annexure - d techinical specification - civil - WorleyParsons.com

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) 

HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) 

ANNEXURE - D 

TECHINICAL SPECIFICATION - CIVIL 

DOC NO: 9000043-HD-10129 (0435-JH0902-00-PP-RFQ-0019 )



CONTENT LIST- CIVIL 

Guru Gobind Singh Refinery Products 

Evacuation Project (GGSRPEP) 

Raman Mandi- Bahadurgarh and Raman Mandi- 

Bhatinda Multiproduct Pipeline 

CONTENT LIST - CIVIL 

0435-JH0902-00-CI-LST-0002 

20 July 09 

Sanghi Oxygen Compound 

1, Mahal Industrial Estate 

Mahakali Caves Road 

Andheri (East), Mumbai - 400 093 India 

Phone: +91-22-67818000 

Fax : +91-22-67818080 

www.worleyparsons.com 

© Copyright 2009 WorleyParsons 

0435-JH0902-00-CI-LST-0002 Page 1 of 6




SYNOPSIS 

Disclaimer 

This report has been prepared on behalf of and for the exclusive use of Hindustan Petroleum 

Corporation Limited (HPCL), and is subject to and issued in accordance with the agreement 

between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons. 

WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or 

reliance upon this report by any third party. 

Copying this report without the permission of Hindustan Petroleum Corporation Limited (HPCL) or 

WorleyParsons is not permitted. 

PROJECT 435/JH0902 - HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT 

(GGSRPEP) 

REV DESCRIPTION PREPARED 

BY 

CHECKED 

BY 

APPROVED 

BY 

DATE 

CLIENT 

APPROVAL 

DATE 

A 

Issued for IDC 

S. Saxena V. Thorat J. Wallace 

20-July 09 

N/A 

B 

Issued for 

Review S. Saxena V. Thorat J. Wallace 

20-July-09 

11-Sep- 

09 

C 

Issued for 

Tender S. Saxena V. Thorat KMNP 

20-Sep-09 

0435-JH0902-00-CI-LST-0002 Page 2 of 6




CIVIL - LIST OF ATTCHMENTS 

Sr. 

Revisions 

No. Document Title Document No. Rev. & Date 

1 Scope of work 

2 Architectural Design Basis 

GENERAL 

0435-JH0902-00-CI-SOW- 

0002 

0435-JH0902-00-AR-BOD- 

0001 

Rev. C 

Rev. 0 

3 Civil/Structural Design Basis 0435-JH0902-CI-BOD-0001 Rev. 1 

SPECIFICATIONS 

4 Specifications for Doors & Windows 

5 Specifications for Flooring Work 

6 

Specifications for False Ceiling & False 

Flooring 

7 Specifications for Plumbing 

8 Specifications for Earthwork 

9 Specifications for Concrete Work 

10 Specifications for Masonry Work 

11 Specifications for Plastering Work 

12 Specifications for Painting Work 

13 Specifications for Roofing Work 

14 Specifications for Water Proofing 

15 Specifications for Roads & Paving 

16 Specifications for Drains 

0435-JH0902-00-AR-SPC- 

0001 

0435-JH0902-00-AR-SPC- 

0002 

0435-JH0902-00-AR-SPC- 

0003 

0435-JH0902-00-AR-SPC- 

0004 

0435-JH0902-00-CI-SPC- 

0001 

0435-JH0902-00-CI-SPC- 

0002 

0435-JH0902-00-CI-SPC- 

0003 

0435-JH0902-00-CI-SPC- 

0004 

0435-JH0902-00-CI-SPC- 

0005 

0435-JH0902-00-CI-SPC- 

0006 

0435-JH0902-00-CI-SPC- 

0007 

0435-JH0902-00-CI-SPC- 

0008 

0435-JH0902-00-CI-SPC- 

0009 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

0435-JH0902-00-CI-LST-0002 Page 3 of 6




17 Specifications for Cable Trench 

18 Specifications for Fencing 

19 Specifications for Miscellaneous Work 

20 Specification for Structural Steel Work 

21 

Specification for Painting to Structural 

Steel 

BILL OF QUANTITIES(BOQ) 

0435-JH0902-00-CI-SPC- 

0010 

0435-JH0902-00-CI-SPC- 

0011 

0435-JH0902-00-CI-SPC- 

0012 

0435-JH0902-00-ST-SPC- 

0001 

0435-JH0902-00-ST-SPC- 

0002 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

22 SOR for SV Station 

STANDARD DRAWINGS 

0435-JH0902-10-CI-SOR- 

0003 

Rev. B 

23 Standard Details (Architectural) 

24 Doors & Windows Schedule 

25 Doors & Windows Schedule 

26 General Notes - Concrete Work 

27 

28 

29 

Standard Drawings - Concrete Works 

(Sheet 1) 


(Sheet 2) 


(Sheet 3) 

30 Standard Details Of Paving 

31 Standard Details Of Roads 

32 Standard Details Of Storm Water Drain 

33 Standard Details Of Pipe Culvert 

34 Standard Details Of Fencing 

0435-JH0902-00-AR-DST- 

0001-001 

0435-JH0902-00-AR-DST- 

0001-002 

0435-JH0902-00-AR-DST- 

0001-003 

0435-JH0902-00-CI-DST- 

0001-001 

0435-JH0902-00-CI-DST- 

0002-001 

0435-JH0902-00-CI-DST- 

0002-002 

0435-JH0902-00-CI-DST- 

0002-003 

0435-JH0902-00-CI-DST- 

0003-001 

0435-JH0902-00-CI-DST- 

0004-001 

0435-JH0902-00-CI-DST- 

0005-001 

0435-JH0902-00-CI-DST- 

0006-001 

0435-JH0902-00-CI-DST- 

0007-001 

Rev. B 

Rev. A 

Rev. A 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

0435-JH0902-00-CI-LST-0002 Page 4 of 6




35 Standard Details Of Ms Gate 

36 Standard Details Of Pump Foundations 

37 Standard Details Of Pipe Sleeper 

38 

Standard Details Of Cable Trench & 

Covers 

39 Standard Details Of Cable Duct Bank 

40 Standard Details Of Manhole 

41 Standard Details Of Septic Tank 

42 Standard Details Of Soak Pit 

43 Standard Details Of Compound Wall 

44 General Notes - Steel Structures 

45 Standard Details Of Ladder 

0435-JH0902-00-CI-DST- 

0008-001 

0435-JH0902-00-CI-DST- 

0009-001 

0435-JH0902-00-CI-DST- 

0010-001 

0435-JH0902-00-CI-DST- 

0011-001 

0435-JH0902-00-CI-DST- 

0012-001 

0435-JH0902-00-CI-DST- 

0013-001 

0435-JH0902-00-CI-DST- 

0014-001 

0435-JH0902-00-CI-DST- 

0015-001 

0435-JH0902-00-CI-DST- 

0017-001 

0435-JH0902-00-ST-DST- 

0001-001 

0435-JH0902-00-ST-DST- 

0006-001 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. C 

Rev. B 

Rev. C 

Rev. C 

CIVIL DRAWINGS 

46 

47 

48 

49 

50 

51 

52 

53 

Ground Floor Plan And Roof Plan-S. V. 

Station Bldg(Type-I) 

Architectural Elevations-S. V. Station 

Bldg(Type-I) 

Architectural Sections-S. V. Station 

Bldg(Type-I) 

Finishing Schedule-S. V. Station 

Bldg(Type-I) 

Ground Floor Plan And Roof Plan-S. V. 

Station Bldg(Type-II) 

Architectural Elevations-S. V. Station 

Bldg(Type-II) 

Architectural Sections-S. V. Station 

Bldg(Type-II) 

Finishing Schedule-S. V. Station 

Bldg(Type-Ii) 

0435-JH0902-70-AR-DRD- 

0001-001 

0435-JH0902-70-AR-DRD- 

0001-002 

0435-JH0902-70-AR-DRD- 

0001-003 

0435-JH0902-70-AR-DRD- 

0001-004 

0435-JH0902-70-AR-DRD- 

0002-001 

0435-JH0902-70-AR-DRD- 

0002-002 

0435-JH0902-70-AR-DRD- 

0002-003 

0435-JH0902-70-AR-DRD- 

0002-004 

Rev. B 

Rev. B 

Rev. B 

Rev. B 

Rev. B 

Rev. B 

Rev. B 

Rev. B 

0435-JH0902-00-CI-LST-0002 Page 5 of 6




54 General Civil Layout S.V. Stations (5 Nos) 

55 

56 

General Civil Layout S.V. Station (Option- 

1)(SV-04) 

General Civil Layout S.V. Station (Option- 

2)(SV-04) 

57 S. V. Station- Main Gate Typical Details 

0435-JH0902-70-CI-DGA- 

0001-001 

0435-JH0902-70-CI-DGA- 

0001-002 

0435-JH0902-70-CI-DGA- 

0001-003 

0435-JH0902-70-CI-DGA- 

0001-004 

Rev. B 

Rev. B 

Rev. B 

Rev. B 

QUALITY ASSURANCE SYSTEM 

58 Quality Assurance System 

0435-JH0902-00-CI-ITP- 

0002 

Rev. C 

0435-JH0902-00-CI-LST-0002 Page 6 of 6



SCOPE OF WORK - CIVIL 

Guru Gobind Singh Refinery Products 

Evacuation Project (GGSRPEP) 



SCOPE OF WORK – CIVIL 

0435-JH0902-00-CI-SOW-0002 

20 July 09 





Phone: +91-22-67818000 

Fax : +91-22-67818080 



435-JH0902-00-CI-SOW-0002 Page 1 of 6




SYNOPSIS 

Disclaimer 









(GGSRPEP) 


BY 

CHECKED 

BY 

APPROVED 

BY 

DATE 

CLIENT 

APPROVAL 

DATE 

A 



20-July 09 

N/A 

B 

Issued for 


21-Aug-09 

11-Sep- 

09 

C 

Issued for 

Tender S. Saxena V. Thorat KMN Pillai 

24-Sept-09 

435-JH0902-00-CI-SOW-0002 Page 2 of 6




1.0 SCOPE OF WORK 

The scope of work of this tender involves detailed engineering and preparation of 

drawings, bill of materials, equipment foundations, pipe supports, supply of all 

materials, construction, inspection, testing as per attached conceptual/ architectural 

drawings and layouts, schedule of rates, specifications and standards for all civil 

works in six nos SV stations of Ramanmandi- Bahadurgarh cross country pipeline 

and residual civil works of cross-country pipeline at Bahadurgarh. 

The scope of work mainly involves, but not limited, to the following. 

1. Clearing of proposed site from all debris, stripping of the area, removing 

vegetation, grass, shrubs, roots etc. 

2. Site Grading including earth filling. 

3. Complete Civil & structural work for Boundary wall, Fencing and Gates 

4. Construction of approach road including culverts from the nearest existing 

asphalted road to the respective SV stations. 

5. General civil works such as internal roads, paving, storm water drain, sanitary 

drain, contaminated/slop drain, rain water harvesting system and cable 

trenches. 

a) Approach road & internal road shall be asphalt road for SV station 

No. 03. For other SV stations (SV No. 01, 02, 04,05 & 06) the 

approach road shall be with concrete paver blocks. 

b) The approximate distance of the SV station plots from the nearest 

existing road are as indicated below. 

 

 

SV No 01, 02, 04,05 & 06 - approx. 15 meters. 

SV No 03 - approx. 100 meters. 

However the contractor shall verify the actual distances before quote 

for the bid. 

6. Wire Cage around Valve pits as per the photographs given below. Details 

shall be finalised in consultation with Engineer-incharge- 

435-JH0902-00-CI-SOW-0002 Page 3 of 6




7. Complete structural work in RCC/Structural steel for pipe sleepers, pipe 

support, operating platforms, cross - overs, MOV, equipment foundations viz. 

Scrapper Launcher, Scrapper Receiver, DG Set etc. for the cross-country 

pipeline. 

8. Buildings including structure, plastering, painting, flooring, water-proofing, 

doors, windows, false ceiling, false flooring, roof sheeting, plinth protection, 

plumbing and sanitary works, ladders etc. 

9. Setting up of WORKSITE establishment and BIDDER’S facilities. 

435-JH0902-00-CI-SOW-0002 Page 4 of 6




10. Removing temporary facilities and clearing site after completion of work. 

11. Repair of existing plant roads, if damaged due to new construction shall be 

repaired by contractors without any extra claim. 

12. Anti termite treatment of buildings. 

13. Topographical survey & Geotechnical investigations with minimum two no. of 

bore holes (at each SV station) & submission of report with recommended 

SBC’s for civil work at SV station locations only. Geotech report for the 

pipeline will be supplied by owner. 

14. Any other work to complete the job in all respect. 

15. Technical requirements for review of Design & AFC Drawings 

a) Submission of detailed design and drawings by the contractor & review of 

them by WP. 

b) No construction shall be taken up at site unless AFC drawings / 

documents incorporating WP comments is available with the Engineer-incharge. 

c) Submission of bar bending schedules for all RCC works and fabrication 

drawings for structural works. 

d) Submission of “AS BUILT” drawings/details for all works 

16. Rain water harvesting system 

Bidder shall refer Specifications, General condition of contract and Special condition 

of contract. 

2.0 SCOPE OF SUPPLY 

Scope of supply includes all material, consumables required to complete the job. No 

free issue material by the owner. 

3.0 BUILDINGS 

All civil and architectural works for building such as excavation, foundations, 

columns, beams, slab, roofing, flooring, plastering, painting, doors/windows, terrace 

water proofing, rain water pipe, false flooring, false ceiling, plinth protection, ramps, 

expansion/construction joints, anti termite treatment, etc. shall be done by the 

contractor as per detailed specifications and approved construction drawings for 

a) SV station building for SV station no. 01, 02, 03,05 & 06 as per 

typical layout no. 0435-JH0902-70-CI-DGA-0001-001. 

435-JH0902-00-CI-SOW-0002 Page 5 of 6




b) SV station buildings for SV station no. 04 as per typical layout no. 

0435-JH0902-70-CI-DGA-0001-002. 

(OR) 

Optional : If the optional item for land acquisition for SV No. 04 is 

operated then the SV station buildings details shall be as per drg. No. 

0435-JH0902-70-CI-DGA-0001-003. 

435-JH0902-00-CI-SOW-0002 Page 6 of 6

HINDUSTAN PETROLEUM CORPORATION LIMITED 

GURU GOBIND SINGH REFINERY 

PRODUCTS EVACUATION PROJECT 

(GGSRPEP) 

DESIGN BASIS FOR ARCHITECTURAL 

0435-JH0902-00-AR-BOD-0001 

0 Issued for Implementation 

RD UDB AK 

08-05-09 

A Issued for Review 

RD UDB AK 

23-04-09 

REV DESCRIPTION PREP CHECKED WORLEY- 

PARSONS 

APPROVAL 

DATE 

HPCL 

APPROV 

AL 

DATE 

Page 1 of 36

CONTENTS 

PART I - DESIGN PHILOSOPHY 

PART II - ARCHITECTURAL FINISHES 

Page 2 of 36

PART I - DESIGN PHILOSOPHY 

Page 3 of 36

1.0 ARCHITECTURAL DESIGN REQUIREMENT 

Architectural design shall be in accordance with the following clauses. 

1.1 REFERENCED PUBLICATIONS 

Provisions of following references shall be taken care in architectural design. 

• National Building Code of India. 

• State Govt. Factory Acts. 

• Local Municipality or any other Authority’s Bye-laws as applicable. 

• TAC (Tariff Advisory Committee) Recommendations. 

• BPE (Bureau of Public Enterprises) Guidelines. 

• Process Control Room Safety - OISD-STANDARD-163. 

• Any other rules/regulations/recommendations as applicable for a particular project. 

1.2 DESIGN REQUIREMENT 

1.2.1 SPATIAL REQUIREMENTS 

Spatial requirements inside a building shall be decided based on activities to be performed in the 

building and consequent occupancy pattern equipment layout etc. Spaces can be generally 

classified as follows, which shall be provided in all the buildings/sheds. 

Functional Spaces 

Functional areas of any building/shed are constituted by the main activity areas for which the 

building is to exist. Various spaces/rooms shall be judiciously sized and shall be integrated logically 

to generate the total building plan taking into account the following parameters. 

• Activities, group of activities and consequent work-flow pattern. 

• Site conditions i.e. dimensions, contours etc. 

• Climatic conditions vis-a-vis orientation. 

• Safety r e gul ations. 

• Lighting and ventilation. 

• A c o u s t i c s . 

• S e r v i c e s . 

• S e c u r i t y . 

• E c o n o m y . 

• A e s t h e t i c s . 

Page 4 of 36

• Any specific requirement pertaining to particular buildings. 

• All other established Architectural design parameters. 

The objective of spatial arrangement shall be to satisfy functional requirements and physical comfort 

and safety regulations as well as aesthetics which has significant role in creating a favourable 

working and living condition. 

Circulation Spaces 

Following spaces are classified as circulation spaces. These spaces shall be provided for integrating 

various types of spaces and as means of access/exit. 

• C o r r i d o r s & p a s s a g e s . 

• S t a i r c a s e s . 

• E n t r a n c e l o b b y / F o y e r i n c l u d i n g R e c e p t i o n & w a i t i n g . 

• G a n g w a y / w a l k w a y s . 

• E q u i p m e n t l o a d i n g / u n l o a d i n g p l a t f o r m s . 

• E m e r g e n c y E x i t s . 

Amenity Spaces 

Following spaces are classified as amenity spaces. 

• T o i l e t ( G e n t s & L a d i e s ) . 

• D r i n k i n g W a t e r F a c i l i t y . 

Toilets & Drinking Water enclosure shall be mandatory requirement for buildings with human 

occupancy. 

Utility Spaces 

Utility spaces are the spaces requirement of which are generated due to provision of services like 

Air-conditioning, pressurisation, fire fighting, electrical, telephone etc. Following are the examples. 

These spaces shall be provided as per specified building services. 

• A i r - c o n d i t i o n i n g p l a n t r o o m . 

• A i r h a n d l i n g r o o m s . 

• E l e c t r i c a l d i s t r i b u t i o n p a n e l s r o o m s . 

• F i r e F i g h t i n g E q u i p m e n t r o o m . 

• T e l e p h o n e E x c h a n g e E q u i p m e n t s r o o m 

• U P S r o o m 

• B a t t e r y r o o m 

However following are the limiting sizes/dimensions for various purposes, which are to be adhered 

to. 

A. Minimum size of any habitable room = 9 sq.m with minimum dimensions 

not less than 2.5m. 

B. Minimum ht. of any habitable room = 3m which may be reduce to 

2.75m for air-conditioned areas. 

C. Maximum ht. of habitable rooms = 3.6m 

D. Scale of accommodation for = @14cu.m. per occupant. 

Page 5 of 36

Industrial work spaces. 

Minimum clear height of such 

workspaces shall be 3 .6m. 

1.2.2 DAY LIGHTING AND NATURAL VENTILATION 

Day lighting 

Established level of illumination shall be maintained for all parts of the buildings by means of 

windows, sky lights etc. Following references shall be adhered to in this regard. 

Natural Ventilation 

National Building Code of India 

S t a t e F a c t o r y A c t 

Established level of ventilation in terms of air charges per hour shall be maintained for all 

spaces. 

Following references shall be adhered to for the purpose. 

A. National Building Code of India. 

B. State Factory Act 

Natural ventilation shall also be supplemented by mechanical or electrical means of ventilation 

in all human occupied areas. 

1.2.3 ACOUSTICS AND SOUND INSULATION 

Specified acceptable noise level and reverberation time shall be maintained inside a 

building/shed. 

Following references shall be referred to for the purpose: 

A. National Building Code of India 

B. S t a t e F a c t o r y A c t 

C. M O E F C l e a r a n c e d a t e d 2 9 - 0 4 - 0 9 i s s u e d f o r t h i s p r o j e c t . 

Required noise level in any space shall be maintained by means of: 

A. Segregating noise sources by buffer zones 

B. Dampening of noise levels by damping devices 

C. Providing Acoustic treatment with acoustic material (on walls, ceilings, floors, 

as required). 

1.2.4 SAFETY REQUIREMENTS 

Safety from fire and like emergencies shall be taken into account in building/shed design. 

Every building/shed meant for human occupancy shall be provided with exits sufficient to 

permit safe escape of occupants in case of emergency. 

The exits shall be in terms of doorway, corridors, and passageways to internal/external 

staircase or to areas having access to the outside. 

Page 6 of 36

Following references shall be adhered to in this regard: 

A. National Building Code of India. 

B. State Factor y Act. 

C. Stipulations of Collector NOC/ CCOE/ Advisor Safety. 

For Control Room safety requirements, provisions of OISD-STD- 163 shall be 

followed. 

1.2.5 SITE PLANNING 

Site planning of buildings shall take into account aspects like inter-relationship of the building 

with the whole system, movement pattern, traffic and road net-work, safety regulations, service 

network, fire safety, climatic and environmental aspects, site conditions like site dimension, 

contour, drainage, noise level, view, future expansion, visual aspects etc. 

Main and service/maintenance entrances of buildings shall be provided with vehicular access. 

All exit points also shall be provided with footpath/vehicular access. Parking space in 

accordance with traffic load shall be provided for all buildings. Road network and open space 

around the buildings shall be designed considering movement and functioning of Fire tenders. 

Climatic factors like wind direction, solar geometry shall be taken into account in orienting the 

buildings depending on type of climate. Orientation of building shall also consider noise and 

smell propagation, views, and visual effect from various directions. 

Sufficient open space shall be provided for planned expansion of buildings. Sufficient open 

space shall also be provided around the buildings for lighting and ventilation in accordance 

with Factory Acts & National Building Code. 

Site plan shall also take into account, landscaping aspects. The inherent characteristics of site, 

such as contours, land form, vegetation, trees, plants, shape shall be fully utilized in the 

design. 

1.2.6 BUILDING SERVICES 

Following services shall be provided for all buildings/sheds as essential services or as 

specified. 

Water supply, distribution and drainage, sanitary services. 

This service is essential for all human occupied bldgs/sheds. All buildings with human 

occupancy shall have provision of toilet and drinking water as per following references. 

A. National Building Code of India 

B. S t a t e F a c t o r y A c t 

Page 7 of 36

Drinking water provisions shall be provided within an enclosure separated from the toilets. 

Space for janitor shall be provided in the toilets. All service pipes showing on the external wall 

hall be suitably concealed or shall be provided within a shaft. 

Electrical Services 

This service shall be provided as essential service for all buildings/sheds. Electrical services 

for buildings shall consist of electrical supply and distributions, Electrical lighting installations, 

telephone network, fans, exhaust fans, lighting protection system etc. including all accessories, 

cabling etc. 

Air conditioning and heating 

Areas of Control room, spaces housing equipments/machinery/panels etc., which require 

conditioned environment and certain specified areas like offices, specific office accommodation 

shall be air-conditioned. 

1.2.7 AESTHETICS 

Apart from the fulfilment of functional & safety requirement, aesthetic requirement of the 

building shall be taken care of in the design. As specific guidelines for achieving required 

aesthetics are difficult to establish, preliminary drawings indicating Architectural treatment shall 

be submitted for Owner’s approval. Elements like Canopies, overhangs & shading devices, 

gutters, door; Window/ Ventilator composition, External wall location with respect to columns, 

Colour Scheme, grooves in plaster etc. shall be considered as contributory elements to 

aesthetics and their design etc. shall be subjected to the Owner’s approval. 

1.2.8 STRUCTURAL AND CONSTRUCTION ELEMENTS 

Type of structure & construction shall be as specified. However following table may be 

followed as a guideline. 

S.NO 

1. 

2. 

3. 

BUILDING 

Control Room, Sub Station, 

D.G.room. 

Pump House, Watch tower, Fire 

Water pump house, Parking 

Shed & other sheds. 

Ware House 

TYPE OF STRUCTURE & 

CONSTRUCTION 

RCC column with brick masonry 

infill walls. 

Steel Structure, Steel truss and 

Precoated sheet roofing & cladding. 

RCC column with brick masonry 

infill walls, steel truss and 

precoated sheet roofing & cladding 

Page 8 of 36

1.2.9 BUILDING ELEMENTS 

Finished Floor Level (FFL) 

In general, FFL of the Buildings, sheds shall be determined with respect to top of approach 

road or pavement. Following schedule shall be adhered to for FFL of various buildings & 

sheds. 

A. Transformer bay - Top of approach Road level + 150mm 

B. Parking shed, Fire - Top of approach Road level + 150mm 

tender bays 

C. False floor areas or cavity - top of approach road level +600 

depth of cavity 

D. Material Loading, - Top of approach Road level + 1100mm 

Unloading Platforms 

E. Other areas - Top of approach Road level + 300 

to 

600mm 

F. Electrical Room - Top of approach Road level + 

1000mm 

or as specified depending on 

cable trench depth. 

Notes: 

A. In case of approaches with different top levels, the highest top level of 

approach road/pavement shall be considered. 

B. FFL shall be same throughout in a building/shed. Split-levels may be 

considered in exceptional cases due to ground terrain etc. or if any 

functional requirement. 

C. FFL of external loading/unloading bays/platforms, toilet, shall be 6 - 12 

mm lower than that of the building/shed’s FFL to check ingress/spillage 

of water. 

Page 9 of 36

2.0 STEPS/RAMPS 

Steps/ramps shall be provided for access to the buildings/sheds for pedestrian/vehicular, equipment 

entry. Minimum 1000 mm wide platform shall be provided in between Entrance door and 

steps/ramps. Following dimensions of the steps/ramps shall be adhered to. 

A. 

minimum 

Tread = 250 mm 

B. 

maximum 

Riser = 175 mm 

C. Slope of Ramp=Not steeper than 1:6 

D. Ratio of Tread & Riser 

i) Control bldgs.Riser + tread = 420-45 0 mm 

ii) Other bldgs. 

2 Riser + Tread = 600-650 mm 

Page 10 of 36

3.0 WALLS 

Following schedule shall be adhered to for wall material and thickness. 

A. External, load bearing walls = Minimum 230 mm thk. 

Brick 

wall 

B. Fire wall (Around Transformers) = Minimum 345 mm thk. 

Brick 

wall or as per TAC 

requirement. 

C. Internal partition wall = 230/115 mm thk. Brick 

wall/ 

Glazed partition 

Notes: 

1. 115 mm thk. Partition walls shall be provided with 230 mm thk. Brick 

pillars & reinforcement at regular intervals for stability. Reinforcement 

will be provided as per structural specifications. 

2. Wherever conduits or pipes are required to be concealed within 

partition wall, the wall thickness shall be increased suitably. 

Page 11 of 36

4.0 DOORS 

Doors shall be provided for access, security and safety at all entry & exits of rooms, functional areas 

& the buildings. Sizes of the doors shall be determined on the basis of the following schedule. 

A. Equipment, Panel area 

including packing. - Size of maximum equipment 

B. Other areas - Volume of movement through the door. 

C. Minimum Ent. door size - 1500 mm x 2100 mm (wall opening 

size) 

D. W.C., Bath Cubicle Door - 750 mm x 2100 mm (wall opening 

size) 

E. Minimum size of other doors - 1000 mm x 2100 mm (wall opening 

size) 

Notes: 

1. Normally, entrance doors shall be provided covering full width of 

the 

Entrance lobby. In that case the door shall be of composite 

type consisting of openable shutters & fixed portions. 

2. Mechanically operated Rolling shutters shall be provided wherever 

area 

requirement of openable shutters exceed 2500 mm x 2500 mm. 

Page 12 of 36

5.0 WINDOWS/VENTILATORS 

Windows/ventilators shall be provided in all areas for natural lighting, ventilation and visibility at 

working level. 

For the purposes of ventilation, total openable area of the windows/ventilators shall be as per 

Factory Act subjected to a minimum of 15% of the floor area to be ventilated. However, for non 

process Control Room, security block of Gate Houses and in office areas etc. where visibility from 

inside is of prime importance, increased window area shall be provided. Areas accommodating 

panels/equipments shall be normally provided with ventilators at high level for unobstructed 

distributed lighting. 

Windows/ventilators/openings of Control Room shall be provided in accordance with OISD-STD- 

163. 

Notes: 

1. Requirement of window/ventilation area as stipulated above is 

for 

maximum room/area height of 4000 mm. For height more than 

4000 mm additional window/ventilator shall be provided in the 

same manner at every work area such as walkway/gangway etc. at 

all such working levels. In such cases additional 

windows/ventilators shall also be provided to ensure min. 

illumination & ventilation at every level of the building/shed. 

2. Wherever due to limitation of external wall area or any other 

reasons, 

stipulated area of window/ventilation cannot be provided, suitable 

mechanical/electrical devices shall be provided. 

Page 13 of 36

6.0 CANOPY/OVERHANG 

Canopy/overhangs shall be provided at all entries & exits for rain & sun protection, accentuation of 

the entry/exit and movement from or to parked vehicle as per following schedule. 

A. For Control Rooms, canopy shall be provided at all entrances. Canopy 

or overhangs shall also be provided for sub stations, warehouses, 

storage sheds where regular vehicular movement & 

loading/unloading takes place. Size of the canopy shall be decided 

based on vehicle parking & covered access to the building/shed, 

movement around the vehicle and aesthetics of the building/shed. 

B. Overhangs shall be provided over all exits. Size of the overhang shall 

be decided based on the aesthetics of the building/shed subject to 

minimum of 900 mm. 

Waterproofing & drainage provision shall be provided for the canopies & overhangs. 

Page 14 of 36

7.0 SHADING DEVICES 

Shading devices shall be provided over all windows, openable ventilators for rain & sun protection. 

These devices shall be in form of horizontal projections, vertical projected fins or combination of 

both as per building facade treatment. Minimum projection shall be 600 mm. The top surface of the 

shading devices shall be finished with cement plaster mixed with waterproofing (laid to slope) 

compound and shall be provided with GI spouts for drainage. 

Page 15 of 36

8.0 PARAPET 

Parapets shall be minimum 500 mm high for non-approachable roof and 900 mm high for 

approachable roof. Parapet shall be of RCC. 

Page 16 of 36

9.0 RAIN WATER PIPES, SPOUTS 

Rain water pipes shall be provided for roof water drainage. Number of rain water pipes shall be 

decided on the basis of roof Area, slope and rainfall intensity. Rain water pipes shall be embedded 

in concrete or brick. RCC or GI spouts may be used for drainage of chajj a/small canopies of ground 

floor only. 

Page 17 of 36

10.0 ENTRANCE LOBBY 

Entrance lobby shall be provided as a common entrance for all Buildings/sheds accommodating 

separate or similar functional spaces integrated together. Individual entries to such functional 

spaces shall be from this lobby by means of passages/corridors. Apart from common entry lobby, 

separate independent entries to these functional spaces shall also be provided if functionally 

required. 

Size of the entrance lobby shall be decided on the basis of volume of the movement subjected to 

the minimum requirement of 9 sq.m 

Page 18 of 36

11.0 PASSAGES/CORRIDORS 

Passages/corridors shall be provided to integrate various spaces. Width of the passages/corridors 

shall be as per following schedule. 

A. Singly loaded passage/corridor = Minimum 1200 mm. 

B. Doubly loaded passage/corridor = Minimum 1800 mm 

But whenever passages/corridors are to be used for equipment/machinery/panels etc. the width 

shall be determined on the basis of equipment/machinery/panel sizes. 

Page 19 of 36

12.0 SERVICE ENTRY 

Separate service entry shall be provided for service areas such as Air-condition plant, Electrical 

Rooms etc. A common service entry may be provided depending on spatial arrangement. 

Page 20 of 36

13.0 EMERGENCY EXITS 

Emergency exits shall be provided for all the building/sheds as per Factory Act & OISD Norms. 

Emergency exits for individual function spaces such as console area, cable cellar, switchgear hall 

shall also be provided. Emergency exits shall be located in such a manner that escape route is 

direct, unobstructed & without passing through any other function areas to safe area. 

Corridors/staircases shall be provided as escape route to the emergency exits. 

Page 21 of 36

14.0 STAIRCASES 

Staircases shall be provided for vertical circulation & emergency exits. Number of staircases shall 

be based on building/shed sizes and emergency exit requirements. At least one staircase/ladder 

shall be provided for access to the flat roofs for maintenance. 

Page 22 of 36

15.0 RAILINGS 

Railings shall be provided in stairs, and in all unprotected openings in slabs as a safety device. 

Railings in loading/unloading bay of Substations shall be of removable type to facilitate the purpose. 

Page 23 of 36

16.0 TOILET 

Toilet shall be provided for all buildings/sheds having human occupancy. Toilet shall consist of 

Gents Toilet, Ladies Toilet (as per requirement), and separate drinking water enclosure. 

Requirement of fittings & fixtures shall be as per National Building Code of India & Factory Act. 

Page 24 of 36

17.0 ELECTRICAL ROOM 

Electrical Room may be provided to accommodate electrical/telephone main distribution box. 

However, depending on size, space requirement, the same may be mounted in wall recess. 

Page 25 of 36

18.0 PARTITIONS 

Partitions shall be provided between console rooms & rack room in Control Room. Glazed panels 

shall be provided for visibility in the partitions as per requirement. 

Page 26 of 36

19.0 FALSE CEILING & UNDERDECK INSULATION 

False ceilings shall be provided for following purposes wherever required. 

A. To reduce room volume and hide ducting etc. for air-conditioned 

space. 

B. To maintain acoustic level inside any space. 

C. To reduce habitable room, corridor, lobby, toilet heights located in 

high ceiling building/shed to min. 3000 mm. 

Underdeck Insulation will be provided wherever air-conditioning is provided in 

single storeyed bldg. whereas in double storeyed bldg., underdeck insulation will be provided under 

the roof of air-conditioned areas on first floor only. 

Page 27 of 36

20.0 FALSE/CAVITY FLOORING 

False/cavity flooring shall be provided to accommodate under floor cabling in Instrumentation 

Console, Rack, Telecom Room etc. 

Page 28 of 36

21.0 PLINTH PROTECTION 

All the buildings /sheds shall be provided with minimum 900mm wide plinth protection around the 

building /sheds. 

Page 29 of 36

PART II - ARCHITECTURAL FINISHES 

Page 30 of 36

22.0 GENERAL 

All the building elements i.e. floor, wall, ceiling, roof, doors & windows etc. shall be provided with 

Architectural finishes as shown in the clauses 2.1 to 2.5. 

Note: 

1. All the Architectural finishes shall be as per attached Specifications, Standards 

& Approved list of vendors. 

2. Color Scheme for all Architectural items shall be approved by the Owner 

(HPCL) 

Page 31 of 36

23.0 FLOOR FINISHES 

Sl. 

No. 

Building Room/Area 

Finish 

1. 

2. 

Console rooms, Telecom room, 

Rack room, 

Entrance foyer, Office rooms, UPS 

room, VSD panel room, corridors 

etc. 

3. Battery room. 

4. 

Equipment rooms, AHU, D.G. 

room, Pump house, Fire water 

pump house, Ware House. 

False / Cavity flooring with high pressure 

laminate (Antistatic) finished particle 

board panels. 

Kota stone flooring/ Kota stone flooring 

with marble borders & skirting. 

Acid Resistant tiles floor finish and dado 

(1.5m high) 

Heavy-duty cement concrete floor finish 

5. Parking Shed, Stores 

6. Toilets 

Cement concrete granolithic floor finish 

or as per other rooms of the building. 

Non slip ceramic tile flooring and dado 

(2. 1m high) 

Skirting shall be provided in all areas. Cement plaster skirting shall be provided in areas having 

cement concrete granolithic/ heavy duty cement concrete flooring. For other areas, skirting shall be 

of same material as that of flooring. 

Panel dividers shall be provided in cement concrete flooring/ cement concrete granolithic/ heavy 

duty cement concrete flooring. 

Page 32 of 36

24.0 WALL FINISHES (PLASTERING, PAINTING) 

Sl. 

No. 

Surface 

ALL BUILDINGS: Internal finish 

Finish 

1. 

2. 

3. 

Console room, Rack room, Telecom 

rooms, Office rooms, Entrance foyer, 

VSD panel room, corridors etc. 

Equipment rooms, D.G. room 

AHU, service rooms etc., Fire water 

pump house, Ware House 

Plastic emulsion paint over cement 

plaster 

Oil bound distemper over cement 

plaster. 

White/ Color wash over cement plaster. 

ALL BUILDINGS: External finish 

1. Control Room. 

Mangalorian tiles cladding, Decorative 

Sandex matt finish over waterproof 

cement plaster, finished with final coat 

of silicon/acrylic based water repellent 

finish. Waterproof cement paint on 

soffits. 

2. 

Sub Station, D.G. room, Fire Water 

Pump houses, Ware house etc. 

Waterproof cement paint over 

waterproof cement plaster/ sand face 

plaster 

Grooves in plaster shall be provided at the junction of different materials and as 

per external facade treatment. 

Page 33 of 36

25.0 INTERNAL CEILING FINISHES 

Sl. 

No. 

1. 

Surface 

All Air-conditioned areas and other 

areas where false ceiling is required. 

Finish 

Aluminium panel False Ceiling 

(Luxlon or equivalent) 

2. Other areas not indicated above White/ Color wash over cement plaster. 

Page 34 of 36

26.0 ROOFING TREATMENT (WATERPROOFING) 

Sl. 

No. 

Surface 

1. Rcc. roofs of all buildings 

Finish 

Ataxic polypropylene modified 

reinforced bituminous waterproofing 

membrane over cement screed laid to 

slope on Rcc. slab. 

Page 35 of 36

27.0 DOORS, WINDOWS & VENTILATORS 

Sl. 

No. 

Building Room/ Area 

Finish 

ALL BUILDINGS: Doors 

1. 

Console room, Rack room, UPS 

room, Telecom rooms, Entrance/ 

Exit doors. 

2. Office rooms, toilets, stores etc. 

3. 

Equipment rooms, D.G. room, 

AHU, Ware House 

Glazed powder coated Aluminium 

doors with toughened glass. 

Pre-laminated flush doors with wooden 

frames. 

Pressed steel doors with pressed steel 

frames. 

ALL BUILDINGS: Windows/Ventilators 

1. Control Room, Security Gate House. 

2. 

Sub Station, D.G. Room and 

Ware house. 

Glazed powder coated Aluminium 

Windows/ventilators with toughened 

glass. 

Glazed powder coated Steel Windows/ 

ventilators with plain glass. 

