Special care shall be taken to establish continuity of the vertical chemical
barrier on inner wall surfaces from ground level up to the level of the filled
earth surface.
A small channel 30 x 30 mm shall be made at all the junctions of wall and
columns with the floor. Rod holes made in the channel up to the ground level
150 mm apart and the chemical emulsion poured along the channel at the
rate of 7.5 litres per square meter of the vertical wall or column surface. The
soil should be tamped back into place after this operation.
3.00.00 ACCEPTANCE CRITERIA
(PCA.775.S034sc23) V.II-D2/S-XXIII : 2

DCPL-K4A02
The Contractor shall give a 10-year service guarantee in writing
supplemented by a separate and unilateral guarantee from the specialised
agency for the job to keep the building free of termites for the specified
period.
4.00.00 RATES
Rates shall be of complete work per unit area as stated in the Schedule.
5.00.00 METHOD OF MEASUREMENT
Complete work of anti-termite treatment shall be measured for plinth area
treated.
This includes treatment, to foundations, walls, trenches, basements, plinth,
burried pipes, conduits etc. The extended portions of foundation and like
beyond plinth limit shall be the part of complete work.
6.00.00 I.S. CODE
Relevant code applicable for this Specification.
IS: 6313 (Part-II) 1981 : Code of Practice of Anti-Termite Measures in
Buildings
Pre-constructional chemical treatment
measures.
(PCA.775.S034sc23) V.II-D2/S-XXIII : 3

VOLUME : II-D/2
ANNEXURE A

DCPL-K9A01
CONTENT
d.AUSENO. DESCRIPTION PAGE NO.
1.0.0 SCOPE V.II-D21S-XXIV: 1
2.0.0 GENERAL V.II-D2IS-XXIV: 1
3.0.0 EXECUTION V.II-02/S-XXIV : 12
4.0.0 TESTING AND ACCEPTANCE CRITERIA V.II-D2IS-XXIV: 34
5.0.0 INFORMATION to BE SUBMlnED V.II-D2IS-XXIV: 35
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DCPl-K9A01
VOLUME: II-Dj2
SECTION-XXIV
TECHNICAL SPECIFICATION
FOR
REINFORCED CONCRETE MULTIFLUE STACK
1,0.0 SCOPE
{ This specification covers plain and reinforced cement concrete work, steel
,
flues and Insulation work. painting and protective treatment work, connected
wIIh construction of RCC MuItif\ue Slack.
2.0.0 GENERAl
2,1.0 Work to be provided for by the Contractor
Work to be provided by the Contractor, unless speCified otherwise, shall
include but shall !lot be limited to the following :
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a) Furnish all labour, supervision, services, Insurance, material, power,
fuel forms, templates, supports, scaffolding, tools, plants, construction
equipment, approaches, transportation etc.' required for the entire
work.
b) Design and prepare working dniwings for formworks, scaffoldings.
suPPQl1s, staging,hoisting arrangement for men and material etc. and
submlt them'for approval.
t c) Prepare and submit for approval, as per approved schedule, detailell
'J
drawings for RCC work In shell, platforms at various levels, roof and
ground floor arid bending schedules for reinforcement bars, showing
the positions and details' of spacers, chairs,' supports, hangers.
openings etc, ',.. ' " " "
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d) Prepare detailed fabrication and erection marking drawings for steel
flues including flue expansion compensators, steel flue supports and
restraint arrangements along wIIh fittings and aocessories and sIJhm['
them for approval.
e) Prepare and submit for approval detailed shop drawings, with list of
materials and material specifICations for load Bearing Insulation
Blocl(Sjji'ld Lateral Restraint Insulation Blocks,
(PCAC[)'o03.se05CSA24.doc.doc) V.II-02JS.XXIV: 1
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DCPL-K9A01
f) Prepare and submit for approval detailed schemes for operations like
material handUng, placement of concrete erection of steel nues, fIXing
of Insulations, Installation, dismantling and maintenanCe of nue
expansion compensator etc. and for items like approaches, services
etc.
g) Design and sUbmit for approval mix proportions for concrete to be
adopted on job.
h) Fumish samples and submit for approval the results of tests for
various properties of the following materials:
i) Ingredients of concrete, (iI) Concrete,
IiQ
AcidlChemical Resistant Tiles, (iv) Castable refractories, (v)
Insulation materials, (vi) Paints. (vii) SIS liner.
i) ,. Provide all incidental itelTls not specified or shown on drawings in
particulars but reasonably implied or necessary for successful
.. completion of the work in accordance with drawings and
specifications.
j) Produce, if directed by the Engil)eer, a guarantee, in approved
proforma, for satisfactory performance, for a speciflEld period. of
material manufactured by specialist firms.
2..2.0 Work .by Others
No work under this specification will be provided fpr by agency other than the
Contractor for this Contract unless specifically mentioned otherwise in the
Contract.
2.3.0
Codes and Standards
All works under this Specification, unless specified otherwise, shall conform
to the latest revIsion&lreplacements of the following Indian Standard Codes,
Cljteri8, SpecifICations, along with those mentioned therein. . In case any
particular aspect. of work Is. not ~red by IrlC:jian.. Slandafds, other s.tanill!rd
specificatiOn, as may be specified.by-tIIe Engineer; sh,,11 be followed.
Specification" shall mean Codes, Criteria etc. of lSI.
"IS
IS:6
IS:t04
IS:158
Moderate heat duty fireclay refractories, Group-A.
Ready mixed paint, brushing, zinc chrome, priming.
Ready mixed paint, brushing, bituminous, black, lead free, acid,
alkali, water and heat resisting for general purposes.
IS:195
SpecifICation for fire clay mortar for laying fireclay refractory
bricks.
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IS:269
IS:383
15:432
15:456
IS:516
IS:732
IS:800
IS:813
IS:814
IS:816
IS:817
Ordinary, and low heat Portland cement
Coarse and fine aggregates from natural· sources for concrete.
Mild steel and medium tensile steel bars.
Code of practice for plain and reinforced concrete.
Methods of test for strength of concrete.
Code of practice for electrical wiring. Installallons (System
Voltage not exceeding 650 Volts).
\
Code of practice for general construction in steel:
Scheme of symbols for welding.
Covefed electrodes for metal arc welding of structural steel.
Code of practice for use of metal arc welding for general
construcllon in mild steel.
.
Code of practice for training and testing of metal arc welders.
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DCPL-K9AOl
15:1554 cables.
15:1566 Hard-

DCPL-K9A01
18:2386
(Part-VIII)
18:2502
18:2505
18:2506
18:2633
18:2722
t8:2750
18:2751
Petrographic examination.
Code of practice for bending and fixing of bars for concrete
reinforcament.
Concrete vibrators, immersion type.
Screed board concrete vibrators.
Methods of testing uniformity of coating on linc coaled
articles.
Portable swing weighbatchers for concrete
(single and double bucket type).
Steel scaffoldings. ,
Code of practice for welding of mlld, steel ,bars used for
reinforcad concrete construction.
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18:2950
18:3025
18:3043
18:3144
18:3346
18:3495
(Part-I to IV)
18:3550 .
IS:3558
IS:38n
18:4014
, (Part-l&II)
18:4031
IS:4457
Code of practice for design and 'construction of raft
foundations.
Methods of sampNng and test (Physical and Chemical) for
water used in Induslty.
Code of Earthing.
Methods of Test for Minelli! Wool Thermal Insulation Material
Method for the determination of thermal conductivity of thermal
Insulation materials (M slab, guarded hot- plate method.!
Method of test for clay building bricks.
Methods of tes/for routine control for water u~
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in indust""
Code of practice for use of immersion vibratorn
consotidating concrete.
Unbonded rock and slag wool for thermal insulation.
Code of practice for steel tubular scaffolding.
Method of physical tests for hydraurlC cament.
Ceramic Unglazed Vitreous acldresislent tiles.
IS:4634 ' Method for testing performance of batch-type concrete mixe
(PCA.C~03.S805CSA24.doc-doe) V.lI-D2IS-XXIV : 5
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DCPL·K9A01
15:4687 Gland packing asbestos.
15:4832 Chemical Resistant mortars.
15:4860 Acid-reslstant bricks.
15:4990 Plywood for concrete shuttering wolll.
15:4998 Criterte for design of reinforced concrete chimneys.
(Part·Q
15:5410 Cement paint, colour as required.
15:5445 Long ftuted machine reemers with Morse taper shanks.
15:5495 Sizes and shapes for firebrick (300 mm. and higher series).
15:6911 stainless Steel plate, sheet and strip.
15:8f12 High slrength ordinary portland cement.
15:8183 Bonded Mineral Wool.
15:9595 Recommendation for Metal Arc Welding of Carbon and
Carbon Manganese steels.
CP326·
British Standard • Protection of structures against lightning.
NEPA NO. 78 Code of protection against lightning.
The Indian Electricity Rules.
The,requirements of Department of CMI Aviation, Gov!. of India.
2.4.0 Con(ormlty with Drawings and Spedficatlons
. . . .
The Contractor Shalfcarry oUt' ali the weill h strict lICCoRlance 'willi the drawings
Stamped "Released for Construction" and'speCification Issued to him and as per
Conlradg~s detailed drawings approved by the Consulting Engineer. Prior to
concreting, the Contractor shall prepare a check list on a set format of all items of
wolll involved, and lnform the Engineer well in advance so that the Engineer
shail have the opportunity of satisfying himself if the works mentioned in the
fom1at are dOne according to drawings and specification, and he can allow the
Contractor in writing to start pouring of concrete. The entire operation of
concreting shall be can1ed on as per specification, to the complete sa6sfaction of
the Engineer. fIIOde'IIation from the drawings wUl be allowed unless otherwise
directed by the Engineer In writing.
For Load Bearing Thennal Insulation block assembly and lateral ,estralnt
InsUlation block assembly, Contractor shall design sizes of all components of the
(PCA.CI).OO3.S905CSA24.4oc.doc) V.U-02JS.XXIV: 6
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DCPL-K9AOl
blocks and details of their connectJons, supply and fabricate the same in
accordance with the approved shop drawings prepared by him.
For steelwOrk and meta! work, the Contrector shall deslgn all connections, inserts
for scaffolding, supply and fabricate all steelwork and metal work and fumish all
connection materials In accordance with approved shop drawings prepared by
him and/or as instructed by the Engineer, keeping in view the maximum utilisationof
the available sIZes ,!nd shapes for metal components.
2.5.0 Mateials to be used
2.5.1 General Requirement
2.5.2 Cement
All materials. whether to be inCOlPOlated in the work or to be used temporalily for
the construction. shall conform to the relevant IS specfflcations unless stated
otherwise and shall be of the quality approved by the Engineer.
Portland Cement shallpe as per the requirements laid down in IS:269.
2.5.3 Coarse Aggregate
Coarse aggregate shall be graded crushed or brok,en slone from approved
sources, free from Impurities and shall be screened free of dust and other
deleterious matter. It shall conform to IS:383 or IS:515 and shall be washed
clean, If nec:essaty:
The maximum sIZe of coarse aggregate for stack
superstructure shall be 25 mm down graded, unless otherwiSe stated (vide serial
5(b) of clause 3.03'cljl). Grading for a particular size shalf confonn to relevant IS
Codes and shall be such as to produce a dense Concrete of specified proportion
and strength and shall be of consistency that will work raadlly Into position
( without segregation. •
2.5.4 AneAggregate
(: Fine aggregate shall be river or pit sand. free from any clay, eerth. vegetable
matters, salt or oIherimpurities and shall be dean and fit for use, to the
~:,
satisfaction of the EngIneer. Sand ~ for the Wort< shall nomnally
.:" have a grading faDIng wiIIlin tile ~mils ~f one .of 1I1e thrae {/1'8de!l: Illentloned .
in the relevant.1S Specifications. . ..... '. '. '. • _'_
( 2.5.5 Water
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The water for both mixing and curing of concrete shall be clean. free from 011,
·acld, alkali. organic or olher deleterious substances. Contractor shall test Ihe
water as end when required by the Enginaer. .
Mild steel or Medium or High Tensne steel defonned bars specified for
reinforcement shall confonn to the latest relevant IS Specifications and shall
be of tested quartly under lSI CertifICation Scheme. The reinforcement shall
t. be free from any oil. foraign material or mill or rust scales. . .
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(PCACO-OO3.S805CSA24.dOe.doe) V.U-02lS-XXIV : 7
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DCPl-K9AOl
2.5.7 steel Rue
a) All mild steel material to be used in construction of steel flue, shall
comply with 15:2062, 15:1239,15:1367, 15:1608, 15:800 and with other
relevant IS 5pec1flCllllons. The ultimate tensile strength of this steel
shall notbe less than 410 NISq.mm.
b) Stainless steel liners shall be fabric:ated using materials conforming to
the requirements of relevant IS Specifications and/or AISI 316l or
85:1449 Part-2. Gredeof S1a1ntess steel shall be equivalent to
85:1449 (Part-2) 3165.12. '
c) Materials to be used for fabrication of Flue expansion compensator
shall be 'sultable for the flue gas tempeeture and shall be acid resisting,
The expansion compensator shall comprise severa! layers of
maieI1aIs gillen below in order from the gas side.
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Two. layer of insulation, each consisting of heavy weight
texturized glass cloth Impregnated with graphite suspension,
having an approximate weight of 1.00 KgISq.m
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A continuous filament glass cloth coated both sides with a
fIouro-elastomer having an approximate weight of 1.5
KglSq.m. '
Two layers of PTFE (Poly Tetra Fiouro-Ethylene) film of
minimum thickness 0.15 mm each.
Iv)
A layer of glass felt of minimum thickness 10 mm and an
approximala weight of 1.5 Kg/Sq.M.'
2.5.S
Paints
Paints to be used for shop

DCPl-K9A01
2.5.10 Insulations
a) On Exterior Surface of Aues
The nonnal flue gas temperature Inside the flue shall be 145 Deg.C
wfth momentary rise upto 400 Deg.C (Maximum) occasionally. The
insulation material shall lie able to withstand this temperature without
any deterioration in thennal properties or breakdown. The thermal
conductivity of the Insulating material shan not exceed 0.06 W/M
Deg.C at a mean temperature of 150 Deg.C. The insulation shall also
not be affected by any acid condensation from flue gas and shall be
free from any impurities which may cause corrosion to the tlue
material.
For steel flues 65 mm thick semi rigid resin bonded fibrous mineral
wool or. density not less than 96 KgICu.m as per IS:8183 or resin
bonded fibrous crown glass YIOOl (high temperature) of same
thickness and density not less than 36 KglCu.m capable of sustaining
temperature to the tune of 540 Deg.C without any loss of material
thermal property, may be used. The mineral wool for eXPOsed top
portion of flue ehall be semi-rigid .with minimum density of 200
KglCu.M or the glass wool for expoeed top portion of flue shall have
minimum density of 75 KglCu;M.
Slag wool insulation. shall not be accepted.
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The insulation free from shots should be supplied in the form of mat to
be foxed with staggered joints on outer surface of.the flue with suitably
spaced stud by galvanlsed wire mesh. Insulation on the top portion
of flue shan be covered by stainless steel claddln9.
b) AI load Bearing and SIde Restraints of Rues
( .": Load bearing insulation assembly 10 have (i) a properly mechined mild
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steel plate with recess at Its top tor seating PTFE (Poly Tetra Fluoro
Ethylene) sheets confot:mIng to 8S:5400 (Ii) saddle plate (MS) in the
l~ middle having stalnIes$ steel plate fIXed at Its bottom surface and
leacf/elasto.mt!Iie· sheet at top, an

