pune metro rail project bid documents for construction … · 2018. 7. 10. · maha-metro tender...

Maha-Metro Tender No. P1C-06/2018 Part-II- Work Requirement & Appendixes (Scope of Work)

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PUNE METRO RAIL PROJECT

BID DOCUMENTS

FOR

CONSTRUCTION OF SEVEN (07) NOS. ELEVATED METRO STATIONS EXCLUDING VIADUCT VIZ. RAMWADI, KALYANI NAGAR, YERAWADA, BUND GARDEN, RUBY HALL CLINIC, PUNE STN &

MANGALWARPETH ON REACH-3 OF PUNE METRO RAIL PROJECT.

MAHARASHTRA METRO RAIL CORPORATION LTD (A joint venture of Govt. of India & Govt. of Maharashtra)

101, The Orion, Opposite Don Bosco Youth Centre, Koregaon Park, Pune- 411001

E-mail: mahametrorail.etenders.in Website: www.punemetrorail.org

Telephone: 020-26051072

TENDER NO.

P1C-06/2018

PART 2- Work Requirement & Appendices

(Scope of Work)

mailto:[email protected]

http://www.punemetrorail.org/

Maha-Metro Tender No. P1C-06/2018 Part-II- Work Requirement & Appendixes (Scope of Work)

Maha-Metro June-18 144

Contents of Part-II

STATION Section VII-A-General Specifications (Stations)

General (Station)

Function (Station)

Construction (Station)

Section VII-B-Particular Specification (Stations)

General Specification - Construction

Structural

Architectural

Public Health Engineering

Electrical & HVAC

Fire Fighting

OTHER TECHNICAL INFORMATION

Section VII-C: Design Basis Report & Schedule of Dimensions for Viaduct & Stations

Section VII-D: Tender Drawings including GAD’s

Section VII-E: Reference Document (Geo-Technical report available with Maha-Metro)

Annexure-III: Station Interface Matrix

APPENDIX 1

MAHA-METRO Tender No. P1C-06/2018 PART-2: Work Requirements

Section VII-A: General Specifications

(Stations)

MAHA-METRO June-18


BID DOCUMENTS

FOR



MAHARASHTRA METRO RAIL CORPORATION LTD (A joint venture of Govt. of India & Govt. of Maharashtra)



Telephone: 020-26051072

TENDER NO.

P1C-06/2018

PART II: WORK REQUIREMENTS SECTION VII-A: GENERAL SPECIFICATIONS

(Stations)



MAHA-METRO Tender No. P1C-06/2018 Part-2: Work Requirement

Section VII-A: - General Specifications (Station)

MAHA-METRO June-18

1. GENERAL

1. INTRODUCTION These Employer's Requirements are divided into four sections as follows:

(a) General: these apply throughout the Contract. (b) Functional: these include the specific core requirements for the design and

performance of the Works. (c) Design: these apply in respect of duties & requirements relating to the design of the

Permanent Works. (NOT APPLICABLE FOR THIS CONTRACT) (d) Construction: these apply in respect of duties and other requirements relating to the

construction of the Works. 2. DEFINITIONS AND INTERPRETATIONS In addition to the words and expressions defined in the General Conditions of Contract (GCC),