Page 36 of 36




(GGSRPEP) 

CIVIL STRUCTURAL DESIGN BASIS 

0435-JH0902-CI-BOD-0001 


ABB VYT KMNP 

07-SEP 

2009 


MSS UDB AK 

08-MAY 

2009 

A Issued for Review 

SUS UDB AK 

05-APR 


PARSONS 

APPROVAL 

2009 

DATE 

HPCL 

APPROVAL 

DATE 

Page 1 of 30

INDEX 

1. INTRODUCTION....................................................................................................................................... 4 

1.1 GENERAL ............................................................................................................ 4 

1.1.1 Applicable Codes and Standards for Design................................................... 4 

1.1.2 Applicable codes and standards for materials. ................................................ 6 

1.1.3 Standard Drawings......................................................................................... 6 

1.1.4 UNIT AND LANGUAGE.............................................................................. 6 

1.2 SITE CONDITIONS ............................................................................................. 6 

1.2.1 Location of Site.............................................................................................. 6 

1.2.2 Topographical & Geological Conditions ........................................................ 7 

2. DESIGN LOADS & DESIGN PHILOSOPHY......................................................................................... 8 

2.1 Dead Loads ( DL )................................................................................................. 8 

2.2 Live Loads ( LL) ................................................................................................... 8 

2.3 Wind Loads (WL).................................................................................................. 9 

2.4 Seismic Loads (SL)................................................................................................ 9 

2.5 Equipment Loads (EEL) ...................................................................................... 10 

2.6 Equipment Operating Loads (EOL) ..................................................................... 10 

2.7 Thermal / Friction Load (TL/FL) ......................................................................... 10 

2.8 Impact & Vibratory Loads ................................................................................... 10 

2.9 Soil and Hydrostatic Pressure (SP)....................................................................... 10 

2.10 Other Loads......................................................................................................... 10 

3. Foundation Design .................................................................................................................................... 11 

3.1 DESIGN CRITERIA FOR FOUNDATION DESIGN.......................................... 11 

3.1.1 Depth of foundation ..................................................................................... 11 

3.1.2 Stability Criteria:.......................................................................................... 11 

3.2 Foundations for Rotating and Reciprocating Equipment ...................................... 12 

4. DESIGN PHILOSOPHY FOR PIPE SUPPORTS................................................................................. 14 

4.1 TYPE OF LOADS............................................................................................... 14 

5. Basic Load Cases & Load Combinations -.............................................................................................. 16 

5.1 For Equipment Foundations................................................................................. 17 

5.2 For Building Design ............................................................................................ 18 

5.3 For Pipe Rack / Sleepers...................................................................................... 19 

6. BUILDING ................................................................................................................................................ 21 

6.1 Building List........................................................................................................ 21 

6.2 Plumbing/Sanitary ............................................................................................... 21 

7. STEEL STRUCTURE .............................................................................................................................. 21 

7.1 Material ............................................................................................................... 21 

7.2 Minimum Thickness of steel elements ................................................................. 21 

Page 2 of 30

7.3 Paint Specification............................................................................................... 22 

7.4 FIRE PROOFING................................................................................................ 22 

7.5 Allowable Deflection........................................................................................... 22 

8. Concrete ..................................................................................................................................................... 23 

8.1 MATERIALS ...................................................................................................... 23 

8.2 Minimum Thickness of Structural Concrete Elements.......................................... 24 

8.3 Minimum Height of Pedestals.............................................................................. 24 

8.4 Grouting & Minimum Grout Thickness ............................................................... 25 

8.5 Allowable Deflection........................................................................................... 25 

9. GENERAL CIVIL .................................................................................................................................... 25 

9.1 Road and Paving.................................................................................................. 25 

9.2 Drainage.............................................................................................................. 27 

10. SOFTWARE TO BE USED FOR THE PROJECT .......................................................................... 30 

Page 3 of 30

1. INTRODUCTION 

This document presents the Civil/Structural Design Basis for the GURU GOBIND SINGH 

REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP) to be used for the design of 

civil, structural and building works. 

Design basis describes the minimum basic requirements for reinforced concrete structure, 

structural steel & general civil work. All items shall be designed for satisfactory performance. 

If any conflict arises between this guideline and the applicable standards or codes, this shall 

be resolved either by application of the most severe design conditions or resolution by the 

Principal Civil/Structural Engineer. 

Civil structural Design/Technical specification for civil, structural and building works are 

summarized herein below. 

1.1 GENERAL 

1.1.1 Applicable Codes and Standards for Design 

The following codes and standards shall be applied to civil, structural and building design. 

Apart from the Indian standard listed in following chapters, all other relevant codes related to 

this job requirement shall be followed wherever applicable. The latest edition of codes, 

standards etc. shall be used. 

(1) Design Loads 

Codes / Standards 

Dead Loads : IS875 (PART 1) 

Imposed Loads : IS875 (PART 2) 

Wind Loads : IS875 (PART 3) 

Special Loads : IS875 (PART 5) 

Seismic Loads : IS:1893 (part-1) 

(2) Building 

- Layout & Planning : NBC 

(3) Steel Construction : IS800 

(4) Concrete Construction : IS456 

(5) General Civil 

- Road : IRC 3,6 , 37 

Page 4 of 30

(6) Machine Foundations : IS 2974 (Part-1 to 5) 

(7) Liquid retaining structures : IS 3370 (Part-1 to 4) 

(8) Fire Protection Facilities for Petroleum 

depots, Terminals & Pipeline Installations 

: OISD-STD-117 

(9) Layout for Oil & Gas Installations : OISD-STD-118 

(10) Process Control Room Safety For Blast 

Resistance Control Room 

: OISD-163 

(11) Ductile detailing of RCC Structure : IS13920 

(12) Code of practice for use of metal arc 

welding for general construction 

(13) Code of practice for construction of stone 

masonry 

(14) Code of practice for structural use of 

unreinforced masonry 

: IS: 816 

: IS: 1597 

: IS: 1905 

(15) Recommended practice for hot dipped 

galvanizing on iron and steel 

: IS: 2629 

(16) Code of practice for design & construction 

of raft foundations 

: IS: 2950 

(17) Code of practice for earthquake resistant 

design and construction of buildings 

(18) Recommendations for metal arc welding of 

carbon and carbon manganese steel 

(19) Code of practice for structural safety of 

buildings – Shallow foundations 

(20) Code of practice for determination of 

bearing capacity of shallow foundations 

(21) Code of practice for calculation of 

settlements of foundations 

: IS:4326 

: IS:9595 

: IS: 1904 

: IS:6403 

: IS: 8009(Pt I, II) 

Page 5 of 30

1.1.2 Applicable codes and standards for materials. 

The following codes and standards shall be applied to the equipment and materials 

to be used for the Facility. 

(1) Building Materials 

Concrete aggregates : IS 6461 PART-I 

Materials : IS 6461 PART-II 

(2) Structural Steel 

Steel Material : IS 2062 

(3) Concrete 

Re-bar : IS1786 ,IS432 PART(1&2) 

Cement : IS269 ,IS455, IS8112, IS12269 

AGGREGATES : IS383 

(4) Ready Mix Concrete : IS 4926 

1.1.3 Standard Drawings 

Drawing Number - 0435-JH0902-00-CI-DST-0001-001 TO 017. 

1.1.4 UNIT AND LANGUAGE. 

(1) Measurement Unit : SI 

(2) Language : English 

1.2 SITE CONDITIONS 

1.2.1 Location of Site 

The site is located in Raman Mandi, Bathinda & Bahadurgarh. 

Page 6 of 30

1.2.2 Topographical & Geological Conditions 

Existing Site Conditions – Generally flat terrain 

Elevation 

From the Raman Mandi take-off elevation of RL.204.521m above MSL the pipeline runs to 

an elevation of 207.729m at Ch. 27 km at Bhatinda. 

From the Raman Mandi take-off elevation of RL.203.522m above MSL the pipeline runs to 

an elevation of 215.589m at Ch. 234.98 km at Bahadurgarh. 

Rainfall Data 

Design Groundwater Level 

As per geotechnical report, the ground water table encountered at depths varying from 9.05 

to 12.01m below existing ground surface. For Ramanmandi and Bhatinda station analysis of 

foundations the design ground water table is considered at approximately 4.0m depth below 

the existing ground level. 

Bhadurgarh water table is at 1.0 m below existing ground level. Depth of Foundation and 

Bearing capacity of structures shall confirm to soil investigation report supplied by HPCL. 

Page 7 of 30

2. DESIGN LOADS & DESIGN PHILOSOPHY 

These loading shall be applicable to all structures irrespective of the material employed for 

construction. 

2.1 Dead Loads ( DL ) 

The weight of all permanent construction including self weight of structural members, walls, 

fire proofing, floors, roofs, partitions, stairways and fixed service and other equipment empty 

weight (excluding their contents). 

Following Unit weight shall be adopted: 

Reinforced concrete 

Plain Concrete 

Structural Steel 

Backfill soil 

= 26 kN/m3 

= 25 kN/m3 

= 78.5 kN/m3 

= 18 kN/m3 

2.2 Live Loads ( LL) 

Live load in general shall be as per IS: 875, following minimum live loads shall be considered 

in the design of structures: 

i. Substation/control Room, S.V. Stations & 

Service Platform 

Panel floor / battery room 

AHU, UPS, Locker Room 

Blower Room 

Stairs for substations 

Warehouse Floor / Grade Slab / Ground floor 

Access / Service Platform 

iii. Roofs 

Non Accessible RC Roof 

Accessible RC Roof 

Sheeted Roof 

v. Staircase 

Plant / Non plant buildings 

Stores 

- 

- 

- 

- 

- 

- 

- 

- 

- 

- 

- 

10.0 kN/m 2 

5.0 kN/m 2 

7.5 kN/m 2 

5.0 kN/m 2 

10.0 kN/m 2 

2.5 kN/m 2 or 3kN Point 

Load at center 

1.5 kN/m2 

2.5 kN/m2 

0.75 kN/m2 

5.0 kN/m 2 

7.5 kN/m 2 or as per actual 

Page 8 of 30

2.3 Wind Loads (WL) 

Basic wind Speed (V b ) 

Risk Coefficient (k1) 

Terrain Category for (k2) = 1 

Structure Class for (k2) 

Terrain, Height and Structure Size 

Factor (k2) 

= 47 m/s 

= 1.00 for all General Category Structures 

= B 

Topography Factor (k3) = 1.00 

Design Wind Speed (V Z ) 

= As given below in the table 

= V b *k1*k2*k3 m/s 

Design Wind Pressure (p Z ) = 0.6*V Z 

2 

N/m 2 

Wind Load – 10 % Extra Equipment area should be considered for connected piping to 

equipment as per IS 875 –part-III 

Wind pressure on Buildings / Structures 

Height 

(m) 

K2 

V Z 

m/s 

p z 

N/m 2 

p z 

KN/m 2 

Up to 10m 1.03 56.65 1925 1.93 

10m - 15m 1.07 58.85 2078 2.08 

15m - 20m 1.10 60.50 2196 2.20 

20m - 30m 1.13 62.15 2319 2.32 

30m - 50m 1.18 64.90 2527 2.53 

50m - 100m 1.24 68.20 2791 2.79 

2.4 Seismic Loads (SL) 

a. Seismic Design shall be done in accordance with IS 1893 (part1 ) - 2002 

b. Seismic Zone : Zone – IV 

c. Zone Factor : 0.24 

d. Importance Factor : 1.50 (For substation, control room and other 

essential facilities) 

1.25 (For Non-Plant Buildings such as guard 

room/admin building) 

e. Soil Type : Type-II (Medium Soil) 

Note: Static seismic analysis shall be performed for structures analysis. 

Page 9 of 30

2.5 Equipment Loads (EEL) 

Equipment loads for various conditions such as EEL - Empty Condition, EOL - Operating 

Condition and ETL - Test Condition are considered. 

For calculating empty weight of the equipment all fixtures, platforms, ladders and attached 

piping but excluding contents shall be considered. When piping weight is not indicated 

separately or included in the weight of the equipment the same shall be taken as 10% of the 

empty weight of the equipment. 

2.6 Equipment Operating Loads (EOL) 

Operating loads shall comprise of the maximum design loads sustained by the equipment 

during plant operation including inventory of product 

2.7 Thermal / Friction Load (TL/FL) 

Horizontal forces due to thermal expansion of horizontal vessels/ Exchangers shall be 

relieved by using slotted holes and slide plates and remaining force derived from product of 

the sliding saddle gravity load and co-efficient of friction (0.3 to steel or 0.08 PTFE), which 

shall be applied to each support. 

2.8 Impact & Vibratory Loads 

Impact load shall be defined as an equivalent static force caused by a moving object. 

Structures subjected to impact or vibratory loads shall be designed as per the provisions of 

IS 875 & IS: 2974.Requirements for monorail shall be as per IS-800, IS-875 or 

manufacturer’s data whichever is more stringent. 

2.9 Soil and Hydrostatic Pressure (SP) 

Pressure on basement walls - In the design of basement walls or similar (approximately 

vertical) structures below grade, provision shall be made for resisting lateral pressure of the 

adjacent soil. If a portion or whole of the adjacent soil is below free water surface, pressure 

computations shall be based on the diminished weight of the soil (due to buoyancy) plus full 

hydrostatic pressure. 

If difference in plot level and surrounding area is more than lm then complete RCC wall shall 

be designed to withstand earth pressure as well as surcharge. 

Uplift on Floors - In the design of basement floors and similar (approximately horizontal) 

constructions below grade, the upward pressure of water shall be taken as full hydrostatic 

pressure applied over the entire plan area. Factors of safety against uplift shall be 1.2. 

2.10 Other Loads 

Apart from the specified live loads, any other equipment load or possible overloading during 

construction/ hydro-test/maintenance/erection shall also be considered in the design. Under 

hydro test condition the wind force shall be taken as 25% of normal loading. 

Page 10 of 30

All buildings/ Structures shall be designed to resist the worst combination of the 

above loads. 

3. Foundation Design 

Depth of foundation, Safe bearing pressure (Allowable net bearing capacity) & other design 

parameters for design shall be based on the following criteria & shall confirm to Soil 

Investigation report supplied by HPCL for respective area - 

Maximum settlement 

S N. 

Foundation 

Settlement (mm) 

1. Foundation for all types of equipments Pipe racks, Plant bldgs.etc 25 

2 Footings for non-plant bldgs.including raft fdns. 40 

3 Foundations for oil storage tanks ( Edge Settlement) 150 

Allowable loss of contact should not exceed 10% for DL+LL and should be less than 20% 

subjected to wind and seismic load. 

3.1 DESIGN CRITERIA FOR FOUNDATION DESIGN 

3.1.1 Depth of foundation 

The type & depth of foundation shall be as per geotechnical report supplied by HPCL. 

Following are minimum depths of foundations: 

Tank Foundation – 800 mm 

Building foundations - 1500 mm 

Equipment foundations - 300 mm 

Pipe sleepers - 300 mm 

3.1.2 Stability Criteria: 

Factor of safety against overturning (For Dead load) – 2.0 

Factor of Safety against overturning (For Wind& seismic loading condition) – 1.5 

Factor of safety for sliding – For plant operating with or without live load shall be 1.75 & with 

wind/earthquake shall be 1.5. 

Factor of safety for Buoyancy – The sum of vertically downward loads shall exceed 1.2xsum 

of all vertically upward loads. 

Subsoil water effect in foundation design: The water table above depth of footing results in 

reduction in soil bearing pressure & shall be incorporated in foundation design. 

Page 11 of 30

Design philosophy for Equipment Foundations – 

Foundation design shall be as per Geo-Technical report / data. Loads acting on Equipment 

foundation are described in Chapter 2.0. 

Equipment foundation pedestal should be 300mm above FGL/Paving. 

3.2 Foundations for Rotating and Reciprocating Equipment 

Unless otherwise specified foundation design shall follow general criteria 

indicated below: 

Design of foundation shall confirm to IS 2974 (Part-1 TO 5) 

Considerable rigidity of the machine foundation is essential to avoid failure of the machine 

bearings. The foundation must have sufficient mass to absorb the vibration. The natural 

frequency of the foundation should be less than 0.8 or greater than 1.2 times the operating 

frequency of the machine to avoid resonance. 

Where structural steel associated with walkways and platforms is to be erected around the 

machine foundation, the attachment of the steelwork to the foundation for support should be 

avoided. If the steel is attached to the foundation the effect of this additional mass on the 

foundation response to vibration shall be included in the design. 

• Reinforcement should be provided on all faces of the concrete to give a minimum 

reinforcement value of 50 kg/m 3 for up stands and 30 kg/m 3 for foundation rafts. 

• The foundation thickness for vibrating machines should be at least 600 mm, unless a 

smaller thickness is given by the machine manufacturer. 

• Proportion the base to ensure that the eccentricity between the centroid of the static 

loads and the centroid of the foundation base and the eccentricity between the centroid 

of the vertical dynamic loads and the centroid of the foundation base are both within 5% 

of the relevant base dimension. 

• The machine foundation should be isolated from any adjacent foundations and 

structures, if possible. 

Page 12 of 30

Pump Foundation shall be block type foundation, depth of foundation shall be 700mm 

and bearing capacity should not exceed 5T/m2. Soil at the foundation base is well 

compacted having density equivalent to 90% of maximum dry density. 

CRITERIA 

APPLICATION 

*Allowable amplitude, 

Rotating : P ≥ 400 KW 

Natural frequency of foundation 

Dynamic 

Reciprocating : P ≥ 100 KW 

analysis Natural frequency of foundation Rotating : P ≥ 100 KW 

Foundation 

weight 

control 

Reciprocating : P ≥ 40 KW 

More than 3 x equip. weight Rotating : P < 100 KW 

More than 5 x equip. weight Reciprocating : P < 40 KW 

P = Rated Power output of equipment (unit KW). 

*If the supplier’s requirement is available, same shall be considered. 

Page 13 of 30

4. DESIGN PHILOSOPHY FOR PIPE SUPPORTS 

Pipe supports shall be entirely in Reinforced Concrete for piping above ground, structural 

supports for manifold piping & supports inside sheds. 

4.1 TYPE OF LOADS 

Dead Loads : DL 

This shall mean, the weights of pipes, fittings, valves, insulation and the fluid contents of 

piping, including the weight of Cable ducts wherever installed. Piping empty load (Ple) 

includes weight of piping and insulation. 

Piping Loads shall be calculated considering the pipe diameters and piping arrangement 

subject to minimum of 1.25 kN/m2 over entire span. 

Friction Force (Longitudinal & Transverse): FL 

Longitudinal friction force equal to 5% of the total pipe weight tributary to that pipe support 

( beam) of carrying more that 3 lines , 10% for carrying 2-3 lines & 20% for carrying one 

line. 

Wind Loads: WL 

Transverse wind load shall be calculated depending on the width of pipe rack as per 

following table. This forces shall be considered irrespective of the height between two tiers. 

Width of pipe Rack 

Up to 4m 

Above 4m but up to 6m 

Above 6m but up to 10m 

Wind force at each tier level (N) 

1.25 x p x s 

1.50 x p x s 

2.00 x p x s 

Where p = Horizontal wind pressure as per IS-875 (Part 3) (in N/m2) 

S = Spacing of portal (in m) 

Piping Load (Operating – Plo) 

Piping operating load includes piping self weight, insulation and material weight carried by 

pipe. 

Piping load (Testing – PLt) 

Piping test load consists of self weight, insulation and test material weight. 

Piping Anchor Load (AL) 

Piping Anchor load shall be supplied from Piping division from stress analysis. 

Page 14 of 30

Loading on Longitudinal Beams 

Longitudinal beams connecting portal columns shall be sufficiently strong to sustain a 

minimum of 25% of the load on the transverse beams or 10kN at center which ever is 

maximum. This total load shall be assumed as two equal concentrated loads acting at 1/3rd 

span. This load shall be in addition to the piping loads transferred from the intermediate 

beams. Other longitudinal axial forces coming on it from the design of the supporting system 

shall also be simultaneously taken into account in the design of the longitudinal beam. Loads 

from monorails, when supported from these beams, shall also be considered to be acting 

simultaneously along with all other loads mentioned above. 

Page 15 of 30

5. Basic Load Cases & Load Combinations - 

DL - 

LL - 

FPL - 

WL - 

SL - 

EEL - 

EOL - 

ETL - 

HOL - 

SP - 

ELL - 

BPL - 

FL - 

AL - 

TL - 

PLe - 

PLo - 

PLt - 

Dead Load 

Live load 

Fire-proofing load 

Wind load 

Seismic load 

Equipment Empty Load 

Equipment Operating Load 

Equipment Test Load 

Horizontal operating load 

Soil Pressure 

Erection load (Temporary Loading) 

Bundle Pull Load 

Friction Load 

Anchor Load 

Thermal Load 

Piping Dead Load 

Piping Operating Load 

Piping Test Load 

Page 16 of 30

5.1 For Equipment Foundations 

Load Combinations DL LL WL SL EEL 

EOL 

& 

HOL 

ETL FL ELL REMARKS 

Equipment foundation design ( For Pressure calculation) 

DL + EEL + WL 1.0 1.0 1.0 - 1.0 - - 1.0 Erection / Empty Condition 

DL +EOL +WL 1.0 - 1.0 - - 1.0 - 

DL+EOL + SL 1.0 - - 1.0 - 1.0 - - - 

DL+EOL+FL+WL 1.0 - 1.0 - - 1.0 - 1.0 - Operating Condition 

DL+EOL+FL+SL 1.0 - - 1.0 - 1.0 - 1.0 - 

DL+EOL+FL 1.0 - - - - 1.0 - 1.0 - 

DL+LL+ETL+WL 1.0 1.0 0.25* - - - 1.0 - - Test Condition 

Equipment foundation design ( For Concrete design) 

DL + EEL + WL 1.5 1.5 1.5 - 1.5 - - 1.5 Erection / Empty Condition 

DL +EOL +WL 1.2 - 1.2 - - 1.2 - - - 

DL+EOL + SL 1.2 - - 1.2 - 1.2 - - - 

DL+EOL+FL+WL 1.2 - 1.2 - - 1.2 - 1.2 - 

DL+EOL+FL+SL 1.2 - - 1.2 - 1.2 - 1.2 - 

DL+EOL+FL 1.5 - - - - 1.5 - 1.5 - 

Operating Condition 

DL+LL+ETL+WL 1.5 1.5 0.375* - - - 1.5 - - Test Condition 

* For Test Condition 25% of Wind Load is considered. 

Page 17 of 30

5.2 For Building Design 

Load Combinations DL LL WL SL EEL EOL& HOL ETL REMARKS 

For Concrete Member Design 

DL + LL 1.5 1.5 - - - - - 

DL + WL 1.5 - 1.5 - - - - 

DL+LL+WL 1.2 1.2 1.2 - - - - 

DL + LL + SL 1.2 1.2* - 1.2 - - - 

DL + SL 0.9 - - 1.5 - - - 

For Foundation Design 

DL + LL 1.0 1.0 - - - - - 

DL + WL 1.0 - 1.0 - - - - 

DL+LL+WL 1.0 1.0 1.0 - - - 

DL + LL + SL 1.0 1.0* - 1.0 - - - 

DL + SL 0.9 - - 1.0 - - - 

For Steel Structure 

DL + LL 1.0 1.0 - - - - - 

DL + WL 1.0 - 1.0 - - - - 

DL+LL+WL 0.8 0.8 0.8 - - - - 

DL + LL + SL 0.8 0.8 * - 0.8 - - - 

DL + SL 1.0 - - 1.0 - - - 

* 50 %. of Live Load on structure. 

Page 18 of 30

5.3 For Pipe Rack / Sleepers 

Load Combinations DL LL WL SL EEL 

EOL 

& 

HOL 

ETL BPL FL ELL PLe PLo PLt TL AL 

REMARKS 

For Pipe Racks / sleepers ( For Pressure calculation) 

DL+ LL+PLo+FL+AL+EOL 1.0 1.0 - - - 1.0 - - 1.0 - 1.0 - - 1.0 Normal 

DL+LL+PLo+FL+AL+SL+EOL 1.0 1.0 - 1.0 - 1.0 - - 1.0 - - 1.0 - - 1.0 

DL+PLe+FL+AL+SL+EEL 1.0 - - 1.0 1.0 - - - 1.0 - 1.0 - - - 1.0 

DL+LL+PLo+EOL+AL+FL+WL 1.0 1.0 1.0 - - 1.0 - - 1.0 - - 1.0 - - 1.0 

DL+PLe+EEL+AL+FL+WL 1.0 - 1.0 - 1.0 - - - 1.0 - 1.0 - - - 1.0 

DL+PLt+ETL 1.0 - - - - - 1.0 - - - - - 1.0 - - 

DL+PLt+ETL+0.5WL 1.0 - 1.0* - - - 1.0 - - - - - 1.0 - - 

DL+WL+PLe+EEL 1.0 - 1.0 - 1.0 - - - - - 1.0 - - - - 

DL+SL+PLe+EEL 1.0 - - 1.0 1.0 - - - - - 1.0 - - - - 

Seismic 

Wind 

` 

Test 

Empty 

For Pipe Racks / sleepers ( For Concrete design) 

DL+ LL+PLo+FL+AL+EOL 1.5 1.5 - - - 1.5 - - 1.5 - 1.5 - - 1.5 Normal 


Seismic 

DL+PLo+FL+AL+SL+EOL 1.5 - - 1.5 - 1.5 - - 1.5 - - 1.5 - - 1.5 

Page 19 of 30


DL+PLo+EOL+AL+FL+WL 1.5 - 1.5 - - 1.5 - - 1.5 - - 1.5 - 1.5 

DL+PLt+ETL 1.5 - - - - - 1.5 - - - - - 1.5 - . 

DL+PLt+ETL+0.5WL 1.5 - 1.5* - - - 1.5 - - - - - 1.5 - 

DL+WL+PLe+EEL 1.5 - 1.5 - 1.5 - - - - - 1.5 - - - 

DL+SL+PLe+EEL 1.5 - - 1.5 1.5 - - - - - 1.5 - - - 

Wind 

Test 

Empty 

Load Combinations DL LL WL SL EEL EOL 

& 

HOL 

ETL BPL FL ELL PLe PLo PLt TL AL REMARKS 

For Pipe Racks / sleepers ( For Steel Structure Design) 

DL+ LL+PLo+FL+AL+EOL 1.0 1.0 - - - 1.0 - - 1.0 - - 1.0 - - 1.0 Normal 


DL+PLo+FL+AL+SL+EOL 1.0 - - 1.0 - 1.0 - - 1.0 - - 1.0 - - 1.0 


DL+PLo+EOL+AL+FL+WL 1.0 - 1.0 - - 1.0 - - 1.0 - - 1.0 1.0 

DL+PLe+ETL 1.0 - - - - - 1.0 - - - - - 1.0 - . 

DL+PLe+ETL+0.5WL 1.0 1.0 1.0* - - - 1.0 - - - - - 1.0 - 

DL+WL+PLe+EEL 1.0 - 1.0 - 1.0 - - - - - 1.0 - - 

DL+SL+PLe+EEL 1.0 - - 1.0 1.0 - - - - - 1.0 - - - 

Seismic 

Wind 

Test 

Empty 

Page 20 of 30

6. BUILDING 

6.1 Building List 

1 Substation 

2 Warehouse 

3 P/L Control room 

4 D.G. room 

5 SV Stations 

6.2 Plumbing/Sanitary 

Material for plumbing and sanitary shall be best quality with ISI mark. Separate water 

tanks shall be provided for each building. List of make shall be provided in the tender 

to avoid dispute in prices. This shall be gravity piped system for flows originating from 

toilet blocks, showers etc. The discharge shall be collected in septic tank and 

subsequently in soak pit. 

7. STEEL STRUCTURE 

7.1 Material 

(1) Material Standard & Grade 

Unless otherwise noted, material code / standard & grade as below shall be 

applied: 

Plate & Shape : IS: 2062 (Grade A) 

Steel Pipe 

: Medium duty (IS1239 (Part1) 

Ordinary Black Bolt : Class 4.6 (IS 1367) 

High Strength Bolt : Class 8.8 (IS1367, IS3757, IS4000 

Checkered Plate : IS: 3502 

Steel Grating : IS: 2062(Grade A) 

Anchor Bolt – Material for Anchor bolt (MS Bars, washer, nuts and plates etc.) shall 

be as per relevant Indian standard. 

Hexagonal bolts and nuts – IS3138 

IS 277-1992 : Galvanized steel sheets (Plain and corrugated). 

7.2 Minimum Thickness of steel elements 

The minimum thickness of various structural components (Hot rolled sections) shall 

be as given: 

General Construction: 

Trusses, purlins, side girths & bracings 

Columns, beams 

6mm 

7mm 

Page 21 of 30

Gussets in trusses & girders 

i) Up to and including 12m span 8mm 

ii) Above 12m span 

Stiffeners 

Base plates 

Chequered plate 

Grating 

10mm 

8mm 

12mm 

6mm (on plain) 

Hot Dip galvanized MS grating 

The minimum thickness of tubes shall be as specified in IS: 806. 

Staircase: Staircase shall be as pre Standard drawings. 

Width – 900mm 

Tread - 250 mm 

Rise - 185-200 mm 

7.3 Paint Specification. 

Painting shall be provided as per Job Specifications and Architectural layout. 

7.4 FIRE PROOFING 

a) Where required by OISD-STD-164 norms, structural steel members shall be 

fireproofed by concrete encasing or guniting (minimum thickness = 50mm). 

b) For column elements steel sections wherever required up to and including 

500mm depth shall be coated by solid fill while section more than 500mm depth shall 

be coated in the shape of the profile. 

c) For Beam elements steel sections up to and including 300mm depth 

shall be coated by solid fill while section more than 300mm depth shall be coated in 

the shape of the profile. 

7.5 Allowable Deflection 

Allowable deflection for steel structure is specified as follows: 

For Pipe Supporting Beam : L/300 , Max. 25 mm 

For Eq’t Supporting Beam : L/500 , Max. 25 mm 

For Crane Girder 

: L/600 , Max. 25 mm 

For Other beams : L/325 

Purlins / Cladding runner : L/200 

Grating/ Chequered. Plate : L/200 or 6mm whichever is smaller. 

Where L = Span length of the Supporting beam 

Column (under normal loads) : (1/325)*H 

H= Height of each story 

Page 22 of 30

Column (wind/ seismic loads) : (1/250)*H H= Height of each story 

8. Concrete 

Concrete construction shall be conforming to IS: 456 -2000 shall be used 

8.1 MATERIALS 

a) Reinforced Cement Concrete (RCC) 

M30 grade concrete or higher shall be used for all RCC structures, pits, 

foundations except grade slab & paving based on exposure condition and 

serviceability. 

Paving: M25 

Grade slab: M20 

b) Lean Concrete 

Lean concrete conforming to IS: 456 shall be used. The grade of concrete 

shall be as per Table below. It shall confirm to standard/detailed drawings. 

i. Under All RCC foundations 

except base of liquid retaining 

structures 

ii Under base of liquid 

retaining structures 

iii. Encasement Concrete 

iv. Filling concrete 

( To be used as filler material 

wherever loose sub grade 

exists by removing loose soil 

or where levels are to be 

made up to desired founding 

level) 

100mm thick PCC 1:4:8 with 100mm projection from 

face of foundation 

100mm thick PCC 1:3:6 with 100mm projection from 

face of foundation 

M15 grade concrete with 10mm down aggregates 

M5 (Nominal Mix) 

c) Plain Cement Concrete (PCC), plinth protection shall be as per job 

specification and job detailed/standard drawings. 

d) Cement 

For Substructure : Ordinary Portland Cement confirming to IS-8112 

(Gr43), Portland Pozzolana Cement confirming to IS-1489 ,Slag Cement 

whichever available in market 

For Superstructure: Ordinary Portland Cement confirming to IS-8112 (Gr 43), 

Portland Pozzolana Cement confirming to IS-1489, Slag Cement whichever 

available in market 

Page 23 of 30

e) Rebar 

For Substructure 

For Superstructure 

: Fe415 confirming to IS:1786 

: Fe415 confirming to IS:1786 

Provision should be kept for Fe 500 , based on market availability. 

8.2 Minimum Thickness of Structural Concrete Elements 

The following minimum thickness shall be followed: 

- Footings (All types including raft foundations without beams) 300mm 

(Note: Tapered footings shall not have thickness less than 150mm at the edges. 

Minimum average thickness shall not be less than 300mm) 

- Basement Walls & Base Slab 150mm 

- Slab thickness in Raft foundations with beam 

& slab construction 

350mm 

- Floor/Roof Slab, Walkway, Canopy Slab resting on beams 125mm 

- Cable/Pipe Trench/Launder Walls & Base Slab 100mm 

- Parapet/Cantilevered Canopy Slab 100mm 

- Louver/Fin. 100mm 

- Pre-cast Trench Cover/Floor Slab 100mm 

- Pre-cast Floor Slab/Louver (in contact with liquid) 100mm 

- Liquid Retaining/Leak proof Structure Walls & Base Slab 150mm 

- Underground Pit/Reservoir (Below ground water table) 

Walls & Base slab 

- Underground Pit (Above ground water table) 

Walls & Base Slab 

250mm 

200mm 

8.3 Minimum Height of Pedestals 

The minimum projection of pedestals supporting any steel structure/stanchion 

bases shall be 300/150mm above the high point of pavement/ finished 

grade/finished floor level whichever is higher, for outdoor and indoor located 

pedestals respectively. The minimum projection of pedestals for staircase/ladder 

shall be 150mm. 

Page 24 of 30

8.4 Grouting & Minimum Grout Thickness 

The minimum thickness of grout shall be 25 mm. All anchor bolt sleeves/pockets 

and spaces under column bases, shoe plates etc. shall be grouted with free flow, 

non-shrink (premix type) grout with 28-day minimum cube crushing strength of 

40N/mm 2 . 

Ordinary cement sand (1:2) grout shall only be used under the base plates of 

crossover, short pipe supports (not exceeding 1.5 m height) and small operating 

platforms (not exceeding 2.0m in height) not supporting any equipment 

8.5 Allowable Deflection 

Allowable deflection for Concrete Structure is specified as follows: 

For Pipe Supporting Beam : L/300 , Max. 25 mm 

For Eq’t Supporting Beam : L/500 , Max. 25 mm 

For Other beams : L/325 

Where L = Span length of the Supporting beam 

Column : (1/200)*H H= Height of each story 

9. GENERAL CIVIL 

9.1 Road and Paving 

Road design shall be as per IRC loading and specifications. 

Main Road : 7.5 m wide bituminous road consisting of 6.0m carriageway & 0.75m 

wide shoulders on either sides. 

Access road : 6.0m wide bituminous road consisting of 4.5m wide carriageway & 

0.75m wide shoulders on either side. 

Foot path: 1.0m wide of PCC. 

Road width shall be as per approved plot plan drawings. 

In principle, classification of paving is assumed as below: 

Inside Plant Area (maintenance area) : Heavy Duty Concrete paving 

Inside Plant Area (other than maintenance area): Light Duty Concrete paving 

Setback Area : Bare 

Around Building : Plinth protection in PCC 

Inside Dike : Bare 

Open/Future Area : Bare 

Paving requirement shall be as marked in plot plan / layout drawings. 

Basic specification for road and paving used for estimation are as follows: 

Page 25 of 30

(1) Specification of Road 

CLASS 

LAYER 

WIDTH 

(m) 

MATERIAL 

THICKNE 

SS 

(mm) 

MAIN 

APPROACH 

ROAD 

MAIN 

INTERNAL 

ROAD 

OTHER 

ROADS 

Surface 

As per 

layout 

Shoulder 2 x 0.75 

Base course 

Sub-base 

Sub-grade 

As per 

IRC 

As per 

IRC 

As per 

IRC 

Surface 6.0 


Base course 

Sub-base 

Sub-grade 

Surface 

As per 

IRC 

As per 

IRC 

As per 

IRC 

As per 

layout 


Base course 

Sub-base 

Sub-grade 

As per 

IRC 

As per 

IRC 

As per 

IRC 

Premix bituminous carpet 

with seal coat 

75mm thick WBM in 

Grade II aggregates 

WBM in Grade II 

aggregates (2 layers of 

75mm thk.) 

WBM in Grade I 


100mm thk.) 

50 

75 

150 

200 

Compacted sub-grade - 







75mm thk.) 



100mm thk.) 

65 

75 

150 

200 








75mm thk.) 



100mm thk.) 

65 

75 

150 

200 


Page 26 of 30

(2) Specification of Paving 

Class. Layer Material Thickness(mm) 

Heavy Duty Surface Conc. 200 

Base-course WBM(2 Layer) 150 

Light Duty Surface Conc. 150 

Base-course Compacted Sand 150 

Light Duty Surface Conc. 150 

(Pump Base-course Compacted Sand 150 

Area) 

Paver Block (For parking and driveway) 

Surface Concrete Paver Blocks 80-100 

Sand cushion 50 

Base-course WBM(2 Layer) 150 

Gravel Paving Surface Gravel 100 

Paving design shall be carried out on rational basis related to predicted wheel load 

application. 

Isolation joint & Construction joints shall be provided as specified in job specification and 

confirming to IRC guidelines. 

Expansion joint shall be provided at interval of 15 m. Details shall be similar to standard 

drawings , slope of paving shall be 1/100UNO. Raised concrete kerb shall be provided 

whenever necessary to contain spillage. 

Provision should be kept for WMM based on availability of material. Refer Job standard 

drawings for other details , paving shall confirm to applicable BIS standards. 

Road Bridges / Culverts 

Storm water drains shall cross the road by suitable pipe culverts or box culverts as the case 

may be. Material of construction of culverts shall be as below : 

Pipe culverts : Precast R.C.C. hume pipe of Class NP3/NP4 (Min. size dia.350 mm) , shall 

confirm to IS458. 

Box culverts: R.C.C. construction (M30 concrete grade) 

9.2 Drainage 

Drainage shall be designed for average rainfall intensity of 25 year frequency , 5 minute 

duration storm for the site geographical area. Drainage design shall be carried out on 

rational basis in accordance with industry practice. 

Page 27 of 30

Rainfall Intensity – 

Storm Water Drain 

a) Type : Rectangular/trapezoidal type open drains 

b) Construction: RCC type along roadsides, Brick masonry type in tank form area. 

Sanitary Sewer 

Sanitary Drain Pipe - Stoneware Glazed pipe 

Domestic drainage from buildings is directed to septic tanks. By gravity system 

Sanitray drainge system shall include septic tank, distribution box and an 

underground drain field. The design of system shall confirm to relevant Indian 

standards and system should adhere to local / state authorities regulation. 

Oily Water Sewer System 

Contaminated mixture from surface drain , scraper barrel pit, etc. shall be directed 

to adjacent oily water disposal system. Transformer compound shall have a waste 

collection pit. Transformer waste oil will be removed from site by tanker. 

Design criteria and short specification for drainage system are as follows: 

(1) Design Flow Rate 

(a) Rainfall: 1250mm (maximum recorded rainfall) 

(b) Fire Water : As per OISD-116 guidelines. 

(2) Discharge Quantity Of Storm Water 

The following equation shall be used to calculate design quantities of storm 

water. 

⎛ 1 ⎞ 

Qr = ⎜ × C × I × A 

6 ⎟ 

⎝ 3.6 × 10 ⎠ 

Where, 

Qr 

: Design quantities of storm water (m 3 /sec) 

C : Run-off coefficient (refer to Table -1) 

I 

: Design rainfall intensity (mm/hr) 

A : Catchment area (m 2 ) 

Page 28 of 30

TABLE -1 RUN-OFF COEFFICIENT 

Surface Condition 

Run-Off Coefficient 

Roof 0.90 

Concrete Road, Paving 0.90 

Asphalt Road, Paving 0.90 

Gravel Road, Paving 0.50 

Soil, Green belt 0.2 

(3) Hydraulic Design 

Flow Velocity and Quantity 

The velocity and quantity of hydraulic flow in open drains or underground pipes 

shall be calculated by using the Manning formula as below : 

1 

n 

R 

2 3 

V = × × 

Q = A× 

V 

Where, 

I 

V : Velocity (m/sec) 

n : Coefficient of Roughness (refer to Table - 2) 

R : Hydraulic Radius (m) 

I : Slope of channel 

Q : Discharge Quantity (m 3 /sec) 

A : Hydraulic section (m 2 ) 

1 

2 

The flow velocity shall not be less than 0.6 m/sec in general at the design 

flow rate except excavated earth channel without lining. 

The flow velocity shall not be more than 2.5 m/sec at the design flow rate. 

Coefficient of roughness is shown in Table -2. 

Closed conduits 

Table -2 Typical coefficient of roughness 

Open Drains 

Steel pipe : 0.013 Concrete lined : 0.017 

Cast iron pipe : 0.013 Stone riprap : 0.025 

Concrete pipe : 0.014 

Excavated earth : 0.028 (Straight) 

Plastic pipe : 0.009 Excavated rock : 0.040 (rough) 

Storm water drainage shall be designed as flowing full and sanitary and other pipes 

shall be designed as flowing half full. 

Page 29 of 30

(4) Type of Sewer / Material 

Ditch/Pipe Mat’l Manhole/Cover. Catch Basin/Cover 

For non-polluted: Open (V) Riprap NA NA 

Or Rect Brick 

For Oily: Pipe CS RC / CI RC / Grat’g 

For Sanitary: Pipe GSW Brick / CI NA / NA 

Legend: RC = Reinforced Concrete, RC Lin’g = RC with protective lining 

CS = Carbon Steel, Grat’g = Galvanized grating 

GSW = Glazed Stoneware, RC*1: RC with acid-proof coating. 