DCPL-K9A01
ii)
iii)
Iv)
Minimum shear strength of 30 NlSq.mm when tested in
accordance with 85:3497-1979.
Thermal conductivity shan not exceed 0.67 W/m Deg.C at a
. mean temperature of 200· Deg.C and its coeff. of linear
expansion not to exceed 1.2 x 10" per Deg.C.
Adhesive used for bonding purposes shall be of material with
equivalent high temperature properties as approved by the
engineer. II may beef "Fortafix Flborclad Adhesive" as
manufactured by Fortafix Ltd •• England.
2.6.0 Stol!lge of Materials
2.6.1 General
2.6.2 Cement
All materials shall be so stored as to prevent deterioration and intrusion of
foreign matter and. to ensure the preservation of their quality and
characteristics for the work. Ani material. which is deteriorated or Is
damaged or Is otherwise considered defective by the Engineer, shall not be
used for construction arfd shall be removed from site immediately, failing
which the Engineer shal~ be. at liberty to get the lI)aterials removed. The
ContraCtor shall maintain an upto date accounts of receipt, issue and balance
ef all materials Issued by the Owner. .
Contractor shall stOre cement In water-tight and properly designe.d stores so
. that the Cement can be kept dry and the stock can be handled in rotation,
The doors of stores shall be at least 30 em. above G. L. Deteriorated cement
shall be removed Immediately from the site. Not more than ten bags of
cement shall be stacked one above the other.
2.6,3 Aggregate
Different materials shan be transported, handled and stored separately in
sUch a manner as to pre,vent damage, deterioration or contamination. Stock
pUes of fine and 'coarse !lggregates. shaD be alloWed to ,drain, so that .
. aggregates'do,notcoritain too much· water. '
2.6.4 Reinforcement
Reinforcement shall be stored preferably under cover and stacked off ground
In size 'and grade-wise separate stacks for easy identification.
2.6.5 Steel, Metal and fittings
All steel, metal and fittings to be ui8d for fabrication and erection shall be
stored sectionwise and lengthwise In separate stacks, off ground, so that they
cal'! be handled, inspected, measured and accounted for easily at any time,
If required by the Engineer, the materials may have to be stored In a covered
shed.
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DCPL·K9A01
2.6.6 Paints
2.6.1 Steel Flue
,r 2.6.8 Insulation Material
Paints shall be stored under cover, in air-tight containers. Paints supplied in
sealed containers shall be used as soon as possible once the container is
opened. Left over paints shall be kept in air-tight containers.
Fabricated pieces of steel (Rue) liner shall be stored systematically for ease
of handling.
All insulation materials fike beaiing insulation blocks, restraint Insulation
blocks, glass or mineral wool. asbestos ropes etc. shall be stored In paddng
boxes, under covered shed, avoiding Ifleir coming in contact with
objectionable matter.
2.1.0 Quality Q:mtrol
. ,
Conltactor shall' establish and maintain quality controf for different items or
work and materials as Il'lIY be directed by the Engineer to assure compliance
with contract requirement and submit to the Engineer .records of the same.
The Contrector shall submit all records and test resuHs in original to the
Engineer for his approval, Ifso desired by him.
The quality control operation shan include but shall'not be limited to the
. following items of work :
a) Cement
b) Aggregate
c,.
.Water
d) Reinforcement
e) Structural
f) Steel Rue
Test to satisfy relevant IS Specifications if
supplied by the Contractor.
Physical, Chemica! and Mineralogical
qualities; grading, moisture contents and
impurities.
,'tmpuritles Tesl ' '
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Miiterial tests or certificates to satisfy relevant
IS Specification If suppned by the Contractor.
Material tests or certificate to satisfy
Steelrelevant IS Specification If supplied by the
Contractor.
Material tests or certificate to satisfy relevant IS
Speciftcation If supplied by the Contractor.
g) Stainless
Material tests or certificale to satisfy
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DCPL·K9A01
relevant IS Specification if supplied by the
Contractor.
h) Acid
Resistant
Compressive and tensile strength. acid tiles&
mortar resistance and water absorption test.
i) Mortar Compressive and tensile strength. adhesion
and acid resistance test. .
j) Insulation TIIemIaI conductivity. densily. heat and acid
resistance tests. Bearing capacity will be tested
for bearing/restraint insulation blocks.
3.0.0 ~~
3.1.0 CIJn(;rete
3.1.1. TriaL Mix, Grades of Concrete
At klsst three weeks befOre commencing aoy concreting in the work the
ConllactOf shall make trial mixes using samples of

DCPL-K9AOl
MIX PROPORTIONS (BY WEIGHT) EXPECTED TO GIVE DIfFERj:NT DEGREES
OF WORKABILITY WI11i DIFFERENT VALUES OF WATER - CEMENT RATIO
(FOR GUIDANCE)
CEMENT[TOTAL AGGREGATES RATIOS
WorkabUity Waterl Ratio by Weight of Cement Ratio by Weight of Cement to
Cement to Gravel Aggregate Crushed Stone Aggregate
Ratio 20 mm. Size I 38 mm. size 20 ITU'I!. size I 38 mm. size
i
Very Low
slump
G-25mm.
"
Low
slump
25-50mm
Medium
slump
5G-100mm.
4, High
slump
100 ­
( 175 mm.
0.4 01:04.8 01:05.3 01:04.5 1:05
0.5 01:07.2 01:07.7 01:06.5 ()1:07·,
0.6 01:09.4 1:10 01:07.8 01:09.6
0.7 1:10 1:12 01:08.7 01:10.6
0.4 01:03.9 01:04.5 01:03.5 1:04
0.5 01:05.5 01:06.7 1~05 01:05.5
0.6 01:06.8 01:07.4 • 01:06.3 1:07
0.7 1:08 01:08.5 01:07.4 1:08
0.4 01:03.5 01:03.8 01:03,1 01:03,6
0.5 01:04.8 01:05.7 01:04,2 1:05
0.6 1:08 01:07.3 01:05,2 01:06.2
0.4 01:03.2 01:03.5 (l1:02.9 01:03.3
0,5 01:04.4 01:05.2 01:03.9 01:04,6
0.6 01:05.4 01:06.7 ' 01:04.7 01:05.7
0.7 01:06.2 01:07.4 01:05.5 01:06.5
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NOTE-2:
Notwithstanding anything mentioned above. the cement I Total aggregatE!
ratio is not to be increased beyI;lnd 1:9 without specific permission of the
Engineer.' "
, It should be n6ied tha!such high aggregate cement ratlos will be required for
concretes of very low slump and high _ter-cement ratios which may be
required to be used in mass concrete work only.
The above figures are for guidance only, the actual cemenV aggregate ratios
are to be wor1

DCPL-K9AOI
slreng1h of the concrete cubes falls below 1he requirement, 1he method
described IIbove shall be repeated till acoepIabIe msults are obtained. The
method may haVe 10 be repeated whenever there is a significant change In the
quality of any of 1he ingredients for concrete, at the discretion of1he Engineer.
3.1.2 Batchlng of Concrete
For !=Ofltrolled collCl8te, only weigh balchlng shall be allowed. All concre1e
ingredients, except water, shall be balched by weight, using an approved'.
rnakil of weigh betcher. Batchlng shall be accurate to 112 Kg. The batcher \
shall be tested for 8CCU11IeY of calibration, fU'Sl before commencement of
work and at least once a fortnight or as directed by 1he Engineer 1hereafter.
Water shall be batchad by weight or by volume measures. as approved by
the Engineer.. •
3.1.3 Mixing of Concrete
Materials for concre1e shall be empt1ed in rotation into the mixer. When all
1he ingredients are In tha drum. 1he drum ~II rot8te for one, minute for dry
mixing. Af1er 1hat "'(aIer shall be edded In measured quantities in the manner
specified. The mixer shaH 1hen rotate for at least two minutes. or at least
forty revolutions or unUl,1here Is apparent uniform distribution of the materials
and tiU 1he masil is unilOrm In colour. The entire content of the drum shall be
discharged before 1he Ingredients for 1he'succeeding batch are fed Into 1he
drum. The mixer shall be 1horoughly cleaned to the satisfaction of 1he
Engineer, before a different quality of concrete is put through the mixer and
also at the end of day's wolk.
3.1.4 Workability of Concrete
The' degree of workability necessary to allow the concrete to be well
consolidated and to be wolked Into 1he comers of formwolk and around 1he '
reinforcement and embedments. and to give 1he required surface finish shall
depend on 1he type and nature of &tructure and shall be based on experience
and tests. 15 mm. to 40 mm. slump In chimney works shall be adopted
~ to Engineer's ap,proval unless stated o1herwise (vide serial 1 (d) of·
~use np. 3.3.6). The usuat ~miIs' of consistency for various types of
structure are given below ; " . .
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UMITS Of CONSISTENCY
DCPL-K9A01
Degree of Slump In mm. with Use for which Concrete is suitable
Workability
Standard Concrete
Min.
Max.
Very Low o 15 large mass concrete work with heavy
compac:tion equipment.
Medium 35 65 Deep and wide RCC structures with
congestion of reinforcement and inserts.
High 65 100 Very narrow and.deep RCC structures
with congestion due to reinfor

DCPL-K9A01
Vibration shall begin as soon as one batch 0( concrete has been placed and
shalf continue tin the entire section being poured has been thoroughly
consolidated.
To secure even and dense surfaces, free from aggregate pockets, vibration
shan be supplemented by tamping or rodding by hand in the comers of forms
and along the form surfaces whllelhe c:oncrele Is plastic, without damaging
or endangering the stabUity 0( the formwork.
A suffICient number of spare vibrators Including petrol vibrators shall be kept
reedily accessible to the place 0( deposition of the concrete to assure
adequate vibration In case 0( breakdown of those in use.
3.1.6 CurI/Ig of Concrete
Curing 0( exposed surface 0( concrete shaU commence immediately after the
concrete has. set. Exposed sides shall be covered with canvas etc.
immediately afieF ·sltlpping 0( forms, and curing shall be continued for a
period 0( not less than 14 days. reckoned from the date and hour 0(
completion of concreting.' All surfaces of the. pour shaD be kept wet with
water at all times after concreting and lUI the curing period Is over. The
Contracior shaD plan and employ proper equipment and sufficient labour
considered adequate by the Engineer under able supervisor for curing.
3.1.7 Construction Joints
In concreting the chimney shell one full ring lift shall be completed in a day's ,
pour. Before the forrnwork for the following pour starts the horizontal surface
of the Chimney shell shall be chipped, cleaned and washed with water, and
when the forrnwork Is complete, the surface shall be cleaned and washed
again and covered with 1:2 sand cement slurry before fresh concrete is
plaoed. The horizontal construction joints shall be so arranged and made
that, they are regular and neat. No vertical joint shall be allowed. No
separate paYment shaU be allowed to the Contrador for forming JOints or
chipping and cleaning them or cover with slurry prior to concreting. The
nlimber ofCX)nstruction joint shall be kept minimum and the spacing should
not exceed three (3) melers. The Conlractor shall submit to the Engineer,
any proposai of ·providing constflJllllon Joints to facilitate his work, for .the
study end approval of the Engineer well In adVance. ".
3.1.8 Ordinary Concrete
Ordinary concrete Ilke lean concrete shall be of nominal mix as per relevant
cl8I!ses 0( 15:456.
,
(PCA.CO.oo3.SS05CSA24.doc.doc) V.lI-D2JS..XXIV: 16
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OCPl-K9A01
3.2.0 Reinforcement
3.2.1
Bending of Reinfortement
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3.2.2 Pladng
All bars shall be carefuny and accurately bent by the Contractor in
accordance with approved Drawings and ber bending schedules. Special
care shall be taken to ensure correct lengths of laps. The bars shall not be
bent or straightened in any manner that wiN Injure the bara or impair the bond
between reinforcement & conae1e. Bends and hooks are to be provided as
laid down in the IS:2502.
All reinforcement shell be placed and maintained in the position shown in the
drawings. Contractor shaR provide approved type of cover blocks to sUit the
requirement of the Drawings. Where reinforcement Is to be provided on two
faces of the shell, the Contractor shell provide adeqoate number of
separators, with the approval of the Engineer. Any additional supporHo the
re1nforcing cage. if required at the time of concreting, shall alSO: be provided,
to the satisfaction of the Engineer. lapping of reinforcemenl as specified in
the drawings or as directed by the Engineer, shall be provided. laps shall be
staggered and too many laps shan be.avoided. Welded laps shall be
provided only when directed or approved by the Engineer. '
3.2.3 Fixing of Reinforcement
18 SWG annealed steel wire shall be used as binding wire. 8ar crossing one
another and contact laps shall be bound with this wire, twisted tight to make
the skeleton or network rigid so that the reinforcement is not displaced during
placing of concrete.
3.10 Fonns
( Construction by Slip-form Method
." 1;.­
Slip-fonm construction 'shaA !:le for constructioiI of the )oYind shield. Type of
,~ Sfip-form proposed should be Indicated In the offer with sketches, drawings
and. constnlCtioo ' statement ·aselCplained herein;;d'ter; !'lumber, type and '
capacities of Jacks, the' control system and achievable rate of progress in
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mmIhour should also be indicated. The chosen scheme shell be of a psst
proven design. A certified perfonmance record of the scheme should be
submitted with the offer to guarantee woikability of the scheme both from
execution time and safety point of view. .
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The Tenderer shQuld fumish a brief but commprehensive statement
indicating the planning & programme and method of work to be followecUor
the approval of Owner at the time of submitting Tender. This slstement shall
include the following Hems:
i) Type and description of SUp:form eq';lipment and its accessories.
(PCA.CD-003.S60SCSA24,doc.dac) V.II-02lS-XXIV: 17
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Ii)
Design of scaffolding and staging.
DCPL-K9A01
il1) Description of materials inCluding admixtures 10 be used for
consltudion.
iv) Manpower ptennlng, conl;truction spaces required , standby
arrangement:
vi)
vii)
viii)
be)
Rate of Slip-fonning.
Proposed workabilitY requirement of concrete and type of cement &
admixture to be used.
Quality assurance programme.
Method ofTraansportalion of melerial
x) Method of curing and rectification of defects.
xi)
xii)
xiii)
Planned'intemlption, if proposed, and activilies during planned
interruption. T reelment of consltuction joint. .
. .
COntingency solution for unptannad interruptions.
Time of completion.
While selecting the COntractor, due consideration will be given to the merit of
the above mentionad statement proposed by the Tenderer.
Not withstanding what have been specified In earlier clauses, following guide
lines are being presented whk:h should be kept In view by Intending
Tenderers. whUe quoting for Slip-fonn method of consltuction :
1. Care to be taken to prevent dragging of concrete aiongwith upward
movement of the shuttering. For this purpose following' steps are
advisable : .
a) ,Shutter··P\ate$ have to be smooth and should be 'thoroughly
clean. BefO/B fildng them in position all the surfaces which Will
be coming in contact with COIICI1Ite to have a coat of epoxy
paint.
b) In arees where concrete thickness Is 750 mm or more rate of
pouring should be such that minimum slipping of shuttering is
100 mm per hour.
c) Mix design should be so done that it will be self: lubricant at
the contact face of shutter and (XlIlCrete and thus reduce
friction. Suitable cement of approved manufacturer
(conforming to relevant I.S. SpecIfication) may be used for the
purpose. An optimum ratio of coarseJllne aggregate should be
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established to suit the purpose depending on availability of
aggregates.
d) M"IX design also should be so done that II has a slump of 50
mm at the point where concrete is placed under an ambient
temperatura of around 40 Oeg.C. This wlll also keep vibration
by needle vibrators to required minimum. Slump should 'not
drop down to zero In less than 45 minutes. Suitable ratarding
agent and plasticizer of approved manufaCture may be added
in mix to achieve this purpose. These admlxturas to be
properly Identified by praliminary tests both for pedormance
and for compatibility with particular type Qf cement propoSed 1(,
be used.
Additlonal steps Ike spraying of water over tha shutters and
keeping down the temperatura of coarse aggregates by
continuous spraying of water over those may be rasorted 10 kl
ambient temperatura is more than 40 Oeg.C.
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2. Cere must be taken to pravent twist. which predominantly occur in the
initial stages because of low ,tipping rate, in the horizontal plane of
Slip-form assembly. A thorough check on this aspect must be kept at
every 15 minutes interval. One person should exclusively be assigned
this work together wfth rectifying any defect.
Every endeavour has to be made so as not to occur any tilt in the
shutter assembly. To achieve thls following steps need be1aken :
a) Performance of jacks has to be closely observed and any
defective one needs Immediate replacement. Difference' In
levels of opposite jaclls at any instant of time should not
exceed 5 mm.
(: b) Loading on Stip-form Inlsslyokes has to be fairly equal.
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c) Sleeve through whlOn jacking rod passes has to be of
sufficient length so' that· later gets an uniform clearance· and
. does not get any chance to bll SJeeveshouldhavea minimum
wan thickness of 3.25 mm and should' bE! such that jacking
#:.:: rod gats a maximum clearance of 1 mm to 1.5 mm alround.
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4. For taper walled chimneys ovellapping of shutt!)rs which are kept te
efIact the tapering. needs careful attention otherwise these may be
ruled with concrete slurry.
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5. . In designing the mix fOllowing aspects should be borne in mind :
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a) Cement used should have an initial selting time of not less
than 50 minutes and preferably should have a specifIC surface
around 3600 Sq.Cm.per gram.
t:. .;, b) Coarse and fine aggregates should be well graded a
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rounded aggregates offer better performance in SUp-form
technique. These help 10 keep down water/cement ratio and
also offers better lubrication between concrete and shutter
surface. 40 mm down size of coarse aggregates should
. praferably be used unies6 ralnforcement detailing calls for
I_r size aggregates.
c) From the point of view of craeP. shrinkage as well as initial
selting property of conaete. cement content should not
p!8ferabiy be more than 40Q Kg. per Cu.M of concrete.
d) Minimum compressive elrength (after 4 to 6 hours of mixing) of
concrete immediately below the shutter as slipform proceeds
should be between 0.1 10 0.2 Newtonl Sq.mm ..
e) It Is advi6able to use cement from a single source during the
entire operation of sIIpform technique since once the .system
starts. there might not be any time left for conducting trial
mixes if the source of procurement of cement changes.,
6. Large diameter YI'bIator needles should not be' used for vibrating
concrete. Sizes of these needles should preferably be restricted to
25 mm diameter and to 40 mm diameter - only in eXCeptional cases.
At least two nos. standby Vibrator units should always be maintained
.on top of worldng deck at all time during the entire period of slipform
operation.
7. It Is preferable to have membrane curing compounds sprayed. on
fresh surfaces emerging out of shutter panels for ensuring proper
curinng at great heights.
In case such spreying is not envisaged then elaborate arrangement
has to be made for adequate supply of water both on Inside and
outslde vertical surfaces with spraying arrangement. necessary
length of pipelines and pump of adequate head to serve the purpose.
It is always advisable to have a stand-by pump for effective utilisation
of the system. .
.8. .' If StipfOrming In::acried. out in summer•.rate of sUpPing should· be .. " ..
around 400 mm per hour. If I_rvalue Is eontemplated appropriate
retarders should be spec:ifled.
9. Exact number and capacity of jlldca as well as spacing of yoke frames
are to be determined taking Into acoount various loadings including
self weight of the system. dead and live loads on working and other
platforms. horizontal load on formwork. wind load etc.
It is desirable that jacking system. based on which the entinrsUpform
system works, should consist of jacks 3 Tonne/6 Tonne capacity and
a hydrautic pump with necessary pipe connections.
Spacing of yoke tegs should preferably be kept within 2 metres to
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DCPL·K9A01
prevent overioading on jacks and consequent faHure resulting In twist
of the formwork.
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Jacking rods should be of 25 mm diameter for 3 Tonne Jacks and 32
mm diameter for 6 Tonne Jacks.
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10. At least 30% spare jacks and Jacking rods should be kept ready
during the entire operation. His obligatory to maintain spare hydraulic
pump aIongwith a set of loose pipes In perfect working condition on
top of working dad(.
11. In sections where thickness Is 500 mm or more it Is prudent It, .;0 if:
for two nos. ofjacks for each sllpfonm yoke,
12. For effective utHity of this technique following areas need careful
attentions at the very conceptual stage :
a) DetaDed quality assurance programme.
b) Advance Planning and preparations.
c) Arrangement for on site supervision and adequate access
'facUities. .
13. Construction methods Including description and types of different
equipment proposed to be used. structural errangement and analysis
of the system, description and type of different materials. planned
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interruptions, description and frequency of various checks and tests
for Sllpfomn lechnlque as well as for material, method of preparing,
transporting and pouring of concrete, solution for probable defects
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~,,' 4llring slipping, sequence of operations during planned Interruptions
elc. should be prepared beforehand by executing agency and to be
apprOlled by Engineer before starting the actual ~rk.
14. Pladng and binding of reinforcement is also a very critical item and
needs special attention. From·pmctical·conslderations· not more than
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OCPL-K9A01
For movement of personnel supervising the work a seperete hoist
must be arranged for.
17. The system being operative round the clock it is obligatory to have
adequate lighting arrangement both on various platform levels as well
as on ground below. Arrangement has to be made for facilitating
continuous upward movement of the entire system alongwith sllpform,
18. Winches for lifting men and material and mixers, if located within
unnsafe area around chimney, should be protected by adequate
shelter from possible damage.
19. Proper tele-communication system has to be established between
the personnel working on top of Chimney and control room below,
20. A small laboratory should be maintained at site for testing different
materials like cement. coarse and fine aggregates, A cube testing ­
machine may also be installed at site for getting quick feed back
results.
Apart -from using ,plumb bobs, level and theodolite Instruments for
survey purpose arrangement should also be kept for lasers,
21. In case of interruption in the course of Slipping of formwork following
measures should be taken :
. a) Provision of a key and additional reinforcement at the Junction
of new and old concrate,
b) Slipforrn system should be brought up freely to have a
minimum overlap of 100 mm or so oyer previously cast
concrete.
c) Washing of old c:oncrate surface with compressed air and
, water jet and thereafter pouring a layer of neat cement grout.
d) Clearing of shuttering panels of loose materials, concrate etc.
by compressed air and· applying a coat of epoxy paint, if felt
necessary' by. Engineer. . _ .
- e) Neatly finishing the interface of old or new 90ncrate as soon as
It comes out of shuller panel.
22, It is preferable to suspend the construction work und~r high wind
condition,
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It is of utmost importance that for effective impiamentatlon of this
system an Engineer fully conversant with Slipform technique with
enough experiern:e In planning and control of formwork should be In
overall command of the site and he should be ably supported by well
trained mid IeVeisupervisory staff, &killed workers and operators.
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24. Operation of sllpfonn method of construction Is a continuous one and
it demands continuouslintennediate inspection of accuracies in line,
level, dimensions and position and Immediate rectification of any
noticed delllation. All these ask for personnel of high quality having
constant vigilance over the construction activity.
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25. While all the activities in effective Implementation of the work needs
utmost care keeping safety of men and material in mind tt Is obligatory
that all activities should be carried out under Ihe. guidance of a
qualified and trained safety Engineer.
Safety measures as listed below must be adhered to but shoul,! ,,,;\
be limited to only thasa :
a) Safety helmets and betts to be provided 10 all supervising staff
and workers. .
b) Safety nels to be provided below both inside and oulside
platforms as instructed by Engineer.
c) Handrailing and 1010 guard 10 be provided around all openings
and platforms. .
d) Regular maintenance of equipmenl, checking of hoists,
scaffoldings etc.
e) Passenger hoist must have muHiple ropes with adeauate
factor of safety.
f) Emergency lights, coloured lamps to be. provided in
(, accordance with relevant Indian Standards' and as
supplemented in Ihe Specification and I!) be operative In case
of sudden power failure Emergency standby generator must
( be kept ready during the enlire period of slipform method 01
construction.
·t~;':.: g) Emergency vehicles; first aid facilities must be kept reedy
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duriog .the entire period of Work: .
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( ,".'- 26. Permissible construction tolerances should be limited to \he following.
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Verialion in wall thickness
Variation from Design Diameter
(-) 5 mm,(+) 25 mm