further following words and expressions shall have the meaning assigned to them except where the context otherwise requires. The clauses under the head 'Design' are applicable only to part of the contract in which the design is the responsibility of the Contractor, except if the context requires otherwise : "As-Built Drawings": means those drawings produced by the Contractor & endorsed by him as true records of construction of the Permanent Works and which have been agreed with the Engineer. "Combined Services Drawings" (CSD): means drawings showing the locations, layouts & sizes of all services including those of other contractors co-ordinated so as to eliminate all clashes. "Construction Phase": has the meaning identified in Clause 4 of the Employer's Requirements - General. "Construction Reference Drawings": means those drawings referred to in Clause 2(8) of the Employer's Requirements - Design in respect of which a Notice has been issued. "Construction Reference Drawings Submission": means the submission of Construction Reference Drawings representing elements of the Permanent Works and for which the Contractor seeks a Notice. "Construction Specification": means those parts of the Standard Outline Specification which relate to construction. "Definitive Design Submission": means the submission of documents which comprise the whole or parts of the proposed Definitive Design and for which the Contractor seeks a Notice. "Design Manual": means the manual to be prepared and submitted by The Contractor as part of the Definitive Design and as described in the Employer's Requirements - Design. "Design Package": has the meaning identified in Clause 2(5) of the Employer's Requirements - Design. "Design Phase": has the meaning identified in Clause 4 of the Employer's Requirements - General. "Design Criteria": means those parts of the Standard Outline Specification which relate to design. “Final Design”: has the meaning identified in Clause 3(5) of Employer’s Requirements – Design. "Notice": means a Notice of No Objection. "Particular Specification": means the combined specifications prepared by the Contractor in CSI format which combines the Employers Design Criteria, the Employer's Outline Construction Specifications and those parts of the Contractor's Technical Proposals which specify standards for design and construction which are developed during the Design Phase. “Preliminary Design”: means the submission of documents which comprise the initial stage of the design phase. "Railway Envelope": means the zone or zones within the Works containing the trackwork and equipment necessary for the operation of the railway. “Services, Electrical, Mechanical Drawings” (SEM) : means those drawings produced by the contractor executing the service works showing the locations, sizes and details for openings in structural elements for mechanical and electrical facilities and other related contracts. "Standard Outline Specification": means the Design Criteria and the Outline Construction Specifications that specify standards issued by the Employer for development by the Contractor for design and construction. "Specification": has the meaning identified in Clause 5 of the Employer's Requirements - General.



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"Structure Gauge": means the profile related to the designed normal co-ordinated axis of the track into which no part of any structures or fixed equipment may penetrate. "Working Drawings": comprise the Construction Reference Drawings and such other drawings and documents, such as bar bending schedules and manufacturing drawings, as are necessary to amplify the Construction Reference Drawings for construction purposes and endorsed as required by the Engineer.

3 RELEVANT DOCUMENTS The Design Criteria shall be read in conjunction with the General Conditions of Contract (GCC), the Special Conditions of Contract (SCC), the Employer’s Requirements, the Drawings and any other document forming part of the Contract. In the event of a conflict between the Employer’s Requirements and any Design Criteria, the Design criteria shall prevail. In the event of a conflict between any Design Criteria and any other standards or specifications quoted, the requirement of the Design Criteria shall prevail. Notwithstanding the precedence specified above the Contractor shall always immediately seek advice from the Engineer in the event of conflicts between Specifications. The order of precedence is:

Design Criteria

Employer’s Requirements

Indian and other International Standards referenced herein.

Indian and other International Standards. 4 PHASES (DESIGN AND CONSTRUCTION) (1) The Contractor shall execute the Works in two phases, the Design Phase (Wherever

applicable) and the Construction Phase. (2) The Design Phase (Wherever applicable) shall commence upon the date of issue of Letter of

Acceptance. This phase shall include the preparation and submission of: (a) the Preliminary Design (b) the Definitive Design; and (c) the Construction Reference Drawings. The Design Phase will be complete upon the issue of a Notice in respect of the comprehensive and complete Construction Reference Drawings Submission for the whole of the Permanent Works.

(3) The requirements for the Preliminary Design, Definitive Design and Construction Reference Drawings are stated in Clause 2 of the Employer's Requirements -Design.

(4) The Construction Phase for the whole or a part of the Permanent Works shall commence immediately upon the issue of a Notice by the Engineer/Employer in respect of the relevant Construction Reference Drawings Submission. Such Notice may be issued by the Engineer in respect of a Construction Reference Drawing Submission covering a major and distinctive part of the Permanent Works. However, construction shall not be commenced until the original negatives of the appropriate Working Drawings have been endorsed: (a) by the Contractor as "Good for Construction"; and (b) by the Engineer that he has no objections to the drawing. The Construction Phase shall include the completion and submission of the Final Design and the preparation and submission of the As Built Drawings and other records as specified.

(5) Notwithstanding Clause 4(4) above, for those elements identified under Clause 2(6) of the Employer's Requirements - Design, the Construction Phase may commence immediately upon the issue of the Notice in respect of the Definitive Design Submission in respect of each such element subject to availability of the site in accordance with agreed programme.

5. SPECIFICATIONS In accordance with the provisions of these Employer's Requirements, the Contract

Specification contained in the Contract shall be developed during the design stage and submitted as part of the Definitive Design Submission. When the Specification has received a Notice of No Objection from the Engineer it shall become the Particular Specifications and shall take precedence over the other Specifications for construction purposes.

6. SPECIFICATIONS IN METRIC AND IMPERIAL UNITS (1) The Contract shall utilise the SI system of units. Codes and Standards in imperial units shall

not be used unless the Engineer has given his consent. (2) Conversion between metric units and imperial units shall be in accordance with the relevant

Indian Standards.