Cable Installation 

Cables are laid in earthen trenches in paved area & buried in unpaved area. Hume pipes & 

PVC conduits will be used for road crossings. 

Dike Wall 

Dike wall is of brick/stone masonry with coping. Dike wall shall confirm to standard drawing 

and approved plot plan layout. 

Boundary wall & Fence 

Compound wall of 3.05m (10’’) high wall with additional 0.6 m anticlimber on top. Wall will be 

RCC framed with brick/ rubble masonry filler. 

SITE PREPARATION 

The grading of the area shall be done by cutting & filling with the following: 

a) Cutting area: Thoroughly rolled & compacted 

b) Filling area: 

Other than roads: Compacted in layers not exceeding 30cm to achieve min.95% of 

max. dry density. (confirming to IS-2720, part-VII) 

For roads: Compacted in layers not exceeding 20cm to achieve min.95% of max. 

dry density. (confirming to IS-2720, part-VIII) 

c) General site grading: 1 in 500 to 1 in 1000 (for drainage of storm water) 

10. SOFTWARE TO BE USED FOR THE PROJECT 

For Analysis and Design: STAAD.Pro 2008 

For Drafting: AutoCAD 

Page 30 of 30




(GGSRPEP) 

SPECIFICATIONS FOR DOORS, WINDOWS AND ROLLING 

SHUTTERS 

0435-JH0902-00-AR-SPC-0001 

C Issued for Tender 

RAR UDB AK 06/06/09 

B Issued for Client Review RAR UDB AK 

29/05/09 

A Issued for SDC RAR UDB AK 26/05/09 


PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE

SPECIFICATIONS FOR DOORS, 

WINDOWS AND ROLLING SHUTTERS 

1. SCOPE 

This Specification defines the requirements regarding material, sizes, construction, 

workmanship, finishes and installation for doors, windows, ventilators and rolling 

shutters. 

2. REFERENCE DOCUMENTS 

2.1 Codes and Standards 

The Indian Standards and other referred standards (including all amendments 

and revisions) shall be considered as part of this Specification. In case any particular 

aspect of work is not covered specifically by these or any other relevant Indian Standard 

Specification, any other good engineering practice as may be specified by the company 

shall be followed: 

Following Indian standards including all amendments and revisions shall be 

considered as part of this specification. 

Indian Standards 

IS 205 Indian Standard Specification for non-ferrous metal butt hinges. 

IS 287 Indian Standard Recommendations for permissible moisture content for 

timber used for different purposes. 

IS 303 Indian Standard Specification for plywood for general purposes. IS 513 Coldrolled 

low carbon steel sheets andtrips 

IS 710 Indian Standard Specification for Marine plywood. 

IS 733 Wrought Aluminum and Aluminum Alloy Bars, Rods and Sections for 

General Engineering Purposes. 

IS 737 Wrought aluminum and aluminum alloy sheet and strip for general engineering 

purposes. 

IS 848 Indian Standard Specification for Synthetic resin adhesives for plywood 

(phenolic and aminoplastic). 

IS 851 Synthetic resin adhesives for construction work (non-structural) in wood. 

IS 1003 Indian Standard Specification for Timber panelled and glazed shutters - 

part 1 - door shutters, Part 2 - windows and ventilator shutters. 

IS 1038 Indian Standard Specification for steel doors, windows and ventilators. 

IS 1081 Indian Standard Code of practice for fixing and glazing of metal (steel and 

aluminum) doors, windows and ventilators. 

IS 1141 Seasoning of Timber – Code of Practice 

IS 1161 Steel Tubes for Structural Purposes 

0435-JH0902-00-AR-SPC-0001 Page 2 of 20



IS 1200 Indian Standard Specification for method of measurement of building 

and civil engineering works, Part 2: wood work and joinery. 

IS 1285 Wrought aluminum and aluminum alloy extruded round tube and hollow 

sections (for general engineering purposes). 

IS 1328 Veneered decorative Plywood 

IS 1341 Indian Standard Specification for steel butt hinges 

IS 1351 Indian Standard Specification for steel door frames. 

IS 1361 Steel Windows for Industrial Buildings 

IS 1477 Indian Standard Code of practice for painting of ferrous metals in buildings 

Part I - Pre- treatment, Part-2 Painting. 

IS 1642 Indian Standard Code of practice for fire safety of buildings (general): 

Details of construction 

IS 1948 Aluminum Doors, Windows and Ventilators 

IS 1949 Aluminum Windows for Industrial Buildings 

IS 2191 Indian Standard Specification for wooden flush door shutters (cellular and 

hollow core typed part 1 - plywood face panels, part 2, particle board and 

hardboard face panels 

IS 2202 Indian Standard Specification for wooden flush door shutters (solid core 

type) part I - plywood face panels, part 2 - particle board face panels 

and hard board face panels. 

IS 2338 Indian Standard Code of practice for finishing of wood and wood based 

materials, part 1 - operations and workmanship, part 2 – schedules. 

IS 2553 Indian Standard Specification for safety glass. part 1 - General purpose. IS 

2835 Indian Standard Specification for flat transparent sheet glass. 

IS 3087 Indian Standard Specification for wood particle boards (medium density) 

for general purposes. 

IS 3097 Indian Standard Specification for veneered particle boards. 

IS 3548 Indian Standard Code of practice for Glazing in buildings. 

IS 3614 Fire check Doors (Parts 1 & 2) 

IS 4020 Indian Standard Specification for door shutters, method of tests, Parts 1 to 17. 

0435-JH0902-00-AR-SPC-0001 Page 3 of 20



IS 4021 Indian Standard Specification for timber door window and 

ventilator frames- Specifications. 

IS 4043 Recommendations for symbolic designations of Direction of Closing and faces 

of Doors, Windows and Shutters 

IS 4218 ISO Metric Screw Threads (Parts 1 to 6) 

IS 4351 Specification for Steel Door Frames 

IS 4454 Steel wires for cold formed springs 

IS 4537 Indian Standard Specification for figured, rolled and wired glass. 

IS 4835 Specification for polyvinyl acetate dispersion based adhesives for wood 

IS 4913 Code of Practice for Selection, Installation and Maintenance of timber 

doors and windows. 

IS 5807 Indian Standard Specification for methods of tests for clear finishes for wooden 

furniture, Part I - resistance to dry heat, part 2 - resistance to wet heat. 

IS 5986 Hot rolled steel plates, sheets, strips and flats for flanging and forming 

operation 

IS 6245 Indian Standard Specification for metal rolling shutters and 

rolling grills. IS 6248 Specification for Metal Rolling Shutters and 

Rolling Grills. 

IS 7452 Hot Rolled Steel Sections for Doors, Windows and Ventilators. 

IS 12406 Indian Standard Specification for Medium density fiber boards for 

general purposes. 

2.2 Other Standard/Specifications 

Specification for Concrete Work 

Specification for Structural Steel Work 

3. TIMBER DOORS, WINDOWS AND VENTILATORS 

Design, manufacturing and installation of timber shall be in accordance with the 

Engineer’s drawings and the following codes IS 1003 (Parts 1 & 2), IS 2191 (Parts 1 & 

2), IS 2202, IS 4021, IS 4043 and IS 4913. The Contractor shall submit for the EIC’s 

approval one or more sample of Door, Window / Ventilator. Mass fabrication shall 

start only after Engineer In-charge’s (EIC) approval, taking his comments into 

consideration. The Contractor shall purchase Flush Doors, Hardware and Fixtures 

from approved manufacturers only. 

3.1 Frames 

3.1.1 Material 

Superior Grade Indian Teakwood 

Or First Grade Deodar Wood 

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Or First Grade Non-Coniferous Timber other than Teak 

Seasoning of Timber shall be in accordance with IS 1141. The timber shall be free from 

decay, fungal growth, pitch pockets, streaks on the exposed edges, borer holes, splits 

and cracks. All members shall be straight without any warp or bow and shall have 

smooth, well planed edges at right angles to each other. The surface touching the wall, 

however, need not be planed. The frames shall have overall joints at the corners. The 

jamb post shall be through tenoned into the mortices of the transom to the full width of 

the transom and thickness of the tenon shall not be less than 15 mm. The tenon shall be 

closely fitted into the mortises and pinned with corrosion resisting star shaped metal 

pins not less than 8 mm dia or with wood dowels not less than 10 mm dia. The depth of 

the rebate in the frame for housing the shutter shall be 15 mm. The contact surfaces of 

tenons and mortices shall be treated with suitable adhesive. The adhesive shall be a 

bulk type synthetic resin adhesive conforming to IS 851 or synthetic resin adhesive 

(Phenolic and Aminoplastic) conforming to IS 848 or polyvinyl acetate dispersion based 

adhesive conforming to IS 4835. 

3.1.2 Sizes of Frames (Unless shown differently on drawings) 

Door Frame: 140 x 65 mm 

Window/Ventilator Frame: 100 x 50 

The general tolerance allowed shall be + 3 mm 

3.1.3 Holdfasts 

For Door and Window Frames 

i. Door Frames - A minimum of 3 Holdfasts on each side 

ii. Window and Ventilator Frames 

For heights less than 1000 mm: 2 Holdfasts shall be fixed at quarter points of frame on 

each side. For height greater than 1000 mm: 3 Holdfasts shall be fixed on either side. 

iii. Holdfasts shall be MS flat 30 x 3 x 300 long, the ends of the flat being bent in 

opposite direction for 75 mm, leaving 150 mm between the bent ends. The face of 

the frame in contact with side walls and top lintel shall be given a coat of coal tar. All 

surfaces of the frame which are to be painted shall be given a coat of white lead 

based primer. In case of frames to be polished or varnished, the surface shall 

receive a priming coat of suitable polish or varnish. Frames without a timber threshold 

shall be braced with a sturdy base tie (12 mm dia MS rod) to hold the frame rigid 

during transit and erection. 

3.1.4 Installation of Frames 

Frames shall be installed either by “Built-in-Method” or “Prepared Opening Method”. In 

“Built-in- Method”, frame shall be installed at the required place. Masonry or 

concrete in the wall shall be built after installation of the frame so that holdfasts and 

pins at the bottom are well anchored into them. 

In the “Prepared Opening Method”, frames shall be placed in the opening already 

provided in the wall. The holdfasts and pins shall then be grouted, Prepared. Built-in- 

Method shall be preferred over Opening Method of Installation. The datum line for the 

sill of door, window or ventilator shall be taken from a fixed point on the wall, finished 

floor or ceiling with the help of a level. 

0435-JH0902-00-AR-SPC-0001 Page 5 of 20



3.2 Door, Window and Ventilator Shutter 

3.2.1 Paneled and Glazed Shutter 

i. Rails, Styles, Glazing Bars 

The material for these shall be same as specified for frames. The jointing shall 

be in mortice and tenon joints. 

ii. 

Shutter Paneling 

The material for this can be either timber or plywood or Float glass. 

Timber Paneling 

The material shall be same as specified for the door frame. The thickness of the panel 

shall not be less than 15 mm. The panel shall be in one single piece and its area 

shall not exceed 0.5 m2. The timber panels shall be framed into the groove and 

faces shall be closely fitted to the sides of the groove. Additional beadings shall 

be provided on one or both sides if specified on drawings. 

Plywood Paneling 

This shall conform to IS 710. Thickness of plywood shall be 10 mm for 2 or more panel 

construction and 12 mm for single panel construction. Panels shall be fixed to the 

shutter frame by providing grooves in frame as described for timber panels or by using 

beading or both. 

Float Glass Panels 

This shall be good and durable weighing not less than 7.5 kg/m2. The glass panel shall 

be embedded in putty and secured to the rebate by wooden beads of suitable size and 

shape. For external glazed doors, windows and ventilators, beading shall be fixed from 

outside. The contact surfaces of tenon and mortice, tongue and grooved joints shall be 

treated before putting together, with suitable synthetic resin adhesive 

as specified for door shutter. 

The thickness of Door shutter shall be 40mm, while for windows/ventilators; shutters 

shall be 20 mm, 25 mm or 38 mm as specified on the drawings. 

Wherever shown in the drawings, the vision panels shall be provided in the 

shutters with teakwood beadings on both sides. Unless otherwise specified, the vision 

panel shall have minimum dimensions of 250 mm height and 200 mm width with bottom 

located at 1400 mm from shutter bottom. 

The minimum hardware and fixtures to be provided shall be according to the Table No. 

1 unless specified otherwise. 

All surfaces of door shutters which are required to be painted ultimately shall be covered 

with a priming coat of suitable primer. In case of doors to be polished or varnished, a 

priming coat of suitable polish or varnish shall be given before installation. 

4. SOLID CORE FLUSH DOOR SHUTTERS 

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4.1 Core 

This shall conform to IS:2202 (Part I). It shall be made from block board consisting of 

pinewood strips placed end to end. The width of each strip shall not exceed 25 mm. The 

strips shall be placed side by side and glued together to form a slab which shall 

then be glued between two or more veneers. The direction of the grain of the core 

blocks shall be at right angles to that of the adjacent veneers. 

4.2 Plywood Surfacing 

Commercial plywood or decorative plywood conforming to IS 303 and Grade I of 

IS 1328 respectively shall be used. Wherever mentioned, marine grade ply conforming 

to IS 710 shall be used. 

Frame 

This will be provided for holding the core. The width of the frame including lipping shall 

be 50 to 100 mm wide. 

Gluing 

Only phenol formaldehyde resin glue shall be used. 

Vision Panel/Venetians 

These shall be provided where specified on the drawings. 

Hardware 

Minimum hardware and fixtures shall be provided as per Table 1. Additional 

hardware shall be as per drawings. 

5. STEEL DOORS, WINDOWS AND VENTILATORS 

Steel Doors, Windows and Ventilators shall conform to IS 1038, IS 1361, IS 1081 and IS 

4351 and shall be as per drawing issued by the EIC. The Contractor shall submit for the 

EIC’s approval the shop drawing covering all dimensions, details of fabrication, 

construction and installation. After approval of shop drawing, the Contractor shall 

submit one or more samples of the fabricated item of each for the EIC’s approval 

before mass fabrication. Engineer’s comments if any shall be incorporated during 

mass fabrication. 

5.1 Frames 

Frames for Pressed Steel Door 

Frames shall be manufactured out of 18 gauge (1.25 mm) Galvanised Steel Sheet. 

Each door frame shall have hinge jamb, lock jamb, head and, if specified in drawing 

angle threshold. The entire assembly shall be welded. Where threshold is not 

specified a temporary base tie shall be screwed to the feet of the frames. The 

base tie shall be out of 18 gauge MS pressed steel section adjusted within floor 

finish thickness. The frame shall have a brass lock strike plate with mortar guard. For 

single leaf door, there shall be a minimum of three rubber buffers fixed to the frame. The 

0435-JH0902-00-AR-SPC-0001 Page 7 of 20



middle buffer shall be fixed on centre line of lock strike plate, and the other two 450 mm 

above and below the middle one. For double leaf door there shall be two rubber buffers 

in the head frame spaced 300 mm symmetrical about centre Line of door, and two 

buffers in the rebate of the lock jambs. 

Frames for Steel Windows and Ventilators 

These shall conform to IS 1361 and shall be made from rolled sections to IS 

7452. The steel shall conform to IS 2830 or IS 2831. The sections shall be cut and 

mitered. The corners of the frames shall be flash butt welded. The frames shall be 

square and flat. Neoprene or silicone seal weather strips shall be provided on the jambs. 

5.2 Shutters 

Pressed Steel Doors 

These are made from 22 gauge (0.8mm) Galvanised Steel Sheets. These shall be 

provided on both sides of the shutter and reinforced by MS stiffener channels from 

inside. All four sides of the shutter shall have an MS channel as stiffener. The shutters 

shall be 45 mm thick unless specified differently on drg. Space between fully flush skin 

sheets shall be filled with core infill of honeycomb kraft paper or polyurethane 

foam (PUF). Vision panel and venetians shall be provided, if specified, as indicated in 

the drawing. The vision panels shall preferably be of flush type – 2 nos, 5 mm thk each 

clear float glasses with spacer frame all around and desiccants in it. The fixtures shall 

be provided as specified in Table 2. 

Windows and Ventilators 

Sashes shall be square and flat. Sashes shall be constructed of sections which 

have been cut to the required length, mitered and welded at corners. All the corners 

shall be through right angles and welds shall be neatly cleaned off. Tee sections for 

glazing shall be tenoned and riveted into the frames and where they intersect, the 

vertical tee shall be broached and the horizontal tee threaded through it, and the 

intersection closed by hydraulic pressure. 

5.3 Procedure for Fixing 

Doors, Windows and Ventilators shall not be built in at the time the walls are 

constructed but shall be subsequently fixed into prepared openings, in accordance with 

IS 1081. Holes for fixing lugs are to be left or cut, and the doors and windows fixed after 

all the rough masonry and plaster work has been finished. The frames of units shall be 

set in the opening by using wooden wedges at the jambs, sill and head, and shall be 

plumbed in position. The lugs shall then be grouted into their holes with concrete (1:2:4). 

When RCC members (beam or column) form the sides of the opening, rawl plugs shall 

be fixed in RCC and frames fixed to the members by 63 mm (2 ½”) x No. 10 galvanised 

wood screws. In the case of steel work openings a mild steel or hard wood fillet shall be 

provided around the frame to facilitate erection. The height of the unfinished opening 

shall depend on whether a threshold is required or not. While fixing the door, care shall 

be taken to see that at least 5 mm space is left between door shutter and finished floor. 

Tolerance 

The sizes of doors, windows and ventilators shall not vary by more than + 1.5 mm than 

the size specified on drawings. 

Finish – Doors 

0435-JH0902-00-AR-SPC-0001 Page 8 of 20



Frames and shutters shall be given a thermosetting polyester powder coating to 70 

micron DFT or PU paint. Colour shades shall be as specified by architects on drgs. 

Finish – Windows & Ventilators 

After the fabrication of units all the steel surfaces shall be thoroughly cleaned free of 

rust, mill-scale, dirt, oil, etc. and two coats of red oxide zinc chromate primer shall 

be applied. Two coats of approved synthetic enamel shall be applied after installation 

of the door, window or ventilator. 

6. ALUMINIUM DOORS, WINDOWS AND VENTILATORS 

Aluminium Doors, Windows and ventilators shall conform to IS:733, IS 1948, IS:1949, 

and IS:1081 shall be as per drawings issued by the Engineer. The contractor shall 

submit for EIC’s approval the shop drawings covering all dimension details of 

fabrication, construction and installation. After approval of shop drawings the contractor 

shall submit one or more samples of the fabricated item of each type for the EIC’s 

approval before mass fabrication. 

6.1 Material 

Aluminium Alloy Extruded Sections 

Aluminium alloy used in the manufacture of doors, windows and ventilators shall 

conform to IS designation HE 9-WP of IS:733 or HV9-WP of IS 1285. Aluminium Alloy 

AA 6063 of hardness T5 or T3 which has the following properties is also acceptable, 

Coefficient of 

Density, Modulus of Ultimate Tensile 

0.2% Proof 

kg/mm 

Linear Expansion, 

Elasticity, Mpa Strength, Mpa 

Stress, Mpa 

3 

m/m.k 

2.7 x 10 -8 69 x 10 3 185 23 x 10 -8 110 

The sectional properties of extruded sections shall be as given in IS 733 or as 

manufactured by Jindal, Hindalco or Bhoruka. The section shall be uniform in 

appearance, free from die lines and handling marks. 

Glass panes 

Glass panes shall be annealed or float glass as specified in the drawing and shall weigh 

at least 7.5 kg / m2. Glass panes shall also be free from flaws, specks or bubbles. All 

panes shall have properly squared corners and straight edges. The sizes of glass 

panes for use shall be in accordance with Table I of IS:1948. 

Thickness of glazing to be used for various pane sizes shall be as follows: 

Size of Pane Thickness of glazing 

up to 1.2 sq.m 4 mm float glass 

1.2 sq.m to 2.0 sq.m 5.5 mm float glass 

0435-JH0902-00-AR-SPC-0001 Page 9 of 20



above 2.0 sq.m 8 mm float glass 

twin style entrance door 12 mm float glass 

Heat strengthening or Toughening of glass wherever required shall be as indicated on 

drgs. 

Screws, Fasteners 

Screws and fasteners shall be of aluminium alloy or brass oxidised. Screw thread 

of machine screws used in the manufacture of aluminium doors, windows and 

ventilators shall conform to the requirement of IS:4218. 

For opaque portion of shutters panels can be of 12 mm thk marine ply cladded on 

both sides with 24 gauge aluminium sheet. 

6.2 Standard sizes, tolerances and designation 

Size 

Overall dimension of windows, doors, ventilators, shall be derived from masonry 

opening minus an allowance of 1.25 cm clearance on all sides for the purpose of fitting. 

However, type and overall sizes shall be in accordance with IS:1948. 

Tolerances 

The sizes for doors, windows or ventilator frames shall not vary by more than ± 1.5 mm 

from overall size as specified in drawing. 

Designation 

Doors, windows and ventilators shall be designated by symbol denoting their width, type 

and height in succession as per IS : 1948. 

Sectional dimensions and weights 

Sectional dimensions and weights per unit length of the section shall conform to 

design drawing. However, uses of specific sections for specified units as per 

manufacturers’ standard may be used with prior approval of Engineer. 

6.3 Fabrication 

Frames 

Frames shall be square and flat, the corners of frame being fabricated to a true right 

angle. Both the fixed and opening frames shall be constructed of sections which have 

been cut to length, mitered and screwed at the corners. 

Shutters 

All hinges, pivots, etc. shall be provided and fabricated in accordance with provisions 

given in IS:1948. However, reference standards and drawings are also to be read in 

conjunction with the IS code. 

6.4 Finishing 

0435-JH0902-00-AR-SPC-0001 Page 10 of 20



The aluminum sections to be used shall be properly buffed, cleaned by using mild acids 

and water. Then the same shall be anodised to have average anodic film thickness of 25 

microns. To prevent damage to metal surfaces, a protective tape shall be applied after 

manufacturing and same shall be removed at site only after completion of rough trades. 

6.5 Handling, Storage 

The extruded section or the fabricated windows/doors shall be protected against 

abrasions, waterstains and any other damages caused by acids or alkaline chemicals. 

Cold metal shall preferably be placed in a dry storage area avoiding contact between it 

and other metals. Use of wood face shelving racks is recommended. It shall also 

be kept away from caustics, nitrates, phosphates, acids and cement. 

6.6 Installation 

The fabricated and assembled windows or door units (without glazing) shall be installed 

in accordance with IS 1081 being fixed in masonry opening properly plastered and 

finished. Straightness and diagonal dimensions of the opening shall not have 

tolerance more than ± 2 mm. Aluminium screws or bolts are to be used with teak 

wood block on the back of the sections to avoid dents and other mechanical damages 

during tightening of screws/bolts. All gaps between the aluminium section and the 

masonry surface must be sealed with gun grade polymer based sealant viz., silicone 

compound, polysulphide compound. 

Cement mortar grout or cement mortar finishing of gaps after installation of aluminium 

units shall strictly be restricted to protect the surface treatments given to the aluminium 

like anodising, precoating, etc. 

All glass panes shall be fixed only after major activities are over in the area. Glazing 

gaskets for doors and frames shall be EPDM elastomeric extrusions. All screws and 

miscellaneous fasteners shall be aluminium, stainless steel or zinc plated. 

6.7 Hardware 

Necessary hardware for aluminium doors and windows shall be compatible with the basic 

material and shall be provided along with the doors, windows and ventilators. 

Minimum hardware necessary to be provided shall be as specified in Table 3. 

6.8 Drawings/Documents 

Prior to fabrication, Contractor shall submit shop drawing indicating details of all 

members, sections and hardware for EIC’s approval. All certificates against tests for 

anodising and other physical properties of material shall be produced to the Engineer for 

acceptance. 

7. METAL ROLLING SHUTTERS AND ROLLING GRILLS 

Metal Rolling Shutters and Rolling Grills shall conform to IS:6248, and shall be as per 

drawings issued by the Engineer. The Contractor shall submit for EIC’s approval, the 

shop drawing covering all details of fabrication, construction and installation. After 

approval of shop drawing the Contractor shall submit one sample for approval before 

mass fabrication. 

0435-JH0902-00-AR-SPC-0001 Page 11 of 20



Rolling shutters shall be of following alternative types depending on the method of 

operation. 

S.No. Type Clear Area of Remarks 

Shutter 

i. Self Coiling or Pushing Pull Up to 8 sq.m Without ball bearing 

Type 8 to 12 sq.m With ball bearing 

ii. Gear Operated 

12 to 25sq.m With ball bearing. Operated by 

bevel gear box and crank 

25 to 35 sq.m With ball bearing operated 

by chain wheel and hand 

iii. Electrically Operated type 35 to 50 sq.m 

7.1 Materials 

Cold Rolled Steel Strips 

Cold Rolled Steel Strips used for rolling shutter lath sections shall conform to temper No. 

5, Dead soft quality of IS 513. 

Mild Steel Sections 

Mild Steel Sheets and Plates used for manufacturing the guide channels, brackets and 

lock plate shall be of hot rolled steel of thickness not less than 3.15 mm conforming to 

IS:5986. These shall be free from surface defects and the edges shall be cleanly 

sheared. 

Steel Pipe 

Mild Steel Pipes used for the suspension shaft of the roller shall be heavy duty 

pipe suitable for mechanical purposes and shall conform to IS:1161. 

Cast Iron Castings 

Cast Iron Castings used for roller pulley wheels, U-clamps and bevel gears shall conform 

to Grade 15 of IS:210. These shall be free of blow holes, surface defects such as cracks, 

burrs etc. 

Springs 

The springs used in the roller for counter balancing the rolling shutter shall be 

made either from high tensile spring steel wire or flat spring steel strip. 

The spring steel wire used for helical spring shall conform to Grade 2 of IS:4454. 

Flat spring steel strip used for spiral spring shall be from 0.8 to 1.0 percent carbon steel 

strip especially hardened and tempered. 

Aluminium Alloy Sheets 

Aluminium Alloy Sheets used for curtains in case of rolling grills, shall conform to 52000 

(NS4), 53000 (NS5) or 64430 (HS30) of IS:737. 

0435-JH0902-00-AR-SPC-0001 Page 12 of 20



Aluminium Alloy Extrusions 

Aluminium Alloy Extrusion for the components of rolling shutters of aluminium 

shall conform to 53000 (NE5) or 64430 (HE30) of IS:733. 

7.2 Fabrication 

Curtain 

This shall be built up from interlocking lath sections. The lath sections shall be from 18 

gauge (1.25 mm) section for curtains up to 9 metres in width. Curtain above 9 metres 

in width should be divided in two parts with provision of one middle fixed or movable 

guide channel or supported from the back to resist wind pressure. The lath section shall 

be rolled so as to have interlocking curls at both edges and a deep corrugation at the 

centre with a bridge depth of 16 mm to provide sufficient curtain stiffness for resisting 

manual pressure and normal wind pressure. Each lath section shall be continuous single 

piece without any welded joint. When interlocked, the lath section shall have a 

distance of 75 mm between rolling centres. Each alternate lath section shall be fitted 

with a malleable cast iron or mild steel clips securely riveted at either end, thus locking 

the lath section at both ends and preventing lateral movement of the individual lath 

sections. The clips shall be so designed as to fit the contour of the lath sections. 

Lock Plate 

The Lock Plate provided at the bottom of the shutter, shall be composed of a mild steel 

plate 3.15 mm thick, reinforced with mild steel angle 35 x 35 x 5 mm at bottom of the 

plate. The lock plate shall be fitted with sliding bolts at either end to engage with 

suitable receiving pockets at the bottom of the guide channel. The sliding bolts shall 

be capable of being locked by means of padlocks both from outside and inside. The 

lock plate shall also be provided with pulling handles, one handle for 2.5 m width 

and 2 handles for widths above 2.5 m. Pulling handles shall be fixed on both inside and 

outside faces of the lock plate. 

Guide Channels 

These shall be of mild steel deep channel section of rolled, pressed or built up 

(fabricated) construction. The thickness of the sheet used shall not be less than 3.15 mm. 

The depth of the guide should be such that there is sufficient clearance between curtain 

and inner surface of guide. The curtain shall project into the guide at least 40 mm for 

shutters up to 3.5 m width and 60 mm for greater widths. There shall be a clearance of 10 

mm between guide wall and the end clips of the curtain. 

Where the shutter is installed in heavy windy zones, special wind locking arrangements 

shall be provided to prevent the curtain coming out of the guide. The clear gap on either 

side of the curtain and inner faces of the guide channel shall be 5 mm. The depth and 

width of the guide channel shall be as follows: 

Clear Width of Depth of Guide Channel 

Up to 3.5 M 65 

3.5 to 8.0 M 75 

8.0 m and above 100 

Width of Guide Channel shall be 25 mm for lath sections with bridge depth of about 12 

mm and 32 mm for lath sections with bridge depth of 16 mm. 

0435-JH0902-00-AR-SPC-0001 Page 13 of 20



Fixing Cleats 

Each guide shall have a minimum of 3 fixing cleats. The spacing of cleats shall 

not exceed 0.75 m. Alternatively, the guide channels may also be provided with 

suitable dowels hooks or pins for embedding in the walls. The guide channel shall be 

attached to the wall plumb and true. 

Bracket Plate 

This shall be fabricated out of mild steel plate of 3.15 mm thick. Thicker plates may be 

used depending upon the height of the shutter. Dimensions shall be as given in IS:6248. 

The bracket plate may be square, circular or hexagonal with a U-shaped cast iron or mild 

steel clamp riveted or welded to it at the centre. The bracket plate should have sufficient 

cross sectional area to resist the shear arising out of the weight of the curtain, 

suspension shaft etc. and shall be held rigidly by suitable foundation bolts. 

Roller 

The suspension shaft of the roller shall be made of steel pipe conforming to heavy duty of 

IS:1161. The diameter shall be sufficient to limit deflection of shaft under the weight of 

the rolling shutter. The deflection of the shaft shall not exceed 5 mm per metre width of 

the shutter. Diameters of the steel pipe for various widths up to 6 m and height 5 m shall 

be as per IS:6248. Sizing of pipe diameter for greater widths and heights shall be 

designed giving due consideration for deflection limit mentioned above. The pipes of the 

suspension shaft which are clamped to the brackets shall be fitted with rotatable cast iron 

pulleys to which the curtain is attached. The pulleys and the pipe shaft shall be 

connected by means of pretensioned helical springs to counterbalance the weight of 

the curtain and to keep the shutter in equilibrium in any partly opened position. 

Hood Covers 

These shall be made of mild steel sheets not less than 0.9 mm thick, and shall be 

hexagonal, square or circular contour depending on the contour of the bracket 

plate. The hood cover shall be stiffened with angle or flat stiffeners at top and 

bottom edges to retain shape. The hood cover shall be fixed to the bracket plate 

by means of angle cleats. The hood cover shall also be supported all along the 

top at suitable intervals to prevent sagging. 

Gears, Worms etc 

These shall be machine cut. Worm gear wheels shall be of high grade cast iron or mild 

steel or phosphor bronze. The worms shall be of mild steel or gun metal or phosphor 

bronze. 

Security Devices 

For shutter widths exceeding 2.5 m, any one or both of the following security devices may 

be provided. Anchoring Rods as described in IS:6248. These shall be provided at the 

rate of one per extra 2.5 m width or part thereof above a clear width of 2.5 m. 

Central Hasp and Staple 

This shall be provided at the centre of the bottom lock plate. The hasp shall be 

embedded in the floor at the centre. The staple shall be fitted at the centre of the bottom 

0435-JH0902-00-AR-SPC-0001 Page 14 of 20



lock plate outside in an accurate position so that the hasp may properly engage with 

staple when the shutter is in a closed position. The hasp shall be embedded within the 

floor so as not to cause any obstruction. Normally one central hasp and outside staple 

will be sufficient for any width of shutter. 

7.3 Optional Features 

Intermediate Posts or Mullions 

These shall be either of fixed, sliding or removable type, and are used for unusually wide 

openings or for providing multiple door entries. The mullion also forms the guide channels 

between the various sections of the rolling shutter. The sliding mullion may also be winch 

operated for large sizes. The fixing of the intermediate post shall be plumb and true 

when in position before closing the rolling shutter. 

Wicket Door 

Large rolling shutter fixed at the main entrance of mills and factories may also be 

provided with a subsidiary door known as wicket door. This is a hinged service door 

allowing pedestrian traffic without the need of rolling up the shutter. The wicket door size 

shall be 600 x 1200 mm for ordinary use and 900 x 1800 mm for large installations. Sizes 

larger than these are not recommended as these cause difficulties in installation and 

operation. The wicket door shall be of good robust construction and shall be fitted with a 

good lever lock operated by key and lockable from both inside and outside. The wicket 

door shall be erected in such a way so as not to foul with the main rolling shutter when 

opening or closing. The wicket door shall be swung clear of the opening before the 

Rolling Shutter is raised. 

Galvanising 

All components of the rolling shutter may be hot dip galvanised with a zinc coating 

containing not less than 97.5% pure zinc. The weight of the zinc coating shall be not less 

than 230 g/sq. m and the coating shall be free from flaking or peeling. 

7.4 Operation 

Push Pull Type 

Push Pull Type shall be operated manually by pulling hooks with appropriate pulling 

handles in the lock plate. The length of the pulling handle shall be sufficient to push the 

lock plate up to the top most position. 

0435-JH0902-00-AR-SPC-0001 Page 15 of 20



Gear Operated Type 

These shall be operated by two types of arrangement: 

i. by bevel gear box and 

crank handle 

ii. 

by chain wheel and chain. 

The height of the bevel gear box or the bottom of the hand chain shall be 0.85 m from floor. 

If specified on drawing, the crank handle operation or hand chain operation shall be provided 

on both sides of the wall. The gear reduction shall be calculated to reduce the pressure 

exerted on the crank handle or the pull exerted on the hand chain to not more than 16 

kgs. 

Electrically Operated Type 

These shall be operated by an electric motor operating on 400/440V, 3 phase 50 

cycles A.C. supply. Arrangements shall also be made for emergency mechanical operation 

of the rolling shutter in the event of failure of the electric equipment or electricity. The 

emergency mechanical operation shall be by an auxiliary chain wheel and hand chain 

drive. The motor shall have a push button control, with a minimum 

of 3 buttons marked “Up”, “Down” and “Stop”. Limit switches shall also be provided to cut off 

current to the motor when the shutter reaches the limit of its travel in the “Up” or “Down” 

directions. 

7.5 Rolling Grills 

These are similar in design and operation to Rolling shutters. Hence, all provisions of Rolling 

shutters are applicable to rolling grills except for the curtain. The rolling grill curtain may be 

manufactured out of 8 mm diameter mild steel or aluminium alloy round bars. 

Rolling Shutter Cum Grill 

These shall be provided in situation where certain amount of ventilation and safety is called 

for, e.g. in substations and transformer rooms. The rolling shutter may have a small grill 

portion as specified in the drawing the height of this grill shall generally be 500 mm. 

7.6 Painting 

All components of Rolling shutter except springs and inside of guide channel shall be 

thoroughly cleaned free of rust, mill-scale, dirt, oil etc. and two coats of red oxide zinc 

phosphate epoxy paint shall be applied. Two coats of approved epoxy finish paint shall be 

applied after installation. Other painting systems shall 

be employed if specified on the drawings. 

Marking 

Each shutter shall be clearly and legibly marked with the following information: 

i. Manufacturer’s Name or Trade Mark 

ii. Size 

iii. Year of Manufacture. 

0435-JH0902-00-AR-SPC-0001 Page 16 of 20



8. FIRE DOORS 

Fire rated doors shall be for a minimum period of two hours (unless specified 

otherwise) and shall be approved by Tariff Advisory Committee (TAC). If sourced from 

outside India, the fire labelled hollow metal doors shall be approved by Underwriters 

Laboratories (UL). Testing conducted by Central Building Research Institute (CBRI), 

Roorkee shall be produced on demand. Testing shall be as per BS 476 Part 

20 & 24, IS 3614 Part 2 and ISO 834. 

The frames shall be made of 16 gauge (1.6 mm) galvanised steel sheets pressed 

bent to shape using bending machine and mitred with square edges. The shutter shall 

be formed by machine bending of 18 gauge (1.25 mm) galvanised steel sheets in the 

form of hollow box making an overall thickness of min 45 mm. Other requirements of 

stiffeners, core infill, finish, etc to be same as for steel doors described in section 5 

of this specification. If vision panels are shown, the glass used shall have fire rating 

for same period as the door. 

9. PVC DOORS AND WINDOWS 

PVC doors and window frames shall be a complete system manufactured from 

acrylic modified high quality impact resistant white (or coloured as specified) 

unplasticised polyvinyl chloride, reinforced, rigid multi-chamber extrusion by a suitably 

qualified fabricator. Door and window fabrication shall meet basic performance 

requirements recommended for climatic and atmospheric conditions of site and in 

strict accordance with the system supplier’s recommendations. 

Door/ window type, size and style shall meet requirements specified in relevant 

door/window schedules. 

Door, window design shall include factory finish glazing as required, purpose made 

thresholds/subcills, trickle ventilators and security/ locking devices as recommended by 

manufacturer. 

All glazing shall meet safety requirements specified by relevant building regulations. 

Fabricator shall submit evidence of door, window performance including method of 

weld finishing, weather tightness exposure category, compliance to relevant regulations, 

etc for approval prior to award of contract. 

0435-JH0902-00-AR-SPC-0001 Page 17 of 20



TABLE 6.1- TIMBER DOOR AND WINDOWS (MINIMUM HARDWARE) 

Door 

Window 

Doubl Doubl 

s 

Singl Single Doubl 

s 

Singl 

Fitting 

Ventilator 

s 

e e Leaf e Leaf e Leaf e Leaf 

Shutter 

Leaf Panele Leaf Panele Shutte Shutt 

Butt Hinges 100mm 

6 6 3 3 - - - 

Heav 

Butt Hinges 75mm 

Heav 

- - - - 4 2 2 

Mortice y Lock (7 1 - 1 - - - - 

Lever) 

Aldrop 300mm - 1 - 1 - - - 

Door Latch 300mm - 1 - 1 - - - 

Flush Bolt 250mm 3 - 2 - - - - 

Tower Bolt 250mm - 3 - 2 3 2 - 

Handle 150mm - 4 - 2 2 1 1 

Hook and Eye Stay 

300m 

- - - - 2 1 2 

Stoppers m (Buffers) 1 1 1 1 - - - 

Notes: 

Peg Stay 2 1 - 

All the fittings shall be oxidized brass type unless otherwise specified. 

Single leaf door shutters and ventilator shutters of more than 0.80 m width shall be 

provided with one extra hinge. 

Where height of window shutter and door leaf exceeds 1.2 m and 2.15 m 

respectively one extra hinge shall be provided for every additional height of 0.5 m 

or part thereof and length of top bolt shall be increased by the height of the 

shutter/leaf above 2.15 m from floor level. 

In double leaf shutters of doors, two tower bolts shall be fixed to the first shutter top and 

bottom and one 

to the closing shutter at the top. In case of double shutter windows, two tower bolts 

shall be fixed to closing shutter top and bottom and one to the first shutter at top. 

All hardware shall conform to the applicable Indian Standards. 

0435-JH0902-00-AR-SPC-0001 Page 18 of 20



TABLE 6.2- STEEL DOOR AND WINDOWS (MINIMUM HARDWARE) 

Fittings Doors Windows Ventilators 

Single 

Shutter 

Double 

Shutter 

Single 

Shutter 

Double 

Shutter 

Top Hung 

Shutter 

Centre 

Hung 

Shutte 

4” x 4” SS 3 6 - - - - 

Hinges with two 

ball bearings 

Hinges (Heavy) - - 2 4 2 - 

75mm Wide 

Aldrop 300mm 1 1 - - - - 

Push and Pull type 2 2 - - - - 

Handle (100mm) 

SS Tower Bolts 1 3 - - - - 

(300mm) 

Two Point nose - - 1 2 1 - 

handle with 

striking plate 

Peg Stay 300mm - - 1 2 1 - 

Notes: 

i. All the fittings shall be in S.S. unless otherwise specified. 

ii. 

iii. 

iv. 