OCPL-K9AOl
3.4.0
3.4.1
steel Flues
General
Fabrication and erec\lon of Steel Flues shall conform to "Technical
Specification for Fabrication and E«ICtion of Structural Steelworks· furnished
in this Specification.
3.4.2
Fabrication
Plates out of which flues will be fabricated, shoukl be bent to the required
shape on an appropriate machine. No smithy process shall be adopted for
the purpose. Plates are to be prevented from distorling by more than the
tolerances specified during tralispollation, storage, handBng, erection and
jointing. All components should be correr,:lly Io

DCPL-K9A01
a) Inlemal diameter shall not
vary by more than '. ±12mm
b) Centre of any section shall nOI
be eccentric from vertical centre
line'by more than
c) Centre of any section at
height 'h' is in mm.
above GL shall
10 mm In any 15 metre
height
(hI2500 + 10 )mm,
Dot be verticat centre
where line by more than
, f.
d) Local deviation from a true circular fonn should not exceed the shell
thid

3.5.2 Cement Paint
OCPL-K9AOl
and ihe drying lime between consecutive coals shall not be less than 5 hours.
The overall combined thickness of paint shall be a minimum of 230 microns.
The outside face of the Chimney shall. unless specified othelWise. shall be
painted with Cement water proof paint. The quality shall be approved by the
Engineer. Necessary samples shall be submitted to the Engineer for his
approval. The sUrfece of the shaH shall be prepared as per paint
manufacturer's specjficalion. In addItion. care shall be taken thai the surface
Is free from stain. honey comb and any rough and uneven surface. The joints
between two shuttering and two lifts of shuttering shall be so prepared that
any uneveness. if by chance exists. shall be removed. If one coat of paint Is
not suffICient to give. the required finish. the Contractor sha. repaint the
surfece. until the engineer is satisfjed with the Workmenship. The paint shall
conform, unless othelWise slated, to 15:5410. Necessary samples, test
certificates and manufacturer's literature shall be submitted.to the Engineer
for approval. . .
3.5.3 Insulation and Packing
AU insulation material should be of dimension and type, shown in the drawing.
Load· bearing insulations at supports and side restraints of Steel liners should
be an assembly of M.S. Plates, Stainless Steel Plates, PTFE (Poly Tetra
Fluoro Ethylene) sheets and or/asbestos fibre reinforr.ed boards (SINOANYO
BLOCKS). Insuliltion to be fIXed on outer surface of steel flues should be
mede of glass or mineral wool.
a) load Bearing Insulation Block
~oad bearing assembly should consist of three units and be fabricated
according to approved drawings. It would be fabricated from mild steel
units with a stainless steel sheet bearing plate and load bearing
insulation blocks as indicated in drawing.
The first unit is bolted to the. supporting beam. 11 consists of a M.S.
base plate with bolt holes on which:a ffiachined M.s. 'plate is welded.
This plate IS. provided with receSs.for .PTFE sheet (conf9rming io. BS :
... 5400) to seal. being lubricaled.with sllicbn grease.'
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The second unit also consists of a M.S. plate having adequate size &
thickness as shown in drawing. While one surface of the plate is
provided with a stainless steel bearing plate the other surface has a
thin layer of lead! elastomeric sheet. The side having stainless steel
surface is placed on PTFE surface of First unit.
The third unit consists of two layers of load bearing insulation blocks
each having a minimum thickness of 50 mm and factory bonded to
top & bottom M.S. plates. These are separated by 100 nnm. long load
bearing insulation dowels as shown in the drawing. These plates are
In tum welded to two additional M.S. plates. Of the two surfaces thus
(PCA.CQ.OO3.SIlO5CSA24.doc.doc) V.iI-02lS-XXIV : 26
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DCPL-K9A01
created one shall be welded to bracket assembly while the other
should rest on the lead sheet of second unit. Bearing assembly, thus
formed, should be levelled by using suHable M.S. shims.
Support afTllngement typically consists of flue support shoe (a part of
flue), flue support bracket connected to the shoe by precision bolted
connection. The bracket in tum Is welded to the bearing assembly,
which in tum is bolted to available supporting beams.
Support brackets and bearing assembly are welded to locally
thickened area of flue. These support ihe flue on support platfrnm at
suitable locations indicated on the drawing.
The arrangement described above should cater for easy and' smooth
thermal mowments of linear element Suitable restraint brackets and
M.S. stop plates need be provided as shown In drawings to prevent
excessive movement and thus keeping different units of bearing
assembly in proper position.
b) lnsulation Block at Lateral Restraints
At flue restraint platforms, necessary restraint arrangement with load
bearing Insulation blocks and stainless steel bearing plates fixed to
the Insulation blocks should be provided as indicated in drawing's.
Restraint and support brackets need be provided for the bottom
supported portion of the flue which rests on the support platform
( provided at the base to cater for bearing and restraint requirements.
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•( c) Glass or Minerai Wool
Insulation thickness of 65 mm as Is specified in clause 2.05.10 shall
be built up using two (2) layers composed of 40mm and 25 mm thick
insulation blocks. Thicker layer shall be put as first layer around the
flue on its exterior surface .
The insulation on the flue shall be fIXed using Chicken G.1. wire
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mesh,
.' .. G.I. wire .lies, inSulation. retaining' studs, wasti~ etc. 'AIljoints shall
be staggered. The Insulation shall be lightly secured to the exterior
~.
surfaca of the flue by Impaling on the studs and fixing in place by
't~4"
means of 63mm round or square metal plated speed washers: 20
gauge galvanized wire netting shaP be wrepJled continuously over the
(;: entire exterior of insulation. The wire mesh shall be 25mm hexagonal
. pattern conforming to IS:1566. All joints in the mesh shall be tapped a
minimum of 150 mm tied by 16 gauge soft annealed wire at 300 mm
spacings. lacing' at joints shan not be used. The Contractor before
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application of Insulation, shall take prior approval of actual fixing
arrangement from the Engineer.
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The insulation shalf be able to sustain structural vibrations and shall
not setue under such conditions during erection, construction &
,~~ operation. The Insulation shan be suitably tied to prevent dislocation-",
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under adverse conditions.
The cladding of slafnless steel &heet over the insulation shall be well
SeaJred using pins. fasteners etc.
d) Vermiculite Concrete
VeniliculKe conCtete shall be made by mixing exfofiated verrnicul~e.
portland cement and water. It &flail be of Grade-B. having a density of
210 Kg./Cu.M. The vermiculite aggregate size shall be maximum 6
mm. The mix shall be 1 cement and 8 vermiculite by volume.
3.6.0 Add-Proof/Olemical Resistant Protedlon to Roof Slab .
. AckI-ProofiChemical Resistant tiles· bedded on acid prooflcheinical resistant
mortar shall be provided for the protection of roof slab. The intervening
space between the tiles shall also be filled up by chemical reslstantiacid-proof
epoxy mortar grouts. The. mortar·sha. be used Imrnadiately after mixing.
Jiles shall be made of clay. feldsper or quartz and· vitrified at a high
temperature in