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7. WORKS PROGRAMME (1) The Key Dates are defined in Annexure-IX-C of Part-C to these Employer's Requirements. (2) The Contractor shall prepare and submit its Works Programme and three months rolling

programmes & the detailed requirements contained in Appendices 3 & 4 to these Employer's Requirements.

(3) In compiling its Works Programme and in all subsequent updating and reporting, the Contractor shall make provision for the time required for co-ordinating and completing the design, testing, commissioning and integrated testing of the Works, including, inter alia, design co-ordination periods during which the Contractor shall co-ordinate its design with those of Designated Contractors, the review procedures, determining and complying with the requirements of all Government Departments and all others whose consent, permissions, authority or licence is required prior to the execution of any work.

(4) MAHA-METRO shall obtain all statutory permissions, NOC, Clearance, approval of design pertaining to main works of METRO. The bidder shall submit his design / planning (if any) to MAHA-METRO for forwarding to authority concerned. The successful bidder shall arrange a follow up & coordination for the same to the authority concerned. (Applicable to main works only)

(5) However successful bidder has to obtain all statutory permission NOC, clearance pertain to their plant, yards, other temporary works/structures, establishments, hutments and others allied work of their own use.

(6) The Works Programme shall take full account of the Design Submission Programme. 8. MONITORING OF PROGRESS (1) The Contractor shall submit to the Engineer three copies of a Monthly Progress Report (MPR),

as described in Appendix 5 to these Employer's Requirements, describing the progress and current status of the Works. The MPR shall address the matters set out in the Works Programme.

(2) The MPR shall be submitted by the end of each calendar month. It shall account for all works actually performed from twenty sixth day of the last month and up to twenty fifth day of the current month

(3) The MPR shall be divided into two sections. The first section shall cover progress and current status relating to design and the second section shall cover progress and current status relating to construction.

(4) A monthly meeting to monitor & review the progress of the project shall be convened by the Engineer. Contractor’s site Representative & Designer Representative of Contractor and site agent of all interfacing contractor shall also attend the meeting. The Employer may also be present in the meeting.

(5) The Engineer or Employer may also conduct progress review meetings on weekly /bi-weekly intervals depending upon the requirements or urgency of works. In these review meetings Engineer may call Contractor’s Supplier/Sub-Contractor/Designer etc. as per the requirements.

9. QUALITY ASSURANCE The Contractor shall establish and maintain a Quality Assurance System in accordance with

Appendix 6 to these Employer's Requirements for design and construction procedures and the interfaces between them. This Quality Assurance system shall be applied without prejudice to, or without in any way limiting, any Quality Assurance Systems that the Contractor already maintains.

10 DIGITAL DELIVERY OF THE PROJECT AND SOFTWARE SUPPORT (A) DIGITAL DELIVERY Maharashtra Metro Rail Corporation Ltd. envisages digitization of the Pune Metro Rail Project through systems such as 5-D BIM (Building Information Model). The Design & Build Contractor and his designer should be familiar with operations of a digital project platform enabling a fully integrated solution for employer & contractors. The Design & Build Contractor and his Designer will be required to work on a digital delivery for built assets based on international standards and methodologies including:

PAS 1192-2 2013 - "Specification for information management for the capital/delivery phase of construction projects using building information modeling"

PAS 1192-3 2014 - "Specification for information management for the operational phase of assets using building information modeling"



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AIA Document E203TM–2013, Building Information Modeling and Digital Data Exhibit

CIC BIM Protocol 2013

BIM Forum LOD Specification 2013

Software packages that may be considered to specify and integrate the system solution that will support the Digital Project Office may include Oracle, SAP, Microsoft Dynamics, CMiC, RiB AG, AutoDesk, Bentley, Trimble, Synchro etc.

(B) SOFTWARE SUPPORT (1) The Contractor shall provide full support to the Employer or Engineer for all computer

programs provided by the Contractor under the Contract. (2) The Contractor shall submit a software support plan at least 90 days before commencement

of software installation. This plan shall require the Contractor to provide all changes, bug fixes, updates, modifications, amendments, and new versions of the program as required by the Engineer.

(3) The Contractor shall provide all tools, equipment, manuals and training necessary for the Employer/Engineer to maintain & re-configure all the software provided under the Contract.