Single leaf door shutters and ventilator shutters of more than 0.80 m width shall 

be provided with one extra hinge. 

Where height of window shutter and door leaf exceeds 1.2 m and 2.15 m 

respectively one extra hinge shall be provided for every additional height of 

0.5 m or part thereof and length of top bolt shall be increased by the height of 

the shutter/leaf above 2.15 m from floor level. 

Double leaf shutters of doors, two tower bolts shall be fixed to the first shutter 

top and bottom and one to the closing shutter at the top. 

v. All hardware shall conform to the applicable Indian Standard. 

0435-JH0902-00-AR-SPC-0001 Page 19 of 20

vi. 

Door Closure 

Requirement of door closure, its type – Surface mounted or concealed, with or without Hold 

Open option 

shall be as mentioned on Architectural drg. 

TABLE 6.3- ALUMINIUM DOORS AND WINDOWS (MINIMUM HARDWARE) 

Fitting 

s 

Mortice Lock 7 

Lever 

Tower s bolts 

300mm 

Butt Hinges 

(heavy) 

Floor 

Notes: 

75m 

Spring 

(Shutter on 

Two point nose 

handle 

with 

Door 

Casement Windows 

Single Shutter 

s 

Double Shutter Single Shutter Double Shutter 

1 1 - - 

1 3 - - 

- - 2 4 

1 2 - - 

- - 1 2 

striking plate 

Peg Stay 300mm - - 1 2 

i. All the fittings shall be anodized aluminium (finish compatible with original frame) type 

unless otherwise specified. 

ii. 

iii. 

iv. 

Single leaf door shutters and ventilator shutters of more than 0.80 M width shall be 

provided with one extra hinge. 

Where height of window shutter and door leaf exceeds 1.2 M and 2.15 M respectively, 

one extra hinge shall be provided for every additional height of 0.5 M or part there of. 

Length of top bolt shall be increased by the height of shutter / leaf above 2.15 M from 

floor level. 

In double leaf shutters of doors, two tower bolts shall be fixed to the first shutter at top & 

bottom and one to the closing shutter at top. 

v. All hardware shall conform to applicable Indian Standards.




(GGSRPEP) 

SPECIFICATIONS FOR FLOORING WORK 

0435-JH0902-00-AR-SPC-0002 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE


1.0 SCOPE 

This specification covers the requirement of providing labour, material, construction 

aids, workmanship etc. for providing and fixing flooring, skirting and dado work on 

floors and walls. 

2.0 APPLICABLE CODES 

Note: - Wherever reference is made to IS Codes, on any page of this Technical 

Specification (including annexures), applicable year of publication of IS Code is as 

stated below. 

Following specifications will be considered as part of this specification: 

IS 383-1999 

IS 1237-1980 

IS 1443-1972 

IS 2114 -1984 

IS 2571-1970 

IS 2386-1963 

(Part 1 - Part 8) 

IS 3461-1980 

IS 3462-1986 

IS 4441 

IS 4443 

IS 4457-1982 

IS 4631-1986 

IS 4832 

Part-1: 1969 

Part-2: 1969 

Part-3: 1968 

IS 4971 

IS 5318-1969 

IS 5491-1969 

IS 13712 -1993 

IS 13630 : (Part 

: Coarse and fine aggregate from natural sources for concrete. 

: Cement concrete flooring tiles. 

: Code of practice for laying and finishing of cement concrete 

flooring tiles. 

: Code of practice for laying in-situ terrazzo floor finish 

: Code of practice for laying insitu cement concrete flooring. 

: Methods of test for aggregates for concrete. 

: Specification for PVC asbestos floor tiles. 

: Specification for unbacked flexible PVC flooring. 

: Code of practice for use of silicate type Chemical resistant 

mortars. 

: Code of practice for use of resin type chemical resistant 

mortar. 

: Specification for ceramic unglazed vitreous acid-resistant 

Tiles. 

: Code of practice for laying epoxy resin floor toppings. 

: Specification for Chemical Resistant Mortars. 

: Part-1 Silicated type. 

: Part-2 Resin type. 

: Part-3 Sulphur type 

: Recommendations for selection of Industrial floor finishes. 

: Code of practice for laying of flexible PVC sheet and tile 

flooring. 

: Code of practice for laying in-situ granolithic concrete flooring 

topping. 

: Ceramic tiles -definitions, classifications, characteristics and 

marking 

: Ceramic Tiles – Methods of test 

0435-JH0902-00-AR-SPC-0002 Page 2 of 14


1 to 13)-1993 

IS 13753 -1993 : Dust-pressed ceramic tiles with water absorption of E 10% 

(group B III) 

IS 13754 -1993 : Dust-pressed ceramic tiles with water absorption of 6% E 

10% (group B IIb) 

IS 13755 -1993 : Dust-pressed ceramic tiles with water absorption of 3% E 6% 

(group B IIa) 

IS 13756 -1993 : Dust-pressed ceramic tiles with water absorption of E 3% 

(group B I) 

3.0 PRIORITY OF REQUIREMENTS 

In case of any variation and discrepancy in condition between the special conditions, 

this specification and codes, order of priority shall be as under:- 

(1) Special conditions 

(2) This specification 

(3) Codes 

4.0 TYPES OF FLOORING 

Various types of flooring and linings materials / systems are used for floor finishing 

over base floor, rigid / flexible viz. concrete, metal, stone, wood, etc., for different types 

of applications viz. Industrial, Non-industrial. 

Although plain concrete Base floor as laid conforming to IS 2571 would be satisfactory 

for many purposes, Various types of floor hardening / topping / coating / lining are 

applied to improve physical, mechanical, and chemical properties of the base floor to 

desired extent. 

5.0 INDUSTRIAL FLOORING 

Generally in Industrial Flooring the purpose of flooring, is one or more combination of 

following requirements 

(a) For heavy duty 

floors, this is subject to heavy loads, severe abrasion and impact 

(b) For dust free and clean environment 

(c) For chemical and corrosion resistance 

Further classification based on material / system used is stated in the subsequent 

paragraphs. 

6.0 METALLIC FLOORING 

For all Industrial plant floors subject to heavy loading, plants requiring dust proof and 

wear resistant floors, use of Metallic floor replaces the brittle, dusty granular properties 

0435-JH0902-00-AR-SPC-0002 Page 3 of 14


of a plain cement floor with toughness, ductility and wear resistant properties of the 

Metallic surfaces. 

6.1 Artificial Patent Stone (APS) Flooring 

Artificial Patent Stone (APS) Flooring shall be laid in overall thickness of 40mm over 

sub base and shall conform to IS: 5491 in workmanship. 

Base layer shall be 25mm thick in M15 grade concrete and wearing layer shall be 

15mm thick in 1:3 (1 cement: 3 course sand by volume) 

Base layer shall be laid over sub base in alternate panels in desired shape and 

pattern. Each panel shall not exceed 1.5m in width. Panel shall be bound by 3x30 PVC 

strip panel dividers, fixed in position with their top at proper level maintaining the 

required levels, slopes, linearity, etc. as required. Before laying the base course, neat 

cement slurry @ 2.75 kg of cement per sq. meter of area shall be applied by brush 

over the prepared sub base. The border of the panel shall have metered joints at the 

corner of the room and intermediate joints shall be in straight line with panel joints. 

Cement concrete shall be placed in position and beaten with trowel and finished 

smooth. Beating shall cease as soon as surface is found covered with cream of mortar. 

Necessary slope shall be provided. 

Wearing layer shall be laid within 15 minutes of laying base layer. The cement and 

aggregates for the top layer shall be mixed dry. After mixing, sufficient quantity of 

washed sand and water shall be added to make the mix plastic but not flowing. The top 

and bottom layer shall firmly grip together. The base course shall be free of excessive 

moisture before starting the floor finishing. Use of dry cement, cement sand mixture 

sprinkled on the surface to stiffen the concrete or absorb excessive moisture shall not 

be permitted. 

While the concrete is still green, cement @ 2.75 kg per Sq.M of floor area shall be 

mixed with water to form thick slurry and spread over the surface. It shall be pressed 

twice by means of iron floats, once when the slurry is applied and second time when 

the cement starts setting. The junction of floor with wall plaster, cladding, skirting shall 

be rounded off uniformly up to a radius of 25mm unless otherwise mentioned. 

Each finished portion of floor, on completion shall be kept wet with ponding for a 

minimum period of 7 days 

Skirting shall be 18 mm thick laid with cement mortar (1 cement: 3 coarse sand by 

volume. The surface on which the skirting is to be applied shall be prepared and 

skirting shall be laid. The junction between flooring and wall shall be rounded off to a 

radius of 25mm if not otherwise mentioned. While the mortar is still green, cement @ 

2.75Kg per square meter shall be mixed with water to form thick slurry and applied 

over the mortar. It shall be pressed twice by means of iron floats, once when the slurry 

is applied and second time when the cement starts setting. The skirting shall be cured 

for 7 days. 

0435-JH0902-00-AR-SPC-0002 Page 4 of 14


6.2 APS Flooring with Ironite Topping (Heavy Duty Flooring) 

Heavy Duty Flooring shall be laid in overall thickness of 50mm over sub base and shall 

conforming to IS: 5491 in workmanship. 

Base layer shall be 35mm thick in cement concrete (1 cement: 1.5 coarse sand: 3.5 

stone aggregates of 10mm to 6mm size by volume). Base layer shall be laid over sub 

base in alternate panels in desired shape and pattern. Each panel shall not exceed 

1.5m in width. Panel shall be bound by 3x30 PVC strip panel dividers, fixed in position 

with their top at proper level maintaining the required levels, slopes, linearity, etc. as 

required. Before laying the base course, neat cement slurry @ 2.75 kg of cement per 

sq. meter of area shall be applied by brush over the prepared sub base. The border of 

the panel shall have metered joints at the corner of the room and intermediate joints 

shall be in straight line with panel joints. Cement concrete shall be placed in position 

and beaten with trowel and finished smooth. Beating shall cease as soon as surface is 

found covered with cream of mortar. Necessary slope shall be provided. 

Wearing Top layer/ finishing layer shall be of cement, hardener and stone aggregate 

mix of 15mm thickness laid over the base course. Unless otherwise mentioned, one 

part of approved quality hardener and four parts of cement by weight shall be mixed 

dry. This dry mixture shall be mixed with stone grit of 6mm and down size in the ratio 

of 1 hardener and cement mixture: 2 stone grit by volume. Just enough water shall 

then be added to the mix. The mixture so obtained shall then be laid on the base 

course within 2 to 4 hours of latter's laying. It shall be firmly pressed into bottom 

concrete so as to have a good bond with it. After the starting of initial setting, the 

surface shall be finished smooth and true with steel floats. 

Each finished portion of floor, on completion shall be kept wet with ponding for a 

minimum period of 7 days. 

6.3 Readymade Brands 

Various brands of metallic floor toppings are available from various manufacturers viz. 

Euco Plate and Diamond Plate from STP Ltd., Chapdur from Sica Qualcrete Ltd. 

7.0 NON-METALLIC FLOORING 

Epoxy resins on account of their qualities of adhesion and chemically resistant are 

used for non-metallic floor topping. 

For industrial plant where floors requiring dust reduction and oil resistance, Non-Metallic 

flooring is recommended. Various brands of Epoxy floor hardeners are available for floor 

hardening while later is still “Green”. Topping, Coating or Lining shall be applied as per the 

extent of requirements specified by Engineer-In-Charge. 

Types and Applications of Epoxy Resin / Non - metallic flooring are stated below. 

7.1 Trowel Type 

0435-JH0902-00-AR-SPC-0002 Page 5 of 14


This is usually heavily filled with sand or other suitable aggregate and the compound is 

applied by trowel. Such compounds are often referred to as mortars or screeds. 

Application of 5 mm to 6mm thick screed for monolithic, dust free, abrassion resistant, 

anti skid chemical resistant flooring is recommended to obtain satisfactory 

performance. 

7.2 Flow Type 

This is usually a solventless compound containing filler and pigment and the mixture 

when poured directly on to the surface will flow and level itself often with little 

assistance to form a smooth continuous coating. Applications of 150 to 300 micron 

thick coating for abrassion resistant and dust free flooring, and 1.5 mm to 2 mm thick 

self levelling floor topping for factory floors is recommended. 

7.3 Terrazzo Floors 

The Portland cement in the conventional terrazzo floors is replaced by epoxy resin 

binder. Such flooring formulations serve the dual purpose of providing a good 

appearance and chemical resistance. Minimum thickness recommended is 10 mm. 

7.4 Non-skid Floors 

This type of floor may be prepared by sprinkling a suitable grit on an epoxy floor 

topping when the later is still in a tacky state. 

7.5 Materials 

7.5.1 Epoxy Resin Blend 

This shall be based on a liquid epoxy resin (which is usually a condensation product of 

Bisphenol) with or without constituents such as plasticizers, diluents and special pigments 

as may be necessary. 

7.5.2 Hardener Blend 

This shall contain a chemical, usually an amine, and amine - adduct or polyamide which will 

react with the epoxy resin at ambient temperatures to give a cured thermoset resin product. 

Hardeners based on amines and amine-adducts exhibit higher chemical resistance than 

polyamides but polyamide hardeners must be used where floors are exposed to frequent 

impact stress and fluctuations in temperature 

7.5.3 Aggregates 

Selected dry aggregates, such as quartz sand or calcined bauxite grit with graded particle 

size as recommended by the resin manufacturer shall be supplied as a separate 

component. 

7.5.4 Coal Tar 

0435-JH0902-00-AR-SPC-0002 Page 6 of 14


Coal tar extenders are used to lower the cost and increase the flexibility of epoxy resin 

formulations. Besides, coal tar blending increases the resistance of water although the 

mechanical and chemical resistance properties are lowered. 

Note: The resin, hardener and aggregate shall be mixed in the proportion as specified 

by the Engineer-In-Charge or Manufacturer’s Specification and used as 

specified in this standard. 

7.6 Surface Preparation 

7.7 Laying 

To ensure proper adhesion of the Epoxy resin mix, surface shall be cleaned, free from 

grease and oil, dry and rough. 

All laitance shall be removed from concrete surface washing the floor with dilute 

Hydrochloric Acid. Sand blasting or hacking may be adopted for roughening the 

surface. 

All cracks and broken areas on an existing concrete base shall be sealed / filled with 

fresh concrete before application of Epoxy resin topping. 

Grease and oil shall be removed by washing the surface with solvents such as 

Acetone or a suitable detergent. 

7.7.1 Mixing of Epoxy resin blend 

The constituents required for a particular epoxy resin topping shall be mixed just before 

use, in correct proportion specified by the Manufacturer. The order of addition of the 

components shall be resin, hardener and aggregate (in dry condition) and duration of 

mixing shall be adequate to ensure through mixing. 

7.7.2 Application 

Application of blended epoxy resin topping shall be done uniformly over the prepared area 

to give the required thickness. The floor area may be divided in sections to get uniform 

thickness. 

7.8 Manufacturers 

For non-metallic flooring, chemical products from various manufacturers are available 

viz. FOSROC, SICA QUALCRETE MC-BAUCHEMIE, STP. LTD., CHEMBOND etc. 

Note: Engineer-In-charge shall approve Product and Manufacturer prior to its use in 

the works 

7.9 Other Types of Industrial Flooring 

7.9.1 Acid Resistant Tiles / Bricks 

Acid Resistant Tiles are used in flooring and lining to prevent corrosion of surface by 

acids and other chemicals as well as to resist abrassion on floors. These tiles are 

made up of materials like clay, feldspar, quartz, and talc and vitrified at high 

0435-JH0902-00-AR-SPC-0002 Page 7 of 14


temperatures in ceramic kilns and kept unglazed to prevent slipperiness when laid on 

floor. 

Chemical resistant mortars as per IS 4832 are used for laying these tiles. Laying and 

finishing procedure similar to the other glazed ceramic tiles described elsewhere. 

7.9.2 FRP Grating / Plate Flooring 

Fiber glass Reinforced polyester (FRP) Grating / Plate Flooring are available in standard 

size panels and are suitable for industrial flooring viz. Platform Staircase, Ramps, Catwalk, 

and Trench covers etc. 

7.9.3 Manufacturers 

1. CHEMGRATE CORP. of USA FRP Products under Brand names CHEMGRATE, 

CHEMPLATE, and CHEMTREAD etc. 

2. INTERNATIONAL GRATING INC of USA FRP Products under Brand names 

KORDEK GRATING / PLATE etc. 

8.0 NON INDUSTRIAL FLOORING 

These are used for non-industrial purpose viz. commercial and residential flooring where 

light duty, dust free, clean environment and decorative purposes are governing criteria for 

choosing type of floor finishes. These are described below: 

8.1 Plain Cement concrete / Mosaic / Terrazzo Flooring 

8.1.1 In Situ Work 

Methods commonly adopted for laying In-Situ Terrazzo Finish Surface shall be as per 

IS 2114. 

8.1.2 Tiling Work 

Terrazzo/Mosaic tiles shall be of approved colour and size and shall be 25 mm thick unless 

otherwise specified. 

a) Tolerance 

Tolerance on length or breadth shall be plus or minus one millimeter and on 

thickness plus 3 mm. 

b) Wearing layer 

Minimum wearing layer shall not be less than 5 mm for tiles. Color and texture 

of the wearing layer shall be uniform throughout its thickness. 

c) Resistance to wear 

0435-JH0902-00-AR-SPC-0002 Page 8 of 14


When tested as per IS 1237, the thickness of wearing shall not be more than 

3.5 mm for tiles. 

The CONTRACTOR shall submit to the Engineer-In-Charge, samples of the 

tiles proposed to be used for the work and shall obtain his approval before 

placing the order. 

The colour and quality of tiles used in work shall be similar to the sample 

approved. If after polishing it is revealed that the quality is not the same as per 

the sample, the work shall be rejected and shall be redone as instructed at the 

CONTRACTOR's cost. 

For odd shaped size, the tiles shall be cut to the required size without 

damaging the tiles. 

d) Laying of tiles 

Surface Preparation: 

The base courses either P.C.C. or R.C.C. slab shall be brushed with a stiff 

bristle broom removing all laitance. The brooming shall expose some of the 

aggregates and roughen the surface adequately to provide a mechanical bond 

for the topping. The base shall be cleared of any deposition i.e. grease, oil, 

paint etc. on its surface which will interfere with the bond and thoroughly 

cleaned of loose particles and dust with water by scrubbing with stiff brush. 

Foreign substance not removed by scrubbing shall be chipped off. After the 

base is chipped clean, it shall be saturated with water overnight. If specified, 

proprietary brand adhesive solution of approved make shall be applied as per 

manufacturer's specification to the old concrete surface so as to ensure proper 

bond between old concrete surface and new in-situ topping. 

Bedding: 

Levels of prepared surface to be checked and verified before starting any 

bedding work. Mortar pads shall be provided at suitable intervals to establish 

the level and slope for the tiling work. Minimum 20mm thick under bed of 1:6 

cement mortars spread uniform on the prepared concrete floor base and 

compacted to proper grade. 

The method of laying the tiles shall be in accordance with IS 1443. Before the 

tiles are laid these shall be soaked in water for about 15 minutes and then 

allowed to dry out for the same time. Just prior to laying the tiles, cement slurry 

of the consistency of a thick paint at the rate of 4 kg per square meter shall be 

spread over a small area of mortar bed at a time and then the tiles shall be set 

on it in the desired pattern. Each tile shall be gently tapped with wooden mallet 

till it is properly bedded. As each tile is placed, its surface level shall be 

checked and any unevenness shall be corrected by rectifying the mortar bed. 

The tiles shall be laid with the side edges absolutely touching each other so 

that the joints shall be as fine and imperceptible as possible. After the entire 

floor of each room is completed, slurry of the same coloured cement as the 

colour of the tiles shall be spread over the surface and rubbed in so as to seal 

even the thinnest joints between the tiles and then make the surface 

impervious. Nobody shall be allowed to walk over the flooring during the first 24 

hours. As soon as the cement slurry in the joints has hardened, the surface 

shall be kept continually wet for at least 7 days. 

0435-JH0902-00-AR-SPC-0002 Page 9 of 14


14 days after laying the tiles, the surface shall be ground smooth with an 

approved type of grinding machine, with carborundum stones of 48 to 60 grit. 

The floor shall be kept wet during the grinding process. Materials ground off 

shall be removed by squeezing and flushing with water. 

Any air holes, pits or other blemishes observed in the surface shall then be 

filled with paste made of 1:2 cement and marble powder and water. After the 

patch filler has hardened the floor shall be cured for another 7 days. The 

surface shall then receive the second and the final grinding with successive 

grades of carborundum stones of 120 and 220 to 350 grit respectively until a 

uniformly smooth and even surface is obtained. Finally it shall be thoroughly 

washed with soap water and mopped clean to the satisfaction of the Engineer- 

In-Charge. 

e) Skirting 

The skirting shall be of the same materials as that of the floor tiles and shall be 

of the exact size specified. It shall be fixed to the wall with cement mortar 1:4 

bedding. Grinding and polishing shall be carried out by hand using 

carborundum of appropriate quality. 

f) Applications 

For Non plant building floorings. 

g) Manufacturers 

Various Manufacturers are available. viz. NITCO, KAJARIA , SPARTECH etc. 

Note: Sample and Manufacturers shall be approved by Engineer-In-charge prior to its 

use in the work. 

8.2 Stone / Marble / Granite Flooring 

Shahabad, Kota, Cuddapah, Stones are readily available in rough or smooth surfaces in 

tile or slab forms and are generally used for non-industrial and light industrial flooring 

purposes where rigid, non porous floor finish is required. Where decorative and easier to 

clean, longer lasting floor finish is required, marble and Granite may be used. Tiles or slabs 

of marble and granite may be fixed by cement mortar or chemical adhesive to the base 

floor. 

8.2.1 APPLICATION 

Stone flooring shall be laid in minimum 40mm overall thickness over sub base. For steps, 

joints in floor shall be permitted only when width / length is more than 0.6 / 2 meter. 

Thickness of the stone slabs shall be 25mm for floor and tread & 18mm for dado / skirting. 

Skirting shall normally be 125mm high unless specified otherwise. 

PREPARATION OF BASE 

0435-JH0902-00-AR-SPC-0002 Page 10 of 14


The base courses either P.C.C. or R.C.C. slab shall be brushed with a stiff bristle 

broom removing all laitance. The brooming shall expose some of the aggregates and 

roughen the surface adequately to provide a mechanical bond for the topping. The 

base shall be cleared of any deposition i.e. grease, oil, paint etc. on its surface which 

will interfere with the bond and thoroughly cleaned of loose particles and dust with 

water by scrubbing with stiff brush. Foreign substance not removed by scrubbing shall 

be chipped off. After the base is chipped clean, it shall be saturated with water 

overnight. If specified, proprietary brand adhesive solution of approved make shall be 

applied as per manufacturer's specification to the old concrete surface so as to ensure 

proper bond between old concrete surface and new in-situ topping. 

LAYING 

The mortar shall be 15mm thick in 1:6 (1Cement: 6 Coarse sand by volume) for flooring 

and 12mm thick in 1:3 (1 cement: 3 coarse sand by volume) for skirting. The mortar shall 

be laid for fixing one slab at a time. The slab shall be washed clean before laying. After 

laying once over cement mortar bedding, the slab shall be pressed, tapped gently to bring it 

in level, then lift & laid aside. Top surface of mortar then shall be corrected by adding fresh 

mortar at hollows & depressions. The mortar shall then be allowed to harden & cement 

slurry of honey likes consistency @ 4.4 Kg of cement per Sq. M. shall be spread over 

mortar. The slab edges shall be buttered with white cement (with necessary pigment) grout 

to match the shade of slabs. The slabs shall then be gently placed in position & tapped with 

wooden mallets till it is properly bedded in level. 

The slabs in flooring shall continue for not less than 10mm under the plaster / skirting. 

GRINDING & POLISHING 

Grinding (with machine except for skirting & small areas) shall be commenced when the 

joints are properly set. First grinding shall be done with carborundum stones of 48 to 60 

grade grit filled in machine. Water shall be properly used during grinding. 

When the floor has been uniformly rubbed, it shall be cleaned with water baring all pin 

holes. It shall then be covered with a thin coat of cement mixed with pigments to match with 

colour of the stone. This grout shall be kept moist for a weak. Thereafter the second 

grinding shall be started with Carborundum stone of 120grit. Grinding & curing shall follow 

again. 

Final grinding shall be with Carborundum of grade 220 to 350 grit using water in 

abundance. The floor shall be washed clean with water, oxalic acid powder shall then be 

dusted at 35 gms / Sq. M on surface rubbed with machine fitted Hessian bobs or rubbed 

hard with woolen rags. The floor shall then be washed clean & dried with a soft cloth or 

linen. 

If any stone slab is disturbed or damaged, it shall be refitted or replaced & properly jointed 

& polished. 

0435-JH0902-00-AR-SPC-0002 Page 11 of 14


8.3 Ceramic Tile Flooring 

Ceramic tiles shall be of approved make, size and shade and shall conform to IS 13756. No 

cracked, chipped or wrapped tiles shall be used in the works. Surface of the tile can be 

smooth, profiled, wavy, decorated, glossy, matt, etc. 

8.3.1 Surface Preparation 

All masonry faces shall be cleaned thoroughly by removing dirt, loose mortar, efflorescence 

etc. The concrete surfaces shall be brushed to remove all laitance and roughened to 

provide a bond for the bedding. 

8.3.2 Fixing tiles 

The masonry and concrete faces shall be given a coat of cement plaster 12 mm thick 

(in proportion 1:4). The surface of the plaster shall be scarified with wire brush for 

getting a good bond between the tiles and the bedding. 

The tiles shall be soaked in clean water for about half an hour before using. After 

soaking, tiles shall be removed from water and stacked on clean surface. The back of 

the tile shall be buttered with 1:2 plastic cement mortar to a thickness slightly in excess 

of the finished thickness required and the tile pressed to the wall and tapped back in 

position. Alternatively a rich fatty mortar shall be applied on the bedding and the tile 

pressed into it, care being taken to ensure that the keys of the tiles are buttered up 

with mortar. 

It shall be ensured that the back of the tile is solid over the whole area. Joints shall be 

uniform, even, straight and as thin as possible in any case not more than 3.0 mm. 

Surfaces of tiles having been fixed, the joints shall be cleaned of gray cement and 

refilled with cement paste of the same shade as that of the tiles. The tiled surface shall 

be left wet for a period of 7 days. 

Glazed rounded corner convex or concave shall be provided where specified and no 

extra cost will be paid for the same. 

After the completion of the work the surface shall be cleaned of all stains etc. 

Alternatively tiles may be fixed with Tile Adhesive chemicals of which, various 

proprietary brands are available. In such case soaking of tile with water before using 

shall not be done. Manufacturer’s specification shall be used for Tile adhesive fixing. 

8.3.3 Applications 

Generally used for walls and floors of toilets and kitchens etc., where constant risk of 

spoiling interior finish due to water, is there. Also it can be used elsewhere for decorative 

surface and clean environment. 


Ceramic Tiles shall be of approved manufacturers such as HR JOHNSON, HINDUSTAN 

SANITARYWARE, NITKO, KAJARIA or equivalent. 

0435-JH0902-00-AR-SPC-0002 Page 12 of 14


Note: Sample and Manufacturers shall be approved by Engineer-In-charge prior to its 

use in the work. 

8.4 PVC Flooring 

PVC Flooring provides dust-free, noise absorbing, resilient, non-porous, decorative surface. 

The two types of PVC Flooring are as follows: 

(a) Flexible PVC Flooring 

(b) Rigid PVC Flooring 

Flexible PVC Flooring is available in sheet form is suitable for lighter traffic. 

Flexible PVC flooring are not suitable for areas exposed to continuous sun light 

and rain. Flexible PVC Flooring is liable to be damaged by burning cigarette 

stumps. Thickness of sheet shall be 2mm unless specified otherwise. 

8.4.1 Adhesive 

Rigid PVC flooring is available in standard tile sizes such as 300 mm x 300 mm 

and comparatively more suitable for heavy traffic and rigid floors. Thickness of tile 

shall be 2mm unless specified otherwise. 

The size, type and shade of the tiles shall be as specified and/or as directed by the 

Engineer-In-Charge and conforming to IS 3461/ IS 3462. PVC Flooring shall be 

anti-static type. 

The adhesive shall be of the type and make recommended by the manufacturer of 

P. V. C. tiles. Preparation and laying shall be done as per IS 5318. 

8.4.2 Surface Preparation 

For concrete base floor, surface shall be scraped free of all foreign material and swept 

clean. Surface shall be kept wet for 24 hours by sprinkling water and then screed topping 

(1:3 cement mortar) of 3 mm thickness shall be provided over the concrete to get required 

even and levelled surface. Before laying is undertaken, it shall be ensured that the 

prepared surface is even and perfectly dry. 

8.4.3 Laying 

The adhesive shall be spread evenly on the base and on the back of the tiles as prescribed 

by the manufacturer. Time shall be allowed, for the solvent in the adhesive to evaporate. 

The tiles shall then be pressed firmly into contact with the surface and smoothed down with 

a suitable tool. Weights shall be used to avoid tendency of curling. Immediately after, the 

tiles shall be rolled with 5 kg wooden roller to get the tiles bonded down properly. The tiles 

shall be laid with butt joints throughout and the joints shall be very fine. After laying, any 

adhesive sticking to the surface of the tiles shall be removed immediately and shall not be 

allowed to harden. After a week of laying the surface shall be cleaned with mild soap and 

wet cloth. 


0435-JH0902-00-AR-SPC-0002 Page 13 of 14


1. PVC flexible flooring sheets under brand name Wonder Floors by Premier Vinyl 

Flooring, “Armstrong” or equivalent. 

2. PVC flooring Tiles under brand name Marblex by Bhor Industries, “Armstrong” or 

equivalent. 

0435-JH0902-00-AR-SPC-0002 Page 14 of 14




(GGSRPEP) 

SPECIFICATIONS FOR FALSE CEILING 

AND FALSE FLOORING WORK 

0435-JH0902-00-AR-SPC-0003 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE



1.0 FALSE CEILING 

False ceiling shall be of gypsum board or Aluminium panel wherever specified in 

drawing or as directed by Engineer-in-charge. 

FIXING SUPPORT SYSTEMS 

CONCEALED G. I. FRAME WORK 

In this system G.I. components are used to form a suspended framework of size 610 

mm x 1220 mm. For sections refer table below: 

EXPOSED ALUMINUM FRAME WORK 

In this system, various aluminum sections are suspended from ceiling to form a 

modular grid. For sections refer table below: 

Exposed 

Concealed G. I. 

Aluminium 

T-Section Section 

Perimeter L-25 Type Section U-25 Type Section 

Section 

Intermediate -- U-45 or C-48 

Support 

Type Section 

1220 mm c/c 

Main T-2535 Type 

Section 

W-Type Section 

@ 

Section @ 615 mm c/c 610 mm c/c 

T-35 Type Section 

@ 615 mm c/c 

Cross T-25 type section W-flat Type / 

Section @ 1230 mm c/c W - Type Section 

@ 1220 mm c/c 

T-35 Type Section 

@ 1230 mm c/c 

Suspenders G. I / M. S. Flat G. I / M. S. Flat 

or Adjustable M.S. 

Rod 

or Adjustable M.S. 

Rod 

FIXING CEILING BOARDS / TILES 

Various types of ceiling Board / Tiles are available from various Manufacturers. Fixing 

of ceiling boards / tiles to GI or Aluminium frame work by means of self tapping 

screws as indicated in Drawing or as per manufacturer’s specifications as approved 

by Engineer-In-Charge. 

The perforations shall be either uniform or at random as approved by Engineer-Incharge. 

0435-JH0902-00-AR-SPC-0003 Page 2 of 5



Necessary openings shall be provided in the false ceiling work for air-conditioning, 

lighting and other fixtures. Perforated fiberboard, if used, shall have beveled 

edges. The boards shall be flame proof or flame retardant quality. It is imperative 

that false ceiling should be perfectly level and all joints uniform. Workmanship shall 

be of the highest order. After the work is completed, the false ceiling shall be given 

2 coats of decorative coating of approved shed as specified by Engineer-Incharge. 

1.1 ALUMINIUM LUXALON FALSE CEILING : 

This work item shall be applied to providing & fixing luxalon lineal ceilings over 

Aluminium frame backing. 

1.1.1 MATERIALS: 

1. Suspension System - 4 mm galvanized steel wire rod with special height 

adjustment clips. Wall angles to be 25mm x 25mm x 1.6mm aluminium 

perimeter angles. 

2. Spacing of hanger rods - 1200 mm C/C maximum 

3. Size of Aluminium panel carrier - 62 mm wide, 29 mm deep and 0.95 mm thick 

of standard module of 100 mm. 

4. Spacing of Aluminium panel carriers: 

(a) 

(b) 

1700 mm C/C without insulation 

1500 mm C/C with insulation 

5. Aluminium panels - 84 mm wide x 16 mm deep x0.5 mm thick made of Dye-cast 

Powder coated aluminium (LUXALON or equivalent) 

6. Insulation: 25 mm Insulation material shall be long fiber resin bonded mineral 

wool spintex 300 (48 kg/m 3 ) conforming to IS 8183.(Only if specified in Bill of 

Quantity) 

1.1.2 SCOPE OF WORK 

Work elements to be included:- 

1. Procuring & transporting all materials at site of work. 

2. Fixing hangers for frame work support including all threading, welding to the 

inserts or brackets in RC slabs, beams or structural steel roof at specified 

spacing as per drawing or manufacturer’s specifications. 

3. Providing and fixing Aluminium panel carriers of specified size at specified 

spacing as per drawing or manufacturer’s specifications. 

4. Providing and fixing Aluminium edge covers as per drawing or manufacturer’s 

specifications. 

0435-JH0902-00-AR-SPC-0003 Page 3 of 5



5. Providing access panels at places indicated for air conditioning works and 

electrical works. 

6. Providing panels of specified size for ceiling hung electrical fittings. 

7. Providing and placing insulation as per drawing (Only if specified in Bill of 

Quantity) 

8. Fixing Aluminium panels of specified shape/size to the carriers. 

9. Protecting false ceiling work till FINAL ACCEPTANCE. 

10. Erection of temporary scaffold. 

2.0 FALSE FLOORING 

This specification covers the requirements of false flooring work over concrete grade 

slab. The False flooring system shall be of approved make (“USG” or approved 

equivalent) 

FIXING SUPPORT SYSTEMS 

This system consists of pedestal studs made of galvanized Mild steel seamless pipe 

30mm dia x 2.5mm thick and having thread at top and bottom for attaching to top head 

attachment and fixing to base plate. Pedestal base plate shall be 100mm x 100mm x 8 

thick galvanized mild steel. 

Channel stringers made of galvanized, machine cut, cold rolled mild steel channels of 

size 30 mm x 20 mm and 1.6 mm thickness. 

Top head attachment shall be made of pressure die cast aluminium alloy and shall be 

provided with check nuts at bottom for attaching top head thread in the shed allowing 

for adjustment up to 25 mm up and down. Fixing of jacks, stringer and false floor 

boards will be as per manufacturer specifications (“USG” or equivalent) as approved 

by Engineer In-charge. 

Pedestal base plates shall be fixed to the base floor by 6mm dia, 40mm long dash 

fasteners as per the grid. 

The pedestal stud locations shall ensure the grid work as per flooring pattern which in 

general shall be of 610 mm x 610 mm dimension. The length of the pedestal studs 

shall be such that clear cavity between false flooring and base flooring is of desired 

depth. 

The top head attachments shall be inserted into the studs and shall be adjusted to 

obtain proper level of the finished floor panels by means of the adjustment nuts. 

Stringer channels then shall be fitted onto the top heads in position to form the 

supporting grid work for the floor panels checking the level once again by adjusting the 

nut position if necessary. Now the check nut shall be finally tightened to secure the 

final level. Floor panels as specified shall be placed over the stringer channels. 

0435-JH0902-00-AR-SPC-0003 Page 4 of 5



Each floor panel shall be marked with positional numbering on the underneath. The 

finished floor panels shall be perfectly leveled, aligned without any gaps in between the 

panels. 

Each individual panel shall be removable maintenance purpose. Necessary cut-outs 

shall be made in the panels for cable routing, control panel fixation etc. as per drawing. 

Necessary ramps, slopes, steps etc. shall be also provided for as per drawing. Around 

a control panel/ rack, the residual space left out shall be filled up with cut panels of 

uniform size as required to fully close the gap between the adjacent full panel and the 

control panel base channel. In this case the part floor panel shall extend up to the full 

width of the base channel and the cut size shall be determined accordingly. An 

additional row of jack pedestals shall be provided along the cut out on which the edge 

of the floor panel shall rest and over which the base channel of control panel shall be 

placed. It shall not directly rest on the jack head pedestal or grid channels. 

The cavity between false flooring and base floor shall be properly cleaned and made 

dust free. 

The finished false flooring shall be able to serve for a distributed load of 1250 kg/ sq. m 

FIXING CEILING BOARDS / TILES 

Various types of Flooring Board / Tiles are available from various Manufacturers. 

Fixing of flooring boards to frame work by means of screws or nails etc. as indicated 

in Drawing and or as per manufacturer’s specifications as approved by Engineer-in- 

Charge. 

The boards shall be flame proof or flame retardant quality. It is imperative that false 

flooring should be perfectly level and all joints uniform. Workmanship shall be of the 

highest order. 

Floor panel of 610 mm x 610 mm in general 35 mm thickness make of unviniard 

three layer flat pressed teak wood particle board. Finished on the underneath 

side with 0.05 mm al foil finished on the top with at least 2mm thick antistatic 

type PVC tile (high pressure laminate). 

0435-JH0902-00-AR-SPC-0003 Page 5 of 5




(GGSRPEP) 

SPECIFICATIONS FOR EARTHWORK 

0435-JH0902-00-CI-SPC-0001 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE


1. SCOPE 

The purpose of this specification is to define the basic requirements for Earthwork 

related to implementation of proposed project. The following section deals with the 

work involved at any facility. 


2.1 Codes and standards 

All work shall conform to the latest requirements of Indian Standards as listed below : 

IS 2720 Soils Method of test for Parts 1 to 40 

IS 4988 Glossary of terms and classification of earth moving machinery Parts 1,2,3, 

4 and 5 

IS 10379 

IS 3764 

Code of Practice for Field Control of Soils 

Excavation Work – Code of Safety 

IS 6313 (Part II) 

Code of Practice for Anti-Termite Measures in Buildings. 

In the event of conflict between various codes and standards, the most stringent condition 

will apply. Unless specified otherwise the International System of metric units (S.I.) is to be 

used. 

2.2 Other Standards / specifications 

Specification for Concrete Work 

Specification for Masonry Work 

3. EARTHWORKS 

3.1 General 

This section of Specification covers the material and construction requirements for 

earthworks for Project areas. The work generally includes: Clearing, Grubbing-out, 

Stripping, Proof-rolling to determine soft spots, excavating, filling, compacting and testing; 

all as described in this document. The extent of the work shall be as shown on the Project 

Drawings. 

3.2 Definition of Materials 

3.2.1 Common Excavation 

Common Excavation shall mean excavation in any material. All common excavated 

material shall be classified as suitable or unsuitable according to 3.2.2 and 3.2.3 below. 

0435-JH0902-00-CI-SPC-0001 Page 2 of 7


3.2.2 Suitable Material 

The fill material shall be granular, well graded, compactable, and possess good drainage 

characteristics, and no swelling properties. It shall be free of vegetation, any organic 

matters and other impurities. In extraordinary circumstances expansive soil of free 

swell index, less than 50 % may be used, however approval shall be sought from the 

engineer in charge. The proposed fill material shall be tested to determine its 

suitability. However, filling material shall have Liquid limit between 20-35 and 

Plasticity index shall not be more than 12. All these testing cost shall be included 

in Contractors scope. 