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additional safety another inner cover or other approved methods may be
adopted. The manhole cover shall be distinctively coded to indicate the type
of drainage involved.
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·3.6.0 Root Drainage
3.6.1 ·General
3.6.2 Pipe Joints
Inside manholes necesS!lry channels and benchings finished smooth by neat
cement in cement concrete (1:2:4) and foot rungs made from 20mm round
bars at 300mm centres and staggered shOuld be provided. Rungs should
project 100mm from wall face and be embedded 200mm Inside cement
concrete block made In that location of brick work. These foot rests shall be
painted with coal tar in 'the projected portions and cement slurry In the
embedded parl Joint of any pipe with brick work shall be rendered perfectly
leak proof.
Pipes and fittings in the connection pipe to the main drainage system shan be
vitrItIed clayware conforming to relevant IS and laid to the line and level
indicated In the drawi"lls.
Rainwater ouUets and down comers to run along inner face of stack wall. shall be
made of standard cast Iron rainwater pipes confonning to IS:1230. The brackets
used to hold the pipes alongside the walls shall be wrought iron clevis type. split
ring type or of perforated strap fron as approved by the Engineer. Each vertical
pipe shall hang freely on Its bracket fixed just below the socket Suitable spacer
blocks are to be kept in between the pipe and wall surface for fixing the pipe. All
bends and junctions shall be provided with water tight ciean-outs.
All joints between pipes. pipes and fittings and manholes shall be gas-tight
when above ground and water tight when under ground. Method of pipe
cutting and jointing shall be as per instruction of the pipe and fittings
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manufacturer or as approved by the Engineer. However folloWing guidelines
may be followed in absence of any Instruction available from the
manufacturer.
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sOcket arid Spigot 'pipes sh311 be pined'by cast lead jOintS. Spigot of the
following pipe should be centred In the SOCket d the preceding pipe by lightly
t> caulking in suffICIent turns of tarred gasket or hemp yam to have unfiUed half
the depth of SOCket After the gasket or hemp yam has been caulked lightl"
.':,
a jointing ring shall be placed round the barrel and tightened against the face
t···· "/
of the SOCket to prevent air lock. Molten lead shall then be placed round the
barrel and tightened against the face of the socket. Thereafter molten lead
should be poured in to fill the remainder of the .socket and caulked wiltl
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suitable tools tight round the joint to malee up for shrinkage of the molten
metal on cooling and should be finished 3mm behind the socket face. If any
Joint Is suspected to be damaged it has to be opened out & redone.
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Joints in cast iron pipes with special JOinting arrangements like "Tyton" joints
etc. shalt follow the instructions of the menufacturer.
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3.9.0 Interi1allllumination System
3.9.1 Lighting fixlures.6haII be j!rovided at the ground lloar and at each interior
platform. .
3.9.2 High pressure sodium vapour lamps of 7011501250 Watt rating with suitable
fittings shall be provided under intenial illumination.
3.9.3 Fixtures installed in rows &hall be aligned veriically and horizontally.
3.9.4 All Ighting flXlures 6haII be suitable for 240 V ± 10%. 50 HZ :t: 5%. single
phase. AC Supply.
3.9.5 The following minimum illumination level shall be achieved and guaranteed by
the Contractor : .
Minimum Illumination Level
Ground lloor. Platforms, stalIt:ase,
landings
Area of diff. Dis\, boards
50 Lux
150 lux
3.10.0 ObsIrud.1on Ughtlog System
3.10.1 The Contraclor shaD supply and Insfallthe aviation obstruction lighting system
on the chimney shall consist of the following items :
a) 4 sets of single obstruction Ilghl!l with fIXtures at each floor level.
b) Complete G.I. conduits, PVC insulated wires, G.I. grounding conductor,
weatherproof outdoor juootlon box and aD accessories viz. supports,
damps, junction boxes, etc. to make the installation complete In aM
respects
3.10:1 Aviation obstriJction lighting system shaD conform 10 the requirements of the
lateiIllndian Standard. the Intemational Civil Aviation organisation (ICAO), the
inSlnx:lioil ismied bY theOlreclcf . Genenll . of ;clvH AviatIoo.oJndi" . and th~
Directoratii of Air'Routeir& Aerodromes' (DARA) ciroularNo, 3 of '987.
3.10.2 The obstruction lights shall be provided at the levels indicated in the drawing.
3.10,3 All aviation obstruction lights at EL (+) 150 M and above shall be high intensity
llashing white light having an effective Intensity of not less than 4000 candelas.
The flash frequency shall be between 4O-6OImin.
. .
3.10.4 All aviation obstruction lights below EL. 150 M shall be medium intensity llashlng
red light having an effective intensity of not less than 1500 candel"s. The IIMh
frequency SMII be 4O-G0imin.
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DCPL-K9A01
3.10.5 All avialion fixtures and accessories shaa be weatherproof, outdoor type
capable of withstanding highly humid and flue-laden almO$phere and generally
conforming to degree of protection IPW-55.
3.10.6 Obstruction lighting system shaU be operated by the Contractor for not less
lhan 60 days. Equipment and work which fails during the test period shall be
repaired or replaced. System performance win be considered satisfactory when
the obstruction rtghting system has operated continuously for a period of at
least sixty (60) days.
3.11.0 Temporary Obstrud:lon lighting
3.11.1 Temporary obstruction lighting shall be provided by the Contractor during
construdlon. Obstruction lights shan be provided at the uppermost part of the
stack or the SUtTOUnding scaffolding as constructiOn proceeds upwants. As
such level spedfied to have permanent obstruction fights Is passed, that level
shall be provided with temporary lighting: For. Temporary obstruction l.ighting.
fixture as per G!§C catalogue "2A750 (l) neon" shaD be used.
3.11.2 Power for operation. of the temporary obstruCtion right shall be obtaineti from
the Construction Power System. Supply circuit for these lights shall be
furnished. installed and maintained by the Contractor.
3.11.3 The temporary ob$Iruction Dghting system shall be operated & maintained by
the Contractor from Sun set to Sun rise. tnl pennanent obstruction Lighting
system is Installed and commissioned.
( 3.11.4 Contractor shall supply six (6) nos. lighting fixtures simftar to the type used by
him for Temporary Obstruction Lighting for Client's use in the event of outage,
if any, of Pennanent Obstruction' lighting fIXtures.
(
3.12.0 Wiring
( 3.12.1 Wires for lightirlg system shaH be PVC insulated. 650 V Ilrade.
l:·"
(.
3.12.2 WIIl!S shall be run in GI conduits suitable for outdOOr installation., Maximum
conduit fill shall be asfollOW$ :
Cable Size
Conduit Size
20 rom 25 mm 32 mm 40 mm 50 Ill'"
If
a) 2.5 Sq. mm Cu 3 5 9
ti
1;', '
...:r
(;
• e
b) 10.0 Sq. mm AI 2 5 7 8
Maximum no. of COJIductors admissible for
conduit
Suitable pull boxes shall be provided at convenient locations.
(PCA.CD.Q03.StlO5CSA24.doc.doc) V.II-D2IS-XXIV: 31
, 339

DCPL·K9A01
3.12.3 lighting fixtures. conduits and junction boxes shall be properly earthed using
galvan~ wire of 14 SWG. Earth wire wiD run along the entire length of the
condult between fixtwes and lighting panels. lighting panels Will be connected
to the grounding system.
3.13.0 Ughtning Protection System
3.13.1 ~I
3.13.2 Air Termlnals
. "
The fighlning protection system to be Installed on the flue duct by the
Contractor shaU be strictly as per specifIcsIioos and shaR satisfy the folloWing
requirements.
The ,flue shall be provided IIIIIth pointed air \enninals uniformly distributed along
the top rim of )he flue. The projected length of the air terminals above the top of
the flue shaU nol be less than 1000 mm. The air terminals shaH be made of lead
coated solid copper rods having a minimum diameter of 20 mm.
3.13,3 Down Conductors
3.14.0 Grounding ,
There WiU be two separate system of varfical down conductors of 50 x 6 mm
Ilats. S(lBI:ed as shown in the drawings. One system. envisaged for lightning
protection. II1II11 have two numbers of down conductors per flue duct starting
from • the top enclreling band leading to the ground: The other system.
envisaged tor earthing of various electrical equipment etc. on the stack. Will
also !lave ground conductors'originating below the platform and leading to
ground.
The connections of the galvanized steel down conductors tQ the nearast
grou,nding grid at the bottom shaH be arc welded. Connection between any two
galvanized steel fIaIs/l)ands shaA be made by arc welding.
A suitable boiled test piece shall be provided at each down conductors at a
convenient height near the bottom of the stack. The galvanization of steel flat
sheH be~at least 610 gmper aq.mIt. of Zinc and m\lSicon1ply with 184759.
3.14.1 Grounding system shaft Include complete grounding for stack electrical
equipment. non current carrying metallic parts including a buried grid around
the stack. All grounding materials shall be suppl'led aod Installed In accordance
with the reterence codes and standards. this SpecifICation and the draWings.
3.14.2 Grounding materials required shall be furnished new and undamaged in
accOrdance with the following requirEments:
i). Grounding EJectrodas 40 rnm diameter 3 metre long
mild steel rods.
(PCA.CO-OO3.S805CSA24.dac.doc) V.II·D2IS-XXIV : 32

!
OCPL-K9A01
ii) Ground Conductor 40 mm diameter mild steel rod.
(
iii) Distribution Boards 50 x 6 mm GS Flat
-
iv) Lighting Panels, Local panels 35 x6mmGS Flat
v) Push Button Station Junction 8SWGGlWire
Box etc.
Distribution Boards
3.15.1 The following distnbution boards have been enVisaged :
a) One (1) No. 415 V AC Distribution Board located at Ground level having
2 Nos. 415 V, 3 ph, 4 wire incamers & castle-key interlock to prevent
paralleling of two supplies. ThiS Distribution Board shall feed two (2)
Nos..L1ghting Distribution Boards.and 63 Amps Receptacles.
b) One (1) No. 415 V AC Emergency Distribution Board located at Ground
level from which emergency supply for staircase and platform lighting of
stack, elevator and aviation lighting panel shall be taken.
This emergency distribution board shall be fed from two different
serVices - one from the above mentioned 415 V AC Nonnal distribution
board and the other from Owne(s 415 V AC e(T1ergency switchgearl
MCC through one 415 V, o"n11 dry type transformer. On failure of
nonnal AC supply, the emergency power will take over by means 01
4 automatic switching.
c) One (1) No.Avtation lighting Panel located suitably from which supply
t
to aviation lights at different elevations have been taken through
conduits. .
t
d) Lighting Distribution Board No. 1 at Ground level shall feed all stairoase
lights and platforms inside staCk upto-IooNer middle half of the stack.
t,
. e) Lighting Distributiol) Board No. 2 suit8b1y·locatedshall feed all staircase
(.
lights and platform at remslning upper portion ofthe stade
(: All bought out electrical equipment shall be from reputed manufacturers who
have manufactured and supp6ed equipment of the type & rating specified and
these equlpments shall have been in successful operation in power plants for at
least three (3) years.
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3.16.2 . The Contractor shall design and prepare detaUed drawings of various electrical
system like Power distribution arrangement, lighting, lightning protection
grounding system etc. and shall submit the same to the OwnerfConsul fot
their review approval.
(PCACO-OO3.se05CSA24.doe.doc) V.lI-D2fS-XXIV : 33
341

DCPL·K9A01
4.0.0 TESTING AND ACCEPTANCE CRITERIA
4.1.0 General
4.2.0 Cement
4.3.0 VVater
4.4.0 Concrete
The Contractor shall cany out aU sampling end testing in accordance with the
relevant IS SpeCifications and as supplemented herein, for the following items
or any other item as may be required by the Engineer unless otharwise
specified in this specification. Tha Contractor shall get the specimens tested
in labolatofy. approved by the Engioeer and shall submit to him, the original
test results in triplicate, within seven days after the completion of the test.
Engineer may present himself while such tests are being carried out.
Representative samples shall be tAken as per the relevant IS SpecifICation
from each consignment of Cement received from the
PurchaserlManufacturerlSupplier for canying out the tests for fineness (by
hand sieving), setting time, compressive strength and soundn~ss tests, and
the Contractor shall cany out the. above tests as per relevant Indian
Standard. If the cement Is suppfled by the Contractor the test shan be carried
out by him. The Contractor shaD cany oljt any or aU the tests on aggregates
as may be required by the Engineer, in accordance with IS:2386 Parts-I to
VIII. The aoceptance crfteria of the samples tested shall be in accordance
withthe requlremenis of the relevant IS specifications..
Sampling and testing of water being used for concrete works shall be carried
out as per IS:3550, by the Contractor, at regular Intervals and whenever
directed by the Engineer. ThiI final acc;eptance crfterion In case of doubt
shan be as per IS:3025.
The Contractor shall take cubes for worXs test as per requirement laid down
,.
in 1$:516 regularly from the day's pour. The.number of test cubes to be taken
~.
.. sheU be. as per 15:456. The. Engineer may also ~ his discretion In deciding .
,.
the rate of cubeS' to be: taken. The. aeeeptance criteria is 'to meet tlie
~~< requirement of 15:456. If the cube test results indicate that some portions or
the work is below the required strength, the Engioeer may order demolition of
f
that portion of work which is below strength and ask the Contractor to
'1
;:. rebuild, provided e satisfactory method of load testing Is not possible. Such
{ testing or demolishing and rebuilding shall be carried out by the Contractor.
?,.
:1
4.5.0 Steel Rue
All site and shop welded joints shaH be inspected and tested in accordance
.£
.: $1
"'
,.
i
I
F:
."
with clause 4.00.00 of Technical specification for Feb. and Eraction of
structural steel work.
(PCACO-OO3.S805CSA24.doc.doc) V.U..o2lS-XXIV : 34
8~2 :..
." I. l'

4.6.0 Insulations
DCPL-K9A01
The Insulating materials shall be tested for its stipulated characteristics and
properties In accordance with the latest editions of IS:3144 and IS:3346
andlor as directed by the Engineer.
('
5.0.0 INFORMATION TO BE SUBMllTED
5.1.0 WlthTender
.~
a)
The following technical Information are required with the tender.
Source and arrangement of processing of aggregates proposed to be
adopted.
b) Type of plant and equipment proposed to be used.
c) Names of firms with which association is sought for to execute the
special Hems of work e.g. nue expansion dlmpensator, load bearing
insulation blocks etc. in the contract. .
d) Types of formwork proposed to be used. All details as per clause no.
3.03.!l6 to be submitted, if slip form method is proposed to be used.
.
-~ e) Shop proposed for fabrication of steel (Rue) liners. Detailed write-up
on procedure of-erection of complete liner system including details of
equipment proposed for the same.
f) For insulating material tests to be offered for inspection & tests for
which test certifICates will be submitted. A drawing showing the
( details of fixing insulation on the nues at bearings, lateral restraints
,
and exterior surface.
(
g) Proposal for lifting of men and material in constructing the chimney.
5.2.0 After Award
.The f

5:2.2 Samples
5,2.3 Deslfin Mix
OCPL-K9A01
The master programme may have to be reviewed and updated by the
Contractor quarterly or at more frequent intervals as may be directed by the
Engineer depending on the exegencles of the work.
Oetalled day to day programme of every month is to be submitted by the
Contractor betore the commencement ot the month.
Samples ot aU materials proposed to be used shall be submitted as directed
by the Engineer, in sufficient quantities. tor approval. All samples shall be
submitted _II In advance of starting work at site. Approved samples wilt be
preserved by tha Engineer for tuture reference. The approval ot the Engineer
shall not, in any _y, relieve the Contractor of his responsibility ot supplying
materiaI'ot specified quaQty.
Design mix as per details of this specifICation giving proportions" ot
ingredients, sources ot aggregates and cement along with accompanying test
results of trial mixes as per relevant IS Specifications shall be submitted to
the Engineer, for his approval, before it can be used on the work.
5.2.4 Detail Drawings
Following items shall be provided by the Contractor which are to be approved
by lIle OWner and Consultant.
a) Detail drawings and destgns of torm work includin9 scaffolding to be
used. If sllpform method of construction is adopted. then detail
drawings showing all the arrangements for slipform technique
including methods tor reducing Internal diameter and providing
raquired slopes on outer diameter.
b) Detail drawings and bar bending schedules for concrete components.
c) Shop drawings forstructunll.steel and 'metai work. including inserts
'. etc. The Contractor shan submit his proposal for testing site and shop
. joints provided insteel·lilembenI. ....... . ' ...
d) Detail drawings for templates and temporary supports tor
embedments.
e) Category wise raql,lirements of MS, tor and structural steel including
GI fiats of various sizes for procurement.
f} Detailed drawings of steel llues indicating details of joints, supports
and restraints including insulation blocks. and details of expansion
compensator.
g} Detailed drawing of hoisting arrangement tor men and material
satisfying statutory regulations laid down tor safety purpose.
(l'CA.C0.()()3.S80SCSA24,doc.doe) V.lI·02l5-XXIV : 36 .
" ('

{
DCPL·K9A01
5.2.5 Reports
Following Test Reports shall be furnished by the Contractor:
a) Mill Test Report for cement and reinforcing steel If Ihe materials are
supplied by the Contractor.
b) Inspection Report of bought ouillems.
c) Inspedlon Report of formworl< and reinforcemenl, insulations ..Ie,
d) Reports of tests of various malerial and concrete.
e) Radiographic lests on welded joints in steel flues.
d) Any other data or report or test result required by the relevant IS
SpecifICations and if required by the Engineer for satisfactory Quafity
control of the worl

VOLUME : II-D/2
ANNEXURE B

OCPL-K9AOI
CONTENT
aAUSENO. DESCRIPTION PAGE NO.
1.00.00 GENERAL V.U-02IS-XIX : 1
2.00.00 .PRODUCTS V.U-02lS-XIX : 2
3.00.00 DOUBLE SKIN INSULATED METAL V.II-D21S-XIX : 4
-CLADDING
4.00.00 EXECUTION V.II-D2I5-XIX ; 4
268
(PCA.CQ.OO3.Sap5CSA19.doc)

OCPL·K9A01
VOLUME: II-D/2
SECTION·XIX
TECHNICAL SPECIFICATION
FOR
SANDWICH METAL ClADDING
1.00.00 GENERAL
1.01.00 . Description
{
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DCPL-K9AOl
iii) Fabricated sandwich melal cladding. Sample size shall be 300
x 300 mm three nos.
iv)
Edge r;eaJing and flashing.
b) Manufacture~s literature indicating the nature of preformed profiled,
colour coating. manufacturer's recommended Installation, Instructions
and maintenanca procedure.
c) Manufacturer's certifICation of compliance with each delivery.
d) Shop Drawings
Showing fabrication details of sandwich/double skin metal cladding
with Insulation, preformed sheet profde and total colour thickness for
profiled top skin and slighlly ribbed bottom skin. thickness and nature
of insulation. inslallationand erection; anchorage. fasteners and
details of acoassories. metal flashing and its fixing including various
openings for doors. windows,louvres, pipes etc,
•
1.03.02
Test Reports
Two copies ofTest Reports and Souroa of Quafity Control Tests.
1.03.03
Supplier Ceitlftcates
Two copies of tedlnic:al data showing that the proposed finish product is
suitabre for the environmental conditions ofthe job site and that the materials
meet specific:ation requirements.
1.04.00
1.04.01
Product Handling
Delivery of Materials to Job site In manufactur~s
packaging .
original unopened
1.04.Q2
1.04.03
. Identify contents with /lame of,mimufacturer. brand name, thermal value and
.appllaitile siandllt'd. .
" ., .....
Store materials In an area protected from adverse ctimStic conditions.
,moisture and open flame or spark and shall be stored off the ground with one
end elevated for drainage. The sheets shall be protected from inclement
weather with a waterproof covering with ventilation to avoid condensation.
2.00.00
2.01.00
Ull.01
PRODUCTS
General
All goods and products covered by these specifications shall be procured
from manufacturer duly approved by the owner
(PCA,CI).OO3.S805CSA19.docl V.tI-02IS-XIX : 2
.' .
270