(4) The Contractor shall submit all new versions to the Engineer for review at least 2 weeks prior to their installation. New Versions of any program shall not result in any non-conformance with the Specification, or degrade the operation of the System. The Contractor shall:

Ensure that all new versions are fully tested and validated on the simulation and development system prior to installation.

Ensure that all new versions are fully tested & commissioned once installed on the Site.

Deliver to the Employer/Engineer any new version, together with the updated Operation and Maintenance Manuals.

(5) The Engineer shall not be obliged to use any new version and that shall not relieve the Contractor of any of its obligations. Any effect upon the performance or operation of the computer controlled system that may be caused by a new version shall be brought to the Engineer attention including updating the files to suit new version.

SECURITY OBLIGATIONS (6) Within 14 days of the installation of any software into the Permanent Works by the

Contractor, the Contractor shall submit to the Engineer for retention by the Employer/ Engineer two backup copies of the software, which shall include, without limitation:

All licenses in favour of Employer for their use.

all source and executable code;

all design documentation relating to the software; and

Any specified development tools required for maintenance of the software, including, but not limited to, editors, compilers and linkers.

ERROR CORRECTION (7) When a fault is discovered within delivered software or documentation, the Contractor shall

take necessary steps to rectify errors or faults at the earliest. (8) The Contractor shall provide written details as to the nature of the proposed correction to

the Engineer. (9) The Contractor shall notify the Employer promptly of any fixes or patches that are available

to correct or patch faults. (10) The Contractor shall detail any effect such fixes or patches are expected to have, upon the

applications. TRAINING

(11) The Contractor shall provide training for the Employer’s staff to enable the Employer to make proper use of any software and its new versions. In case Contractor fails or unable to provide training, the Engineer may ask for value engineering proposal.

11. CO-ORDINATION WITH DESIGNATED AND OTHER CONTRACTORS - General (1) The Contractor is responsible for detailed co-ordination of his design and construction

activities with those of the Designated Contractors, Civil Contractors, Utility Agencies, Statutory Authorities, Private Service Providers, Developers, Consultants and other Contractors whether or not specifically mentioned in the contract, that may be working on or adjacent to the site for the purpose of the Project. For the purpose of this Specification, all of the above parties shall be referred to as Interfacing Contractors. The Contractor shall note that there are other contractors, consultants, etc. which the Employer will engage from time to time with whom the Contractor shall have to similarly co-ordinate. Such co-ordination responsibilities of the Contractor shall include the following:



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(a) To provide all information reasonably required by the Interfacing Contractors in a timely and professional manner to allow them to proceed with their design or construction activities, and specifically to meet their contractual obligations.

(b) To ensure that the Contractor’s requirements are provided to all other Interfacing Contractors before the cut-off dates to be identified in the Interface Management Plan (IMP).

(c) To obtain from the Interfacing Contractors information reasonably required to enable the Contractor to meet the design submission dates as identified in Appendix 2B.

(d) Where the execution of the work of the Interfacing Contractors depends upon the site management or information to be given by the Contractor, the Contractor shall provide to such Interfacing Contractors the services or correct & accurate information required to enable them to meet their own programme or construct their work.

(e) To co-ordinate access and delivery routes, and to ensure that all provisions for access & delivery of Plant is co-ordinated with and reflected in the Interfacing Contractor’s Delivery Route Drawings. The Interfacing Contractors shall ensure that all Plants are delivered at the time agreed to allow openings left in the structure for such delivery to be sealed in accordance with the Contractor’s programme.

(f) To co-ordinate with the Interfacing Contractors on attendance. (g) To attend regular co-ordination meetings convened by the Engineer with the

Interfacing Contractors. The Contractor shall conduct separate meetings with the Interfacing Contractors as necessary to clarify particular aspects of the interfacing requirements of the Works. The party who convenes the meeting shall prepare minutes recording all matters discussed and agreed at the meeting.

(h) To ensure that copies of all correspondence, drawings, meeting minutes, programmes, etc. relating to the Contractor’s co-ordination with the Interfacing Contractors are issued to all concerned parties and four (4) copies issued to the Engineer no later than two (2) calendar days from the date of such correspondence and meetings.

(2) The Contractor, shall in carrying out his co-ordination responsibilities, raise in good time and provide sufficient information for the Engineer to decide on any disagreement between the Contractor and the Interfacing Contractors as to the extent of services or information required to pass between them. If such disagreement cannot be resolved by the Contractor despite having taken all reasonable efforts, then the decision of the Engineer shall be final and binding on the Contractor.