3.2.3 Unsuitable Material 

The following type of material will be considered unsuitable for filling: 

1. Material with vegetation and shrubs 

2. Material in frozen condition or susceptible to combustion 

3. Material resulting in leaching of embankment. 

4. Any material which classifies as CH, OH, Ol, LI as per IS: 1498 

5. Material with swelling index more than 50. 

3.3 General Site Preparation 

3.3.1 Clearing 

The Project area shall be cleared of all materials above or at the natural ground surface. 

Materials to be cleared include trees, bushes, vegetation, and obstructions. However, in 

certain specified areas like green belts, trees and bushes shall be retained and preserved. 

3.3.2 Grubbing 

The entire area within the limits of clearing shall have all stumps and roots removed. 

3.3.3 Stripping 

All turf and topsoil shall be stripped from the areas shown on the drawings or as directed 

by the Construction Manager to suit requirements at job-site. Turf and topsoil shall be 

stored for re-use in stockpiles separately from other excavated material. The location 

and finished levels of the stockpiles shall be as directed by the Construction Manager. 

3.3.4 Disposal 

Debris from clearing operations shall be burned or disposed off in a manner approved by 

Engineer -in - charge. Material too wet to burn shall be piled in windrows for later burning. 

Material from grubbing operations shall be removed to the designated spoils disposal 

areas. 

0435-JH0902-00-CI-SPC-0001 Page 3 of 7


3.3.5 Ground Markers 

A suitable number of permanent ground markers, shall be constructed before any 

setting-out work is commenced. Temporary Reference Monuments shall be constructed 

when and where required, as approved by the Engineer-in-charge. 

4. BULK EXCAVATION 

Excavations and cut and fill areas shall be kept free of water by pumping, temporary 

ditches or other approved means. The surface of cut and fill shall be sloped to prevent 

ponding. Excavation shall be performed to the lines and levels shown on the drawings. 

Slope of cuttings and embankments shall be as shown on the drawings. 

Excavation beyond the limits shown on the drawings shall be replaced with approved 

material, compacted in accordance with this Specification. 

All excavated material shall be separately stockpiled for re-use or taken to the designated 

storage area, as directed by the Engineer in charge. Where cut areas have been reduced 

to level; any unsuitable material apparent at the surface shall be separately excavated 

and the resulting pockets filled with suitable material and compacted in accordance 

with this Specification. In case of blasting of rock, Contractor shall prepare and submit a 

comprehensive procedure to the engineer in charge for approval. The blasting in rock 

shall only be carried out with the prior written approval of, and under the 

supervision of a certified Blasting Engineer. All local regulations shall be complied with. 

Adequate safety precautions shall be carried out by means of Timber Shoring, Sheet 

Piling or similar protective measures as directed by the Engineer in charge, to ensure the 

safety of existing structures, pipelines and other installations. 

5. FILL 

5.1 Preparation for Fill 

Only approved suitable material from excavation or stockpiles shall be used, as described 

in Clause 3.2.2. The proposed methods to be used in fill operations for the compaction of 

material shall be approved prior to starting of work. Before filling commences the area 

shall be proof rolled with at least four passes of a 10-ton vibratory roller. 

5.2 Placement of Fill 

The Contractor shall at least 7 days before commencement of placement submit the 

following to the Engineer in charge: 

(i) The dry density of fill material against moisture content plot and values of 

maximum dry density and the optimum moisture content obtained in accordance 

with IS 2720 (Part 7) using the light compaction method. 

0435-JH0902-00-CI-SPC-0001 Page 4 of 7


(ii) Proposed method of placing the fill in maximum lifts of 200 mm to achieve the 

requirement of 95% maximum dry density as determined from the above 

information. The maximum thickness for placing fill material layer in large areas 

shall be maximum 300 mm and is determined by field tests and governed by type of 

compaction equipment. 

Once the above information is approved by the Engineer in charge, it shall form the basis 

for compaction. Fill shall be compacted to at least 95% of the maximum dry density. 

Places inaccessible to rollers shall be compacted with mechanical or hand tampers. Plant 

areas within the primary roads and paved areas which do not contain equipment or 

buildings shall after completion of cut, fill, compaction, and final grading be proof rolled 

with at least four passes of a 10 ton vibratory roller. Field density test (sand replacement) 

at bottoms of excavations for individual foundations shall be carried out at the rate of 1 per 

foundation or every 10 sq. m of foundation on plan whichever is the greater. The final 

requirement of these tests to suit strata conditions shall be determined by the Field 

Engineer. 

In areas to be paved, the sub-grade will normally be graded to the under side of paving 

level, but in predominantly fill areas the filling operation may be temporarily halted, at an 

agreed lower level, until after the construction of equipment foundations. 

5.3 Broken Rock Fill 

Sound clean broken rock to a maximum size of 150 mm may be used as fill 

material subject to the approval of the Engineer in charge. All voids are to be filled with 

approved fine material. The rock material shall be spread in layers not exceeding 

400mm compacted thickness and shall be compacted by a minimum of 5 passes of a 

vibratory roller having a static weight 8-10 tonnes and until there are no signs of 

deformation 

6. TOLERANCES 

The grade shall be properly shaped to the required elevations and parallel to the required 

surface. The elevation of any point and the line of any edge or centre of the earthworks 

shall conform to that shown on the drawing within the tolerances of +/- 50 mm to final 

grade and slopes. 

7. EMBANKMENTS 

Embankments shall be formed of suitable material as described in Clause 3.2.2. The 

material shall be built up evenly over the full width of the embankment. The surface shall 

be maintained, at all times, with sufficient camber to enable surface water to drain 

off. 

8. EARTHWORK FOR FOUNDATIONS 

8.1 Excavation for Foundations 

0435-JH0902-00-CI-SPC-0001 Page 5 of 7


Excavation shall be generally performed in accordance with Section 4. Excavated material 

shall not be deposited at the immediate edge of any excavation. The proximity and height 

of the excavated material shall be controlled so as to prevent danger of instability or 

damage to other structures and services. Excavated materials designated as 

surplus to requirements or material deemed unsuitable as fill shall be loaded and 

removed offsite to a properly sanctioned area. All excavations shall be kept free from 

water from whatever source so that the works shall be constructed in dry 

conditions. 

If any excavation pit gets filled by water due to rain seepage or for any other reason, the 

water shall be removed and the bottom of the excavation shall be cleared of all silt / slush 

by the Contractor at his own expense. Further the extra depth, if any, created during the 

clean up shall be made with PCC/sand 

The bottom of any excavation shall be kept dry and not used as a watercourse to drain the 

excavation to other areas. Shoring shall be in accordance with the Indian Standards. 

During excavations, safety measure shall be implemented in accordance with IS 3764.If 

in-situ material at specified foundation depth does not meet the bearing capacity 

requirements, it shall be removed to the depth as directed and filled with approved 

material and method 

8.2 Preparation 

The bottom of any excavation ready to receive the permanent works shall be mechanically 

compacted using a vibrating plate or suitable sized roller and any soft spots or 

pockets of unsuitable material exposed, shall be excavated and replaced as 

approved by Engineer in charge. Precautions shall be taken to protect the bottom of 

the excavation, and should the bottom of the excavated material become 

unsuitable, either by exposure to weather conditions, water, or due to lapse of 

time between excavation and subsequent works, it shall be removed and replaced. 

8.3 Inspection 

When the bottom of any excavation is prepared, further work shall not proceed 

until the excavated bearing surface is approved. 

8.4 Protection 

Following completion of the excavation, and preparation of the bottom of the excavation to 

receive the permanent works, and once approval has been given, the blinding concrete, 

polythene membrane or such other protection as may be called for on the drawings shall 

be immediately applied. 

9. BACKFILLING 

Backfilling of all foundations/trenches shall not be carried out until the foundations or 

0435-JH0902-00-CI-SPC-0001 Page 6 of 7


structures within the excavation have been approved and approval to commence backfill 

has been given. The backfill material shall normally be the material excavated from the pit 

or trench. Boulders, lumps of concrete and other foreign matter shall be excluded. The 

backfill shall be placed and compacted evenly around the structure in layers not exceeding 

200 mm and to 95% maximum dry density as determined under section 5.2 above. 

Mechanical compaction shall be used wherever possible and accordingly the thickness of 

layers adjusted. Care shall be taken during backfill operations to prevent damage to the 

permanent works. Compacting within 1 m of existing structures shall be performed by 

hand operated compactors. In particular damage to waterproof membranes/cables etc. 

shall be repaired before backfilling is continued. Planking, strutting, trench sheets and 

other supports in excavations shall be removed as backfilling proceeds to maintain the 

stability of the side until backfill is completed. Temporary supports shall not be left in the 

ground. Areas of settlement or areas of fill that do not comply with the required tolerances 

shall be investigated to determine the extent of non-conformance. Soft spots shall be 

excavated to remove all unsuitable material, which shall be replaced with suitable material 

and re-compacted to the required density. High spots shall be scarified and excess 

material removed as necessary, the area shall then be re-compacted to the required 

density. 

0435-JH0902-00-CI-SPC-0001 Page 7 of 7




(GGSRPEP) 

SPECIFICATIONS FOR CONCRETE WORK 

0435-JH0902-00-CI-SPC-0002 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE

SPECIFICATIONS FOR CONCRETE 

WORK 

1. SCOPE 

This Specification covers the general requirement for plain and reinforced concrete to 

be used as in-situ and pre-cast concrete. It covers requirements in regard to the 

quality, proportioning, batching, mixing, transporting, placing, curing, protecting, 

repairing, finishing and testing of concrete. 


2.1 Codes and Standards 

The Indian Standards and other referred standards (including all amendments 

and revisions) shall be considered as part of this Specification. In case any particular 

aspect of work is not covered specifically 

by these or any other relevant Indian Standard Specification, any other good 

engineering practice as may be specified by the company shall be followed: 

Following Indian standards including all amendments and revisions shall be 

considered as part of this specification. 

Indian Standards 

IS-SP23 Handbook on Concrete Mixes 

IS-269 Sand Cement Dry Pack Grout 

IS-280 Binding Wire 

IS-383 Coarse and fine aggregates from natural sources for concrete 

IS-432 (Part 1) Mild steel and medium tensile steel bars and hard-drawn steel 

wire for concrete reinforcement: Mild steel and medium tensile steel 

bars 

IS-432 (Part 2) Mild steel and medium tensile steel bars and hard-drawn steel 

wire for concrete reinforcement: Hard-drawn steel wire 

IS-455 Portland slag cement 

IS-456 Code of practice for plan and reinforced concrete 

IS-516 Method of test for strength of concrete 

IS-650 Standard sand for testing of cement 

IS-1199 Method of sampling and analysis of concrete 

IS-1343 Code of practice for pre-stressed concrete 

IS-1489 (Part 1) Portland pozzolana cement: Flyash based 

IS-1489 (Part 2) Portland-pozzolana cement: Calcined clay based 

IS-1786 High strength deformed steel bars and wires for concrete reinforcement 

0435-JH0902-00-CI-SPC-0002 Page 2 of 30


WORK 

IS-1791 Batch type concrete mixers 

IS-1834 Specification for hot applied sealing compound for joint in concrete 

IS-1838 Specification for preformed fillers for expansion joints in concrete 

pavements and structures (non extruding and resilient type) : Part 1 & 2 

IS-2386 (Part 1) Methods of test for aggregates for concrete: Particle size and shape 

IS-2386(Part 2) Methods of test for aggregates for concrete: Estimation of 

deleterious materials and organic impurities 

IS-2386 (Part 3) Methods of test for aggregates for concrete: Specific gravity, density, 

voids, absorption and bulking 

IS-2386 (Part 4) Methods of test for aggregates for concrete: Mechanical properties 

IS-2386 (Part 5) Methods of test for aggregates for concrete: Soundness 

IS-2386 (Part 6) Methods of test for aggregates for concrete: Measuring mortar making 

properties of fine aggregates 

IS-2386 (Part 7) Methods of test for aggregates for concrete: Alkali aggregate reactivity 

IS-2386 (Part 8) Methods of test for aggregates for concrete: Petrographic examination 

IS-2502 Code of practice for bending and fixing of bars for concrete reinforcement 

IS 2645 Specification for integral cement water proofing compounds 

IS 3025 Method of sampling and testing water 

IS-3085 Method of test for permeability of cement mortar and concrete 

IS-3096 Safety Code for scaffolds and ladders 

IS-3370 (Part 1) Code of practice for concrete structures for the storage of liquids: 

General requirements 


Reinforced concrete structures 


Prestressed concrete structures 


Design tables 

IS 3812 Specification for fly ash for use as pozzolana and admixture 

0435-JH0902-00-CI-SPC-0002 Page 3 of 30


WORK 

IS-4082 Recommendation on staking and storage of construction materials at site 

IS-4926 : Ready mixed concrete (RMC) 

IS-5525: Recommendations for detailing of reinforcement in reinforced concrete works 

IS-5816: Method of test for splitting tensile strength of concrete cylinders 

IS-6461 (Part 2) Glossary of terms relating to cement concrete: Materials 

IS-64661 (Part 3) Glossary of terms relating to cement concrete: Concrete 

reinforcement 

IS-6461 (Part 4) Glossary of terms relating to cement concrete: Types of concrete 

IS-6461 (Part 5) Glossary of terms relating to cement concrete. Formwork for concrete 

IS-6461 (Part 6) Glossary of terms relating to cement concrete: Equipment, tools and 

plant 

IS-6461 (Part 7) Glossary of terms relating to cement concrete: Mixing, laying, 

compaction, curing and other construction aspects 

IS-6461 (Part 8) Glossary of terms relating to cement concrete: Properties of concrete 

IS-6461 (Part 9) Glossary of terms relating to cement concrete: Structural aspects 

IS-6461 (Part 10) Glossary of terms relating to cement concrete: Tests and testing 

apparatus 

IS-6461 (Part 11) Glossary of terms relating to cement concrete: Pre-stressed concrete 

IS-6461 (Part 12) Glossary of terms relating to cement concrete: Miscellaneous 

IS-7861 (Part 1) Code of practice for extreme weather concreting. Recommended 

practice for hot weather concreting 

IS-7861(Part 2) Code of practice for extreme weather concreting: Recommended 

practice for cold weather concreting 

IS-8041 Rapid hardening Portland cement 

IS-8112 43 Grade ordinary Portland cement 

IS 8142 Method of test for determining setting time of concrete by penetration 

resistance 

IS-9013 Method of making, curing and determining compressive strength of 

accelerated cured concrete test specimens 

IS-9103 Admixtures for concrete 

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IS-9417 Recommendation for welding cold worked bars for reinforced concrete 

construction 

IS-10262 

Recommended guidelines for concrete mix design 

IS-10790 (Part 1) Methods of sampling of steel for prestressed and reinforced concrete: 

Prestressed steel 

IS-10790 (Part 2) Methods of sampling of steel for prestressed and reinforced concrete: 

Reinforcing steel 

IS-11433 One Part Grade Polysulphide based joint sealant Part I & II IS-12269 

53 grade ordinary Portland cement 

IS-12330 Sulphate resisting cement 

IS-13311 

velocity 

Non-destructive testing of concrete methods of test: Ultrasonic pulse 

IS 4031 Part 1 to 15 method of physical tests for hydraulic cement 

IS 4032 Method of chemical analysis of hydraulic cement 


Specification for Earthwork 


3. CONCRETE GRADES 

Concrete shall be designated by grades as below. 

Grades of Concrete 

Grade 

M10 10 

M15 15 

M20 20 

M25 25 

M30 30 

M35 35 

M40 40 

Specified Characteristic Compressive Strength At 28 Day 

N/mm2 

In the designation of concrete mix, the letter 'M' refers to the mix and the 

number to the specified characteristic compressive strength of 15 cm cube at 28 days 

expressed in N/mm2. 

4. MATERIAL 

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4.1 Cements 

4.1.1 General 

Cement delivered hot from the factory shall not be used until its temperature is below 

350C. 

4.1.2 Cement types 

The following cement types of locally available best quality shall be used : 

i. Grade 43 OPC to IS 8112. 

ii. Grade 53 OPC to IS 12269. 

iii. Factory blended Portland Pozzolana Cement (PPC) contain fly ash grade 1 to IS 

3812. 

iv. Rapid hardening Portland cement to IS 8041. 

v. Sulphate resisting cement to IS 12330. 

vi. Cement with pulverized fuel ash. 

4.1.3 Tests and Analysis 

Manufacturer’s certificates shall be provided confirming that cement delivered to the site 

has been tested and found to comply with the requirements of the appropriate 

Standard. If subsequent tests on any consignment of cement show it not to 

comply with Specification requirements, then the whole consignment shall be 

removed immediately from the site notwithstanding the manufacturer’s certificate 

results. 

Access to the cement store shall be provided during working hours for the 

purpose of sampling the cement for further testing. 

4.1.4 Cement Store 

Cement shall be kept at all times in covered storage in an approved manner. 

No cement shall be kept on the site longer than three months before use. Any cement, 

which is stored on site in excess of 90 days, shall be tested in accordance with 

relevant Indian Standard prior to use. Sufficient cement for one week’s consumption 

shall be available at all times. Cement shall be used in the sequence in which it is 

delivered. 

The cement store for bagged cement shall be a weatherproof building or shed, 

ventilated, lit and free of dampness. The size will be sufficient to hold enough cement 

for continuous execution of the works. Bags for cement shall be lined in polythene or 

other damp-proof material. If cement in bulk is to be used, prior approval must be 

obtained. 

4.2 Aggregates 

4.2.1 General 

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All aggregates shall be from approved sources and shall comply with IS 383. Fine and 

coarse aggregates shall be considered separate ingredients. Both shall meet the 

grading requirements of IS 383. 

Aggregates shall be clean, hard, durable, chemically inert and impermeable.They 

shall be free from adherent coatings, laminated particles or admixtures of materials 

likely to be deleterious to the concrete. 

Dune and beach sand shall not be used for fine aggregate. 

In general, coarse aggregate shall be max. 20 mm. However, this may be increased to 

a maximum of 40mm for certain structures/foundations, as shown on the drawings 

or directed by the Construction Manager in the field. 

4.2.2 Sampling and Testing 

Sampling and testing of aggregates shall be carried out in accordance with IS 

2386. If adequate laboratory facilities do not exist on site, samples must be sent 

to a convenient approved testing laboratory. Samples of fine and coarse aggregate 

shall be sent in suitable airtight containers. 

Chlorides and other contents in the coarse aggregates and fine aggregates shall be 

limited as follows: 

Course Aggregates 

Chlorides as CL 0.03% Max. Sulphates as SO3 0.40% Max. Fine Aggregates 

Chlorides as CL 0.06% Max. 

Sulphates as SO3 0.40% Max. 

Aggregates shall be tested in accordance with IS 2386 or be obtained from a supplier 

whose aggregates have previously been proven to meet these requirements. 

Compliance certificates shall be submitted for approval. 

The maximum quantities of clay, fine silt, fine dust and organic impurities in sand when 

tested accordance to IS 2386, shall not be more than 5 % by mass in natural sand, or 

crush gravel sand or crushed stone sand. For organic impurities, the colour of liquid 

shall be lighter than indicated by standard solution specified in IS 2386. 

Any aggregates that do not meet the requirements of the relevant standards 

shall not be used in the works. 

Tests shall be carried out from each source as follows: 

4.2.3 Acceptance 

The site engineer has the right to reject any materials that do not meet the 

requirements of this specification. 

4.2.4 Storage 

Sufficient quantities of each type of aggregate shall be maintained on site at all times to 

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ensure continuity of work. Each type and grading of aggregate shall be stored 

separately in such a manner that mixing of the various size particles shall not 

occur. The floors of the storage areas at the batching plants shall be of concrete or 

other approved material, and shall be sloped sufficiently to ensure adequate 

drainage of surplus water. 

A random check for dust contamination in the stock pile shall be carried prior to loading 

the batch plant bins with aggregates. As a minimum, aggregate storage shall satisfy the 

requirements of IS 4082. 

4.3 Water 

Water used for the following shall be free of dirt, chemicals organic materials 

and litter in suspension conforming to IS 456 clause 4.3 and tested to IS 3025: 

i. Mixing concrete, 

ii. Mixing cement/sand mortar, 

iii. Mixing grouts, 

iv. Ice production, 

v. Rinsing aggregates, 

vi. Cooling aggregates, 

vii. Curing concrete. 

4.4 Admixtures 

4.4.1 General 

Admixtures conforming to IS 9103 may be used subject to approval. In no 

circumstances shall admixtures containing chlorides or other corrosive agents be 

allowed. No air entraining agents shall be used without prior trials and approval. Sample 

of packed admixtures shall be obtained as per IS 3535. The Contractor shall prove 

compatibility with the type of cement used. 

4.4.2 Super Plasticizers 

In hot weather, after trials and approval, a naphthalene sulphate retarding super 

plasticizer can be used to increase workability of the concrete and retard the initial 

set.The concrete mix with plasticizer shall comply with IS 1199 and IS 8142 

respectively. The plasticizer shall be of approved brands. Confirmation shall be 

obtained that the super plasticizer is compatible with any Pozzolana, which is used. 

5. CONCRETE MIX PROPORTIONING 

The mix proportion shall be selected to ensure adequate workability when 

handling and placing. On hardening, concrete shall have the required strength, 

durability and surface finish. The determination of the proportions of cement aggregates 

and water to attain the required strength shall be either: 

i. By determining the concrete mix; such concrete shall be called “Design Mix 

Concrete”, or 

ii By adopting nominal concrete mix; such concrete shall be called “Nominal Mix 

Concrete”. Concrete of grade M20 and above shall be ‘Design Mix Concrete’ unless 

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otherwise specified. 

In either case, the Contractor shall be solely responsible to ensure that the concrete 

has all the essential properties, i.e. characteristic compressive strength, and any 

additional properties that may be specified. 

5.1 Design Mix Concrete 

At least two weeks before commencement of concreting of a particular grade in 

permanent works, the Contractor shall have obtained the Engineer’s approval of the 

Design Mix for that particular grade. 

5.1.1 Trial Mixes 

Structural Concrete 

The mix(s) shall be designed mixes in accordance with IS SP23 Handbook on 

Concrete Mixes and IS:10262 and as specified in this document. The relative 

proportions of the fine and coarse aggregates, the workability and strengths of the 

mixes shall be determined by production equipment trial mixes. The trial mixes shall be 

carried out in order to produce a concrete which can be properly placed and 

compacted, so that a dense impermeable concrete can be produced which shall 

adequately resist the ingress of damaging salts. If an admixture is proposed it shall 

be used in the trial mixes. The required workability for large foundations will differ from 

that for tall thin sections of structural concrete cast above ground and the trial mixes 

shall allow for both cases. 

When the proposed workability and proportion of the aggregates and admixture (if any) 

for each of the grades of concrete has been established, test concrete shall be 

produced for approval. The following tests shall be carried out for each grade of 

concrete: 

Four separate test mixes shall be prepared and six test cubes shall be made from each 

test mix for each grade of concrete. The test cubes shall be made and cured in 

accordance with IS 516. 

Testing shall be made in threes or multiples of threes. Only 28-day result shall be 

considered and the mean strength and standard deviation established for each grade. 

The test mixes shall be accepted provided that: 

a) The mix proportions and workability are in accordance with this Specification. 

b) The standard deviation for all the different grades shall be worked out as per clause 

2.1 of IS: 10262-1982. 

c) The acceptance criteria shall be in accordance with clause 16 of IS 456. 

Maximum Water Cement Ratio in Cement Concrete to Ensure Durability under 

specified Exposure. 

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Condition of Exposure Plain Concrete Reinforced 

Concrete 

Mild- For Example Completely Protected 0.6 0.55 

− Against weather, or aggressive conditions, except for a brief period of exposure to 

normal condition during construction 

Moderate- For Example Sheltered from 0.6 0.50 

− Heavy and wind driven rain and against freezing, whilst saturated with water, buried 

concrete in soil and concrete 

− Continuously under water 

Severe- For Example Exposed to Sea 0.5 0.45 

− Water, alternate wetting and drying and to freezing while wet, subject to heavy 

condensate or corrosive fumes 

Based on the results of the preliminary test, the contractor shall select a final design mix 

for the trial mixes and shall furnish the same to the Engineer. The contractor 

shall demonstrate that the proposed design mix will produce the grade and 

quality of concrete required with adequate workability 

A fresh mix design shall be arrived at each time there is a change in the quality or 

source of materials Water, alternate wetting and drying and to freezing while wet, 

subject to heavy condensation or corrosive fumes. Based on the results of the 

preliminary tests, the Contractor shall select a final design mix from the trial mixes and 

shall furnish the same to the Engineer. The Contractor shall demonstrate that the 

proposed design mix will produce the grade and quality of concrete required with 

adequate workability. A fresh mix design shall be arrived at each time there is a change 

in the quality or source of materials. Minimum Cement Content (Ref IS 456, Table 5) 

Plain Concrete 

Exposure 

Min. Grade of 

Concrete 

Min. Cement Content 

(kg/m3) 

Mild - 220 

Moderate M15 240 

Severe M20 250 

Very 


Extreme M25 280 

Reinforced Concrete 

Exposure 

Min. Grade of 

Concrete 

Min. Cement Content 

(kg/m3) 

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SPECIFICATIONS FOR 

CONCRETE WORK 

Mild M20 300 

Moderate M25 300 


Very 


Extreme M40 360 

5.1.2 Nominal Mix Concrete 

No mix design or preliminary tests are necessary for Nominal Mix Concrete. 

Nominal Mix Concrete shall be restricted to works of minor nature in which 

the strength of concrete is not critical as decided by the Engineer. The limit 

of chloride content of concrete shall be as follows: 

Type or Use of Concrete 

1. Concrete containing metal 

and steam cured at elevated 

temperature and prestressed 

CONCRETE. 

Max. Total Acid 

Soluble chloride content 

expressed as kg/m 3 of concrete 

0.4 

2. Reinforced or plain concrete 

containing 

embedded metal 

0.6 

3. Concrete not containing 

embedded metal 

3.0 

5.2 Batching 

In proportioning concrete, the quantity of both cement and aggregate shall be 

determined by weight. In case uniformity of aggregate has been established 

over a period of time, and where weigh batching is not practicable, the 

quantity of fine and coarse aggregate (not cement) may be determined 

by volume if permitted by the Engineer. If fine aggregate is moist and 

volume batching is adopted, allowance shall be made for bulking in 

accordance with IS 2386 (Part III). All measuring devices shall be accurate to 

+ 3% and shall be regularly checked. 

The water-cement ratio shall be maintained constant at its correct value. To 

this end, determination of moisture content in both fine and coarse aggregate 

shall be made by the Contractor at no extra cost. The frequency of tests shall 

be determined by the Engineer according to weather conditions. 

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5.3 Mixing 

Concrete shall be mixed in a mechanical mixer. The mixer shall comply with 

IS 1791. The mixing shall be continued until there is uniform distribution of 

the materials and the mass is uniform in color and consistency. If there 

is segregation after unloading from the mixer, the concrete shall be 

remixed. For guidance, the mixing time may be 1-1/2 to 2 minutes. 

Workability of the concrete shall be controlled by direct measurement of water 

content. Workability shall be checked at frequent intervals (See IS 1199). 

6. FORMWORK 

6.1 General 

The design and construction of the formwork shall be the responsibility 

of the Contractor. However, if instructed by the Engineer, the drawings 

and calculations for the design of the formwork shall be submitted to 

the Engineer for approval. Design of formwork shall take account of 

safety and surface finish. The formwork shall be sufficiently rigid and tight to 

prevent loss of grout or mortar from the fresh concrete. Props used for 

support shall be of steel tubes. 

Formwork shall be designed to withstand the worst combination of self 

weight, reinforcement weight, wet concrete weight, concrete pressure, 

construction and wind loads together with dynamic effect caused by placing, 

vibrating and compacting the concrete. Forms shall be designed and 

constructed to maintain rigidity throughout the placing, ramming, vibration 

and setting of the concrete to the required shape, position and level 

and specified class of finish within the allowable tolerances. All joints 

shall be sufficiently tight to prevent leakage of grout. If movement or 

deflection of the formwork or loss of grout occurs, the damaged concrete 

supported by such formwork shall be removed and the concrete re-cast so 

that the required finish is obtained. Formwork and its supports should be 

designed to withstand the worst combinations of self-weight, reinforcement 

and wet concrete weights, concrete pressure, construction and wind loads. 

Due regard shall be taken to the type of mix when considering the design 

pressure on the formwork. The formwork shall be pre-cambered by an 

amount equal to the expected maximum deflection shall be as shown on the 

drawings. 

If timber forms are used they shall be of sound, well-seasoned timber free 

from loose knots. The forms shall be faced to give the specified class of 

finish for the structures. The formed surfaces of exposed concrete shall 

be smooth, true and free from all irregularities. 

For below ground concrete except against existing structures, rough 

formwork, steel pans etc., provided all joints prevent the loss of grout. 

The formwork shall be capable of being dismantled and removed from the 

cast concrete without shock, disturbance or damage. The arrangement shall 

be such that the soffit forms properly supported on props, can be retained in 

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position for such period as may be required by maturing conditions or 

specifications. 

6.2 Cleaning and Treatment of Forms 

All rubbish shall be removed from the interior of the forms before the concrete 

is placed. The faces of the forms in contact with the concrete shall be 

clean and treated with a suitable release agent, where applicable. 

Release agent shall be applied so as to provide a thin uniform coating to the 

forms without contaminating the reinforcement. 

6.3 Striking of Form work 

In normal circumstances where Ordinary Portland Cement is used, forms 

shall generally be removed after the expiry of the following periods: 

a) Walls, Columns and vertical 

faces of all structural members 

24 to 48 hours as may be 

decided by the Engineer 

b) Slabs (Props left Under) 3 Days 

c) Beam Soffits (Props left Under) 7 Days 

d) 

Removal of Props under Slabs: 

1) Spanning upto 4.5m 

2) Spanning over 4.5m 

e) Removal of Props under Beams 

and Arches: 

1) Spanning upto 6.0m 

2) Spanning over 6.0m 

7 Days 

14 Days 

14 Days 

21 Days 

For other cements, the stripping time recommended for Ordinary 

Portland Cement shall be suitably modified. The number, size and position 

of props left under shall be such as to be able to safely carry the dead load of 

the slab, beam or arch, together with any live load likely to occur during curing 

or further construction. 

Sleeves for through bolts shall not be provided in formwork for liquid 

retaining structures as they are potential hazard for leakage. Special 

devices shall be fabricated using two ordinary M20 nuts separated by two 

numbers 10 mm rounds welded to opposite flat side of the nuts. The faces of 

the nuts will have a compressible rubber bushing 20 mm thick. The overall 

dimension of the assembly shall be 50 mm less than the designed thickness 

of the concrete. Adjusting bolt shall pass through formwork and will lock into 

the nuts. While these bolts are tightened, the formwork will travel inwards. 

Once the desired dimension is achieved, concrete will be poured. During 

deshuttering, the bolts will be removed to loosen the shuttering plates. The 

depression will be sealed using suitable concrete sealant. 

6.4 Surface Finishes from Formwork 

Generally formwork shall be specified as either wrought or unwrought 

depending on the 

required surface finish. 

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6.4.1 Unwrought Formwork 

Unwrought Formwork shall consist of sawn boards, brick or concrete 

block work, sheet metal or other suitable material to give adequate support 

to the concrete. 

Appearance is not of primary importance for this class of formwork. 

Surfaces to which plaster, granolithic or other finish is to be applied shall be 

roughened while the concrete is still green. 

6.4.2 Wrought Formwork 

Wrought formwork shall be provided for concrete surfaces that are required to 

be finished smooth. Wrought formwork shall be lined with metal or plywood 

having smooth surfaces and edges. Formwork shall be furnished in largest 

practicable sizes to minimize the number of joints. Care shall be taken that 

there are no irregularities or roughness between successive sections of 

shuttering such that finished surfaces shall be free of board or shutter marks. 

Upon removal of formwork, surfaces of finished concrete shall be rubbed 

down with carborundum stone where necessary to obtain a uniform and 

smooth appearance. 

The finish shall be such as to require no filling of surface pitting, butt fins, 

surface discoloration and other minor defects shall be remedied by approved 

methods. Rendering of defective concrete as a means of making good will not 

be permitted except that, in case of 

minor porosity on the surface, approval may be given for the surface to be 

treated by rubbing down with a cement mortar of the same fine 

aggregate/cement ratio as the concrete. The treatment shall occur 

immediately after removing the formwork. Both cement and aggregate shall 

be from the same source as the concrete materials. 

Concrete containing honeycombing, major air holes or similar defects shall be 

cut out and replaced as directed. No repair shall be executed without 

approval. 

6.4.3 Ties 

Where it is required to use internal ties and spacers, their type, spacing and 

use shall be approved. No part of any such tie or spacer remaining 

permanently embedded in the concrete shall be nearer than the specified 

cover to the finished surface of the concrete. Wire ties projecting through the 

concrete face shall not be permitted. 

6.5 Permanent Formwork 

Permanent formwork for elevated concrete floors in steel structures 

shall be profiled steel sheet. The sheet shall be of sufficient thickness to 

sustain all construction loads plus the weight of fresh concrete between 

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supporting beams without excessive deflection. The underside of the sheet 

shall be coated with an approved corrosive resistant paint. The material shall 

conform to IS 513. The deflection shall be limited to span / 150. The sheet 

shall be fixed on the supporting beams at every alternate valley by 10 mm dia 

fusion welding with 22 mm dia x 2.5 mm thick reinforcing washer. 

Minimum 100 mm overlap shall be provided. The deck sheet end resting 

on wall shall have a seating of 150 mm minimum. Side laps shall be secured 

with tack welding to ensure that the slurry does not leak down. End laps shall 

always be on the supporting walls or on supporting beams. The overhang 

of the deck sheet shall be limited to 300 mm maximum. Temporary 

supports, where ever advised by the construction manager, shall be firm, and 

at the same level as the permanent supports and shall be in place till the 

concrete attains its full strength. While removing the temporary supports, care 

shall be taken that the slab is not disturbed. 

6.6 Formwork for Vibrated Concrete 

If external vibrators are to be used for compacting the concrete, the 

type of vibrator, design of the formwork and the method of fixing the 

vibrators shall all be approved. 

6.7 Cleaning and Treatment of Forms 

Before concreting is commencing the forms and previously cast concrete 

shall be thoroughly cleaned and free from all sawdust, tie wire, shavings, 

dust, dirt and other debris. Temporary openings shall be provided where 

necessary to drain away water and remove rubbish. 

Release agents shall be applied and be compatible with the class of finish. 

Care shall be taken not to contaminate the reinforcement. 

7. CONSTRUCTION JOINTS 

7.1 General 

The number of construction joints shall be kept to the minimum necessary for 

the execution of the work. Their location shall be carefully considered and 

approved by Engineer before concrete is placed. Construction joints shall 

normally be at right angles to the general direction of the member. The 

concrete at the joint shall be bonded with that subsequently placed 

against it, without provision for relative movement between the two. When 

the work has to be resumed on surface, which has hardened, such surface 

shall be roughened. It shall then be swept clean and thoroughly wetted. 

For vertical joint neat cement slurry shall be applied on the surface before it 

is dry. For horizontal joints the surface shall be covered with a layer of mortar 

about 10 to 15 mm thick composed of cement and sand in the same ratio as 

the cement and sand in concrete mix. This layer of cement slurry or mortar 

shall be freshly mixed and applied immediately before placing of the concrete. 

Where the concrete has not fully hardened, all laitance shall be removed by 

scrubbing the wet surface with wire brushes, care being taken to avoid 

dislodgement of particles of aggregate. The surface shall be thoroughly 

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wetted and all free water removed. The surface shall then be coated with neat 

cement slurry. On this surface, a layer of concrete not exceeding 150 mm in 

the thickness shall first be placed and shall be rammed against old work, 

particular attention being paid to corners and close spots; work thereafter 

shall proceed in the normal way. The number, size and positions of props left 

under shall be able to carry safely the dead load of the slab, beam or arch 

together with any live load likely to occur during curing or further 

construction. Cambers and chamfers, wherever shown in drawing shall be 

provided accordingly. 

7.2 Expansion Joints 

Expansion joints and joints around equipment in concrete paving shall be as 

detailed in the drawing and shall be formed with an approved bitumen 

impregnated fibreboard. The upper 20 mm shall be sealed with an approved 

two part, Polysulphide, oil resistant sealant (H.C. grade) 

applied strictly in accordance with the manufacturer’s instructions. 

The joint filler shall be fixed firmly to the first placed concrete before the 

adjoining concrete is placed. The concrete must be thoroughly compacted on 

both sides of the joint. The location of expansion joints shall be shown on the 

engineering drawings. 

7.3 Contraction Joints 

Contraction joints (either complete or partial) shall be located on the drawings 

and formed with a building paper membrane interface, or equivalent 

separating membrane and the upper 25 mm depth sealed. The steel 

reinforcement shall be continuous through partial contraction joints. The 

use of contraction joints should be kept to a minimum compatible with 

freedom from cracking. 

7.4 Joint Fillers 

Joint fillers and sealing compounds shall comply to IS 1834, IS 1838 and IS 

11433. 

8. REINFORCEMENT 

Reinforcement shall comply with IS 1786 or IS 432. Reinforcement shall be 

cut and bent in accordance with approved bar bending schedules. 

8.1 Cutting and Bending 

Reinforcement shall be cut and/or bent in accordance with IS 2502. It is 

essential that reinforcement shall not be subjected to mechanical damage 

prior to embedment. In general, reinforcement shall be bent cold. 

Bends in reinforcement shall have a substantially constant curvature. 

It is permissible to bend mild steel reinforcement projecting from concrete 

provided that care is taken to ensure that radius of bend is not less than that 

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specified in IS 2502. Grade Fe.415 bars shall not be re- bent or straightened 

without the Engineer's approval. 

8.2 Fixing 

Reinforcement shall be secured against displacement outside the specified 

limits. Actual concrete cover shall be not less than the required nominal cover 

minus 5 mm or two third the nominal cover whichever is more. In slabs, the 

actual concrete cover shall be not more than the required nominal cover plus. 

1 5 mm on bars up to and including 12 mm size 

2 10 mm on bars over 12 mm and up to 25 mm 

3 15 mm on bars over 25 mm 

Spacers and chairs shall be used to maintain the specified nominal 

cover to the steel reinforcement. 

Spacers or chairs shall be placed at a maximum spacing of 1 meter. 

Wherever reinforcing bars are intended to be in contact, they shall be 

securely bound together with 18 gauge annealed soft iron wire. 

The mix used for spacer blocks made from cement, sand and fine 

aggregates shall 

be comparable in strength, durability and appearance to the surrounding 

concrete. 

The position of reinforcement shall be checked before and during concreting, 

particular attention being directed to ensure that the nominal cover is 

maintained within the limits, given, especially in the case of cantilever 

sections. 

8.3 Surface Conditions 

Concrete shall not be placed around reinforcement unless the reinforcement 

is free from mud, oil, paint, loose rust, grease or any other substance which 

can be shown to adversely effect the steel or concrete chemically or reduce 

the bond. 

8.4 Laps and Joints 

Laps and joints shall be made only by the methods specified and at the 

positions shown on the drawings or as agreed by the Engineer. 

8.5 Welding 

Welding on site shall be avoided if possible, but may be permitted 

where suitable safeguards and techniques are employed. Generally, 

however, all welding shall be carried out in a workshop. The 

competence of the welder shall be demonstrated prior to and 

periodically during welding operations. Welding of mild steel bars shall 

be carried out in accordance with IS 2751. Welding of high strength 

deformed bars shall be in accordance with IS 9417. The carbon content of 

high yield strength deformed bars conforming to IS 1786 shall not be more 

than 0.25%. If carbon content exceeds the limits specified herein, specifically 

written down welding and testing procedure shall be followed. 