DCPL·K9A01
2.01.02
2.01.03
2.01.04
Roof insulation shall have a ·mlnlmum R-velue of 2:083 M" "KiWatt.
Thickness of sandwich cladding shall be as required to meet the specified
"R"values. .
Sandwich material shan be of "Rib and Flute" design to ensure wide spanning
and quick recovery after being subjected to excessive load. Double skin
materials shall be interlocking type 150mm wide strip and inner sheet shall be
mild rib & flute type profile to ensure quick recovery after being subjected to
excessive load.
Matel1al
t
t
t
l

DCPL-K9AOl
3.00.00
3.01.00
3.01.01
3.01.02
DOUBu: SKIN INSULAlE> METAL a.ADOING
General
Metal cladding may be of double skin separated by an approved insulation
in between. External sheet shall be of in,terlocklng type.
Double skin wall cladding shaH be comprising ofl50F external panels
manufactured out of 0.6 mm TCT (TomJ coated thickness) aluminium alloy
AA310515050 with stove enameled coil coaled finish, sufficient to withstand
most aggressive climate. on both sides of approved shade. The 150mm wide
panels (150F) shall be clipped on 10 the concealed runners and shall be
interlocked with e8!fi other. The inner sheelingshall be Hi Rib 0.5mm TCT
siuoon modified polyesler coated galvalume steel (AZ-l5Q gsm aluminium­
Zinc alloy metal metallic coaling of total 550 Mpa yield stress as per AS-
1397).The extemal panels shall be 1S0mm wide 17mm deep. The inner sheet
shall have 1000-1020 mm cover width 28-30. mm high crests @2S0-25Smm ,
cJc with side laps. The Inner sheet shall be fixed to structural system by
means of corrosion projected ,\IeIf-drilU!lg. Self-tapping fasteners. The· sub
girts of size 5Ommx50mmx50mm manufactured out of 16 G G.I (1.6mm) 'Z'
shape shall be fixed 10 inner sheeting on face side at purune locations. The
external panels shaH I?e fixed with the help of concealed runners 34.5 wide
x48mm deep ou1 of 0.95 mm thick atuminlum strip with cut outs to hold the
panels In a module of 150mm al1600mm clc and fastened on side girts. The
runners shall be concealed and no fasteners are to penetrate the panels. An
insulation of 50mm thick resin bonded fiberglass roll Insulation .of density
16kg/m s shSll be fixed In \he cevity between two sheets. Contractor shall
make cut oul of doors, windows. louvres. pipe. ducts or other cut outs as
reqUIred as per contract drawings along with flashing. leak proof sealing etc
as required for these cut outslwall openings.
4.09.00
4.01.00
'·4.01'.!)1
4.01.02
4.02.00
·, 4.02.01
4.02.02
EXEOJTION
. Inspection
the .:ontraetor iIhali exernlile UJe area. wtiiilh will be covered; lindlhe·
masOnry wall where the edge of the s8ndwichldouble skin cladding will be
fixed and the structural alignments.
Contractor shall correct any unsatisfactory cond~ions prior to start of work.
Installation
Sandwich panel shail be fixed over structural members with jOints overlapped
and· fastened using stainless steel fasteners self-drilling type or as
reccmmended by the manufacturer.
Double skin wall cladding shaU be installed slriclly as per manufacturer
specifICation and details.
V.II-D2IS-XIX : 4
272

f·
DCPl-K9A01
4.02.03 All ~nd laps of profiled sheeling and jOints of fiashing shall be /jealed properly
wffh non-hardening natural cure smcon sealant or as recommended bV the
manufacturer. .
4.02.04 Accessorles like fasteners, tape, and foam fillers, flashing etc. as required
shall be provided as per recommendation of manufacturer.
4.03.00 Oean-lJp
Remove sealant splatters and smears remove steel particles generated by
drilling to avoid damage.
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(PCAC()"oo3.S80SCSA19.doe) V.I!..o2lS-XIX : 5 273

TITLE: 1X250 MW EXTENSION UNIT-8 AT
DURGAPUR PROJECTS POWER STATION
SPECIFICATION FOR ELECTRICAL WORKS
SPECIFICATION NO. PE-TS-360-620-C001
VOLUME - II B
SECTION - D SUB SECTION :II
REV.NO. 0
SHEET
OF
THE DURGAPUR PROJECTS
LIMITED
DURGAPUR PROJECTS POWER STATION
1 x 250 MW EXTENSION UNIT- 8
VOLUME – II B
SECTION – D
SUB SECTION II
Bharat Heavy Electricals Limited
Project Engineering Management
PPEI Building, Power Sector,
Plot No. 25, Sector 16A,
Noida (U.P.)-201301

TITLE SPECIFICATION NO. PES-509-02A
LIGHTNING PROTECTION &EARTHING
OF CHIMNEY
(SUPPLY & INSTALLATION)
VOLUME
II B
SECTION
D
REV NO. 0 DATE 08.02.2002
SHEET 3 OF 4
1.0 GENERAL
1.1 This section includes the design, fabrica tion, supply, installation and testing of
Lightning Protection system for the Chim ney(s). The requirem ents of this specification
shall be complied with in relation to the requirements set out in Data Sheet-A & Section-
C.
1.2 The contractor’s scope, besides m aterial s upply shall include com plete installation of
Lightning Protection System , protective coating application, and testing of the system .
All m aterials, consum ables, erection equipm ent etc. as required for the com pletion of
installation and testing facilities shall be supplied.
2.0 CODES & STANDARDS
2.1 The latest revisions of the following codes & standards shall be applicable:
IS:2309 Code of practice for protection of bu ildings & allied structures against
lightning.
IS:3043 Code of Practice for earthing
IS:4759
Hot-dipped galvanised coating on structural steel
IS:2629
Recommended practice for Hot-dipped galvanising for Iron & Steel.
IS:2633
Methods of Testing Uniformity of Coating on zinc-coated Articles.
IS:1731
Dimensions for Steel flats for structural & General Engineering Purposes.
IS:1752
Electroplated Coatings of Cadmium on Iron & Steel
Indian Electricity Rules, 1956,
Indian Electricity Act, 1960.
IS:4990(Part-I) Criteria for Design of Reinforced concrete Chimney.
3.0 DESIGN REQUIREMENTS
3.1 Lightning Protection system for the chim ney shall consist of air-term ination network
comprising requisite num ber of vertical coppe r rods, 20m m in dia, projecting at least
1000mm above the top of the chim ney and th e flues, spaced uniform ly along the top
periphery of the outer shell of the Chim ney and that of the flues. A ring of 75x6m m GI
strip shall be laid along the top periphery of the flues and the Chim ney, form ing the

TITLE SPECIFICATION NO. PES-509-02A
LIGHTNING PROTECTION &EARTHING
OF CHIMNEY
(SUPPLY & INSTALLATION)
VOLUME
II B
SECTION
D
REV NO. 0 DATE 08.02.2002
SHEET 3 OF 4
annular horizontal air term inations. The vertical air term inations shall be electrically
connected (Brazed) to the horizontal air term inations, the vertical term ination of the
flues and those of the Chim ney to the hor izontal term ination of the Chim ney. The
vertical terminations shall be spaced not more than 3m apart from each other.
3.2 The air term inations shall be secured to the top of Chim ney top by an arrangem ent of
substantially strong construction to withstand high wind pressure prevalent in the area
commensurate with the height involved. A ll m aterials for the securing arrangem ent
shall be of the sam e grade as the conductors and must be galvanised. The vertical air
terminals at the top of the shell shall also be secured to the guard ring at the top of the
shell.
3.3 A minimum of two num bers of equally spaced conductors, each consisting of 50x6m m
GI strip, shall be brought down from their connecting points on the annular rings at the
top of the Chim ney/flues. The down-conductors originating at the top of the flues shall
be brought down along the walls of the flues a nd electrically connected (welded) to the
annular ring at the top of the outer sh ell of the Chim ney. The down conductors
(minimum two num bers) from the chim ney top shall be brought down to the bottom of
the Chimney all along the exterior Chimney wall.
3.4 A test link of copper black/phosphor bronze gunm etal bolted to the conductor for the
purpose of isolation & testing shall be provided on each down conductor 1000mm above
ground level.
3.5 Down conductors shall be cleated to the wall at an interval of 1500m m all along the
length of the Chimney.
3.6 Down conductors near ground level shall be protected against m echanical injuries by
means of wood-m oulding or non-m etallic cove r. A rem ovable cover of the sam e
material shall be provided over the test- link for easy access.
3.7 The connection between the downconductor from the test link onwards upto an annular
ring of galvanised steel running around the en tire periphery of the chimney bottom shall
be provided through risers which shall be of 40mm dia MS rods.
3.8 The risers shall be term inated on the annular ring of 40m m dia MS rod running around
the periphery of the chim ney buried 1 m etre deep in the ground and clearing all
foundation by at least 2 metres.
3.9 From the term ination points of the downconductors on to this underground ring, m ild
steel rods shall terminate at test pits complete with test-links and electrodes.
3.10 The test pits at para 3.9 shall in turn be connected to the m ain earthmat of the power
house through 40mm dia MS rod.
3.11 All joints, except for testing purposes, shall be welded type lap joints with an overlap of
100mm. The welding shall be com plete around the joint and not tack welded. Electric
arc welding shall be used for all joints.
3.12 After welding, two coats of anti-corrosive (red-oxide) paint followed by a coat of
bituminous paint shall be applied to each joint.
3.13 The 40m m dia MS rods shall be protected against corrosion by applying a coat of
barium chromate paint and two coats of bitumen below the test link.

TITLE SPECIFICATION NO. PES-509-02A
LIGHTNING PROTECTION &EARTHING
OF CHIMNEY
(SUPPLY & INSTALLATION)
VOLUME
II B
SECTION
D
REV NO. 0 DATE 08.02.2002
SHEET 3 OF 4
3.14 The com plete lightning protection system arrangem ent including air-term inations,
conductors, connections, fittings etc. and m aterials located on the exterior within 10m
from the top of the chimney shall have lead coating of 2.0mm thickness.
3.15 All exposed m etal structures such as ha nd rails, platform s, ladders/stairs shall be
connected to the downconductors through earthing band rings, of 50x6m m GI strip
located 2000mm above each platform . Ladders and platforms shall be bonded together
for electrical continuity. A strip of 25x3 mm GI shall be used for connection between
equipment and earthing band rings. Similarly, all lighting fixtures shall be earthed.
3.16 Temporary lightning protection system shall have to be provided and m aintained during
the construction of chimney or till f inal lightning protection system is installed by the
contractor free of cost and in line with IS:4998(Part-I).
3.17 For general reference and guidance, Below Ground Earthing Typical Details drg.no.
PE-DG-XXX-509-0004 & drg.no.PE-DG-XXX-509-003 may be used.
4.0 GALVANISING
4.1 All steel strips and m aterials requiring ga lvanisation shall be hot-dip galvanised
according the IS:2629 & IS:4759. Galvanising shall be done at a place where
galvanising and testing facilities conforming to the relevant Indian Standards exist. The
galvanising shall be sm ooth, clean, uniform , continuous & free from acid spots. The
thickness of zinc deposit at any spot shall not be less than 75 m icrons. The purchaser
reserves the right to m easure the thickness of zinc deposit and reject any com ponent
which shows thickness of zinc at any loca tion less than 75 m icrons. Should the
galvanising of the sample be found defective, the entire batch of the steel will have to be
re-galvanised at the seller’s cost.
4.2 All nuts, bolts and washers, wherever used, shall be cadmium coated or zinc passivated,
the thickness of plating conforming to the relevant Indian Standards.
5.0 INSPECTION & TESTING
5.1 The following stages of manufacture/installation shall be stage inspected by purchaser or
his duly authorised representative:
5.1.1 Inspection of all material such as vertical ai r terminals, steel strips, electrodes, test links
including hardware items such as bolts, nuts etc.
5.1.2 Inspection of m anufacturing processes su ch as shearing, punching, beinding, welding,
galvanising, painting etc.
5.1.3 Inspection of installation procedures
The actual inspection will be carried out as per the agreed Quality Plan.
5.2 TESTING
5.2.1 The supplier shall perform all tests nece ssary to ensure that the m aterial and
workmanship conform to relevant standard s and that such tests are adequate to

TITLE SPECIFICATION NO. PES-509-02A
LIGHTNING PROTECTION &EARTHING
OF CHIMNEY
(SUPPLY & INSTALLATION)
VOLUME
II B
SECTION
D
REV NO. 0 DATE 08.02.2002
SHEET 3 OF 4
demonstrate that the equipm ent shall co mply with the requirem ents of this
specification.
5.2.2 The tolerance in dimensions shall be in accordance with appropriate Indian Standards.
5.2.3 Forged steel below 10mm thick is subject to Magnetic Particle Testing.
6.0 DRAWINGS, DATA & DOCUMENTS
6.1 Data sheet-A of this specification gives th e details of m aterials to be used for the
Lightning Protection system for Chimney.
6.2 The tenderer shall subm it his design(s) a nd drawings for Dir ect stroke Lightning
Protection System of Chimneys for purchaser’s evaluation/scrutiny and approval.
6.3 The contractor shall furnish his design(s) and installation drawings for approval.
6.4 The contractor shall furnish the requisite num ber of prints & RTF’s of all drawings as
specified elsewhere in this specification.
6.5 The site modifications/deviations shall be m arked on the latest revision of the drawings
& submitted as ‘As Built’ drawings to the purchaser after completion of installation.
6.6 Tenderer shall submit all filled up schedules as per Volume-III.
6.7 The tenderer shall subm it reports on Type tests & Special tests conducted on lightning
protection materials & accessories.
7.0 COMPLETENESS
7.1 The offer for supply and erection shall be co mplete in all respects & shall include all
materials, tools and appliances, whether speci fied or not, required for the com pletion of
the job.
7.2 Supply/arrangements of all accessories and material etc. shall be the responsibility of the
contractor.

TITLE SPECIFICATION NO. PES-509-02A
LIGHTNING PROTECTION &EARTHING
OF CHIMNEY
(SUPPLY & INSTALLATION)
VOLUME
II B
SECTION
D
REV NO. 0 DATE 08.02.2002
SHEET 3 OF 4
SPECIFIC TECHNICAL REQUIREMENTS
MATERIALS & SIZES
The following are the m inimum sizes of m aterial to be used for lightning protection
system:
S.No. Material
Minimum Size
1. COPPER RODS (Lead Coated)(for vertical air
Terminations projecting 1000mm above the Chimney/
flues)
20mm dia
2. GI STRIP
(for annular horizontal band ring at the top of the
Chimney/flues) 75x6m m
3. GI STRIP
(for downconductor) 50x6m m
4. GI STRIP
(for earthing band ring each platform)
50x6mm
5. MS ROD
(for risers) 40m m dia
6. TEST LINK
com
patible with size at
Sl.No.3
& 5 above
7. MS ROD
(for annular ring buried 1 metre in the ground around
the chimney) 40m m dia
8. MS ROD
(for electrodes) with Test Pits
40mm dia
9. MS ROD
(for connection between test pit and customer’s
earthmat)
40mm dia
10. GI STRIP/WIRE
(for connection between equipment and earthing
band rings) 25x3m m/As required
1.0 GUARANTEED TECHNICAL PARTICULARS:

TITLE SPECIFICATION NO. PES-509-02A
LIGHTNING PROTECTION &EARTHING
OF CHIMNEY
(SUPPLY & INSTALLATION)
VOLUME
II B
SECTION
D
REV NO. 0 DATE 08.02.2002
SHEET 3 OF 4
The tenderer shall fill up and submit the following technical particulars:
1.01 Name of Manufacturer :
1.02 Place and country of Manufacture :
1.03 Standards applicable :
i/ For materials & sizes :
ii/ For galvanisation/Electroplated coating :
iii/ For testing uniformity of Galvanization :
iv/ For code of practice :
v/ For hexagonal bolts, nuts washers :
vi/ For welding :
1.04 Thickness of galvanizing on steel :
1.05 Thickness of Electriplated coatings :
1.06 Thickness of Lend coating on copper :
1.07 Materials and sizes offered :
i/ Below ground conductor :
ii/ Electrodes :
iii/ Risers :
iv/ Down Conductors :
v/ Air terminations (Vertical) :
vi/ Air termination (Horizontal) :
vii/ Test Pits :
viii/ Test Links :
1.08 Whether all type test certificates furnished
1.09 Whether all schedules of Vol.III filled up and submitted.