(3) Where an Interfacing Contract is yet to be awarded the Contractor shall proceed with the co-ordination activities with the Engineer until such time when the Interfacing Contractor is available. The Contractor shall provide the Interfacing Contractor with all information necessary to enable the Interfacing Contractor to follow-on and proceed with their co-ordination.

(4) The cut-off dates to be identified in the IMP are the latest dates. Any claim of additional costs by the Interfacing Contractors as a result of the Contractor’s failure in adhering to these dates shall be borne by the Contractor. The Contractor shall note that the information exchange is an iterative process requiring the exchange and update of information at the earliest opportunity and shall be carried out on a regular and progressive basis so that the process is completed for each design stage by the cut-off dates.

(5) The Contractor shall co-ordinate with the Engineer on all matters relating to works that may affect the Operation & Maintenance of the already operational Section corridor of the Employer in general. Such work shall be subject to the rules and regulations imposed by the Employer.

Dedicated co-ordination team (6) The Contractor shall establish a dedicated co-ordination team, led by a Chief Co-ordinator in

Pune reporting to the Contractor’s Site Agent (Team Leader). The primary function of the team is to provide a vital link between the Contractor’s design and construction teams and the Interfacing Contractors.

(7) The Chief Co-ordinator shall assess the progress of the co-ordination with Interfacing Contractors by establishing lines of communications as indicated in the co-ordination model shown in Figure 1 and promote regular exchange and updating of information so as to maintain the Contractor’s programme.

(8) The complexity of the Project and the importance of ensuring that work is executed within time limitations require detailed programming and monitoring of progress so that early



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programme adjustments can be made in order to minimise the effects of potential delays. (9) The Chief Co-ordinator in conjunction with the Interfacing Contractors shall identify

necessary provisions in the Works for plant, equipment and facilities of the Interfacing Contractors. These provisions shall be allowed by the Contractor in his design of the Works.

(10) During the course of the contract, information will be obtained in a number of ways. These may include direct inspection, regular site meetings, the obtaining of progress reports and the use of turn round document to obtain design and programme data. Turn round document shall be issued to the Interfacing Contractors to be returned giving the current positions on their programme.

Design & Construction Interface (11) The dates shown in Employer’s Requirements Appendices 2B are critical to the timely

completion of the project. The Contractor shall commence design interface with the Interfacing Contractors as soon as he has been notified by the Engineer that such Interfacing Contract has been awarded. In the case of utility agencies and other statutory boards, interface shall commence as soon as it is practicable. Where no design interface date has been established, whether because the Interfacing Contractor(s) have not been identified, or for whatever reason, the Contractor shall liase with such Interfacing Contractors, as soon as they have been awarded.

(12) The Contractor shall immediately upon award of the Contract gather all necessary information and develop his design to a level where meaningful interaction can take place as soon as the Interfacing Contracts are available. The Contractor shall submit together with each of his Design Submissions a joint statement from the Contractor and the relevant Interfacing Contractor confirming that design co-ordination has been completed and that they have jointly reviewed the appropriate document to ensure that a consistent design is being presented.

(13) The design interface is an iterative process requiring regular exchange and update of interfacing information. The Contractor shall ensure that the information he requires from the Interfacing Contractors is made known at the outset of each design interface and vice versa so that the information can be provided in time for the Contractor and the Interfacing Contractors to complete their design to meet their various design submission stages.

Construction Interface (15) Construction interface will be necessary throughout the duration of the Works commencing

from the time the Contractor mobilises to the Site to the completion of the Works. Construction interface will overlap design interface, involving cast-in and buried items such as pipes for electrical and mechanical services, supports, brackets, plinths, ducts, service buildings, openings, cableways, trenches etc. that are to be incorporated at the early stage of the construction up to provision of attendance during the testing and commissioning stage.

(16) The Contractor shall ensure that there is no interference with the Works of the Interfacing Contractors and shall maintain close co-ordination with them to ensure that his work progresses in a smooth and orderly manner. The Contractor shall carry out and complete the Works, or any part thereof, in such order as may be agreed by the Engineer or in such revised order as may be requested by the Engineer from time to time. The Contractor shall, unless otherwise provided, be liable for and shall indemnify the Employer against all costs, charges, expenses and the like resulting from failure of the Contractor to co-ordinate the Works as specified.