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8.6 Tolerances on Placing 

Reinforcement shall be placed within the following tolerances: 

1. For effective depth 200 mm or less + 10 mm 

2. For effective depth more than 200 mm + 15 mm. 

8.7 Tying of Reinforcement 

Bars crossing each other, where required shall be secured by binding wire 

(annealed) conforming to IS:280. Every compression bar will be tied at least 

in two perpendicular directions. 

9. TRANSPORTING, PLACING, COMPACTING AND CURING OF 

CONCRETE 

9.1 Transporting 

Concrete shall be transported from the mixer to the formwork as rapidly as 

possible by methods that will prevent the segregation, loss of any ingredients 

or ingress of foreign matter or water and will maintain the required workability. 

The concrete shall be deposited as close as possible to its final 

position to avoid handling or moving the concrete horizontally by vibrating. 

The addition of water at point of discharge is prohibited. 

9.2 Placing and Compacting Concrete 

All placing and compacting shall be carried out under suitable supervision and 

as soon after mixing as is practicable. 

Placing of concrete shall commence only after embedment in the concrete is 

securely fixed in position. 

Care shall be taken to avoid displacing reinforcement and damage to the 

faces of formwork, particularly when the concrete is allowed to fall freely 

through the depth of lift. The concrete shall not be dropped from a height of 

over 1.5 meter unless it is dropped by a tremie or chute. 

Immediately before concrete placement, surfaces of previously placed 

concrete, which shall be in contact with the concrete to be placed, shall be 

covered with a bonding mortar grout. The bonding medium shall have the 

same cement-sand content as the concrete to be placed on it. Bonding 

planes shall generally be horizontal. 

No concrete shall be placed in flowing water. Under water, concrete shall be 

placed in position by tremies or by pipeline from the mixer and never allowed 

to fall freely through the water. 

Concrete shall be placed in successive horizontal layers in thicknesses not 

exceeding 500 mm. Concrete shall be thoroughly compacted by vibration 

or other means during placing and worked around the reinforcement, 

embedded fixtures and into corners of the formwork to form a solid void free 

mass having the required surface finish. When vibrators are used, vibration 

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shall be applied continuously during the placing of each batch of concrete 

until the expulsion of air has practically ceased and in a manner that does not 

promote segregation. Over vibration shall be avoided to minimize the 

risk of forming a weak surface layer. 

When internal or immersion type vibrators are used they shall have frequency 

of 7000 RPM. They shall be inserted in a vertical position at an interval of 

about 600 mm. Vibrators shall not be used to transport concrete inside the 

formwork. When external vibration is used, the design of formwork and 

disposition of vibration shall be such as to ensure efficient compaction and to 

avoid surface blemishes. 

The Contractor shall keep a complete record of the work of concreting 

showing the time and date of placing. This record shall be available for 

inspection at any time by the Engineer. Structural concreting against open 

excavation will not be permitted. 

9.3 Curing 

Curing is the process of preventing the loss of moisture from the concrete 

while maintaining a satisfactory temperature. The prevention of moisture 

loss from the concrete is particularly important if the water/cement 

ratio is low. 

Curing and protection shall start immediately after the compaction of the 

concrete to prevent it from: 

1 Prematurely drying out, particularly by solar radiation and wind, 

2 Leaching out by rain and flowing water. 

Where members are of considerable bulk or length, the cement content 

of the concrete is high, the surface finish is critical; the method of curing 

shall be specified in detail. 

Surfaces shall normally be cured for at least for 7 days. The most 

common methods of curing are: Covering the surface with a damp 

absorbent material like sacking and keeping the material constantly wet. 

By ponding top surface with water (sea water not permitted) for slabs 

and the like. By continuous or frequent applications of water to the surface, 

avoiding alternate wetting and drying and the application of cold water to 

warm concrete surfaces. 

Spraying the surface with an efficient curing membrane. The curing 

compound shall conform to relevant Indian Standards and shall be applied in 

accordance with the manufacturer’s instructions to provide a water loss not 

greater than 0.55 kg/ m2 in 72 hours. Curing compound shall be used where 

conventional curing by water cannot be accomplished, following approval 

of construction manager. 

10. PROTECTIVE COATINGS 

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The protective coating for underground and over ground structures will be 

decided on case-to-case basis based on duty conditions and the importance 

of the structure and the same shall be described in detail in the project 

specific specification and drawings. In general, method ‘A’ or ‘B’ shall be 

followed 

METHOD A 

concrete shall be cast or placed onto polythene sheeting 1000 gauge 

laid over the concrete blinding. 

Overlap shall be 150 mm and the sheeting shall extend 150 mm 

beyond the edge of all foundations. Approved membranes are 

‘Visqueen’ by I.C.I. Plastics or ‘Duraplane’ by British Cellophane Ltd. Or 

approved equal. 

Surfaces below ground level shall be coated with two coats of a proprietary 

combined curing compound and damp proof membrane (DPM). 

A square scrape master sample shall be taken to determine the weight of 

specified thickness of coating from a 300 mm x 300 mm patch. The weight 

can then be compared with test samples. Concrete shall also be wrapped in 

1000 gauge polythene sheeting. 

Backfill material shall be select fill material so as to avoid damage to 

protective coatings. Exposed external concrete surfaces for a depth of 

150 mm below ground level and 300 mm above, or to the underside of 

base plate, whichever is the lowest, shall be primed with a low viscosity 

primer and coated with two coats of a light grey colored epoxy paint with a 

minimum thickness of 125 microns per coat. This will protect the concrete in 

the splash zone against ingress of aggressive salts. Application trials shall be 

carried out on the chosen coating. Concrete surface preparation and 

application shall be strictly in accordance with the Manufacturer’s 

recommendations. 

METHOD B 

Concrete shall be cast or placed onto polythene sheeting 1000 gauge 

laid over the concrete blinding. Overlap shall be 150 mm and the 

sheeting shall extend 150 mm beyond the edge of all foundations. 

Approved membranes are “Visqueen” by I.C.I plastics or “Duraplane” by 

British Cellophone Ltd. Or approved equal. 

After the foundations have been painted as specified below the 150 

mm extension shall be folded up flush with the sides of foundations. 

Surfaces below ground level shall be coated with 3 coats of modified 

bitumen to give a total coat thickness of 1mm. A square scrape master 

sample shall be taken to determine the weight of specified thickness of 

coating from a 300 mm x 300 mm patch. The weight can then be 

compared with test samples. 

0435-JH0902-00-CI-SPC-0002 Page 20 of 30


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Backfill material shall be select fill material so as to avoid damage to 

protective coatings. 

Exposed external concrete surfaces for a depth of 150mm below ground level 

and 300mm above, or to the underside of base plate, whichever is the 

lowest, shall be primed with a low viscosity primer and coated with two 

coats of a light grey colored epoxy paint with a minimum thickness of 125 

microns per coat. This will protect the concrete in the splash zone 

against ingress of aggressive salts. Application trials shall be carried out 

on the chosen coating. Concrete surface preparation and application shall be 

strictly in accordance with the Manufacturer’s recommendations. Where 

saline water has been used to compact site fill. Surface protection for 

concrete below ground level shall be as per Method A except that wrapping 

with 1000-gauge polythene can be omitted. 

Where fresh water has been used to compact site fill no applied protection is 

required. 

10.1 External Surfaces Exposed to Saline Waters 

Details shall be specified on construction drawings. 

11. CONCRETING IN HOT WEATHER 

In hot weather (above 40 deg C) special precautions shall be 

necessary to avoid the loss of moisture and/or rapid stiffening of the 

concrete, which prevents its proper compaction, can cause thermal and 

plastic cracking and a reduction in strength and durability. 

During hot weather, the concreting shall be done as per the procedure set out 

in IS 7861 Part 1. At the time of placing, no part of the concrete shall have a 

temperature exceeding 35 deg C. The temperature of concrete can be 

reduced by cooling the water and aggregate. 

During hot dry weather at the point of placement the fresh concrete shall be 

protected from drying winds and solar radiation by the provision of PVC or 

similar tented shelter, which shall remain to avoid exposure to the sun. 

Suitable method to shelter the surface shall be adopted such that finishing 

operations can be carried out whilst it is in place. To prevent early drying and 

cracking, the relative humidity shall be kept high and the concrete surfaces 

kept moist by spraying with clean water and covered with wet hessian. 

11.1 Placing Concrete within the Tidal Range 

When concreting is to be carried out under tidal conditions the 

CONTRACTOR shall ensure that concrete is placed and compacted before 

the seawater rises to the level of the concrete so placed. 

No concrete shall be disturbed after salt water has made contact with it. The 

top surface of the concrete shall be covered after the initial set has taken 

place, to protect it against water action if there is any risk of this occurring. 

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The CONTRACTOR shall submit to the CONSTRUCTION MANAGER 

for approval details of the proposed method for complying with these 

requirements. 

11.2 Concreting in Adverse Weather 

Concreting shall not be permitted when storm or rain appears to be imminent. 

In the event that the rain storms or other severe weather conditions occur 

unexpectedly, concreting shall be stopped and appropriate temporary stop 

ends, vee grooves etc., placed as necessary. To meet such circumstances 

the contractor shall always have in readiness on site approved framed 

sheeting or tarpaulins for protection of newly placed concrete. Under water 

concreting shall be permitted only with the approval of construction manager. 

Concrete placed under water may be lowered in bottom opening skips or may 

be fed continuously through an approved tremie pipe. Unless otherwise 

agreed with the construction manager, the cement content of any concrete 

mix to be placed under water shall be increased by 20%. 

12. SAMPLING AND STRENGTH OF CONCRETE 

Samples from fresh concrete which is to be used in the works shall be taken 

as per IS 1199 and cubes shall be made, cured and tested at 28 days in 

accordance with IS 516. The Contractor shall carry out the tests in an 

approved laboratory or in the field at his own expense, with prior consent of 

the Engineer. 

Facilities required for testing materials and concrete in the field such as 

testing machine with an operator shall be made available at the Engineer's 

request. 

Frequency of sampling and acceptance criteria for strength tests shall be as 

per clauses 15 and 16 of IS:456. Concrete test cubes may be cured by 

accelerated methods as described in IS 9013. Cubes may also be optionally 

tested at 7 days or at the time of striking the formwork. However, in all cases, 

the 28 days compressive strength specified in IS 456 shall be the 

criterion for acceptance or rejection of the concrete. 

For pre casting work additional cubes shall be taken and tested at 3 days or 

prior to lifting. Higher rate of sampling will be required at the beginning of 

the Construction period in order to establish the level of quality control 

or where there are critical elements. All samples shall be clearly 

marked with their identification and accurate records shall be maintained. 

These records shall include but not be limited to: 

• Identification of test cube 

• Date and time of sampling 

• Mix designation 

• Location of sample after batching (e.g. Drawing No,) 

• Method of compaction 

• Date of testing 

• Cement type and source 

0435-JH0902-00-CI-SPC-0002 Page 22 of 30


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• Volume of pour 

• Age of sample in days 

• Weight of sample in KGs 

• Density in kg/m3 

• Crushing load in Newton 

• Crushing strength N/mm2 

• Signature of person taking sample 

• Signature of person carrying out tests 

The concrete will be deemed to comply with the specified design 

strength provided the acceptance criteria in IS 456 are met. 

If any test results fail to comply with the above then the quantity of concrete 

represented by the results shall be at risk, and may be required to be 

removed and replaced. The 28 days cube crushing results shall be grouped 

consecutively in different groups and each group shall have standard 

deviation as specified IS 456 

If the standard deviation is greater than this, the concrete production shall be 

reviewed. 7-Day Tests (In situ Concrete) 

• Tests shall be carried out at 7 days to establish a relationship between the 

7-day and 28 day strengths. The relationship shall be used to interpret further 

test results in order to predict the probable value of the corresponding 28-day 

strengths. 

• Notice shall be given without delay of any 7 day test results which indicates 

that the corresponding 28 day test results are likely to fail to meet the 

specified strength, so that necessary action can be taken to minimize the 

effect of such possible failure. 

3 Day Tests (Pre-cast Concrete) 

• For pre-cast concrete tests shall be carried out at 3 and 7 days to establish 

the relationship with the 28 day results. 

There shall be no production tests on blinding concrete. 

13. OPTIONAL TESTS 

If the Engineer feels that the materials, i.e. cement, aggregates, 

reinforcement, and water, are not in accordance with specification or if 

specified concrete strengths are not obtained, he may order tests to be 

carried out on these materials in an approved laboratory as per relevant IS 

codes. The Contractor shall not be required to bear the costs of such tests 

unless they reveal defective material workmanship. If the works cubes do not 

give the stipulated strengths, the Engineer reserves the right to ask the 

Contractor to dismantle and reconstruct such unacceptable work at the 

Contractor's cost. In such a case, any other tests such as load tests, 

taking out concrete cores and tests on cores, sonic testing etc shall be carried 

out by the Contractor if directed by the Engineer. The Contractor shall carry 

out all such tests at his own cost. 

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14. INSPECTION 

All materials, workmanship and finished construction shall be subject to 

the continuous inspection and approval of the Engineer. All materials 

supplied by the Contractor and all construction performed by the Contractor, 

rejected as not in conformity with the specifications and drawings shall 

be immediately replaced by the contractor at no cost to the Owner. 

15. CLEAN UP 

Upon the completion of concrete work, all debris, scraps of wood, etc., 

resulting from the work shall be removed and the premises left clean. 

16. SPECIAL REQUIREMENTS FOR LIQUID RETAINING 

16.1 STRUCTURES 

To ensure that strength, durability and impermeability will be adequate for 

liquid retaining structures; the minimum cement content shall be 330 kg/m3. A 

maximum water/cement ratio of 0.45 shall be used. For reinforced concrete 

the cement content shall not exceed 400 kg/m3 when ordinary Portland 

cement is used. 

In general, external type PVC water bars, minimum 230 mm wide, are 

preferred and shall be incorporated 

where suitable in all construction and expansion joints as shown on the 

drawings. Intersection pieces shall be factory made. Only butt jointing of 

identical sections shall be carried out on site, strictly in accordance with 

manufactures specifications. Care shall be taken at all times to ensure that 

water bars are not perforated or damaged in any way, concrete shall be 

carefully placed and compacted to ensure dense impervious concrete. 

Particular attention shall be paid to the placing and vibration of the concrete 

to ensure well-compacted concrete around the ribs of the water bars. At all 

joints the concrete shall be placed up to the centre line of the water bar. 

16.2 Testing Of Liquid Retaining Structures 

For a test of liquid retention, the structure shall be cleaned and initially filled to 

the normal level with the specified liquid (usually water) at a uniform rate of 

not greater than 2 m in 24h. When first filled, the liquid level shall be 

maintained by the addition of further liquid for a stabilizing period of seven 

days. After the stabilizing period the level of the liquid surface shall be 

recorded at 24h intervals for a test period of 7 days. During this 7 day test 

period, the total permissible drop in level, after allowing for evaporation, shall 

not exceed 40 mm. 

Notwithstanding the satisfactory completion of the test, any evidence of 

seepage of the liquid at the outside face of the liquid retaining walls shall 

be given remedial treatment from the liquid face. Should the structure not 

satisfy the 7 day test, then after completion of the remedial work, it shall be 

0435-JH0902-00-CI-SPC-0002 Page 24 of 30


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retested. 

16.3 Testing of Roof 

The roof of liquid retaining structures shall be watertight and shall be tested 

on completion by flooding the roof with water to a minimum depth of 25 

mm for 24 hours or longer. The roof shall be considered satisfactory, if 

no leaks or damp patches show on the soffit. Should the structure not 

satisfy the test, remedial work shall be carried out after obtaining the 

Engineer’s approval. After completion of the remedial work it shall be 

retested in accordance with this clause. Waterproofing to the roof shall 

be completed as soon as possible after satisfactory testing. 

17. PLUM CONCRETE 

Stone aggregate of size up to 300-mm cube, but less than 1/3 of the least 

dimension to be concreted, called plums, shall not exceed 20% of total 

volume of finished concrete, and they shall be well dispersed throughout the 

mass. This shall be achieved by placing a layer of normal concrete, then 

spreading the plums, followed by another layer of concrete and so on. 

Each layer shall be of such thickness as to ensure at least 100 mm of 

concrete around each plum. Care must be taken to ensure that no air 

is trapped underneath the stones and that the concrete does not work 

away from their underside. The plums must have no adhesive coating. 

18. WORKABILITY 

The concrete mix shall be designed by varying the relative proportion of fine 

and coarse aggregates to ensure adequate workability for working it into 

corners and angles of the formwork and around the reinforcement 

without segregation of the materials or bleeding of the free water at the 

surface. On striking the formwork, the concrete shall present a face, 

which is uniform, free from honeycombing, surface crazing or excessive 

dusting. To confirm the workability of the designed mix for each grade of 

concrete, a series of workability tests shall be carried out on the preliminary 

trial mixes, unless acceptable data exists. 

19. INITIAL SETTING TIME 

The initial setting time shall be not less than ½ hour after the production 

concrete is discharged into he forms and with a maximum time between 

mixing and completion of placing concrete shall not exceed 1 hour. The total 

time between mixing and initial set shall be a minimum of 1 hour. 

There shall be a maximum setting time of 6 hours. 

When trial mixes are made to determine the workability of the 

concrete, the initial setting time of the cement paste shall be determined 

as per IS 8142. 

20. SLUMP 

The slump of the structural concrete mixes shall be such that the concrete 

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can be transported, placed into the forms, and compacted without 

segregation. Slump for pumpable concrete shall be determined by site trials 

and shall at least be 100 mm on site of pouring. 

21. PRECAST CONCRETE 

21.1 General 

The requirements of this Specification relating to concrete and reinforcement 

shall be observed so far as they are applicable to reinforced concrete. In 

addition the following requirements specifically relating to pre-cast work 

should be met. 

21.2 Recasting Yard 

The yard in which precasting work is to be undertaken shall be clean 

and shall have firm level beds, preferably of concrete, with drainage 

channels between the beds. The beds shall have a surface of suitable 

quality to give the pre-cast units the required class of finish. 

Where pre-cast units have projecting reinforcement the moulds shall, if 

necessary, be raised on stools above the general level of the precasting yard. 

21.3 Moulds for Pre-cast Concrete 

The moulds shall be strongly constructed, closely jointed and true to 

the required shape with edges, corners and surfaces which comply with the 

relevant class of finish. Moulds are to be so designed that they can be readily 

taken apart and reassembled. 

21.4 Marking 

All units shall be marked on the face which will not be exposed in the 

permanent works, with the date of manufacture and such distinguishing 

letters or numbers required for erection identification. 

21.5 Curing, Maturing and Stacking 

The production schedules shall allow for proper curing and maturing of 

pre-cast concrete and shall be carried out as approved. The sides of the 

moulds may be removed after not less than 12 hours provided that the 

concrete has thoroughly set. All concrete surfaces shall be kept covered with 

thoroughly wetted hessian for at least 7 days. 

Slinging, transporting and stacking may take place when designed handling 

stresses have been attained, but building or setting in the works shall not 

be permitted until the 28 days cube strength has been reached. 

The time periods required for gain of strength of concrete may be 

reduced where approved special techniques are adopted such as vacuum 

or pressed concrete, steam curing or when a rapid hardening cement is used. 

No methods of accelerated curing shall be used without prior approval. 

21.6 Cement/Sand Mortar 

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Cement/sand mortar for bedding and jointing pre-cast members shall be of 

equivalent strength, quality and color to that of the concrete member being 

bedded or jointed. Cement/sand mortar shall be mixed in small quantities and 

used immediately. Particular attention shall be paid to compacting the 

cement/sand mortar to prevent the formation of voids and air pockets. The 

mortar mix shall bedetermined from tests following the recommendations of 

Indian Standard, alternatively grouting may be considered. 

21.7 Surfaces for Structural Connections (Marine Structures) 

The surfaces of pre-cast concrete slabs and other units, which are to be in 

contact with in situ concrete, shall be prepared to achieve a good bond 

between the concrete unit and the adjoining concrete. The 

CONTRACTOR shall submit to the CONSTRUCTION MANAGER his 

proposals for preparation of a suitable surface. 

22. GROUTING 

22.1 General 

• Where equipment manufacturer’s drawings define a grouting 

procedure, said procedure shall be followed, subject to the approval of 

Construction Manager. 

• All recommendation and instructions of the grout manufacturer shall be 

followed by contractor. 

• No grout shall be placed when the outside temperature is below 5 °C unless 

special approval provisions are made against freezing. 

• The minimum compressive strength of grout shall be at least equal to the 

parent concrete. 

22.2 Material 

• Sand cement dry pack shall be proportioned at the site, but all non-shrink 

grouts shall consist of only pre-measured, pre-packaged material supplied by 

the grout manufacturer, except water. 

• Water to be used for mixing Portland cement grout shall be clean, potable 

and free from all deleterious materials such as oils, acids, alkalis and organic 

materials. 

22.3 Grout Types 

Sand Cement Dry Pack and Ordinary Mortar Grout 

• Cement shall be Portland cement and shall conform to the requirements of 

IS 269. 

• Sand shall be mixed at two to one ratio by weight with the cement with a 

ramming consistency and shall have a minimum compressive strength of 15 

0435-JH0902-00-CI-SPC-0002 Page 27 of 30


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N/mm2 at 7 days. 

Non-shrink Cement Based Grout 

• Non-shrink cement based grout must have a full range of consistencies, 

including dry pack, plastic and flowable state to be suitable for used in a 

variety of applications. 

• Grout should be capable of being pumped flowable without segregation. 

Vibration only when expressly stated by manufacturer. 

• Grout working time shall be minimum of 60 minutes regardless of application 

consistency used. 

• The grout shall contain no metallic substances (catalyzed or non catalyzed), 

aluminum powder, water reducing agents, fluidizers, accelerators, super 

plasticizers, or other materials known to increase drying shrinkage and/ or 

compromise long term durability. 

• Non-shrink cement based grout shall have a minimum compressive strength 

of 50 N/mm2 at 7 days. 

Non-shrink Epoxy Grout 

• Grout shall be 100 % solids system with the ability to be placed in flowable 

state. 

• Non-shrink epoxy shall have a minimum allowable compressive strength of 

60 N/mm2 at 7 days. 

22.4 Grout Type Selection 

• When the application is an unobstructed bearing plate or void which is not 

subject to impact 

or vibrations and allows the easy placement of grout without undue man-hour 

expenditure, used a sand cement dry pack or an ordinary mortar grout. 

• If one of the criteria cited in 1 is not met (i.e. obstructed bearing plate or void 

or subject to impact or vibration) then use a pre-packaged, pre-measured, 

non-shrink, cement based grout. 

22.5 Storage 

• Non-shrink cement based grout and epoxy grout aggregates shall be 

prepared by contractor in sound, dry bags and epoxy grout liquid components 

in sealed hardener and resin containers. Contractor shall be responsible for 

storing the grout in a dry, weatherproof area and within a temperature range 

of 4 °C to 32 °C. 

• Any material which becomes damp or otherwise defective shall be 

immediately removed from the site by contractor at his own expense. 

22.6 Surface Preparation 

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CONCRETE WORK 

• All surfaces to be grouted shall be entirely free of oil, grease, dirt, wax, 

laitance, curing compounds and other foreign substances that may interfere 

with complete bearing or bonding. 

• When removing laitance, a hand held pneumatic chipping hammer shall be 

of the largest tool, contractor shall take the utmost care to prevent any 

possible structural damage that could be caused by improperly or negligently 

removing the laitance. 

• When any cement based grouts are used, concrete surfaces shall be 

saturated with water for 24 hours prior to grout placement. Excess water shall 

be removed just prior to grouting. 

• When epoxy grouts are used, all surfaces shall be made completely dry 

prior to grouting. 

22.7 Leveling and Alignment 

• Prior to commencing grouting equipment bases, column bases or anchor 

bolts, leveling and alignment shall be performed to place and maintain said 

items in their final position during grouting. 

• A minimum grout space of 25 mm shall be provided unless specified 

otherwise on the drawing. 

• All metal surfaces which are to be in direct contact with the grout shall be 

thoroughly cleaned and made free of all grease, oil, dirt, wax or other foreign 

substance. 

• Leveling shims shall be removed when they would prevent uniform bearing 

under the base support such as tower bases rings. Removal of the shim shall 

be delayed long enough to ensure against disturbing the grout. Voids where 

shims have been removed shall be completely packed with grout before 

finishing. 

22.8 Mixing 

• Grout types shall be mixed according to manufacturer’s recommended 

procedures. 

• Epoxy grout component ratio shall not be changed from that recommended 

by the 

manufacturers. No solvent or thinners shall be added to the mix. 

• The amount of water added to a non-shrink cement based grout will 

determine its consistency. The lowest water/ grout ratio need to get the 

grout in place should be used. 

22.9 Placement 

• Grout placement shall proceed in a manner that assures the filling of all 

voids and the intimate contact of grouting materials with surfaces to be 

0435-JH0902-00-CI-SPC-0002 Page 29 of 30


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grouted. 

• The placement of grout shall be rapid and continuous so as to avoid cold 

joints under any base plate. 

• All grouting shall be done in one direction only, placing grout on one side 

and working it to the other. Placement will be such as to provide full and 

uniform bearing under all foundation bearing surfaces. 

• All exposed grout shall be provided with a 25 mm, chamfer, unless 

otherwise directed by purchaser’s Construction Manager. 

22.10 Curing 

• Grout shall be cured according to manufacturer’s recommendations. 

• Forms shall remain in place with a minimum of 24 hours regardless of 

whether grout is cement based or epoxy. 

• Cement based grout shall be protected from extreme drying conditions. 

• Epoxy grout shall not be wet cured. 

• The temperature of the base plate, concrete foundations and grout shall be 

maintained between 4°C and 32 °C during grouting and for a minimum of 24 

hours thereafter. 

22.11 Testing 

Field-testing of non-shrink grouts shall be as directed by Construction 

Manager. Contractor shall be responsible for preparing, storage, curing and 

transporting the test samples to a laboratory for testing, as required by 

Construction Manager. 

23. READY MIX CONCRETE 

Contractor may use ready-mix concrete locally available provided that ready 

mix concrete satisfies all the criteria for materials as specified in this 

specification. Prior approval shall be taken from WP/HPCL before selecting 

source of ready mix concrete with necessary results of ready mix concrete 

quality. Contractor shall not make extra claim on use of ready mix concrete. 

0435-JH0902-00-CI-SPC-0002 Page 30 of 30




(GGSRPEP) 

SPECIFICATIONS FOR MASONRY WORK 

0435-JH0902-00-CI-SPC-0003 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE


1. SCOPE 

This specification covers the material and workmanship requirements for the following masonry 

works in foundations, substructure, parts of super-structure, security wall, nibble soling for floors 

on grade, etc. as applicable. This specification also defines the materials and workmanship 

requirements for pointing and plaster. 

i. Brick masonry 

ii. Stone masonry 

iii. Precast concrete block masonry 

iv. Allied works 

All masonry work shall be true to line and level as shown on drawings and shall be tightly built 

against structural members and bonded with dowels, inserts, etc-, as shown in drawings. 


2.1 Codes and standards 

The Indian Standards and other referred standards (including all amendments and 

revisions) shall be considered as part of this Specification. In case any particular aspect of work 

is not covered specifically by these or any other relevant Indian Standard Specification, any other 

good engineering practice as may be specified by the company shall be followed: 

Following Indian standards including all amendments and revisions shall be considered as 

part of this specification. 

IS 269 

Specification for 33 grade ordinary Portland cement 

IS 456 

IS 1077 

IS 1123 

Code of Practice for Plain & Reinforced Concrete 

Specification for Common Burnt Clay Building Bricks 

Specification for Method of- Identification of Natural Building Stones. 

Specification for Method of Test For Determination of Water Absorption. Apparent Specific Gravity 

and Porosity of Natural Building Stones. 

IS 1127 

Recommendations for Dimensions and Workmanship of Natural Building 

Stones for Masonry Work 

IS 1129 

Recommendation for Dressing of Natural Building Stones. 

IS 1200 

Indian Standard for Method of Measurement of Building 

and Civil Engineering Works, (Part 3 - Brickwork: Part 4 - Stone 

IS 1397 

Indian Standard Specification for Kraft paper. 

IS 1597(Parts 1 & 2) Code of Practice for Construction of Stone Masonry 

IS 1661 

Finishes 

Code of Practice for Application of Cement and Cement Lime Plaster 

IS 1725 Specification for Soil Based Blocks used in General Building 

0435-JH0902-00-CI-SPC-0003 Page 2 of 16


Construction. 

IS 1905 

Masonry. 

IS 2116 

Indian Standard Code of Practice For Structural use of Reinforced 

Specification of Sand for Masonry Mortar. 

IS 2180 Specification for Heavy duty burnt-clay building bricks. IS 2185 

Concrete masonry Units 

Part 1: Hollow and Solid concrete blocks 

Part 2: Hollow and solid light weight concrete blocks. Part 3: Autoclaved cellular Aerated concrete 

blocks. 

IS 2212 

Code of Practice for Brick work 

IS 2250 

Code of Practice for Preparation and Use of Masonry Mortars. 

IS 2386 Method of Test for Aggregates for Concrete : 

Part 1: Particle size and shape. 

Part 2: Estimation of deleterious materials and organic impurities. Part 3: Specific gravity, density, 

voids, absorption and bulking. 

IS 2402 

Code of practice for External Rendered Finishes. 

IS 2572 

IS 2645 

IS 2691 

Code of practice for Construction of hollow concrete block masonry 

Specification for Integral Cement Water Proofing Compounds. 

Indian Standard Specification for Burnt Clay Facing Bricks. 

Methods of sampling and test (physical and chemical) for water used in industry. 

IS 3316 

Specification for Structural granite. 

IS 3495(Parts 1 to 4) Methods of Tests of burnt Clay Building Bricks. 

IS 3620 

IS 3696 

Specification for Laterite stone block for masonry. 

Indian Standard Safety Code of Scaffolds and Ladders (Part 1 – Scaffold 

Part 2 - Ladders) 

IS 5454 

IS 6042 

IS 8112 

Methods of Sampling of Clay Building Bricks 

Code of Practice for Construction of lightweight concrete masonry. 

43 grade ordinary Portland cement various applicable standards. 

0435-JH0902-00-CI-SPC-0003 Page 3 of 16



Specification for Concrete Work. 

3. MATERIALS 

3.1 General 

Material to be used for masonry shall comply with the IS codes listed in section 2. 

Water used for mixing and curing shall be clean and free from injurious amount of oils, acids, 

alkalies, salts, sugar, organic materials or other substances that may be deleterious for the 

masonry or concrete surfaces. Permissible limits for solids tested according to IS 3025 shall be as 

given in Table 1 of IS 456. 

3.2 Sand for Masonry and for Plaster 

Sand or fine aggregate shall consist of natural sand, crushed stone sand or crushed gravel 

sand or a combination of any of these. Sand shall be hard, durable, clean and free from 

adherent coatings and organic matter and shall not contain the amount of clay, silt and fine dust 

more than specified as given in the table below. 

Deleterious Material 

Sand shall not contain any harmful impurities such as iron, pyrites, alkalis, slates, coals or other 

organic impurities, mica, shale or similar laminated materials, soft fragments, sea shale in such 

form or in such quantities as to adversely affect the hardening, strength or durability of the 

mortar. The maximum quantities of clay, fine silt, fine dust and organic impurities in sand shall not 

exceed the following limits: 

Clay, fine silt and fine dust, in natural sand or 

crushed gravel sand and crushed stone when 

determined in accordance with IS 2386 

Not more than 5% by mass 

Mica 

Organic impurities when determined in accordance with IS 

2386 (part 2) 

Not more than 2% by mass 

Colour of the liquid shall be lighter than the 

standard solution prepared as per section 6.2.2 

of IS 2386 (part 2) 

Grading of sand for use in masonry mortar shall conform to IS 2116. 

Grading of sand for use in plaster shall conform to IS 1542. 

Sand or fine aggregate shall be tested for organic impurities, particle size, silt content and bulking 

in accordance with IS 2386 Part I, II and III. 

3.3 Brick 

Bricks for masonry works shall conform to IS 1077 and shall be of class 7.5 with minimum 

0435-JH0902-00-CI-SPC-0003 Page 4 of 16


compressive strength of 7.5N/mm2. Specific requirement for any other class of bricks shall be as 

shown on drawings. Physical requirements, quality, dimensions, tolerances, etc., of common burnt 

clay building bricks shall conform to the requirements of IS 1077. 

Bricks shall be hand-molded or machine molded and shall be made from suitable soils. The bricks 

shall have smooth rectangular faces with sharp corners and shall be well burnt, sound, 

hard, tough and uniform in colour. These shall be free from cracks, chips, flaws, stones or lumps 

of any kind. 

A clear metallic ringing sound shall be emitted when two bricks are struck together. After 

24 hours immersion in cold water, water absorption by weight shall not exceed 20% of the dry 

weight of the brick. They shall not break when thrown on ground on their flat surface from a height 

of 1.6 metre, in saturated condition. 

The tolerance permitted in the accepted size of bricks shall be plus or minus 3mm in any 

dimension. Only bricks of one standard size shall be used in one work unless specifically 

permitted by the COMPANY. Each brick shall have the manufacturer's identification mark or initial 

mark clearly in the frog. 

All bricks proposed to be used shall conform to the approved samples in all respects. Any brick 

found not up to the specification shall be removed from the site immediately at the 


3.4 Stone 

All Stones used for masonry works shall conform to the requirements of IS 1123, IS 1127, and IS 

1129. Stones shall be of approved quality, hard, dense, strong, sound, durable, clean and 

uniform in colour. 

They shall also be free from veins, adherent coatings, injurious amount of alkalis, vegetable 

matters and other deleterious substances such as iron pyrites, coal, lignite, mica, sea shells, 

etc. Unless otherwise approved, stones from one single quarry shall be used for any one work. 

The strength of stones should be adequate to carry the imposed load. The minimum crushing 

strength of building stones shall be 20 N/mm2 unless higher minimum strength is specified in any 

particular case. The percentage of water absorption, when tested in accordance with IS 1124, shall 

not exceed 5%. 

Stones used shall normally be small enough to be lifted and placed by hand. The length of the 

stone shall not exceed 3 times the height. Width of stone on base shall not be less than 

150mm and in no case exceed 3/4th thickness of the wall. Height of the stone shall not be more 

than 300mm. 

3.5 Cement 

Unless otherwise specified, cement used for cement-sand mortar shall be Grade 33 OPC 

conforming to IS 269. 

3.6 Lime 

Hydrated lime used for masonry mortar shall conform to IS 712. Hydrated lime shall be 

supplied in suitable containers such as jute bags lined with polythene or high density polythene 

woven bags lined with polythene or craft paper bags preferably containing 50 kg. of dry lime. 

0435-JH0902-00-CI-SPC-0003 Page 5 of 16


3.7 Water 

Water used for masonry work shall be clean and free from injurious amounts of 

deleterious materials. Potable water are generally considered satisfactory for mortar making and 

curing in masonry work. 

4. MORTAR 

4.1 Cement Mortar 

Mortar for brick work shall be prepared in accordance with IS:2250. 

4.1.1 Proportioning 

Cement bag weighing 50 kg shall be taken as 0.035 cubic metre. Other ingredients in specified 

proportion shall be measured by volume using gauge boxes of suitable capacity. Sand shall be 

measured on the basis of its dry volume. 

Unless otherwise specified on drawings, the cement-sand mix proportion (by volume) for the 

mortar shall be as follows 

Brick masonry less than one brick thick 1:4 

Brick masonry equal to and more than one brick thick 1:6 

Stone masonry 1:6 

Concrete block masonry 1:6 

The minimum compressive strength of masonry mortar shall be as follows: 

1:4 Mortar 7.5 N/mm2. 

1:6 Mortar 3 N/mm2. 

4.1.2 Mixing 

The mixing of mortar shall be done in mechanical mixers operated by power or manually as 

decided by the Engineer. The Engineer may however, permit hand mixing at his discretion taking 

into account the nature, magnitude and location of the work and practicability of the use of 

mechanical mixers or where item involving small quantities are to be done or if in his 

opinion the use of mechanical mixers is not feasible. 

In cases, where mechanical mixers are not to be used, the Contractor shall take 

permission of the Engineer in writing before the commencement of the work. 

4.1.3 Mechanical Mixing 

Cement and sand in the specified proportions shall be mixed dry thoroughly in a mixer. Water shall 

then be added gradually and wet mixing continued for at least three minutes. Only the 

required quantity of water shall be added which will produce mortar of workable 

consistency. Only the quantity of mortar which can be used within 30 minutes of its mixing shall 

0435-JH0902-00-CI-SPC-0003 Page 6 of 16


be prepared at a time. Mixer shall be cleaned with water each time before suspending the work. 

4.1.4 Hand Mixing 

The measured quantity of sand shall be leveled on a clean water tight platform and cement 

bags emptied on top. The cement and sand heap shall be thoroughly mixed dry by being 

turned over and over, backwards and forwards, several times till the mixture is of a 

uniform colour. The quantity of dry mix, which can be used within 30 minutes, shall then be 

mixed in a masonry trough with just sufficient quantity of water to bring the mortar to a stiff paste of 

necessary working consistency. 

4.1.5 Precautions 

Mortar shall be used as soon as possible after mixing and before it begins to set, and in any case 

within half an hour after the water is added to the dry mixture. 

4.2 Cement Lime Sand Mortar 

Cement-lime-sand mortar for masonry works shall be prepared in accordance with IS 2250. 

The proportioning of mix shall be as shown in drawings. 

Lime putty shall be obtained by adding hydrated lime to water in a tank and stirring it to the 

consistency of cream and allowing it to stand not more than 2 days. The putty shall be allowed to 

mature but not allowed to dry out till it is used. 

Sand shall be measured on the basis of its dry volume. In case of damp sand, its 

quantity shall be suitably increased to allow for bulkage54 as per IS 2386 (part 3) 

Cement, lime putty/dry hydrated lime and sand shall be taken in specified proportions. Lime 

putty and sand shall be ground in a mortar mill before mixing the same with cement. In case where 

factory made dry hydrated lime powder is used, prior grinding of lime and sand in a mortar mill is 

not necessary. In that case the mixing may be done in one single operation in the mechanical 

mixer. 

In case of small works, where the COMPANY permits hand mixing, in view of mortar mill and 

mechanical mixer not being feasible, cement and sand shall be mixed in clean watertight 

masonry platforms or troughs. Milk of lime prepared by mixing water and lime putty, shall be 

added to mixture of cement and sand. Then the mixture shall be hoed back and forth for about 10 

minutes with addition of milk of lime, care being taken to add this milk of lime to the extent required 

for giving the mortar the consistency of a stiff paste. 

The mortar thus prepared shall be used as soon as possible after mixing and in any case within 

one hour the cement is mixed wet. Mixture of lime putty and sand can be kept for a period of 72 

hours, provided it is kept damp with wet sacks or by suitable means approved by the COMPANY 

and not allowed to dry. 

Mortar not formed as per specifications or laying unused after the periods specified above or found 

partly set or dried or otherwise spoilt shall be rejected and removed from site of work at 


Unless otherwise specified in drawings, the mortar used for masonry work shall be of 

0435-JH0902-00-CI-SPC-0003 Page 7 of 16


proportion 1 cement: 1 lime: 6 graded sand. 

5. BRICK MASONRY 

5.1 General 

Bricks used in masonry shall be common burnt clay bricks conforming to IS 1077 or IS 2180. 

Common burnt clay bricks shall be classified on the basis of average compressive strength as 

given in Table 1. 

Table 1- Classes of Common Burnt Clay Bricks 

Class Designation Average Compressive Strength 

Not 

Less Than, N/mm2 

50 50.0 

35 35.0 

30 30.0 

25 25.0 

20 20.0 

17.5 17.5 

15 15.0 

12.5 12.5 

10 10.0 

7.5 7.5 

5 5.0 

3.5 3.5 

Wherever the construction site is within a radius of 100 kms from a coal/ lignite based thermal 

power plant, fly ash shall be used in manufacturing bricks as per MOE&F – see Appendix 1. 