TITLE:
LIGHTING NOTES AND DETAILS
SPECIFICATION NO. PES-558-0004
VOLUME - II
SECTION - C Sub Sec -II
REV.NO. 0 DATE
SHEET 1
OF
LIGHTING NOTES AND DETAILS
SPECIFICATION NO. PES-558-0004

TITLE:
LIGHTING NOTES AND DETAILS
LIGHTING NOTES
SPECIFICATION NO. PES-558-0004
VOLUME - II
SECTION - C Sub Sec -II
REV.NO. 0 DATE
SHEET 1
OF
1.0 These lighting notes and details shall be read and construed in conjunction with the
lighting specifications and drawings
2.0 Contractor shall develop final conduit/cable routings based on fixture location and
other site conditions.
3.0 Unless otherwise shown, the mounting heights of lighting fixtures and accessories
shall generally be as follows.
3.a. Lighting fixture in general areas of powerhouse, miscl. Pump house etc.
3.a.i. Low bay type : 3000 mm to bottom.
3.a.ii. Medium bay type : bet 3500 mm to 8000 mm to bottom.
3.a.iii. High bay type : above 8000mm to bottom.
3.b. Bracket lights over door opening : 300 mm bot of fixture above opening.
3.c. Receptacles
3.c.i. In control room office : 450 mm floor to center.
3.c.ii. Elsewhere : 900 mm floor to center.
3.d. Local switches
: 1500 mm floor to center
3.e. Lighting panels
: 1800 mm floor to top
4.0 All outdoor illumination fixtures unless it fed from photocell/tank-switch controlled
lighting panel shall be provided with outdoor type local switches.
5.0 Separate neutral wire shall be provided for each circuit. Wiring throughout the
installation shall be such that there is no break in the neutral wire in the form of switch
or fuse.

.
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET 1 O 3
CHARACTE-
RISTIC
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-558-00-Q-001 / 01 TITLE
SYSTEM ITEM ILLUMINATION SECTION VOLUME III
EXTENT O
CHECK
6
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
10
ORM No. PEM — 6041-0
REMARKS
1.0 CABLES & WIRES 1. SURACE MA VISUAL SAMPLE BHEL SPEC., BHEL SPEC., INSPN. 3/2 2 1 TO BE PROCURED
DEECTS IS:694 , IS:694 , REPORT & TEST ROM APPROVED
IS:1554 IS:1554 REPORT ROM SOURCE
MANUACTURER
2.0 JUNCTION BOXES, LIGHTING
PANELS AND DISTRIBUTION BOARDS
2.DIMENSIONS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 3/2 2 1
3. TYPE CR ELEC. ONE/TYPE BHEL SPEC., BHEL SPEC., TEST CERT. 3 2 1
TESTS TESTS & SIZE IS:694, IS:694,
IS:1554
IS:1554
4. ACCEP- MA -DO- SAMPLING -DO- -DO- -DO- 3 2 1
TANCE
TESTS
5. ROUTINE MA -DO- 100% -DO- -DO- -DO- 3 - 2,1
TESTS
6. RLS CR RLS TESTS SAMPLES BHEL SPEC. BHEL SPEC. -DO- 3 2 1
PROPS.
2.1 JUNCTION BOXES 1.DIMENSIONS MA MEASUREMENTS 100% BHEL DRG. BHEL DRG. INSP. REPORT 3 - 2 COMPONENTS TO BE O
APPROVED MAKE.
2.PAINT SHADE/ MA VISUAL / MEAS. SAMPLE BHEL SPEC./DRG. BHELSPEC./DRG. -DO- 3 - 2
THICKNESS
3.HV / IR / HV MA ELECT. TESTS 100% 2KV AC OR 2KV AC OR -DO- 3 - 2
1 MINUTE 1 MINUTE
4.DEGREE O MA TESTS 1/SIZE IS:2147 IS:2147 TEST CERT. - - 2,1
PROTECTION
5.SPECIAL TESTS MA -DO- -DO- IS :2148 IS:2148 -DO- - - 2,1
I ANY, EXPLOSION
PROO ETC.
2.2 LIGHTING PANELS AND LIGHTING 1. DIMENSIONS MA MEASUREMENT SAMPLE BHEL DRG. BHEL DRG. INSPT. REPORT 3 2,1 - COMPONENTS TO BE O
DISTRIBUTION BOARDS
APPROVED MAKE.
11
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE

.
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET 2 O 3
CHARACTE-
RISTIC
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-558-00-Q-001 / 01 TITLE
SYSTEM ITEM ILLUMINATION SECTION VOLUME III
EXTENT O
CHECK
6
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
10
ORM No. PEM — 6041-0
REMARKS
11
2. PAINT SHADE/ MA VISUAL/ -DO- BHEL SPEC./DRG. BHEL SPEC./DRG. INSPT. REPORT 3 2,1 -
THICKNESS
MEASUREMENT
3.DEGREE O MA TESTS 1/SIZE BHEL SPEC./ BHEL SPEC./ TEST CERT. - - 2,1
PROTECTION RELEVANT IS RELEVANT IS
(INCLUDING
EXPLOSION
PROO I ANY)
4.PERORMANCE MA ELEC. 100% BHEL SPEC. BHEL SPEC. INSPT. REPORT 3 2,1 - BHEL SHALL WITNESS ON
TESTS
RANDOM ONE SAMPLE,
THOUGH EACH ITEM SHALL
BE CHECKED BY THE
MANUACTURER.
5.HV/IR/HV MA ELEC. 100% 2.5 KV AC OR 2.5 KV AC OR -DO- 3 2,1 - -DO-
1 MINUTE 1 MINUTE
6. TEMP. RISE MA ELEC. 1/RATING BHEL SPEC. BHEL SPEC. -DO- 3 2 1
TEST (OR COM-
PLETE ASSEMBL-
ED LDB)
3.0 TUNGSTEN ILAMENT LAMPS, 1. - ACCEPTANCE MA TESTS SAMPLE BHEL SPEC./ BHEL SPEC./ TEST CERT. 3,2 - 1
TUBULAR LUORESCENT LAMPS, TESTS RELEVANT IS RELEVANT IS
H.P. MERCURY VAPOUR LAMPS,SODIUM
VAPOUR LAMPS,BALLASTS, LUMINAIRES
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE

.
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET O 3
CHARACTE-
RISTIC
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-558-00-Q-001 / 01 TITLE
SYSTEM ITEM ILLUMINATION SECTION VOLUME III
EXTENT O
CHECK
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
4.0 CONDUITS 1. MATERIAL MA VISUAL, MECH. AS PER SPEC./ IS:9537 IS:9537 INSPT. REPORT 3 2 1
AND CHEMICAL IS : 9537
6
2. DIMENSIONS MA MEASUREMENT AS PER SPEC./ IS:9537 IS:9537 -DO- 3 2 1
IS : 9537
3. OTHER TESTS MA TESTS AS PER SPEC./ AS PER SPEC./ IS:9537, -DO- 3 2 1
IS:9537,
IS:9537,
10
ORM No. PEM — 6041-0
REMARKS
11
5.0 ELECTRIC POLES
5.1 MATERIAL 1. CHEMICAL MA CHEM. ANALYSIS SAMPLE IS:2713, IS:2713 -DO- 3/2 - 2,1
COMP.
IS:228 &IS:228 &
IS:1894
IS:1894
2. PHYSICAL MA PHYS. TESTS -DO- -DO- -DO- -DO- 3/2 - 2,1
PROP.
5.2 INAL INSPECTION 1. WORK- MA VISUAL & MEAS. SAMPLES BHEL DRG./IS:2713 BHEL DRG./IS:2713 -DO- 3/2 2,1 -
MANSHIP
& INISH
2. DIMENSIONS MA -DO- -DO- -DO- -DO- -DO- 3/2 2,1 -
3. WEIGHT MA -DO- -DO- -DO- -DO- -DO- 3/2 2,1 -
4. TESTS AS MA -DO- -DO- IS:2713 IS:2713 -DO- 3/2 2,1 -
PER IS:2713
NOTE : IN CASE TYPE TEST CERTIICATE OR DEGREE OPROTECTION /EXPLOSION PROONESS ROM INDEPENDENT LAB. IS NOT
AVAILABLE, THE ITEM SHALL BE TESTED AT AN INDEPENDENT LAB.
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE

TITLE:
SPECIFIC TECHNICAL REQUIREMENT
SPECIFICATION NO. PE-TS-Q11-600-C051
VOLUME - IIB
SECTION “C”
Sub Sec-II
REV. 00 DATE: 22 – 10 - 2003
SHEET 1 of 3
1.00.00 CODES AND IS:1554, IS:7098, IEC:502, IS:6380, IS:9968
STANDARDS
2.00.00 TYPE All cable shall be Flame retardent low smoke type
3.00.00 RATING As p er requirement specified in Gen eral Electrical
Requirements.
4.00.00 OPERATIONAL REQUIREMENTS
All cable s shall be suita ble for high ambient, hig h humid tro pical India n climati c
conditions. All cabl es shall be d esigned to withstand the me chanical, ele ctrical and
thermal stresses under the foreseen st eady state and tr ansient/fault conditions, and
shall be suitable for the proposed method of installation.
5.00.00 DESIGN AND CONSTRUCTIONAL FEATURES
5.01.00 Parameters of the cables are as follows :
-- -----------------------------------------------------------------------------------------------------------------
Particul ars Power cables Control cables Trailing cables
------------------------
XLPE PVC
-- -----------------------------------------------------------------------------------------------------------------
a
) Conductor
b) Main Insulation
i) Material Stranded Stranded plain Tinned copper of
Aluminium annealed copper class 5 of IS:8130
ii) Size As required, but As required, but As required, but
Min. 6 sq.mm min. 1.5 sq.mm. min. 1.5 sq.mm.
size. size. size.
iii) Shape Circular/ Circular/
sector sector
shaped. shaped
Circular
only for
HT cables
i) Material XLPE PVC PVC Heat resistant elastomeric
compound
based on Ethylene
Propyline Rubber
(EPR)

TITLE:
SPECIFIC TECHNICAL REQUIREMENT
SPECIFICATION NO. PE-TS-Q11-600-C051
VOLUME - IIB
SECTION “C”
Sub Sec-II
REV. 00 DATE: 22 – 10 - 2003
SHEET 2 of 3
-- -----------------------------------------------------------------------------------------------------------------
Particul ars Power cables Control cables Trailing cables
------------------------
XLPE PVC
-- -----------------------------------------------------------------------------------------------------------------
ii)
Continuous
withstand 90 70 70 90
temperature
(deg.C)
iii) Short circuit
withstand 250 160 160 250
temperature
(deg.C)
iv) Colour identification
As per relevant codes and standards
c) Inner Sheath All armoured and multicore unarmoured cables have distinct
extruded inner sheath
i) Material PVC PVC PVC Heat resistant
elastomeric
compound.
ii) Colour Black Black Black Black
d) Armour, wherever provided
i) Material Aluminium wire for GS wire/flat as Nylon cord
single core cable per relevant IS. reinforcemenet
and GS wire/flat for Min. coverage
multi-core cables of 90%.
as per relevant IS.
Minimum Coverage
of 90%
ii) Breaking 95% of normal 95% of normal armour
load of armour
joint
e) Outer sheath All power & control cable shall have extruded outer sheath.
i) Material PVC PVC PVC Heat resistant,
(Polyethe-
oil resistant &
lene based
flame retardant
halogen free
heavy duty elastmaterial
not
tomeric
accepta ble) compound

TITLE:
SPECIFIC TECHNICAL REQUIREMENT
SPECIFICATION NO. PE-TS-Q11-600-C051
VOLUME - IIB
SECTION “C”
Sub Sec-II
REV. 00 DATE: 22 – 10 - 2003
SHEET 3 of 3
-- -----------------------------------------------------------------------------------------------------------------
Particul ars Power cables Control cables Trailing cables
------------------------
XLPE PVC
-- -----------------------------------------------------------------------------------------------------------------
ii) Colour Black Black Grey Black
5.01.02 HT cables
iii) Marking - Cable size & Same as for Same as for
voltage grade Power Cables Power Cables
(by embossing)
- Word “FRLS”
@ m 5by
(
embossing)
- Sequential marking
@1m
f) FRLS Oxygen Index : Min. 29 (As per ASTMD 2863)
properties on Acid gas generation: Max. 20% (As per IEC754-I)
outer sheath Smoke density rating: 60% (As per ASTMD 2843)
g) Flamability As per Swedish chimney test F3 as per SEN 4241475
test on all As per IEC 332 Part-3 (Category B)
types of cables
For HT ca bles cond uctor scree n and insulatio n scre en shall b e of extrude d semi -
conducting compou nd an d shall b e a pplied al ongwith XLPE insul ation in a singl e
operation by triple extrusion process. Method of curing for 11kV/6.6kV cables shall be
“Dry cu ring/gas curing/steam cu ring” whereas fo r 3 3KV cable s i t shall be " Dry/Gas
curing". 11kV/6.6kV cables shall be provided with copper metallic screen suitable for
carrying allo wable earth f ault current for 2 secs. All other voltag e grad e HT cables
shall be provided with cop per metallic screen suitable for carrying earth fault current
as per E0. For single core armoured cables, the a rmouring shall co nstitute th e
metallic part of screening.
5.01.03 LT Cables of size 150 sq.mm. and above shall be with XLPE insulation.
5.01.04 Core identification
5.01.05 Armouring
For cables having more than five (5 ) cores, each core shall be identified by number
marking. However, for cables upto five (5) cores, the sam e shall be by col our as pe r
IS.
Cables buried direct in ground and cables in switchyard shall be armoured.

Clause No.
POWER AND CONTROL CABLES
...........................................................
(Bidder's Name)
POWER AND CONTROL CABLES
(Use separate sheet for each type and size of cables)
1.00.00 Make ............................ .....................
1.02.00 Country of Manufacturer ............................ .....................
1.03.00 Type & designation ............................ .....................
1.04.00 Applicable standard ............................ .....................
1.05.00 Cable size & no. of cores ............................ .....................
1.06.00 Rated voltage ............................ .....................
1.07.00 Catalogue attached as Annexure No. ............................ .....................
1.08.00 Continuous current rating ............................ .....................
for max. conductor temperature
a) When laid in air at an ambient ............................ .....................
temperature of 50 deg. C
b) When buried in soil having ............................ .....................
thermal resistivity of 150 deg.C
cm/n at a depth of 1000 mm
at ground ambient temperature
of 40 deg. C
1.09.00 Short circuit withstand capacity and ............................ .....................
duration for
a) Conductor ............................ .....................
b) Screen ............................ .....................
c) Armour ............................ .....................
1.10.00 Conductor ............................ .....................
a) Material ............................ .....................
b) Nominal cross section ............................ .....................
area in sq. mm
TECHNICAL DATA REQUIREMENT SHEETS VOLUME - III BOOK 2 PAGE
FOR POWER PLANT TURNKEY PACKAGE SECTION - DE-3 1 OF 2
DOC. NO. : CW-9272-C-O-M-003

Clause No.
POWER AND CONTROL CABLES
...........................................................
(Bidder's Name)
1.11.00 Insulation
c) Shape of conductor ............................ .....................
d) DC resistance at 20 o C ............................ .....................
a) Material ............................ .....................
b) Nominal thickness (in mm) ............................ .....................
c) Type of curing (for XLPE) ............................ .....................
1.12.00 Metallic screen (wherever applicable)
a) Material ............................ .....................
b) Type ........................... ....................
c) Rating KA, Sec
1.13.00 Material & Type of Inner sheath ............................ .....................
1.14.00 Armour material & shape ............................ .....................
1.15.00 Outer sheath material & type ............................ .....................
1.16.00 Over all dia of cable (in mm) ............................ .....................
1.17.00 Guaranteed value of minimum ............................ .....................
oxygen index of outer sheath
1.18.00 Maximum acid-gas generation ............................ .....................
by weight (%) of outer sheath
1.19.00 Smoke Density rating of outer sheath ............................ .....................
TECHNICAL DATA REQUIREMENT SHEETS VOLUME - III BOOK 2 PAGE
FOR POWER PLANT TURNKEY PACKAGE SECTION - DE-3 2 OF 2
DOC. NO. : CW-9272-C-O-M-003