5.2 General Quality 

Bricks shall be hand moulded or machine moulded and shall be made from suitable soils. They 

shall be free from cracks and flaws and nodules of free lime. The bricks shall have smooth 

rectangular faces with sharp corners and shall be uniform in colour and shall emit ringing sound 

when struck simply. 

5.3 Dimensions 

0435-JH0902-00-CI-SPC-0003 Page 8 of 16


The standard modular or non modular size of common building bricks shall be as follows: 

Type Of Brick Length Width Height 

Modular Brick 190 mm x 90 mm x 90 mm 

Modular Tile Brick 190 mm x 90 mm x 40 mm 

Non Modular Brick 230 mm x 115 mm x 70 mm 

Non Modular Tile Brick 230 mm x 115 mm x 40 mm 

5.4 Sampling and Test 

5.4.1 Sampling 

Sampling of bricks shall be in accordance with IS:5454. 

5.4.2 Dimensional Tolerances 

The dimensions of bricks when tested in accordance with IS:1077 shall be within the limits 

specified therein. 

5.4.3 Compressive Strength 

The bricks, when tested in accordance with the procedure laid down in IS:3495 Part I 

shall have a minimum average compressive strength for various classes as given in Table 

3. The compressive strength of any individual brick tested shall not fall below the minimum 

average compressive strength specified for the corresponding class of brick. 

5.4.4 Water Absorption 

The average water absorption of bricks when tested in accordance with the procedure laid 

down in IS:3495 Part 2 shall not be more than 20% by weight up to Class 12.5 and 15% 

by weight for higher classes. 

5.4.5 Efflorescence 

The rating of efflorescence of bricks when tested in accordance with the procedure laid down in 

IS:3495 Part 3.Appendix D shall be not more than "moderate" up to Class 12.5 and "slight" for 

higher classes. All efflorescence shall be removed on the affected surfaces with a solution 

of muriatic acid in water washed fully with clear water and allowed to dry thoroughly. 

5.5 Burnt Clay Brick Work 

Brickwork shall generally conform to IS 2212. 

5.5.1 Classification 

The brickwork shall be classified according to the class designation of bricks used. 

5.5.2 Mortar 

Brickwork shall be constructed in cement mortar 1:5 or as specified (also see section 5.5.13). Lime 

shall not be used where reinforcement is provided in brickwork. 

0435-JH0902-00-CI-SPC-0003 Page 9 of 16


5.5.3 Soaking of Bricks 

Bricks shall be soaked in water such that water just penetrates the whole depth of the bricks. The 

soaked bricks shall be removed from water early enough to be skin-dry when lying. Alternatively 

bricks may be adequately soaked in stacks by profusely spraying with clean water at regular 

intervals for a period not less than six hours. Soaked bricks shall be stacked on a clean place 

where they are not spoiled by dirt, earth and the like. 

Note: The period of soaking shall be found at site by a field test. The bricks shall be soaked in 

water for different periods and then broken to find the extent of water penetration. The 

least period that corresponds to complete soaking will be the one that shall be allowed for in 

construction work. 

5.5.4 Laying 

Bricks shall be laid in English Bond unless otherwise specified. 

Half or cut bricks shall not be used except as closers to complete the bond. Closers in such cases, 

shall 

be cut to the required size and used near the ends of the wall. Header bond shall be used 

preferably in all courses in curved plan for ensuring better alignment. 

Note: 

Header bond shall also be used in foundation footings unless the thickness of walls (width 

of footing) makes the use of headers impracticable. Where the thickness of footing is 

uniform for a number of courses, the top course of footing shall be headers. All loose materials, 

dirt and set lumps of mortar which may be lying over the surface on which brick work is to be 

freshly started, shall be removed with a wire brush and the surface wetted. Bricks shall be laid on a 

full bed of mortar. When laying, each brick shall be properly bedded and set in position 

by gently pressing with the handle of a trowel. Its inside face shall be buttered with mortar before 

the next brick is laid and pressed against it. Joints shall be filled and packed with mortar such that 

no hollow space is left. Walls shall be taken up truly in plumb or true to the required batter where 

specified. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical. 

Vertical joints in alternate courses shall come directly one over the other. Quoin, jambs and other 

angles shall be properly plumbed as the work proceeds. 

A set of tools comprising of wooden straight edge, masonic spirit levels, square, one meter rule 

line and plumb shall be kept at the site of work for checking during the progress of work. Each set 

of tools shall suffice for three masons. All quoins shall be accurately constructed and the height of 

brick courses shall be kept uniform. This will be checked using a graduated wooden straight 

edge or a story rod indicating height of each course including thickness of joints. The position 

of damp proof course, window sills, bottom of lintels, top of the wall etc. along the height of the wall 

shall be marked on the graduated straight edge or story rod. Acute and obtuse quoins shall be 

bonded, where practicable in the same way as square quoins. 

Obtuse quoins shall be formed with squint showing three quarters brick on one face and quarter 

brick on the other. The brick work shall be built in uniform layers. No part of the wall during its 

0435-JH0902-00-CI-SPC-0003 Page 10 of 16


construction shall rise more than one metre above the general construction level. Parts of wall left 

at different levels shall be raked back at an angle of 45 degrees or less with the horizontal. 

Toothing shall not be permitted as an alternative to raking back. For half brick partition to be keyed 

into main walls, indents shall be left in the main walls. Block work shall not be carried out in more 

than a height of 1200 mm in any one day unless otherwise permitted by relevant Indian standards. 

All pipe fittings and specials, spouts, hold fasts and other fixtures which are required to be built into 

the walls shall be embedded, as specified in their correct position as the work proceeds 

unless otherwise directed by the Engineer. Top courses of all plinths, parapets, steps and top of 

walls below floor and roof slabs shall be laid with brick on edge, unless specified otherwise. Brick 

on edge laid in the top courses at corner of walls shall be properly 

radiated and keyed into position to form cut corners. Where bricks cannot be cut into the 

required shape to form cut corners, cement concrete 1:2:4 (1 cement:2 coarse sand: 4 

graded stone aggregate 20 mm nominal size) equal to thickness of course shall be provided 

in lieu of cut bricks. Bricks shall be laid with the frog up. However, when the top course is exposed, 

bricks shall be laid with the frog down. For the bricks to be laid with frog down, the frog shall be 

filled with mortar before placing the brick in position. 

In case of walls, one brick thick and under, one face shall be kept even and in proper plane, while 

the other face may be slightly rough. In case of walls more than one brick thick, both the faces 

shall be kept even and in proper plane Pipe sleeves shall be provided for taking service lines 

without excessive cutting of completed work. Such sleeves in external walls shall be sloped down 

outward so as to avoid passage of water inside Top of the brick work in coping and sills in external 

walls shall be slightly tilted. Where brick coping and cills are projecting beyond the face of the wall, 

drip course / throating shall be provided where indicated. Care shall be taken during construction 

that edges of jambs, sills and projections are not damaged in case of rain. New built work shall be 

covered with jute bags or tarpaulins so as to prevent the mortar from being washed away. 

Damage, if any, shall be made good to the satisfaction of the Engineer. In retaining walls and the 

like, where water is likely to accumulate, weep holes, 50 to 75 mm square shall be provided at 2 m 

vertically and horizontally unless otherwise specified. The lowest weep hole shall be at about 30 

cm above the ground level. All weep holes shall be surrounded by loose stones and shall have 

sufficient fall 

to drain out the water quickly. 

5.5.5 Joints 

The thickness of all types of joints including brick wall joints and cross joints shall be 

such that four courses and three joints taken consecutively shall measure as follows: 

390 mm, in case of modular bricks conforming to IS:1077. 

310 mm, in case of non-modular bricks 

Note: 

Specified thickness of joints shall be 10 mm. 

5.5.6 Finishing of Joints 

The face of brick work may be finished flush or by pointing. In flush finishing either the face joints 

of the mortar shall be worked out while still green to give a finished surface flush with the face of 

the brick work 

0435-JH0902-00-CI-SPC-0003 Page 11 of 16


or the joints shall be squarely raked out to a depth of 10 mm while the mortar is still green for 

subsequent plastering. The faces of brick work shall be cleaned with wire brushes so as to remove 

any splashes of mortar. 

5.5.7 Openings 

Openings shall be square with the jambs vertical and formed with the uncut faces of 

blocks using temporary framing installed for this purpose. The jamb walling shall be built up 

against framework all around as the work proceeds. 

5.5.8 Intersecting Walls and Partitions 

Walls and partitions shall be bonded or tied to one another at angles and junctions, unless 

movement joints are indicated. Wherever ties are used, they shall consist of 3x20 mm 

galvanized steel plate fully embedded in the horizontal mortar joints at vertical spacing not 

exceeding 600 mm. The ends of ties shall project a minimum of 75 mm into each wall partition. 

5.5.9 Penetrations 

Penetrations for services through both external and internal walls shall be properly sealed against 

fire and gas. 

5.5.10 Fixings 

Where fixing blocks, anchors, accessories, wall ties, etc are specified, they shall be built into the 

walls or partitions and solidly bedded in mortar. Fixings, which are not built in shall be drilled to the 

block work. Expanded bolt fixings shall only be drilled into solid blocks or blocks having their 

cavities filled solid. 

5.5.11 Curing 

The brick work shall be constantly kept moist on all faces for a minimum period of seven days. 

Brick work done during the day shall be suitably marked with the date on which the work 

is done to monitor the curing period. 

5.5.12 Scaffolding 

Scaffolding shall be strong enough to withstand all dead, live and impact loads which are likely to 

come on them. Scaffolding shall be provided to allow easy approach to every part of the 

work. Only double scaffolding shall be used. Single scaffolding shall be used only when 

specifically permitted in writing by Engineer In Charge. 

• Single Scaffolding 

In single scaffolding, one end of the put-log/pole shall rest in the hole provided in the header 

course of rick masonry. Not more than one header for each put-log/pole shall be left out. Such 

holes shall not be allowed in the case of pillars, brick work less than one metre in length between 

the openings or near the skewbacks of arches or immediately under or near the structural member 

supported by the walls. The holes for put logs/poles shall be made good with brick work and wall 

finishing as specified. 

0435-JH0902-00-CI-SPC-0003 Page 12 of 16


• Double Scaffolding 

Where the brick work or tile work is to be exposed and not to be finished with plastering 

etc. double scaffolding having two independent supports; clear of the work, shall be provided. 

5.5.13 Half Brick Work 

Brick work in half brick walls shall be constructed in the same manner as described in 

Clause 5.5.4 except that the bricks shall be laid in stretcher bond. These walls shall be 

constructed in cement mortar. 1:4. Lime mortar shall not be used. When the half brick work is to be 

reinforced two MS bars of 6 mm diameter shall be embedded in every third course. OR 75 mm 

thick RCC M15 beams with 2 numbers 8 mm dia high strength deformed bars shall be 

provided at a vertical spacing of 1 metre. The reinforcement shall be securely anchored at the end 

of the wall. The free ends of reinforcement shall be keyed into the mortar of the main work to which 

the half brick work is joined. Laps in reinforcement if any shall not be less than 30 cm. 

Depending on the dimensions of the wall, 200 mm x 115 mm RCC mullions at every 3 

metres and at corners shall be provided with reinforcement of 4 numbers 8 mm diameter high 

strength deformed bars. The steel in the horizontal beams in such cases will run through these 

mullions. These partition walls shall be constructed in two stages. In the first stage, brick work with 

binders shall be constructed leaving gaps equal to and at the locations of the mullions. In the 

second stage mullions shall be constructed. 

5.5.14 Acceptance Criteria 

The acceptable deviations for brick work shall be as follows: 

Deviation from position shown on plan of any brick work shall not exceed 12.5 mm. 

Relative displacement between load bearing wall in adjacent stories shall not exceed 6 mm. Brick / 

Block work shall be built into the following tolerances: 

Tolerance on Line 

Length up to and including 5 m 

610 mm 

Length over 5 m, up to and including 10 m 615 mm Length over 10 m 

620 mm 

Tolerance on Height and Level 

Height up to and including 3 m 

65 mm 

Height over 3 m, up to and including 6 m 615 mm Height over 6 m 620 mm 

Tolerance in Plumb 

Height up to 4 m 

10 mm 

Tolerance in Straightness 

Deviation from line shall not be more than 5 mm 

Deviation from the specified thickness of all joints shall not exceed one-fifth of specified thickness. 

0435-JH0902-00-CI-SPC-0003 Page 13 of 16


5.5.15 REINFORCED BRICKWORK 

Where specified, brick walls less than one brick thick shall be provided with 2 numbers 6 mm dia. 

M.S. reinforcement bars at every fourth course embedded inside the joint. The free ends of 

reinforcement shall be keyed into the mortar joint of main brick work. Round bars shall be 

properly lapped, and joints staggered. For brick walls equal to or more than one brick thick, 

reinforcement shall be as specified in drawings. Bars shall be lapped with dowels left in R.C. 

columns, beams or welded to steel stanchions. Other requirements shall be as applicable for 

un-reinforced brickwork. 

5.5.16 HONEYCOMB BRICKWORK 

Honeycomb brickwork shall be done with wire cut bricks of specified class and size in specified 

mortar as per drawings. The thickness of honeycomb brickwork shall be that of half brick 

unless otherwise specified. The openings shall be equal and alternate with half brick laid with a 

bearing of 20mm on either side. The honeycomb work shall present a uniform pattern. All joints 

shall be struck flush to give an even surface. Upon completion of masonry installation, all 

exposed brickwork shall be cleaned of all mortar droppings. As the cleaning progresses, all 

masonry work shall be examined and all imperfect joints, nail holes, cracks, etc., carefully pointed 

and filled with mortar where required and the horizontal ratings left tooled and clean. The brickwork 

shall be cured and protected as specified under clause 5.5.11 

5.5.17 CAVITY WALL 

One or both leaves of a cavity wall may be of brick (the other being of concrete or other material). 

The two leaves of the cavity wall shall be tied by means of specially made wall ties spaced at not 

more than four brick lengths apart horizontally and not more than five brick courses 

vertically and staggered. Additional ties shall be used near opening. There shall be at least five 

ties per square meter of surface area of the wall. Ties shall be sloped away from the inner leaf of 

the cavity wall. Ties shall be of hot dip galvanized/non-ferrous metal/stainless steel suitably 

twisted at the middle to prevent water flowing along it or round bars bent to oval shape and 

twisted in the middle. Small openings shall be left in the exterior leaf approximately 2 meters apart 

at the start of masonry so as to facilitate hand cleaning out by means of a rake. These holes 

should be closed at the end of construction of the wall after doing the necessary cleaning at 

the cavity. During construction of cavity wall, mortar droppings are quite likely to fall into the cavity 

and get lodged over ties and become a constant source of transmittance of moisture. For 

preventing this, a wooden batten should be kept over ties during the construction of wall to catch 

any mortar droppings. 

The batten should be lifted up every time when the next row of ties is reached and the process 

repeated as the construction of wall proceeds. The inner surface of outer leaf of the wall 

should not encourage splash of dripping water that may penetrate through the outer leaf 

and thus transmit dampness to the inner leaf. To avoid this, projections from outer leaf 

extending in the cavity should not be allowed. The mix proportion and joint thickness for the mortar 

shall be as specified in drawings. 

6. RUBBLE MASONRY 

Uncoursed Rubble Stone Masonry 

6.1 Stone 

0435-JH0902-00-CI-SPC-0003 Page 14 of 16


The stone shall be obtained from quarries approved by the Engineer and shall conform to IS:1597 

Part I. Stone shall be hard, sound, durable and free from weathering decay and defects like 

cavities, cracks, flaws, sand holes, veins, patches of loose or soft materials and other similar 

defects that may adversely affect its strength and appearances. As far as possible, stone shall be 

of uniform colour, quality or texture. Generally stone shall not contain crypts crystalline silica or 

chart, mica and other deleterious materials like iron oxide, organic 

impurities etc. Stone with round surface shall not be used. For Basalt stone the minimum 

compressive strength shall be 400 kg/cm2 and the percentage of water absorption shall not 

exceed 5%. 

6.2 Size of Stone 

Unless otherwise indicated, the length of stones shall not exceed three times the height and the 

breadth or base shall not be greater than three fourth the thickness of wall or not less than 150 

mm. The height of stone may be up to 300 mm. Stones having sharp corners or round surfaces 

shall, however, not be used. 

6.3 Dressing 

Each stone shall be hammer dressed on the face, the sides and the bed. Hammer dressing shall 

enable the stones to be laid close to neighbouring stone such that the brushing in the face shall 

not project more than 40 mm on the exposed face and 10 mm on the face to be plastered. 

6.4 Laying 

All stones shall be wetted before use. Each stone shall be placed close to the stones already laid 

so that the thickness of the mortar joints at the face is not more than 20 mm. Face 

stones shall be arranged suitably to stagger the vertical joints and long vertical joints shall be 

avoided. Chips or sprawls of stones may be used for filling of interstices between the 

adjacent stones in heartening and these shall not exceed 20% of the quantity of stone 

masonry. No hollow space shall be left anywhere in the masonry. The masonry work in wall shall 

be carried up true to plumb. Before commencing the masonry work the foundation trenches shall 

be leveled right through and bottom of the same watered and well rammed down. The 

trenches shall be kept free of water while masonry work is in progress. 

6.5 Bond Stones 

Bond or through stones running right through the thickness of walls shall be provided in walls up to 

600 mm thick and in case of walls above 600 mm thickness a set of two or more bond stones 

overlapping each other by at least 150 mm shall be provided in a line from face of the wall to the 

back. At least one bond stone or a set of bond stones shall be provided for every 0.5 sq m of the 

area of wall surface. 

6.6 Quoin and Jamb Stone 

The quoin and jamb stones shall be of selected stones neatly dressed with hammer or chisel to 

form the required angle. Quoin stones shall not be less than 0.01 cu.meter in volume. Height of 

quoins and jamb stones shall not be less than 150 mm. Quoins shall be laid header and stretcher 

alternatively. 

6.7 Curing 

Curing shall be done till the mortar used in masonry is sufficiently set. Masonry work in cement 

0435-JH0902-00-CI-SPC-0003 Page 15 of 16


mortar of 1:5 shall be kept constantly moist on all faces for a minimum period of seven days. 

6.8 Protection 

Green work shall be protected from rain by a suitable covering. The work shall also be suitably 

protected from damage, mortar dropping and rain during construction. 

7. CEMENT POINTING 

The joints of masonry shall be raked at least 12 mm deep for burnt clay bricks and 6 

mm deep for concrete block whilst the mortar is green and not later than 48 hours of time of lying. 

The dust shall then be brushed out of the joints and the wall, washed with water. 

The mortar shall be of specified mix. Mortar shall be filled into joints and well pressed with special 

steel trowels. The joints shall not be touched again after it has once begun to set. The joints of the 

pointed work shall be neat. The lines shall be regular and uniform in breadth and the joints shall be 

raised, flat, sunk or "V" as may be directed. No false joints shall be allowed. The work shall be kept 

wet for a week after the pointing is complete. Whenever colored pointing has to be done, the 

colouring pigment of the colour required shall be added to cement in such proportion as 

recommended by the manufacturer and as approved by the Engineer. 

8 Damp-Proof Course 

Unless otherwise specified, damp-proof course shall be minimum 40 mm thick cement concrete of 

grade 1:11/2:3 by weight using 10 mm and down graded coarse aggregate, with admixture of a 

water-proofing compound as approved by the COMPANY. The percentage of admixture shall be 

as per manufacturer's specification but not less than 2% by weight of cement. The top surface 

shall be double check and cured by pending for seven days. 

0435-JH0902-00-CI-SPC-0003 Page 16 of 16




(GGSRPEP) 

SPECIFICATIONS FOR PLASTER WORK 

0435-JH0902-00-CI-SPC-0004 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE


1. SCOPE 

This specification covers plaster work for both interior and exterior surfaces of masonry and 

concrete. 

2. Materials 

Cement and water shall be as specified in specifications for concrete works. 

Sand for plastering and pointing shall conform to IS 1542. Sand shall be hard, durable, clean and 

free from adherent coatings and organic matter and shall not contain any appreciable amount of 

silt, clay balls or pallets. Sand shall not contain impurities such as iron pyrites, coal particles, 

lignite, mica shale etc. 

Fine sand shall be obtained from river beds not affected by tidal water of the sea and shall be 

clean, sharp and free from excessive deleterious matter. The sand shall not contain more than 8 

percent of mud and silt as determined by field test with a measuring cylinder. 

3. BASIC REQUIREMENT 

3.1 Texture Finish shall be applied with CM 1:3. Ornamental treatment in the form of horizontal or 

vertical rib texture, fan texture shall be applied by means of suitable tools to freshly applied 

plastered surface, as approved by Engineer-in-charge. 

3.2 SCAFFOLDING 

Only steel scaffolding shall be used. Scaffolding shall be properly planned and designed by the 

CONTRACTOR. It shall be approved by Engineer-In-Charge before commencement of work. 

Double scaffolding, sufficiently strong so as to withstand all loads likely to come upon it and having 

two sets of vertical supports, shall be provided. Where two sets of supports are not possible, the 

inner end of the horizontal scaffolding member shall rest in a hole provided in the header course 

only. Only one header for each member shall be left out. Such holes shall be filled up immediately 

after removal of scaffolding. 

For internal plastering, scaffolding shall be erected independent of walls. No member of scaffolding 

shall be allowed to be housed in the walls being treated with plaster. Scaffolding for external 

plaster shall be supported independent of walls as far as possible to avoid patchy appearance. 

The following measures shall be considered while designing and erecting of scaffolding. 

(a) 

(b) 

(c) 

(d) 

(e) 

(f) 

Sufficient sills or under pinning in addition to base plates shall be provided particularly 

where scaffoldings are erected on soft grounds. 

Adjustable bases to compensate for uneven ground shall be used. 

Proper anchoring of the scaffolding/ staging at reasonable intervals shall be provided in 

each case with the main structure, wherever available. 

Horizontal braces shall be provided to prevent the scaffolding from rocking. 

Diagonal braces shall be provided continuously from bottom to top between two adjacent 

rows of uprights. 

The scaffolding shall be checked at every stage for plumb line. 

0435-JH0902-00-CI-SPC-0004 Page 2 of 7


(g) 

(h) 

All nuts and bolts shall be properly tightened. 

Wherever steel tubes are used care shall be taken that all the clamps/ couplings are firmly 

tightened so as to avoid any slippage. 

3.3 PREPARATION OF SURFACES 

The surfaces shall be cleaned off all dust, loose mortar droppings, traces of algae, oil, 

efflorescence and other foreign matter by wire brushing, hacking, chiseling, etc. If the Engineer-In- 

Charge is not satisfied with the roughening achieved by these methods, he may order other 

methods such as washing with acid etc. 

Joints shall be raked to a depth of 10mm minimum. Care shall be taken, not to damage masonry 

edges while raking. 

All surfaces of concrete, old plaster and masonry shall be roughened sufficiently for bond. 

Soft or crumbling masonry work and other surfaces shall be dismantled and remade if required as 

per instructions of Engineer-In-Charge. 

In case of concrete work, projecting burrs of mortar formed due to the gaps of joints in shuttering 

shall be removed. Such surface shall be scrubbed clean with wire brushes. The surface shall be 

marked with a pointed tool at spacing of not more than 50mm centers. The marks shall not be less 

than 3mm deep to ensure a proper key for the plaster. 

All surfaces to be plastered shall be thoroughly wetted for 24 hours before commencing plaster 

and shall be kept damp during the progress of work. Wetting shall be uniform and shall be ensured 

by damping evenly. 

To avoid cracks at the junction of concrete with masonry work, the plaster shall be reinforced at 

such junctions by fixing standard wire mesh IRCS-6 (6 x 6 x 6/6) as directed by the Engineer-In- 

Charge. The wire mesh shall overlap concrete and masonry surface by at least 50mm. 

The preparation of surfaces shall be inspected by the Engineer-In-Charge. Plastering shall not be 

commenced, until the preparation of surfaces is approved by the Engineer-In-charge. 

4. CEMENT PLASTER 

4.1 General 

Cement mortar shall be prepared by mixing cement, sand and water in specified proportions. The 

mortar shall be used as soon as possible after mixing and before it has begun to set and in any 

case within 30 minutes after the water is added to the dry mixtures. Mortar unused for more than 

30 minutes shall be rejected and removed from the site of work. 

4.2 Proportioning 

The unit of measurement for cement shall be a bag of cement weighing 50 Kgs and this shall be 

taken as 0.035 cubic meter (M3). Sand in specified proportion shall be measured in boxes of 

suitable size. It shall be measured on the basis of its dry volume. In case of damp sand its quantity 

shall be increased suitably to allow for bulkage. 

0435-JH0902-00-CI-SPC-0004 Page 3 of 7


4.3 Mixing 

The mixing of mortar shall be done in mechanical mixer operated manually or by power. The 

Engineer-In-Charge may, however, relax these conditions at his discretion, taking into account 

the nature and location of work, practicability of the use of these machines. For items, where the 

mixers are not to be used, the CONTRACTOR shall take the approval of the Engineer-In-Charge 

before the commencement of work. 

4.3.1 Mixing in Mechanical Mixer 

Cement and sand in specified proportions shall be mixed dry thoroughly in a mixer. Water shall 

then be added gradually and wet mixing continued for at least one minute. Care shall be taken 

not to add more water than that which shall bring the mortar to the consistency of a stiff paste. 

Only the quantity of mortar which can be used within 30 minutes of its mixing shall be prepared at 

a time. 

Mixer shall be cleaned with water each time before suspending the work. 

4.3.2 Hand Mixing 

The measured quantity of sand shall be leveled on clean water tight platform and cement bags 

emptied on top. The cement and sand shall be thoroughly mixed dry by being turned over and 

over, backward and forward, several times till the mixture is of a uniform colour. The quantity of dry 

mix which can be used within 30 minutes shall then be mixed with just sufficient quantity of water 

to bring the mortar to the consistency of a stiff paste. 

5. CEMENT PLASTER WITH WATERPROOFING COMPOUND 

Water proofing compound shall conform to IS 2645 (CICO or approved equivalent). The compound 

shall be well mixed with dry cement in the proportion of 2% by weight or as recommended by 

manufacturer. 

6. SEQUENCE OF OPERATIONS 

For external plaster, the plastering operations shall be started from the top floor and carried 

downwards. For internal plaster, the plastering may be started wherever the building frame, 

roofing, and brick work are ready. 

The first under layer shall be applied to ceilings. After the ceiling plaster is complete, 

plastering on walls shall be started. 

7. SAND FACED PLASTER (18 mm thick) 

First coat 

The first coat shall be 12mm thick of 1:4, cement-sand proportion by volume. Guide stripes 150mm 

wide and of suitable length shall be first put up on the surface for the first coat. These guide strips 

shall be brought to absolutely plumb vertically and to the same plane horizontally all through. 

0435-JH0902-00-CI-SPC-0004 Page 4 of 7


These guide strips shall be put up sufficiently earlier, so that at the commencement of plaster, 

these guide strips shall have sufficiently hardened. The plastered surface then shall be firmly 

pressed to a uniform plumb and plane. The surface shall then be sufficiently scratched to receive 

the second coat. The surface of the first coat shall be thoroughly combed, so that 5mm deep 

grooves at 12mm apart are formed, when the mortar is in the plastic stage. The surface shall be 

cured for at least 3 days. 

Second coat 

Sand used for the second coat shall be sieved. Sand passing through 3mm sieve shall be used. 

The sand shall be of uniform size. 

The second coat shall be 6mm thick of 1:4, cement sand proportion by volume. The second coat 

shall be struck uniformly over the first scratched coat and firmly pressed and leveled using a 

batten. The surface shall than be firmly trowelled and sponge floated to remove excess moisture 

and to bring the sand to the surface. 

A sponge dipped in cement water shall be used with circular motion to get the sandy appearance. 

The surface thus prepared shall be uniformly roughened for texture by running a fine wire brush 

lightly over the surface, as per the instructions of Engineer-In-Charge. 

The surface of the plaster shall be kept moist, for a minimum period of 7 days and shall be 

protected from sun rays. 

8. SMOOTH FINISHED CEMENT PLASTER 

The preparatory work shall be similar to as described above, except for the following. 

Single Coat Plaster 

The first coat shall be 1:6 cement sand proportion by volume and of the following 

thickness: 

12mm thick overall plaster 

6mm thick overall ceiling plaster 

Double Coat Plaster 

First coat 

The first coat shall be 1:6 cement sand proportion by volume and of the following 

thickness: 

12mm for 18mm thick overall plaster 

9. GYPSUM PUNNING 

Material shall be as approved by Engineer-in charge. 

0435-JH0902-00-CI-SPC-0004 Page 5 of 7


Work involves roughen plastered surface with light wire brush, taking care to see that the plaster 

does not fall off during such roughening operation. 

Applying plaster of Gypsum in two coats having thickness of 8 mm each. 

Smoothening the surface with trowel to obtain a uniform surface without any waves. 

Permissible variations in final level of plaster: + 1 mm per meter in vertical plane. 

All undulations in final level of plaster shall be checked with straight edge, spirit level and line 

strings (stretched). 

Any undulations exceeding permissible limits shall be rectified by CONTRACTOR at his own cost. 

Any hollowed plaster detected by tapping shall be rectified by CONTRACTOR at his own cost. 

10. DAMAGE RECTIFICATION 

Any cracks, damages, any part of work which sound hollow when tapped or found damaged or 

defective otherwise shall be cut out in rectangular shape and redone as directed by Engineer-In- 

Charge at no extra cost. 

11. POINTING 

Surface Preparation 

The joints of the masonry either brick stone or laterite to be flat pointed shall be raked to a depth of 

at least 12mm. Raking shall be done carefully and on no account shall any chipping of the 

masonry be permitted. In new work the raking out shall be done when the mortar in the joint is still 

green and fresh. 

Before pointing is commenced, the whole raked surface shall be properly cleaned with wire 

brushes, washed with water and kept well wetted. 

Application 

Unless stated otherwise, the mix for pointing shall be of 1:2 (cement – sand) proportions. It shall 

be properly worked with sufficient water to produce a smooth paste. 

The mix shall be pushed into the joints and superfluous mortar properly removed with a trowel. 

The pointing lines shall be regular and uniform in breadth and shall be finished flush, raised etc as 

specified. 

The edges of the pointing shall be cut off parallel so as to leave well defined lines. 

In recessed pointing, the mortar shall be struck off, with a trowel and the work left, showing the 

natural irregularities, in line and surface of the stones themselves. 

In case of raised pointing, it shall project from the wall facing with its edges cut parallel, so as to 

have a uniformly raised band of about 6mm and width 10mm or more as directed, showing the 

natural irregularities in line and surface of stones themselves. 

The pointing shall be kept wet for 7 days or as directed by Engineer-In-Charge. 

0435-JH0902-00-CI-SPC-0004 Page 6 of 7


12. CURING 

All plaster and mortar works shall be kept damp continuously for a minimum period of 7 days after 

the application of the final coat. 

Curing shall commence, 24 hours after the plaster is laid. 

To prevent excessive evaporation on the sunny or windowed sides of buildings in hot dry weather, 

matting or gunny bags shall be hung over the outside of the plaster and kept moist. 

In case the plaster/mortar cracks through neglect of watering or any other fault of CONTRACTOR, 

the plaster shall be removed and redone at his cost. 

0435-JH0902-00-CI-SPC-0004 Page 7 of 7




(GGSRPEP) 

SPECIFICATIONS FOR ROOFING AND SIDING WORK 

0435-JH0902-00-CI-SPC-0006 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE

SPECIFICATIONS FOR ROOFING AND 

SIDING WORK 

1. SCOPE 

The work covered by this specification shall consist of installing roofing and providing all materials, 

labour and equipment necessary to complete the work in strict accordance with drawings. 


2.1 Codes & Standards 

All work shall conform to the latest requirements of Indian Standards as listed below. 

IS 277-1992 : Galvanized steel sheets (Plain and corrugated). 

IS 513-1994 : Cold rolled low carbon steel sheets and strips. 

IS 730-1978 : Hook bolts for corrugated sheet roofing. 

IS 1728-1960 

: 

Specification for sheet metal rain water pipes upto 100mm 

Nominal size, gutters, fitting, accessories. 

IS 2629-1985 : Recommended Practice for hot dip galvanizing on iron and steel. 

IS 2858-1984 : Code of Practice for roofing with Mangalore tiles. 

IS 3978- 1993 : 

IS 6745-1972 

: 

IS 13229-1991 : Zinc for galvanizing. 

Code of Practice for manufacture of burnt clay Mangalore pattern 

roofing tiles. 

Methods for determination of mass of zinc coating on zinc coated 

iron and steel articles. 

2.2 Other Standards / Specifications 


Conflict, if any, between this specification and related specifications, standards and documents 

shall be referred to the Engineer for resolution before proceeding with the work. 

3. ROOFING 

3.1 General 

The roof slope shall be as specified and in general not pitched flatter then 1:6. Materials shall be 

supplied by approved manufacturer. The items supplied shall be free from cracks, chipped edges 

or corners or other damages. Storage and safety precautions shall be taken to avoid damage to 

the accessories. 

3.2 Materials 

i. Corrugated GI Sheet, Ridges, Hips, Valleys, Flashings and Gullets 

GI sheets shall be of specified thickness and of class-3 galvanized as per IS: 277 and shall be 

bent to the required shape and dimensions as per drawings without damaging the sheet in the 

process of bending 

0435-JH0902-00-CI-SPC-0006 Page 2 of 6


SIDING WORK 

ii. 

Wind Ties 

Wind ties of MS flats shall be of specified size subjected to minimum size of 40 mm x 6 mm. 

Corrugated 

Non Asbestos Cement (AC) Sheet Roofing/Cladding 

iii. Asbestos Cement Sheets 

These shall be of specified thickness and as per IS:459 and shall be of approved brand. 

iv. Ridges and Hips 

These shall be of the same thickness of CGl sheets as specified. The type of ridges shall be 

suitable to the type of sheets used and location. 

v. Other Accessories 

Accessories such as flashing pieces, caves filler pieces, northlight and ventilator curves, 

barge boards etc. shall be of approved brand and shall be suitable to the location of items as 

specified. 

3.3 Workmanship 

3.3.1 Corrugated GI Sheet Roofing 

i. Spacing of Purlins 

One Purlin (each) shall be provided at the ridge and the eaves. Spacing of the purlins 

shall be as specified. Purlins shall coincide with the centerline of the end lap. Ridge purlins shall 

be placed such that ridges can be placed properly. Portion overhanging the wall support should 

not be more than one-fourth the purlins spacing. 

ii. 

Finish for Purlins 

The top surfaces of the purlins shall be painted before fixing the sheets and the embedded portion 

shall be finished with two coats of coal tar 

iii. Laying of Sheets 

Sheets shall be laid on the purlins to a true plane with the lines of corrugation truly parallel or 

normal to the sides of area to be covered unless otherwise specified. They shall be bent up along 

their side edges close to the wall and the junction shall be protected by flashing on projecting drip 

course as specified. 

iv. Laps 

End laps shall be 150 mm for 1:2 slope and 200 mm for flatter ones. Side lap shall be of two ridges 

0435-JH0902-00-CI-SPC-0006 Page 3 of 6


SIDING WORK 

of corrugations on each side, 

v. Cutting of sheet 

Sheets shall be cut according to the dimensions and as specified as per drawings. Sheets shall be 

cut with a straight edge and chisel to give a straight finish. 

vi. Fixing of Sheets 

The sheets shall be fixed to the roof members with J or L polymer coated bolts, polymer cap, seal 

washer and thrust washer. The bolts shall be long enough to project at least 12 mm above the top 

of their nuts. The grip of J or L hook bolts on the side of purlins shall not be less than 25 mm. 

There shall be at least three hook bolts placed at the ridges of corrugations in each sheet in every 

purlin and their spacing shall not exceed 300 mm. Sheets shall be joined together at side laps by 

polymer coated bolts and nuts as specified, each bolt shall be with a polymer cap (grease 

filled) seal washer and polymer coated thrust washer. Bolt shall be placed zig zag on 

overlapping corrugations. The spacing of the beam bolts shall not exceed 600 mm in each of the 

staggered rows. 

vii. Holes 

Holes for all bolts shall be drilled in the ridges of the corrugations from the underside before 

placing in position. The holes in the sheet shall be at least 50 mm from the edge. These holes in 

the washers shall 

be of diameter of the hook bolts or the seam bolts. The nuts shall be tightened from above to give 

a leak proof roof. 

viii. Ridges and Hips 

The overlap for ridges and hips on either side of CGI sheet and end lees shall be at least 225 ruin, 

Ridges 

& hips shall be fixed to the purlins with polymer coated hook bolts, thrust washer and polymer cap. 

At least one of the fixing bolts shall pass through the end laps of ridges and hips on either side. If it 

is not possible extra hook bolts shall be provided. Each end lap of ridges and hips shall be joined 

together by at least galvanized iron seam bolts and GI washers. 

Ridges and hips shall fit squarely on the sheets 

ix. Valleys and Flashings 

The edge, wherever the roof sheeting or valley gutter is turned up against a wall shall be made 

weather proof with flashing. Flashing shall be bent to shape and fixed as specified. Lap over the 

sheet shall be minimum 150 mm. End laps between flashing sheets shall not be less than 225 mm. 

Flashing shall be inserted into brickwork or masonry joints to a depth of 50 mm and shall be filled 

with 

cement mortar (1:3). When flashing has to be laid at a slope, it shall be stepped at each 

course of masonry. The steps shall be cut back at an angle of at least 300. 

Valleys shall be bent to shape and shall have at least 225 mm end lap and projection on either 

side under CGI sheet. Valleys shall be fixed to the roof members below with polymer coated GI 

bolts, polymer cap, seal washer and polymer coated thrust washer. At least one fixing bolt shall 

pass through end laps of the valley piece. 

0435-JH0902-00-CI-SPC-0006 Page 4 of 6


SIDING WORK 

x. Gutters 

The longitudinal edges shall be turned back by 12 mm and heater) to form a rounded edge. The 

ends of the sheet at junctions of pieces shall be hooked into each other and beaten flush to avoid 

leakage. 

Gutters shall be laid to minimum 1:120 slope. Gutters shall be true to line and slope and 

shall be supported by brackets as specified. 

xi. Wind Ties 

Wind ties shall be of 40 mm x 6 mm flat iron section and other size as specified. These shall be 

fixed at the two eaves end of the sheet. Fixing shall be done with the same loose bolts, which 

secure sheets to the purlins. Slot holes shall be cut in the wind ties to allow for temperature 

variations. 

3.3.2 Precoated Galvanised steel Sheet Roofing/Cladding 

i. Material 

The base metal of the roofing shall be Cold Rolled Steel Sheet conforming to IS-513. It 

shall be galvanized by Hot-dip process as per IS-277. The bottom unexposed surface shall then 

be coated with alkyd backer of minimum 7 microns, Top exposed surface shall have epoxy primer 

of minimum 5 microns followed by polyester top coat of minimum 20 microns of specified colour. 

ii. 

Properties 

The precoated galvanized steel standards 

Pencil Hardness : H-2H 

Formability : 2-3 t 

Impact Resistance : 40”/IB 

Salt spray test : 750 hours 

QUV-Wealterometer Test : 1000 hours 

Humidity Test : 1000 hours 

Temperature Resistance : 1500C 

Fire performance : Class - I 

The free overhang of the sheets at the eaves shall be as per manufacturer’s catalogue. 

iii. Profile 

The profiles shall have a depth of not less than 30 mm and pitch of 198 mm. Overall sheet 

thickness shall be 0.60 mm minimum weight shall be 5.24 kg/Sq.M. 

iv. Accessories 

All roofing accessories like ridge, gutters, north light curves, lovers for roof monitors, etc. 

shall be fabricated out the approved pre-coated sheet as per drawing. Metallic Fasteners and 

Fixing accessories shall be corrosion proof. Non metallic fasteners shall be of neoprene. Sealants 

0435-JH0902-00-CI-SPC-0006 Page 5 of 6


SIDING WORK 

shall be neutral cure type and cold setting variety. 