.
.
44
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET 1 O 6
CHARACTE-
RISTICS
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-507-00-Q-002 / 02 TIITLE
SYSTEM ITEM PVC POWER & CONTROL CABLE SECTION VOLUME III
EXTENT O
CHECK
6
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
10
ORM No. PEM — 6041-0
REMARKS
11
1.0 RAW MATERIAL
1.1 PVC COMPOUND (FOR INSULATION- 1. PHYSICAL PRO- MA PHYS TESTS SAM- IS:5831/ IS:5831/ LOG BOOK 3/2 - 2
AND SHEATH) PERTIES PLE BHEL SPEC- BHEL SPEC /TEST
IFICATION IFICATION CERT
2. ELEC. PROPER- MA ELEC TEST -DO- -DO- -DO- -DO- 3/2 - 2
TIES
3.MAKE & TYPE MA VISUAL 100 % PLANT STD. PLANT STD. DO 2 - -
1.2 GALVANIZED STEEL WIRE / STRIP 1. PHY. AND ELEC MA PHY. ELEC.TESTS SAM-* IS:3975, IS:3975 -DO- 3/2 - 2 * SAMPLE FROM EACH
PROPERTIES PLE BHEL SPEC BHEL SPEC BATCH / LOT
2. DIMENSION MA MEASUREMENT -DO- -DO- -DO- -DO- 3/2 - 2
3. GALVANIZAT- MA GALV. TESTS -DO- -DO- -DO- -DO- 3/2 - 2
ION QUALITY
1.3 COPPER / ALUMINIUM RODS / WIRES 1. PHYSICAL MA PHY.TESTS -DO- IS:613 IS:613 -DO- 3/2 - 2
PROERTIES. IS:5484 IS:5484
IS:8130
IS:8130
AND BHEL AND BHEL
SPEC.
SPEC.
2.CHEM COMPOS- MA CHEM ANALYSIS -DO- -DO- -DO- -DO- 3/2 - 2
ITION & PURITY
3. ELECTRICAL MA ELECTRICAL -DO- -DO- -DO- -DO- 3/2 - 2
PROPERTIES
TESTS
4. DIMENSION MA MEASURMENT -DO- -DO- -DO- -DO- 3/2 - 2
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE
DATE
BIDDER’S / VENDOR’S COMPANY SEAL

.
.
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET 2 O 6
CHARACTE-
RISTICS
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-507-00-Q-002 / 02 TIITLE
SYSTEM ITEM PVC POWER & CONTROL CABLE SECTION VOLUME III
EXTENT O
CHECK
6
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
10
ORM No. PEM — 6041-0
REMARKS
11
2.0 IN PROCESS
2.1 WIRE DRAWING, TINNING 1. PHYSICAL, CR PHY. & ELECT- SAMPLE BHEL SPEC., BHEL SPEC., LOG BOOK 2 - 1
AND ANNEALING ELECT. FINISH TESTS IS-8130 IS-8130
& DIMEN.
VISUAL, MEAS.
2. CHEMICAL CR CHEMICAL -DO- -DO- -DO- -DO- 2 - -
TEST FOR
TEST
TINNING
2.2 STRANDING OF WIRES 1. NO. OF WIRES MA COUNTING SAMPLE VENDORS/ VENDORS/ LOG BOOK 2 - -
BHEL SPEC. BHEL SPEC.
& APPD.
& APPD.
DATA SHEET & DATA SHEET &
RELEVANT IS RELEVANT IS
2 SEQUENCE,LAY MA VISUAL, -DO- -DO- -DO- -DO- 2 - -
LENGTH AND
MEAS
DIRECTION
3. SURFACE
FINISH MA VISUAL -DO- -DO- -DO- -DO- 2 - -
4. DIMENSION MA MEASURE- -DO- -DO- -DO- -DO- 2 - -
MENT
FREE FROM -DO- 2 - 1
2.3 CORE - INSULATION 1 SURFACE MA VISUAL 100% - BULGING, BURNT
(NO REPAIR PERMITTED) FINISH PARTICLES
LUMPS, CUTS &
SCRATCHES
2. INSULATION CR MEASUREMENT SAMPLE APPD.DATA SHT. APPD.DATA SHT. -DO- 2 - -
THICKNESS IS : 1554 IS : 1554
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE
DATE
BIDDER’S / VENDOR’S COMPANY SEAL

.
.
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET 3 O 6
CHARACTE-
RISTICS
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-507-00-Q-002 / 02 TIITLE
SYSTEM ITEM PVC POWER & CONTROL CABLE SECTION VOLUME III
EXTENT O
CHECK
6
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
10
ORM No. PEM — 6041-0
REMARKS
3. CONCENTRI- CR MEASUREMENT SAMPLE MFR. STD. MFR. STD. -DO- 2 - 1 # TO BE CHECKED
CITY. # ./APPD. DATA /APPD. DATA AT STARTING & FINISH
SHEET. SHEET. END OF EXTRUDED LENGTH
4. DIA OVER INS- MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - -
ULATION
11
5. SPARK TEST CR ELECTRICAL 100% MFR. STD. MFR. STD. -DO- 2 - 1
OR WATER
IMMERSION TEST
6. CORE IDENTIF- MA VISUAL 100% IS:1554 IS:1554 -DO- 2 - -
ICATION.
2.4 CORE - LAYING 1.DIA OVER LAID MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - -
UP CORE
2.SEQUENCE OF MA VISUAL & MEAS. SAMPLE MFR. STD/ MFR. STD/ LOG BOOK 2 - -
LAY, LAY LENGTH RELEVANT IS RELEVANT IS
& DIRECTION
UP CORE
2.5 INNER SHEATH EXTRUSION 1. SURFACE MA VISUAL 100% _ FREE FROM -DO- 2 - -
FINISH
BULGING,BURNT
PARTICLES,
LUMPS CUTS &
SCRATCHES
2. SHEATH MA MEASUREMENT SAMPLE IS:5831 & IS:5831 & -DO- 2 - -
THICKNESS DATA SHEET DATA SHEET
IS-1554
IS-1554
3. DIA OVER INN- MA -DO- -DO- -DO- -DO- -DO- 2 - -
ER SHEATH
2.6 ARMOURING 1. NO. OF WIRES/ MA COUNTING AT THE START BHEL SPEC./ BHEL SPEC./ -DO- 2 - -
STRIPS OF THE APPD.DATA SH. APPD.DATA SH.
PROCESS IS:3975 & IS:1554 IS:3975 & IS:1554
2. LAY DIRECTION MA VISUAL -DO- -DO- -DO- -DO- 2 - -
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE
DATE
BIDDER’S / VENDOR’S COMPANY SEAL

.
.
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET 4 O 6
CHARACTE-
RISTICS
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-507-00-Q-002 / 02 TIITLE
SYSTEM ITEM PVC POWER & CONTROL CABLE SECTION VOLUME III
EXTENT O
CHECK
6
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
3. LAY LENGTH MA VISUAL, MEAS. -DO- -DO- -DO- -DO- 2 - -
10
ORM No. PEM — 6041-0
REMARKS
11
4. COVERAGE MA MEASUREMENT -DO- -DO- -DO- -DO- 2 - -
5. DIA OVER - MA MEASUREMENT -DO- -DO- -DO- -DO- 2 - -
ARMOURING
2.7 OUTER SHEATH EXTRUSION 1. SURFACE MA VISUAL 100% - FREE FROM BUL- LOG BOOK 2 - -
FINISH GING, BURNT PA-
RTICLES, LUMPS
CUTS & SCRATC-
HES.
2. SHEATH THICK- MA MEASUREMENT SAMPLE IS:5831 & IS:5831 & -DO- 2 - -
NESS IS-1554 IS-1554
DATA SHEET DATA SHEET
3.DIA OVER OUT- MA -DO- -DO- -DO- -DO- -DO- 2 - -
ER SHEATH
4. MARKING MA VISUAL 100% IS:1554 & IS:1554 & TEST REPORT 2 - - SEQUENTIAL MARKING
BHEL SPEC. BHEL SPEC. SHALL BE DONE BY
PRINTING.
2.8 FINISHED CABLE 1. ROUTINE TEST CR ELEC. & MEAS. 100% IS:1554 & IS:1554 & TEST REPORT 2 - 1
BHEL SPEC. BHEL SPEC.
2.TYPE AND FRLS CR ELEC. PHY SAMPLE * -DO-/APPD. DATA -DO-/APPD.DATA -DO- 2 - 1 *ONE DRUM / SIZE / LOT
TESTS & MEAS SHEET. SHEET.
3.0 FINAL INSPECTION 1. FINISH & MA VISUAL (SEE REMARK ) BHEL SPEC. FREE FROM -DO- 2 1 - ONE DRUM EACH FOR
LENGTH IS: 1554 BULGING,BURNT POWER AND CONTROL
PARTICLES LUMPS CABLES IN A LOT
CUTS & SCRATC-
HES.
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE
DATE
BIDDER’S / VENDOR’S COMPANY SEAL

.
.
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET 5 O 6
CHARACTE-
RISTICS
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-507-00-Q-002 / 02 TIITLE
SYSTEM ITEM PVC POWER & CONTROL CABLE SECTION VOLUME III
EXTENT O
CHECK
6
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
10
ORM No. PEM — 6041-0
REMARKS
11
2. DIMENSION MA MEASUREMENT AS PER IS APPD.DATA APPD.DATA -DO- 2 1 -
SHEET.
SHEET.
IS:1554
IS:1554
IS:10810
IS:10810
3. ARMOURING- MA VISUAL & MEAS. AS PER IS -DO- -DO- -DO- 2 1 -
COVERAGE
NO.OF WIRES
/STRIPS
4.MARKING/COL- MA VISUAL -DO- -DO- -DO- -DO- 2 1 -
OUR CODING
5 ACCEPTANCE CR PHY. & ELECT. -D0- -DO- -DO- -DO- 2 1
TESTS
TESTS
6. TYPE & FRLS CR MEASUREMENT (SEE REMARK) BHEL SPEC. , BHEL SPEC. -DO- 2 1 - TYPE TEST SHELL BE
TESTS APPD. DATA APPD. DATA WITNESSED ON ONE
SHEET SHEET SAMPLE PER TYPE
(POWER / CONTROL)
OF EVERY LOT.
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE
DATE
BIDDER’S / VENDOR’S COMPANY SEAL

.
.
S.
NO.
1
COMPONENT / OPERATION
2
QUALITY PLAN
SHEET 6 O 6
CHARACTE-
RISTICS
CHECK
3
CAT.
4
TYPE/
METHOD O
CHECK
5
CUSTOMER PROJECT SPECIICATION
TITLE
NUMBER
BIDDER / QUALITY PLAN SPECIICATION
VENDOR NUMBER PED-507-00-Q-002 / 02 TIITLE
SYSTEM ITEM PVC POWER & CONTROL CABLE SECTION VOLUME III
EXTENT O
CHECK
6
REERENCE
DOCUMENT
7
ACCEPTANCE
NORM
8
ORMAT O
RECORD
9
AGENCY
P W V
10
ORM No. PEM — 6041-0
REMARKS
11
NOTES:
A) JOINTS IN WIRES SHALL BE AS PERMITTED BY IS/BHEL SPECIFICATION. VENDOR TO CERTIFY THE SAME
B) NO REPAIR OF CORE INSULATION FERMITTED.
C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION.
D) PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE.
E) RECORD OF RAW MATERIAL, PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDOR’S Q.C. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER.
F) FILLERS / DUMMY CORES ETC. SHALL BE AS PER BHEL SPECIFICATION.
G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER VENDOR’S SAMPLING PLAN.
H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION.
LEGEND :- P - PERORMER : W-WITNESSER : V - VERIYER:
1-BHEL/BHEL'S CUSTOMER : 2- VENDOR : 3-SUB VENDOR
BHEL PARTICULARS BIDDER / VENDOR
NAME
SIGNATURE
DATE
BIDDER’S / VENDOR’S COMPANY SEAL

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
GENERAL TECHNICAL REQUIREMENTS
OF
LIGHTING DISTRIBUTION BOARD
&
LIGHTING PANEL
SPECIFICATION NO. PES-559-01A

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
3.2.3 Independent gasketted hinged door with operating handle shall be provided for
access to transformer & its taps. Operating handle shall have built-in key locking
arrangement.
3.2.4 Suitable ventilation arrangement for the transformer compartment to dissipate the
heat of the transformer shall be provided. The arrangement shall be in the form of
louvers and the same shall be provided with galvanized wire mesh with dust catchers
on the inside.
3.2.5 The degree of protection for transformer compartment shall be IP:42 unless
mentioned otherwise in Data Sheet A.
3.2.6 Connections between transformer secondary terminals and the busbars shall be
made by using PVC insulated flexible copper cables or busbars.
3.2.7 Warning plate shall be provided on transformer enclosure. The inscription of warning
plate shall be as given below:
- DO NOT OPEN DOORS WHEN ENERGISED
- KEEP TAPS AT SAME POSITION FOR ALL PHASES
3.2.8 Transformer enclosure shall be provided with a danger plate.
3.3 Lighting Transformer
3.3.1 Lighting transformer, where specified shall form an integral part of lighting distribution
board.
3.3.2 Lighting transformer shall be dry type, natural air cooled and suitable for mounting
inside the lighting distribution board. Transformer shall be non-encapsulated type,
unless specified otherwise in Data Sheet A.
3.3.3 Rating of transformer shall be 50 kVA as per type of LDB.
3.3.4 Voltage rating shall be given in Data Sheet A.
3.3.5 Percentage impedance shall be 3% for 50kVA and 4% for 100 kVA transformers,
unless specified otherwise in Data Sheet A.
3.3.6 Off circuit tap changers/links shall be provided for + 5% in steps of 2.5%.
3.3.7 Transformer winding insulation shall be class “F” or better.
3.3.8 Transformer shall be of vector group Dynl.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
3.3.9 Winding shall be of copper material maximum winding temperature at full load and
under site conditions shall not exceed 120 Deg. C.
3.3.10 Transformer shall be suitable for cable connections on the primary side and flexible
cable or busbar connectin on the secondary side.
3.3.11 The secondary neutral of the transformer shall be brought out for getting a grounded
4 wire supply system.
3.3.12 The transformer neutral shall be brought outside the LDB for earthing. The neutral
busbar shall be insulated from the LDB enclosure.
3.3.13 Transformer shall be provided with the rollers, pulling holes, lifting lugs, jacking
positions etc.
3.4 Busbars, Connections and Joints
3.4.1 Busbars shall be made of aluminium grade E 91E or high conductivity copper (ETC),
Busbar material shall generally be aluminium unless mentioned otherwise in Data
Sheet A.
3.4.2 Busbars shall be supported on non-hygroscopic and non-inflammable insulators of
material such as glass reinforced moulded plastic material, epoxy cast resin etc.
Separate supports shall be provided for each phase of the busbars, Insulation level
of neutral busbar shall be same as that of phase busbars.
3.4.3 Busbars shall be contained in a separate vermin-proof compartment within the LDB
and shall have bolted sheet steel covers for providing suitable access.
3.4.4 Busbar clearances in the air shall be as per applicable standard for 500V, 3 phase
system.
3.4.5 Temperature of busbars, droppers and connections shall not exceed 90 Deg. C for
an ambient of 50 Deg. C while carrying maximum continuous current.
3.4.6 The busbar, busbar connections and supports shall have sufficient strength to
withstand thermal and electromechanical stresses produced by the specified short
circuit level of the system.
3.4.7 Busbars (including neutral busbar) shall be capable of carrying the short-time current
specified in Data Sheet A. The duration of short-time current shall be 1 sec unless
mentioned otherwise in Data Sheet A. For the specified current and duration, there
shall be no damage to the equipment.
3.4.8 The neutral bus shall be rated same as phase bus.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
3.4.9 Main busbars and connections shall be prominently marked and displaced for
standard sequence counting from rear to front top to bottom, or left to right as viewed
from the switching device operating mechanism side.
3.4.10 Busbars and connections shall be provided with colour coded PVD sleeves. All live
parts shall be properly shrouded with insulating material.
3.4.11 Earth busbar shall be provided separately. Material of earth busbar shall be GI
unless mentioned otherwise in Data Sheet A.
3.4.12 Busbar Joints
a) Busbar and tap off joints shall be bolted type.
b) Busbars shall be thoroughly cleaned before jointing. Suitable contact greae
shall be applied to remove oxide film just before jointing.
c) For copper busbars, the connecting portion shall be tinned or silver plated.
3.5 Wiring and Terminals
3.5.1 All internal wiring for connections to remote equipment shall be brought to terminal
boards. Spare contacts of devices shall also be wired upto terminal board as per
schemes. Wires shall not be jointed or teed-off except at terminal points.
3.5.2 Wiring shall be made by 1000 volt grade three / seven strand PVC insulated copper
wire having a cross-sectional area of not less that 1.5 sq.mm. All connections from
CT leads upto instruments, terminals shall be made by copper wires of minimum 2.5
sq.mm. size.
3.5.3 All wiring shall be made with the Colour Codes specified below:
a) 3 phase AC Connections
Phase 1 ( R )
Phase 2 ( Y)
Phase 1 ( B )
Neutral Black
Red
Yellow
Blue
b) 1 phase AC Connections
Phase Red/ Yellow / Blue
(as per associated circuit)
Neutral Black
c) DC Connections