3.3.3 Precoated Galvalume Sheet Roofing/Cladding 

i. Material 

The base metal of the roofing shall be Cold Rolled Steel ASTM A446 Grade E having yield 

stress of 550 MPa. The alloy coating comprises of 55% aluminum, 43.5% zinc and 1.5% silicon 

with coating class AZ 150 (150 gm/m2 minimum coating mass). 

Minimum Thickness of sheet shall be 0.5mm without coating and 0.58mm with coating. 

ii. 

Properties 

The precoated galvanized steel standards 

Pencil Hardness : H-2H 

Formability : 2-3 t 

Impact Resistance : 40”/IB 

Salt spray test : 750 hours 

QUV-Wealterometer Test : 1000 hours 

Humidity Test : 1000 hours 

Temperature Resistance : 1500C 

Fire performance : Class - I 

The free overhang of the sheets at the eaves shall be as per manufacturer’s catalogue. 

iii. Profile 

Cladding sheets shall have an effective cover width of 406mm with ribs of approximately 41mm 

height spaced at 203mm between rib centers. The sheets should be installed with compatible 

proprietary interlocking clips, which lock over the male rib. The clip should lock firmly into the 

underside of the center and female ribs and should be fastened to supports with wafer-head self 

drilling zinc coated fasteners. The clips shall be concealed and fasteners are to penetrate the 

cladding. 

iv. Accessories 

All roofing accessories like ridge, gutters, north light curves, lovers for roof monitors, etc. 

shall be fabricated out the same material as that of roof/ cladding. Metallic Fasteners and Fixing 

accessories shall be corrosion proof. Non metallic fasteners shall be of neoprene. Sealants shall 

be neutral cure type and cold setting variety. 

4. MEASUREMENT OF WORK 

Measurement shall be on covered area of sheet. Laps shall not be measured separately. Work 

shall be inclusive of providing accessories such as capping, flashing, ridge piece, fixing bolts, etc. 

Eaves/Ridge gutter & rain water pipes shall be paid separately. 

0435-JH0902-00-CI-SPC-0006 Page 6 of 6




(GGSRPEP) 

SPECIFICATIONS FOR DRAINS 

0435-JH0902-00-CI-SPC-0009 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE


1.0 SCOPE 

The work covered under this specification consists of providing labour, materials, tools, plant 

equipment necessary for the proper execution and installation of drains and sewers in strict 

accordance with this specification, and applicable drawings. The work includes Sanitary 

Drains & Process Waste Drains 

3.0 TECHNICAL REQUIREMENTS 

The general arrangement of drainage and the related work shall be as detailed in the relevant 

drawings. If actual field conditions or any other reasons necessitate any modifications to the 

arrangements detailed in the drawings, the contractor shall prepare detailed report and sketches 

showing such proposed modifications for the approval of the Owner / Consultant, prior to the 

commencement of work. 

The contractor shall carefully examine all the related drawings, sketches, specifications, and shall 

be responsible for proper installation of these works in best workmanlike manner. The contractor 

shall be responsible for the provisions of all the materials and fittings which shall form the part of 

the installation work, and these shall be approved by the Owner / Consultant prior to the 

commencement of the work. 

The contractor shall submit any technical literature and other information regarding the materials 

whenever called for. The contractor shall investigate all the actual site conditions and other details 

affecting the planning and execution of the works, and shall arrange the timely procurement of all 

the materials and plant and workmanship to meet such conditions as required for t he completion 

of the work as scheduled. 

Dismantling of any existing work shall be undertaken by the contractor only on the written 

permission by the Owner / Consultants. Damages to the existing construction and installation other 

than those to be dismantled and caused as a result of the contractor doing dismantling work, or as 

a result of his opening trenches for drainage works, shall be made good by him by employing 

skilled tradesmen for such repairs. The contractor shall take all the precautions to avoid any 

damages to the existing construction and / or installations. 

3.1 DRAINS 

3.1.1 Drains and / or sewers shall be laid to the alignment and grades as shown on the drawings, 

subject to any modifications done from time to time to meet the requirements of the works. 

No deviations from the lines, depths of cuttings, gradient of drains or sewers shall be permitted 

except on the specific permission from the Owner / Consultant. Before commencement of work, 

accurate surveys and levels of the grade shall be recorded. The excavation and filling as required 

on this grade for the purpose of laying drainage shall be measured on the basis of such records. 

The levels and surveys shall be based on the benchmarks and reference points decided by the 

Owner / Consultant. Any instruments and technical assistance, manpower, required for such 

surveys and levels shall be made available whenever required. The materials required for 

preparation of benchmarks, pegs, pillars shall be furnished by the Contractor. 

3.1.2 Setting out drainage : Setting out of drainage shall conform to approved drawings and shall 

be set out with the aid suitable bearing rods and site rails at intervals not more than 15 metres. 

Necessary materials for bearing rods and site rails and the instruments required for setting out and 

fixing such demarcations and reference points shall be provided by the contractor when checking 

is undertaken. All site rails and posts shall be of well-seasoned timber and such sizes as would be 

required for proper stability. The wooden members used for such purposes shall be planed and no 

warped or defective material be used. The posts shall be kept sufficiently away from the edge of 

trenches and shall be properly embedded in concrete. Site rails shall be fixed to these posts by 

0435-JH0902-00-CI-SPC-0009 Page 2 of 6


any approved means so that the same do not get disturbed. The centre lines shall be accurately 

marked on the site rails either by saw cut or paint marks. At any time, at least 4 site rails shall be 

kept at correct level, and alignment along the centre line of drainage lines. Any additional site rails 

wherever required shall be provided as and when directed. The proper maintenance of the site 

rails shall be the responsibility of the Contractor. The checking of levels and other marks on the 

site rails shall be done at least once a day. The number of site rails and posts, their tiers material, 

mode of securing site rails to posts, tiers, sizes of timber to be used for site rails and bearing rods 

shall be approved by the Owner / Consultant prior to use. 

3.1.3 Excavation 

The excavation for drainage lines shall be open -cut unless otherwise necessary. The excavated 

soil shall be stacked at locations approved by the Owner / Consultants, and shall be removed 

beyond specified lead and brought back for back-fill whenever necessary. Necessary traffic 

diversions, barriers on the trenches, danger signals, watch and ward shall be provided by the 

contractor at his own cost. Dimensions of excavations shall be approved by the Owner / 

Consultant in advance and at no time the trench be excavated more than 20 metres or the 

distance between 2 successive manholes, whichever is less. The least distance to which the 

trench is excavated to full depth shall be five metres at a time. 

It will be the responsibility of the contractor to clean the site off the shrubs, grass, soil tree roots, 

stumps and other burdens. The excavated soil shall be sprinkled with water to avoid dust 

nuisance. The contractor shall utilise minimum width of the roads if the drainage work is by the 

side and / or within the road so that no obstruction is created to usual traffic. Wherever necessary, 

the excavation shall be done deeper than required and the depth so made shall be filled with 

concrete or any other approved material to required level. Such cases, however, shall be dealt with 

only when permitted by the Owner / Consultant in writing. 

The sides of excavation shall be supported effectively by means such as timbering, sheet piling, 

which shall be closely joined in all loose or sandy strata and below sub -soil water level. Any such 

temporary supports shall be removed when work is completed unless otherwise specifically called 

for. In soft or waterlogged areas, timbering shall be done with tongue and grove joint and shall be 

close driven to such depths below bed levels as ordered by the Owner / Consultants. The 

timbering shall be done out of adequate section of wooden members, and shall be fully braced and 

strutted to avoid any falls, side slips, subsidence and all cavities shall be solidly filled-in. The 

contractor shall be responsible for the sufficiency of all timbering, bracing, sheet piling, strutting, 

and repair for all damages to the property and surroundings due to improper quality, strengths, 

placement, stability of the existing foundations shall be done by the Contractor, wherever 

necessary at his own cost. The responsibility due to improper shoring shall rest with the contractor. 

At all times, during the progress of works, the contractor shall keep the trenches and excavated 

pits free of water which shall be drained in the most harmless manner. The contractor shall provide 

all the materials, plant, labour, fuel and other necessities for dewatering of trenches in the manner 

best suited to the particular condition. Any damages to surrounding structures and / or foundations 

due to improper dewatering shall be to the Contractor's account. 

In addition to the necessities of proper excavation described above, all necessary precautions for 

the safety of persons and structures shall be taken by the contractor. 

3.1.4 Back-fill, consolidation & removal of surplus earth 

After the drainage lines are constructed and tested, as per requirements, the trenches shall be 

backfilled in such a manner that it would avoid damages to the line laid. The back-filling shall be 

done in layers of 150 mm thick selected earth / sand / murrum shall be properly watered and 

consolidated. The strutting and timbering shall be removed gradually to avoid side collapses. 

0435-JH0902-00-CI-SPC-0009 Page 3 of 6


3.1.5 Laying & jointing of RCC pipes for drains 

Materials shall conform to relevant Indian Standards. Materials shall be approved by Owner / 

Consultants prior to placement of the same. RCC pipes shall conform to IS:458. Pipes shall be laid 

on concrete bed or cradles, if necessary. Pipes shall be lowered gradually in trenches without 

causing damage to trenches and bed concrete / cradles. Extra earth at joints shall be scooped out 

to accommodate the collar. Pipes shall be laid to required levels and alignments throughout the 

length. In case pipes are laid on cradles, the underside of pipes shall be grouted with cement 

slurry and clean fine sand to avoid gaps and foreign materials prior to placement of pipes. Cradles 

shall be cured sufficiently prior to lowering of pipes and any damages caused to the same while 

lowering pipes shall be made good by the contractor. 

Joints shall be made by using Standard Collars which shall have rough surface inside to have 

proper grip. The jointing material shall be cement mortar in proportion 1:2. Prior to sealing of joints, 

the joints shall be caulked with tarred hemp. The joints shall be finished with cement paste laid at 

45 deg angle to the length, and shall be finished all round the periphery of the pipe. The interior of 

the pipes shall be cleaned off prior to testing of the drainage lines. In case of pipe with socket and 

spigot, the joint should be made with rubber ring conforming to IS:5382. The joints shall be 

sufficiently cured and the drains shall be tested under a head of at least 2 metres of water above 

the crown of pipes. A strong approved colour shall be added to the water for testing. The defective 

pipes shall be replaced by good ones. All defective joints shall be made good by cutting and 

redoing. The joints where leakage persists shall be encased in P.C.C. 1:2:4 at the cost of the 

contractor whenever permitted. The size of such encasement shall be decided by the Owner / 

Consultants. The test for leakage shall be conducted at least for an hour after application of water 

head. 

3.2 MANHOLES AND CHAMBERS, ETC. 

The manholes and chambers shall be constructed at locations and as detailed on drawings. 

Additional manholes and / or junctions chambers shall be constructed whenever required and as 

instructed by Owner / Consultant. 

3.2.1 Construction of Manholes / Chambers 

Construction of manholes shall be as described below unless otherwise stated elsewhere. 

i) Floor shall be in PCC 1:3:6 concrete. 

ii) Side walls shall be in brick or concrete block or concrete. 

iii) Bending shall be done in concrete screed and shall be finished smooth in cement rendering the 

shape and curvature shall be best suited to the inlet and outlet pipes, and no sharp bends shall be 

given. 

iv) Relieving arches in the brickwork shall be around pipes. 

v) All M.S. rungs, ladders, as required shall be provided. The rungs shall be firmly anchored in 

walls and painted with anticorrosive paint. 

vi) Foundations and sidewalls shall be in RCC whenever required. The RCC work under such 

circumstances shall be governed by relevant specifications. 

vii) The manhole cover shall conform to the relevant standards and shall be embedded in PCC 

coping. 

viii) Inside and outside surface of the manhole / chamber shall be plastered in C.M. 1:4 rendered 

smooth, outside surface shall also be plastered similarly whenever called for. (Inside shall be with 

water proofing compound). 

3.2.2 Brickwork 

Bricks shall be of good quality and of homogeneous texture, free from flaws, cracks, stone, 

nodules of lime and such undesirable defects. The bricks shall be of uniform size and shall not be 

over burnt. 

0435-JH0902-00-CI-SPC-0009 Page 4 of 6


The bricks shall be well-soaked in water prior to use. Joints shall not be more than 10 mm thick, 

not more than 10 courses shall be raised in a day which shall be raised uniformly. Cement mortar 

of 1:6 shall be used unless otherwise stated. All the joints shall be raked to 12 mm depths prior to 

receiving of plaster. All the inserts shall be firmly grouted prior to plaster. 

3.2.3 Plaster 

Sand and cement shall be clean and of the best quality. The same should be free from clay and 

any other inorganic or organic impurities. Mixing shall be done to required proportions on hard 

platforms. Materials shall be first dry mixed and water added later to achieve required condition. 

Use of mortar which has started setting shall not be permitted. Such mortar shall be removed from 

site. Surfaces to be plastered shall be soaked in water 24 hours in advance. First coat of plaster 

shall be applied to have even surface and the coat of cement rendering (of 2mm thick) shall be 

applied over the first coat in row. The second coat shall be pressed finished smooth with trowel. 

External plaster shall be done in the same manner. Plaster shall be cured for at least seven days. 

Concrete shall be in proportion specified. The aggregate shall be clean and graded. The cast iron 

covers shall be of duty specified and shall conform to relevant standards. They shall be of best 

quality foundry grey iron metal, close g rained, tough without flaws, blister and all other casting 

defects. They shall have smooth surface, and shall be placed in PCC coping to level and shall be 

even. All the frames and inserts such as rungs shall receive two coats of anti-corrosive bitumastic 

paint, one prior to placement and the other after fixing the same in position. 

The manholes shall be made watertight by proper plastering inside and outside. The manholes 

shall be tested along with the main drainage lines. During testing the external surface shall be 

checked for visible leakages. The leakages so found shall be corrected. On completion of the 

testing for leakages outside, the trenches by the side of the manholes shall be filled in and the 

excavated pit of the manhole shall be flooded with water for testing the leakage from outside to 

inside. The particular testing shall be done whenever called for and the leakage so observed shall 

be repaired. 

3.3 STONEWARE PIPES 

3.3.1 Materials 

The materials shall conform to IS -3006. They shall be of best quality stoneware, salt glazed, 

thoroughly burnt through the whole length and thickness, free from air-holes, fire blisters, cracks 

and other blemishes. They shall be of close and even texture. The manufacturer of the same shall 

be approved by the Owner / Consultants prior to the procurement of these pipes. The pipe shall be 

stacked at approved locations and protected against all damage. All the pipes shall be close fitted 

and shall be tested before lowering them into trenches. Barrels, spigots and sockets shall be 

cleaned, scraped and brushed. 

3.3.2 Laying 

The pipes shall be carefully and gradually lowered into the trenches and shall be laid to correct line 

level, and to the gradient as shown on the drawings. The laying shall generally conform to IS - 

1742. Care shall be taken to prevent any foreign matter getting inside the pipes while lowering. 

The pipe lines between the successive manholes shall be without any undulation horizontally and 

vertically. These pipes shall be laid, sockets facing up the gradient beginning at the lower end up 

and all sockets laid to levels in the holes or scoops out for the purposes. Each pipe shall be 

brought up to placement one at a time. 

3.3.3 Jointing 

This shall be done generally as stated in IS -1742. This shall be taken up only after the final 

alignment is made and gradients and inverts are checked by the Owner / Consultants. A gasket of 

0435-JH0902-00-CI-SPC-0009 Page 5 of 6


tarred hemp yarn shall be placed around the joint in the annular space between spigot and socket 

and the same shall be inserted by suitable tools and packed up properly. Additional strands of yarn 

shall be used if necessary. Such yarn shall be soaked in water prior to placement. Complete 

caulking operations with cement mortar in proportion 1:1 of cement to sand or as specified, shall 

be made in suitable quantities with wooden caulking tool to fill up the annular space completely 

and fully. On completion of sealing of the joints the same shall be struck off at 45 deg to the 

longitudinal axis of drain using same mortar and finishing the same by neat cement rendering. 

Depths of sockets yarn, mortar shall be approximately as stated below under Table I. Whenever 

necessary, the pipes shall have PCC concrete bedding and / or concrete encasement. 

Table - I 

Sr.No. Diameter of pipe Depth of Socket Depth of Yarn Depth of Mortar 

1. 100 mm 50 22 28 

2. 150 mm 56 28 28 

3. 250 mm 65 28 37 

4. 300 mm 75 32 43 

Each joint shall be adequately cured by placing wet cloth or canvas wrapped around the joint and 

kept wet continuously for 3 days. 

3.3.4 Testing 

After the joints are cured for at least three days, the pipeline shall be tested for leakage to water 

head of 2 metres. The testing shall be deemed to be satisfactory if the water level does not fall by 

more than 12 mm in a length of approximately 90 metres of drain pipes within a period of one hour. 

Upon application of test head, all the joints shall be inspected for leakages which shall be repaired 

and the line retested in the similar manner. After satisfactory tests of such line, the back-filling shall 

proceed in the similar manner described previously. For the back-filling prior permission shall be 

obtained from the Owner / Consultant. 

3.4 CAST IRON PIPE DRAINS 

Materials and laying of pipes and fittings shall conform to IS-1536, 1537, 1538, 3989. The pipes 

shall be embedded in concrete whenever necessary. The pipes shall be jointed either by cement 

mortar joints or by lead caulking or rubber ring as specified. Other operations such as excavation, 

laying, testing and backfilling shall be as described in the preceding various paragraphs. 

3.5 HDPE PIPE 

HDPE pipes shall conform to IS:4984 with pressure rating of 6 kg / sq. cm. The HDPE pipe 

moulded fittings shall conform to IS:8008 and fabricated fittings to IS:8360. All fittings shall be 

fabricated at factory under ideal conditions. The pipe shall be embedded in PCC or sand wherever 

necessary. Hexagonal head bolts and nuts shall be of galvanised mild steel conforming to IS:1363. 

The pipe shall be jointed by heated tool welding (with mirror); hot gas welding (with torch and filler 

rod); electro fusion. Hydro testing (at 1.5 times than working pressure) / spark testing (at 20-25 kv) 

shall be carried out. All butt joints of fittings shall have FRP mesh for at least 100 mm on both side 

of the butt joint. 

0435-JH0902-00-CI-SPC-0009 Page 6 of 6




(GGSRPEP) 

SPECIFICATIONS FOR CABLE TRENCH 

0435-JH0902-00-CI-SPC-0010 




29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE

SPECIFICATIONS FOR CABLE TRENCH 

1.0 SCOPE 

This specification covers requirement for construction of RCC cable Trench. 

2.0 Materials 

Cable Trench shall be of RCC having base and wall in cast-in situ concrete and cover 

slab shall be in pre-cast concrete. 

Concrete work shall be carried out as per WP specifications for concrete works. 

Wherever required, suitable insert plates having minimum thickness of 10mm shall be 

provided in side the cable trench. For protection of edge, corner angle shall be 

provided. 

3.0 Workmanship 

Work elements involved shall be as per specifications for concrete. 

For workmanship involved for steel items , refer specification for steel works. Slope 

shall be provided inside the cable trench so as to route rain water to neaqrest storm 

water drain. 

4.0 Pre-cast covers 

Pre-cast concrete covers shall be provided over wall. Covers shall be provided with MS 

lifting kook as indicated in drawings. Pre-cast cover shall be of maximum weight of 750 

kg. 

0435-JH0902-00-CI-SPC-0007 Page 2 of 2




(GGSRPEP) 

SPECIFICATIONS FOR FENCING AND GATES 

0435-JH0902-00-CI-SPC-0011 

D 

Revised & Issued for Tender 

SUS VYT JJW 18/08/09 

C Issued for Civil Tender 



29/05/09 



PARSONS 

APPROVAL 

DATE 

HPCL 

APPROVAL 

DATE

SPECIFICATIONS FOR FENCING AND 

GATES 

1.0 SCOPE 

This specification specifies the requirements of fence and associated gate work including 

foundation and earthwork thereof. The height of the fence shall be approximately 2.0m to the 

top of the chain link fencing at the posts and approximately 2.5m in vertical height at the top 

line of barbed wire attached to the cranked tops of the posts unless stated otherwise. 

2.0 APPLICABLE CODES 

Note - Wherever reference is made to IS Codes, on any page of this Technical 

Specification (including annexures), applicable year of publication of IS Code is 

as stated below. 

All work shall be strictly in accordance with the Technical Specifications, unless 

otherwise approved by the Engineer-In-Charge in writing. 

The Indian standard codes applicable to this section shall include but not limited to the 

following: 

IS: 432 (Part 1) : Mild steel medium tensile steel bars and hard drawn steel wire 

- 1982 for concrete reinforcement: Part 1 Mild steel and tensile steel 

bars. 

IS: 432 (Part 2) : Mild steel medium tensile steel bars and hard drawn steel wire 

- 1982 for concrete reinforcement: Part 2 Hard-drawn steel wire. 

IS: 456 -2000 

IS: 1786 - 1985 

IS: 278 - 1978 

IS: 2721 - 2003 

: Code of practice for plain and reinforced concrete. 

: High strength deformed steel bars and wires. 

: Galvanized steel barbed wire for fencing. 

: Galvanized steel chain link fence fabric. 

3.0 REFERENCE SPECIFICATIONS 

Refer Standard specifications for earthwork and concrete work. 

4.0 CHAIN LINK FENCING 

4.1 Materials 

4.1.1 Chain Link Fencing 

The material requirement shall confirm to IS: 2721. The chain link fencing shall be 

woven from 3.15mm diameter wire with mesh size of 50mm. The mesh wire shall not 

vary from the specified diameter by more than +0.05mm. 

4.1.2 Galvanized Wires 

All steel wires shall be hot dipped galvanized wires and diameter of the wire shall be 

3.15mm. The diameter shall be measured over the galvanized coating. 

The line wire shall be 4mm diameter mild steel. 

0435-JH0902-00-CI-SPC-0011 Page 2 of 4


GATES 

The stirrup wire for securing the line wires to the concrete intermediate posts shall be 

2.5mm diameter mild steel. 

The tying wire for securing the chain link fencing to the line wire shall be 1.6mm 

diameter mild steel. 

Hair pin staple for fastening down the bottom of galvanized chain line fencing to the 

concrete sill shall be of 3.15mm wire. The ends shall be bent outwards to secure 

anchorage. 

4.1.3 Cleats for Eye Bolts 

Cleats for eyebolts shall be of uniform size and shall consist of mild steel angle of 

65 x 65 x 6mm. 

4.1.4 Eye Bolt Strainers 

The eyebolt strainer shall consist of bolts with welded eye sufficiently threaded and fitted 

with a nut and washer. 

Two-way eyebolt strainers shall have a suitable ring nut fitted after the wires have been 

strained on one side. 

4.1.5 Stretcher Bar 

Stretcher bar shall consist of mild steel flat 25mm x 4.75mm. They shall be secured to 

the cleats by steel bolts. 

4.2 Erection of Chain Link Fencing 

4.2.1 Erection of Posts and Struts 

Straining posts L65x65x6, shall be provided at all ends and corner of fences, at changes 

in direction or acute variations in level and at intervals not exceeding 18m on straight 

lengths of fence. Intermediate posts shall be spaced at regular intervals not exceeding 

2.5 m. 

Struts shall be fitted to all straining posts behind the chain link fabric in the direction of 

the line of fence. 

4.2.2 Fixing chain link fencing. 

There shall be four evenly spaced rows of line wire. The top wire shall be doubled 

making five line wires in all. The bottom wire shall be close to the ground unless 

otherwise noted in the drawings. 

Each line wire shall be strained lightly by means of eyebolt strainers or winders at each 

straining point. 

Each line wire shall be secured to each intermediate post by a wire stirrup passed 

through a hole in the posts and secured to the line wire by three complete turns on each 

side of the post. 

The chain link fencing shall be strained between each pair of straining posts and 

secured to each straining post by means of a stretcher bar. On the top line wires shall 

be threaded through the appropriate adjacent rows of mesh, care being taken that no 

meshes in the rows are bypassed by the line wire except where deviation is necessary 

at the straining posts. The second top line wire shall be strained in front of the fencing. 

The fencing shall be attached to the top and bottom line wires by wire ties spaced 

150mm and to the other line wires by wire ties spaced 450mm apart. 

0435-JH0902-00-CI-SPC-0011 Page 3 of 4


GATES 

The bottom of the fencing shall be treated as follows: 

Continuous concrete sill 125mm wide x 225mm high for full length between post shall be 

cast with top 25mm above FGL and 25mm below the chain link fencing. Hairpin staples 

shall be threaded through the bottom row of mesh at 750mm centers and set in the sill 

to a depth of 150mm. 

4.2.3 Barbed Wire 

Barbed wire shall conform to size Designation 1 as per IS: 278. The weight of the 

completed barbed wire shall be 136 gm/m. The coating on the wire shall be smooth and 

relatively free of lumps, globes or points. Wire with excessive roughness blisters, 

salammoniac spots shall be rejected. Barbed wire shall be made from two strands of 

galvanized, twisted 2.5mm (12 gauges) steel wire with 4 points of barbs. Each barb shall 

have two turns, tightening around one or both line wires making altogether four complete 

turns. The barb shall be so finished that four points are set and locked at right angles to 

each other. 

Bracing of the rows of barbed wire shall be as indicated in the drawing. 

The barbs shall have a length of not less than 13mm and not more than 18mm. 

The spacing of bars shall be 75 mm. 

5.0 M.S. Gate 

The Technical Specification for the mild steel gates and fixtures shall be as specified in 

drawing. For general specification for fabrication and erection in steel, refer 

specifications for steel work. 

Gate shall be painted with 2 coats of Synthetic enamel paint over a coat of primer. 

0435-JH0902-00-CI-SPC-0011 Page 4 of 4

CLIENT - HPCL 

Schedule of Rate For 

Ramanmandi- Bahadurgarh Cross 

Country Pipeline 

PROJECT – GGSR PRODUCTS 

EVACUATION PROJECT 

DOC. NO : 0435-JH0902-70-CI-SOR-0003 

S. No. ITEM DESCRIPTION UNIT QUANTITY 

RATE (Rs) 

Figures & Words 

AMOUNT 

(Rs) 

1.00 

All work shall be carried out as per Approved for 

Construction Drawings, Item description as 

specified in this column, specifications of work 

and standard drawings. In case of conflict 

following priority shall be followed. However such 

conflict shall be brought to the notice of HPCL/WP 

prior to start of work. 

1) Approved for Construction Drawings. 

2) Item descriptions as specified here. 

3) Specifications of work. 

4) IS codes. 

GENERAL CIVIL, ARCHITECTURE, 

CIVIL & STRUCTURAL WORK FOR SV 

STATIONS 

BIDDERS STAMP 

BIDDERS 

SIGNATURE 

REV DATE PURPOSE BY CHECKED APPROVED 

Page 1 of 7

CLIENT - HPCL 






DOC. NO : 0435-JH0902-70-CI-SOR-0003 

GENERAL CIVIL WORKS : Design, carrying out geotechnical 

survey and topographical survey, detail 

engineering, preparing construction and fabrication 

drawings, obtaining approval of drawings and designs 

from Engineer-in-charge, and construction of all 

general civil works viz. site grading inlvolving filling and 

cutting as per actual site conditions, compound wall, 

gates, approach road from existing road, internal 

roads, drains, culverts, road crossings for electrical 

and instrumentation cables, pavements, footpath, 

drinking water system, plumbing work for toilets, 

construction of tube well including supply and 

installaiton of submersible pump, obtaining approval 

for tubewell from the statutory authorities, structural 

cage for all valves including preparing desing and 

drawing as per actual site details of valves, water 

harvesting system, and other miscellaneous works at 

SV stations including supply of all labour, material, 

equipment etc complete as per specification, 

preliminary and conceptual drawings, design basis, 

approved drawings, codes and standards, other terms 

and conditions and as per the direction of Engineer-In- 

BIDDERS STAMP 

BIDDERS 

SIGNATURE 


Page 2 of 7




CLIENT - HPCL 



DOC. NO : 0435-JH0902-70-CI-SOR-0003 

Charge. Doc.no. 0435-JH0902-00-CI-SOW-0002), 

Specifications, Construction Standards, Drawings and 

direction of Engineer-in-Charge. 

BUILDING WORKS : Design, detailed engineering, 

preparing construction and fabrication drawings, 

obtaining approval of drawings and designs from the 

Engineer-in-charge, construction of structural and 

architectural works for civil buildings and other 

miscellaneous structures, transportation, erection, 

fabrication, painting,finishing etc.,all complete to make 

ready for commissioning including switchgear & control 

room building for all SV stations and other buildings for 

SV 4 as indicated in the attached layout plans, 

including supply of all labour, material, equipment etc 

complete as per specification, preliminary and 

conceptual drawings, design basis, approved 

drawings, codes and standards, other terms and 

conditions and as per the direction of Engineer-In- 

Charge. 

Reference documents: 

BIDDERS STAMP 

BIDDERS 

SIGNATURE 


Page 3 of 7

CLIENT - HPCL 






DOC. NO : 0435-JH0902-70-CI-SOR-0003 

(1) Scope of work : Doc. No. 0435-JH0902-00-CI- 

SOW-0002 

(2) Architectural specification: Doc. No. 0435-JH0902- 

00-AR-SPC-0001 to 0004 

(3) Architectural design basis : Doc. No. 0435-JH0902- 

00-AR-BOD-0001 

(4) Civil/Structural specification: Doc. No. 0435- 

JH0902-00-CI-SPC-0001 to 0012 & 0435-JH0902-00- 

ST-SPC-0001 to 0002 

(5) Civil/Structural design basis : Doc. No. 0435- 

JH0902-CI-BOD-0001 

(6) SV Station Building Type-1 (SV-01,02,03,05,06) 

Station- Arch Drgs(Ground Floor And Roof Plan, 

Elevations & Sections, Finishning Schedule) : 0435- 

JH0902-70-AR-DRD-0001-001 to 0435-JH0902-70- 

AR-DRD-0001-004 

BIDDERS STAMP 

BIDDERS 

SIGNATURE 


Page 4 of 7

CLIENT - HPCL 






DOC. NO : 0435-JH0902-70-CI-SOR-0003 

1a 

1b 

1c 

(7) SV Station Building Type-2 SV-04 Station-Arch 

Drgs(Ground Floor And Roof Plan, Elevations & 

Sections, Finishning Schedule) : 0435-JH0902-70-AR- 

DRD-0002-001 to 0435-JH0902-70-AR-DRD-0002-004 

(8)General Civil Layout Plan for SV Station (SV-04) : 

0435-JH0902-70-AR-DGA-0001-002 & 003 for option- 

1 & 2. 

(9)General Civil Layout Plan for SV Station (SV- 

01,02,03,05,06) (5 Nos) : 0435-JH0902-70-AR-DGA- 

0001-001 

ALL GENERAL CIVIL WORKS AND BUILDING 

WORKS AS ABOVE COMPLETE FOR S.V. STATION 

NOS. 1,2,5,6 

ALL GENERAL CIVIL WORKS AND BUILDING 


NOS. 3 

(i) ALL GENERAL CIVIL WORKS AND BUILDING 


NO. 4 ( as per Option-1) 

NO 4.00 

NO. 1.00 

NO. 1.00 

BIDDERS STAMP 

BIDDERS 

SIGNATURE 


Page 5 of 7

CLIENT - HPCL 






DOC. NO : 0435-JH0902-70-CI-SOR-0003 

2.0 

(ii) ALL GENERAL CIVIL WORKS AND BUILDING 


NO. 4 ( as per Option-2) 

Note- This item will be operated only if the land for the 

SV No. 4 required tobe acquired by the contractor. 

CIVIL AND STRUCTURAL WORKS 

FOR SUPPORTS AND FOUNDATIONS 

FOR PIPE LINE AT RAMANMANDI, 

BATHINDA, AND BAHADURGARH. 

SUPPORTS AND FOUNDATIONS : Design, detailed 

engineering, preparing construction and fabrication 

drawings, obtaining approval of drawings and designs 

from the Engineer-in-charge, construction of supports 

and foundations, pipe sleepers, transportation, 

erection, fabrication, painting,finishing etc.,all complete 

for the scrapper launcher and receiving facilites of 

cross-country pipeline as indicated in the scope 

drawings, including supply of all labour, material, 

equipment etc complete as per specification, 

preliminary and conceptual drawings, design basis, 

approved drawings, codes and standards, other terms 

NO. 1.00 

BIDDERS STAMP 

BIDDERS 

SIGNATURE 


Page 6 of 7




CLIENT - HPCL 



DOC. NO : 0435-JH0902-70-CI-SOR-0003 

2a 

and conditions and as per the direction of Engineer-In- 

Charge. 

All related civil and structural works for scrapper 

launcher and receiver at Ramanmandi (2nos), 

Bahadurgarh(1 no.) and Bathinda(1no). 

LS 4.00 

BIDDERS STAMP 

BIDDERS 

SIGNATURE 


Page 7 of 7



QUALITY ASSURANCE SYSTEM - CIVIL 

Guru Gobind Singh Refinery 

Products Evacuation Project 

(GGSRPEP) 




0435-JH0902-00-CI-ITP-0002 

08 August 09 





Phone: +91-22-67818000 

Fax : +91-22-67818080 



Doc. No.: 0435-JH0902-00-CI-ITP-0002 Page 1 of 24




SYNOPSIS 

Disclaimer 









(GGSRPEP) 


BY 

CHECKED 

BY 

APPROVED 

BY 

DATE 

CLIENT 

APPROVAL 

DATE 

A 



08-Aug- 09 

N/A 

B 

Issued for 


10-Aug- 09 

11-Sep- 

09 

C 

Issued for 

Tender S. Saxena V. Thorat KMN. Pillai 

18-Sep-09 





1) PURPOSE 

The purpose of this document is for uniform understanding and implementation of 

quality Management and quality control by contractor during construction. The 

management of quality shall also cover co-ordination, review, approval audit and 

proper documentation of the works performed. Indicative Inspection and Test Plans 

(ITPs) are forming part of this document as attachments. 

2) SCOPE 

This document shall be applicable for all construction works to be followed by 

contractors as well as WP for achieving overall objective of quality of various 

activities during Construction. 

3) CONSTRUCTION QUALITY REQUIREMENTS 

The Contractor shall establish and maintain an effective Quality Management 

System (QMS). Contractor’s QMS will be reviewed and approved by WP/HPCL 

before proceeding with the job. The QMS shall consist of plans, procedures, and the 

organisation necessary to provide material, equipment, and workmanship that 

comply with the Contract documentation. The system shall cover operations both onsite 

and off-site, and shall be aligned with the proposed sequence of work. 

The Contractor will prepare a Quality Plan compliant with the requirements set-out in 

the Contract documents. The plan shall supplement the Contractor’s approved 

Quality Manual. The Contractor’s detailed Quality plan is required to be submitted for 

approval prior to commencement of any work. 

The Quality Plan shall provide controls for ensuring that the procurement, shipping, 

handling, fabrication, installation, cleaning, inspection, construction, testing, storage, 

examination, commissioning, and required modifications of all materials, equipment, 

and elements of the work comply with the requirements of the Contract documents 

and that all materials incorporated in the work will perform satisfactorily for the 

purpose intended. 

Contractor’s Quality Plan will be reviewed to ensure that the following are captured 

as part of the Project specific quality processes and that the Contractor takes into 

consideration all the quality control requirements of the Project: 

• Equipment identification or item reference numbers given on drawings shall, 

where practical, be utilised as the basis for identification and verification of 

purchased or produced material. Where practical the identification mark shall be 

retained as the basis for identification during storage and installation. 

Identification shall be controlled in accordance with the project procedures. 





• Material control will be undertaken in accordance with the project procedures 

and/or Project requirements to ensure the correct material is received, handled 

and stored. 

• Traceability requirements for equipment and material used for the project shall be 

based on quality records kept during the progress of the project. These records 

will be maintained in accordance with the Project procedures. 

• The site Contractor will maintain a calibration register for all inspection, 

measuring and test equipment used on site. The Contractor shall ensure that all 

measuring and test equipment used by subcontractors is fit for purpose and in a 

known state of calibration prior to use. To facilitate calibration control, a register 

shall be maintained by the Contractor’s Construction Quality Coordinator in 

accordance with the Project requirements. 

• Inspection and Test Plans (ITPs) and/or Manufacturing & Test Quality Plans 

(MTQP) will be used throughout the Procurement, Construction and 

Commissioning phases. ITPs/MTQPs, record sheets and/or marked-up 

drawings, as appropriate, shall provide the basis for indicating inspection and test 

status. Specific ITPs/MTQPs will be developed by the Contractor and approved 

by WP prior to being used for non-standard activities. 

• Contractor shall maintain CTE/ Quality register given by WP during job stage. 

• WP site QA/QC Engineers shall ensure that vendor shop and field inspection, 

hydro-testing inspection, painting inspection, radiography, etc. are completed 

jointly by the WP QA/QC and Contractor in accordance with the approved 

ITP/MTQP and Project requirements. 

Contractor shall not progress to subsequent operations until the record of inspection 

has been endorsed by the Contractor’s Quality Coordinator and WP site QA/QC 

Engineer or Resident Manager or representative as nominated in the relevant 

ITP/MTQP. 

4) DOCUMENTATION 

The documentation plays a very important role in quality management including 

quality control. Necessary documentation shall be maintained by Contractor during 

completion of project and handed over to WP. Area(s) wherever WP personnel are 

directly involved, particularly in witness and hold point, the copies of the same shall 

also be provided to them on inspection of those activities. The documentation shall 

include the following but not limited to:- 

(i) Approved Quality Assurance Plan. 

(ii) Approved inspection and Test Plans. 

(iii) Inspection and test documents covering. 

a) Manufacturer’s Test Certificate. 





b) Material Receipt Report including Inspection Release Note applicable and 

site inspection and acceptance report on quality and quantity of material. 

c) Site test/laboratory test report reviewed by contractor for acceptance vis-à 

vis to contract/code requirements of materials/ including PMI report at 

warehouse. 

d) In process verification reports of contractor representative to WP as 

applicable. 

e) Final verification report including any test checks done for compliance. 

f) As-built vis-à-vis to contract/drawings including tolerances. 

g) As-built for erection. 

h) Non conformance resolution raised by contractor//WP. 

i) Deviation approval by WP. 

j) Waiver / approval by WP in case there is variation from contract/drawings. 

5) CONSTRUTION QUALITY AUDIT 

The WP will carry out a Construction Quality Audit of the project facility near Mechanical 

completion of the Project by independent group of WP personnel. 

6) GENERAL NOTE 

Before start of work, the contractor shall develop and submit for approval of HPCL / 

WPEL, a detailed stagewise micro level Inspection & Test Plan depending upon the 

construction Process/technology to be deployed. 





LEGEND 

HP : Hold Point: 

A point which requires inspection/verification and acceptance by HPCL/WP before 

any further processing is permitted. 

The Contractor shall not process the activity /item beyond a Hold Point without 

written approval by HPCL/WP except where prior written permission for further 

processing is available. 

W : Witness Point: 

An activity which requires witnessing by HPCL/WP when the activity is performed 

After proper notification has been provided (notification modalities and period shall be 

finalised before hand) the contractor is not obliged to hold further processing if 

HPCL/WP is not available to witness the activity or does not provide comments 

before the date notified. Basis of acceptance shall be as per relevant technical 

specification. 

Rw : Review of Contractor’s Documentation by WPEL 

S : Surveillance Inspection by HPCL/WP: 

Monitoring or making observations to verify whether or not material/items or services 

conform to specified requirements. Surveillance activities may include audit 

inspections, witness of testing, review of quality documentation & records, personnel 

qualifications etc. 

WC : 100 % Examination by Contractor. 

(Prime responsibility for execution of the inspection is with the Contractor. HPCL/WP only 

monitors Contractor’s performance) 





7.0 ATTACHMENTS 





















































D PAINTING 

1) SURFACE PREPARATION Wc W 

2) PROPORTIONING & MIXING OF PAINTS Wc W 





3) PAINT APPLICATION & THICKNESS Wc S

annexure - d techinical specification - civil - WorleyParsons.com

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