Positive
Negative
TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
While
Grey
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
d) Earth Connection Green
3.5.4 Where wiring passes from one compartment to another, the aperture shall be
‘Bushed’ to prevent damage to wires against sheet metal edges. Bushes may
comprise of good quality rubber/ PVC grommets.
3.5.5 Every wire end shall be fitted with numbered ferrules of white or yellow colour having
glossy finish with identification number engraved in black, Ferrules shall be made of
moisture and oil resisting insulating material. Ferrules shall be or interlocked type or
tight fitting type. Ferrules shall be so fitted that they will not get detached, when the
wire is removed from the terminal.
3.5.6 System of marking of wiring shall be as per applicable standard.
3.5.7 All wires used internally shall have crimped on tinned copper lugs for terminations.
3.5.8 Terminal boards shall be stud type with insulating barriers of adequate height.
3.5.9 Terminal boards shall have separate terminals for incoming and outgoing wires with
not more than two wires connected to any one terminal.
3.5.10 Terminal boards shall be mounted vertically or in the horizontal rows and properly
spaced to have clean wiring arrangement, adequate access for putting ferrules,
making terminations etc. It shall be possible to read the ferrule numbers when the
wiring is complete. Where terminals may be live when the equipment is isolated from
the main supply, these shall be clearly marked near the terminal boards.
3.6 Controls
The controls shall be provided as per purchaser’s requirements covered in the
specification and control schemes.
3.7 Switch Fuse Units
3.7.1 These units shall preferably comprise of switches having integral fuses, called
composite units. Alternatively, combination units of separate switch and fuse may
also be acceptable.
3.7.2 These units shall be provided for general purpose i.e. incoming or outgoing units.
3.7.3 The units shall be of the air break air insulated type and designed to ensure safety to
operating personnel.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
3.7.4 Composite units shall have integral fuses i.e. fuse carrier with fuse link (fuse link
forming the moving contact). The design shall ensure that the moving contact is not
live when switch is open i.e. in OFF position, so as to facilitate removal of fuse.
3.7.5 The switch shall be capable making and carrying the system prospective fault
current, but limited in magnitude and duration by the cut off characteristics of the
largest HRC fuse link that may be fitted to that unit.
3.7.6 The fixed contact shall be so shrouded that maintenance of the unit can be carried
out in safety with the busbars live.
3.7.7 Where one isolating switch is used as the incoming device, the incoming side fixed
contacts shall be shrouded to ensure that maintenance can be carried out with the
remote fuse and switch closed.
3.7.8 Composite switch-fuse or the combination of switch and fuse shall meet the
requirements of its components as follows:
3.7.9 Isolating Switch
a) Switches shall be air-break, quick make, quick break heavy duty type
conforming to applicable standard.
b) All switches shall have visible ON / OFF position indication and shall be
padlockable in any (ON /OFF) position.
c) Switches shall be door interlocked such that it shall not be possible to gain
access to inside the unit unless the isolating switch is in OFF position.
d) The switches shall be suitable for independent manual operation.
e) The switch contacts shall be of silver alloy or silver plated copper and springs
of non corrosive material.
f) Inter-phase barriers shall be provided to prevent possibilities of phase to
phase fault in the switch. The switch shall also be shrouded from all sides to
prevent access to live parts on the switch after opening the unit door. The
barriers and shrouding shall extend upto the height of switch to fully enclose
both side terminals of the device. The arrangement shall permit easy
maintenance.
3.7.10 High Rupturing Capacity (HRC) Fuses
a) The fuse serving as the short-circuit protective device in isolating fuse-switch
units shall be of HRC cartridge, current limiting and plug-in non-deteriorating
type.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
b) The fuse carriers shall be easily withdrawable for replacement of fuse,
Insulated fuse pullers shall be provided where fuses are not mounted in
insulating carriers to remove and replace fuses in live conditions.
c) Fuses shall preferably be fitted with a device to indicate operation (i.e. when
the fuse has blown).
d) Live terminals of fuse bases shall be shrouded to prevent contact with
personnel where fuse links are not mounted in carriers and are directly
plugged into the fuse base. Inter-phase barriers extending throughout the
length of the fuse base shall be provided to prevent inter-phase short circuit.
They shall be shrouded from all sides to prevent accidental contact.
e) Fuse carriers and bases shall be of good quality moulded insulating material.
Porcelain fuse bases and carriers will not be accepted.
3.8 Cable Terminations
3.8.1 All cable, either incoming or outgoing to the LDB, shall be terminated in a cable
chamber. For each panel, there shall be a cable chamber on the side. The door of
cable chamber should open or be locked with the help of a tool. Unless stated
otherwise in Data Sheet A, all cables shall enter from the bottom.
3.8.2 Removable undrilled gland plates of sheet steel shall be provided in the cable
chamber for entry of cables. Minimum thickness of gland plate shall be 3mm. The
gland plate shall be of adequate size for connecting requisite number of cable glands
for power and control cables.
3.8.3 Heavy duty bolt-on termination tinned copper lugs of compression type shall be used
in for power cable termination.
3.8.4 For supporting and clamping of cable cores at regular interval in cable alleys,
suitable slotted angle upto the respective terminal blocks shall be provided.
3.8.5 The supply of tinned copper cable lugs for power cables from part the supply of
equipment.
3.9 Earthing
3.9.1 An earth busbar of adequate size of galvanized MS shall be provided at the bottom
for the entire length of the LDB.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
3.9.2 Every metal part other than those forming parts of an electrical circuit shall
connected to the earth bus by means of high conductivity copper wire of size not less
than 2.5 sq. mm cross-sectional area.
3.9.3 Doors shall have a flexible copper wire for earth connection to fixed unit.
3.9.4 Each LDB shall be fitted with two earthing studs located in accessible position on
sides for connection of internal earth busbar to the external earthing connection.
3.9.5 Earth busbar shall be brought outside LDB for making external connections.
3.10 Type of LDBs
The LDBs shall be of following type:
a) LDB-H (n) - AC LDB with 100 kVA transformer
b) LDB-F (n) - AC LDB with 50 kVA transformer
c) LDB-N (n) - AC LDB with no transformer
d) LDB-D (n) - DC LDB
NOTE: (n) indicates number of outgoing feeders.
3.10.1 AC LDBs (LDB-H, LDB-F, LDB-N)
Each LDB shall comprise of the following and comply with the enclosed single line
diagrams:
a) One lighting transformer (LDB-H & LDB-F)
LIGHTING SYSTEM
b) One incomer of TP / TPN switch-fuse unit or MCCB / MCCB with neutral link
as per Data Sheet A. It shall be provided on the primary side of transformer
for LDB type LDB-H & LDB-F.
c) Set of busbars with 3 phase and neutral.
d) TPN switchfuse units for each outgoing circuit.
e) Three indicating lamps with fuses for indicating bus supply ON.
f) CT operated ammeter with selector switch.
g) VT operated voltmeter with selector switch.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
h) Power & control terminals, earth-stud, earth busbar, designation labels,
internal wiring, power cable lugs, glands etc. shall be provided to complete
the LDB in all respects.
3.10.2 DC LDBs (LDB-D)
Each LDB shall comprise of the following and comply with the enclosed single line
diagrams:;
a) One incomer of two pole switch-fuse unit.
b) Two pole DC contactor on the incoming circuit for changeover to DC in case
of AC normal supply failure.
c) One under voltage relay of suitable range, if specified in Data Sheet A.
d) One ON delay timer.
e) One test push button.
f) Set of busbars for positive and negative.
g) Two pole switch-fuse units / MCB for outgoing feeders.
h) Two indicating lamps with fuses for indicating but supply ON.
i) Power & control terminals, earth busbar, designation labels, internal wiring,
power cable lugs, glands etc. shall be provided to complete the LDB in all
respects.
4.0 LIGHTING PANELS (LPs)
4.1 General Requirements of Lighting Panels
4.1.1. LPs shall be totally enclosed, suitable for electrical system data as specified ind Data
Sheet A.
4.1.2 Panels shall be suitable for indoor / outdoor application as per Data Sheet A and
BOQ. Outdoor panels shall have a sloping canopy.
4.1.3 LPs shall be constructed from CRCA sheet. Sheet thickness shall be 2.0mm, unless
mentioned otherwise in Data Sheet A. The construction of LPs shall ensure
adequate rigidity.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
4.1.4 All components of the LP shall be fully mounted inside the panel, LPs shall have only
one operational front. Door shall be provided to give full access to all the
components. Door shall have padlocking arrangement.
4.1.5 LPs shall consist of dust and vermin proof cubicles without the use of louvers.
4.16 Good quality synthetic rubber / neoprene gaskets shall be put around the door. The
door when closed, shall compress the gasket uniformity.
4.17 Unless mentioned otherwise in Data Sheet A, degree of protection for completed LPs
shall be IP:52 for indoor LPs and IP:55 (with weather-proof protection & canopy) for
outdoor LPs.
4.1.8 The LPs shall be designed to prevent contact with live parts when the front door is
open.
4.1.9 All busbars (phase, neutral, positive, negative as applicable) within a panel shall be
of the same size.
4.1.10 All control wiring inside the panels shall be carried out with 1100 V grade, PVC
insulated flexible copper wire of 2.5 sq.mm size.
4.1.11 The rated continuous current of the equipment and components
4.1.12 Each LP shall be fitted with MS. Mounting brackets.
4.1.13 Panel shall be suitable for top / bottom cable / conduit entires. However, outdoor
LPs shall have bottom cable / conduit entry. Removable undrilled undrilled gland
plate of sheet steel shall be provided for entry of cables. Minimum thickness of gland
plate shall be 3 mm. The gland plate shall be of adequate size having knock-outs for
requisite number cable connections. Gland plate shall be provided with gasket.
4.1.14 The lighting panel shall be complete with copper busbars, and shall incorporate
switch fuse or MCB on the incoming side, single pole miniature circuit breakers
(MCBs) for AC outgoing circuits and double pole MCBs for DC outgoing circuits.
Number of outgoing circuits shall be as per BOQ.
4.1.15 Each lighting panel shall be fitting with two GI earth studs located in accessible
position on the outside of the panel on opposite sides.
4.1.16 All metal parts of the panel except current carrying parts shall be bonded together
electrically to the earthing stud.
4.1.17 Each panel shall be fitted with phase barriers of fireproof insulating material in such a
manner that it is not readily possible for personnel to touch the phase busbars.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
Insulating sheet shall be fitted around the MCBs such that only the surface and
toggle of the MCBs are available on the front.
4.1.18 The supply of cable lugs for power and control cable connections forms part the
supply of equipment.
4.1.19 Each panel shall be provided with a circuit directory plate with inscriptions neatly
typed and laminated fitted on the inside of door.
4.2 Type of Lighting Panels
a) LP-A (n) - AC Lighting Panel
b) LP-D (n) - DC Lighting Panel
c) LP-F (n) - Fancy Lighting Panel (Decorative)
d) LP-V (n) - Aviation Lighting Panel
NOTE: (n) indicates number of outgoing circuits.
4.3 AC Lighting Panel (LP-A)
4.3.1 LPs shall be provided with TPN switch as incomer.
4.3.2 Requisite number of single pole MCBs shall be provided for outgoing circuits.
4.3.3 Separate neutral shall be available at terminal block for each outgoing circuit.
4.3.4 Construction of AC Normal and AC Emergency panels shall be same.
4.4 DC Lighting Panels (LP-D)
4.4.1 LPs shall be provided with double pole switch as incomer.
4.4.2 Requisite number of double pole MCBs shall be provided for outgoing circuits.
4.5 Decorative Type Lighting Panels (LP-F)
4.5.1 Decorative lighting panels shall be designed for use in areas like administrative
building, service building, canteen, residential premises etc.
4.5.2 Thickness of sheet steel shall be as per manufacturer’s practice.
4.5.3 LPs shall be of tone colour with elegant finish.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
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OF
4.5.4 LPs shall be provided with TPN switch as incomer and requisite number of MCBs
shall be provided for outgoing circuits.
4.5.5 LPs shall be suitable for either surface or flush mounting as per Data Sheet A and
BOQ. Flush mounted panels shall have the collared door suitable for matching with
the wall.
4.5.6 Lighting Panels may be provided with transparent acrylic cover for operation of
MCBs, if asked for in Data Sheet A.
4.5.7 LPs shall be provided with knockouts on the top, bottom and sides.
4.6 Aviation Lighting Panel (LP_V)
4.6.1 Aviation Lighting Panels shall be provided for feeding power supply to Aviation
obstruction luminaries.
4.6.2 Each Aviation Lighting Panel shall comprise of the following:
a) One TPN door interlocked switch-use unit. Interlock defeat feature shall also
be provided.
b) Three pole AC Contactor
c) 00-24 hrs timer and a photo-electric switch for automatic switching of
contactor
d) Three phase & neutral busbars
e) Single pole or three pole MCBs for each outgoing circuit as per Data Sheet A
f) Two lamps for bus supply ON & OFF indications
g) Complete wiring arrangement as per control scheme.
h) Auto-Manual selector switch
i) ON push button
j) OFF push button
k) Photo switch
4.6.3 Switching ON and switching OFF shall be through both 00-24 hrs timer and light
sensor in automatic mode.
4.6.4 One number light sensor in weather proof enclosure having IP:55 degree of
protection shall be supplied loose along with each SLP.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
4.6.5 Internal power wiring shall be done with PVC insulated Cu wire of suitable size. All
control wiring inside the panel shall be carried out with 1100 V grade, PVC insulated
flexible copper wires.
5.0 Guaranteed Performance Requirements
5.1 The vendor shall guarantee satisfactory performance of the equipment under all
conditions and requirement as laid down by this specification.
5.2 For the general requirements of performance guarantees refer to other parts of the
specification.
6.0 PAINTING
7.0 TESTS
(All metal surface shall be cleaned, phosphated and given two coats of rust-resistant
primer followed by two coats of synthetic enamel paint in light grey shade (IS:5 shade
631).
Each panel shall be completely assembled, wired, adjusted and tested at the factory
prior to shipment. The test shall include wiring continuity tests, insulation tests and
functional tests to ensure satisfactory operation and control of individual equipment.

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
1.0 SYSTEM DESIGN DATA
1.1 Design Ambient : 50 Deg.C
1.2 Relative humidity :
a) Average : As per project synopsis
b) Maximum : -do-
1.3 Details of Operating parameters
a) AC Supply
i. Rated voltage : 415 V
ii. Rated frequency : 50 Hz
iii. Voltage variation : + 10 %
(Permissible)
iv. Frequency variation : + 5 %
(Premissible)
v. Combined voltage & : 10%
Frequency variation
(sum of absolutes
permissible)
vi. System fault level : 50 kA for 0.25 sec.
At rated voltage
vii. System grounding : Solidly
b) DC Supply Not applicable
i. Rated voltage : V
ii. Voltage variation : %
(Permissible)
iii. System fault level :
at rated voltage
c) AC Emergency luminaries : Not applicable %
as per percentage of total luminaries
2.0 APPLICABLE STANDARDS : As per Annexure I

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
3.0 LIGHTING DISTRIBUTION BOARDS
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
3.1 Sheet thickness : 2.0 mm
3.2 Degree of protection :
a) Main panel : IP 54
b) Transformer cubicle : IP 33
3.3 Type of Incomer : Switch-Fuse
3.4 Type of Outgoing Feeders : Switch-Fuse
3.5 Voltage rating of transformer : 415 V
3.6 Whether transformer is encapsulated: No
3.7 Transformer impedance
a) 100 kVA : - %
b) 50 kVA : 4.0 %
3.8 Bus bar material : Aluminium
3.9 Earth busbar material : GI (50X6 mm)
3.10 Cable entry : Bottom
3.11 Whether under voltage relay : Not applicable
required in DC LDB
4.0 LIGHTING PANEL
4.1 Application : Both Indoor & outdoor
4.2 Sheet thickness : 2.0 mm
4.3 Degree of protection
a) Indoor : IP : 54
b) Outdoor : IP : 55
(weather-proof
protection with canopy)
4.4 Type of Incomer : Switch-Fuse
4.5 No. of poles for Aviation lighting : 1 / 3
panel MCBs

TITLE:
LIGHTING DISTRIBUTION BOARD
& LIGHTING PANEL
SPECIFICATION NO. PES-558-01A
VOLUME - II B
SECTION - D
REV.NO. 0 DATE
SHEET 1
OF
4.6 Type of mounting of decorative : Not applicable
lighting panel
4.7 Whether decorative lighting panel : Not applicable
required with acrylic panel
5.0 LABELING : As per specification
6.0 PAINTING :
6.1 Shade (as per IS:5)
Interior Exterior
a) LDBs : Glossy white 631 of IS:5
b) LPs : -do- -do-
6.2 FINISH
a) Interior : Semi-glossy
b) Exterior : Semi-glossy
6.3 Paint thickness (min.) : 50 microns
7.0 MAKE OF COMPONENTS : Shall be subject to BHEL approval