(17) Auto CAD Operator: - The contractor shall provide one experienced Auto CAD operator exclusively for the Office of the Engineer till six months beyond the date of completion of project. For effective document/record control consisting Design reports and GFCDs to make the design interface more efficient.



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18. SURVEY AND SITE INVESTIGATIONS (1) The datum used for the Contract shall be Mean Sea Level Datum (2) The Contractor shall carry out all further site investigations necessary for the design

of the Permanent Works & to enable the determination of the methods of construction and the nature, extent and design of the Temporary Works.

19. CLIMATIC CONDITIONS Pune experiences moderate climatic conditions and tenderers must acquaint themselves about the same before submitting the tender. The Employer shall in no way be responsible on this account.

20. PROJECT MANAGEMENT INFORMATION SYSTEM (PMIS) The Contractor shall devise and utilize a PMIS such that all documents generated by the Contractor can be transmitted to the Engineer by electronic means (and vice versa) and that all documents generated by either party are electronically captured at the point of origin and can be reproduced later, electronically and in hard copy. A similar link shall also be provided between the Engineer office at site and the Employer's Office by the contractor. 5D BIM Platform shall be invariably used by the Contractor for PMIS.

21.1 IT Requirement of Employer 1.1 IT Requirement of Employer

THE EMPLOYER

CONTRACTOR'S

DESIGN &

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THE ENGINEER

TS

DESIGNATED

CONTRACTORS

OTHER

INTERFACING

CONTRACTORS

APPROVALS REPORTS

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FEEDBACK

LIASON STATUS/

ACTION REPOR

FEEDBACK &

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MEET

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LIASO

N

STAT

US/

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REPORTS

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STATUSREPORT

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REG

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SITE

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CONTRACTOR' ORGANIZATION

Figure 1



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1.1.1 Employer is in the process of implementing an Enterprise wide cloud based IT system project titled “Integrated Project Management Platform”. The objective of the IT project is to develop a working environment that enables higher efficiency and effectiveness, not only in internal functions, but also across the entire ecosystem of the Employer including Contractors. The IT project envisaged following application stack:

(a) Scheduling services (using Oracle Primavera P6 Enterprise Project Portfolio Management (EPPM) or equivalent)

(b) Collaborative document control and management services (using Bentley Project Wise and Asset Wise solution or equivalent)

(c) Progress and performance reporting (using RIB TWO 5D BIM solution or equivalent) (d) Enterprise wide ERP implementation 1.1.2 The proposed IT system has been conceptualized for facilitating preservation of

important artifacts (plans, drawings, notes, documents, reports etc.) in a secure and manageable environment in digitized format. Appropriate triggers shall generate dashboards and management reports every time an event causes a substantial shift in the project risk or a deviation in processes is developed. The envisaged system would expedite decision-making, ensure better planning and coordination between different functions, better data management, effective reporting, knowledge management etc. Program management shall provide senior management with critical information related to various contracts, activities and funds in the form of management dashboards with inbuilt triggers to ensure timely decision-making.

1.1.3 The effective use of such IT platform requires availability of front end of web-based system at all requisite locations i.e. with Employers’ various offices, Engineer’s offices, Contractors’ end, major sub-contractors’ end, design consultant ends etc. with certain definite users’ rights. Data uploading by various authorized and trained users is key to effective implementation of the IT system. Employer has recognized this aspect, and the Contractors are required to consider in their proposal the cost of software licenses (payable to Maha-Metro) and IT staff for data uploading as under:

Table 4-1: Software licenses and IT staff (minimum requirement)

Sr. No.

Contract value User licenses (below or equivalent software packages)

IT staff

P6 SAP ERP

Bentley Project Wise & Asset Wise

RIB TWO 5D BIM

1 Rs 25 to Rs 50 crore 1 1 5 5 3 (three)

2 Rs 50 crore to Rs 100 crore 1 3 5 5 3 (three)

3 Rs 100 crore to Rs 250 crore 3 5 8 8 6 (six)

4 Rs 250 crore to Rs 400 crore 3 8 8 10 6 (six)

5 Rs 400 crore and above 3 10 10 10 6 (six)

1.1.4 In view of the above, the Contractor shall be required to :-

(a) Follow and comply the system guidelines to be issued by Employer (b) Comply all the software system competency requirement by taking training from

Employer’s Training Academy. (c) Upload / definition of Project Plans as per the template and using software defined

by the Employer; (d) Maintenance and updating of uploaded Project Plans in software used by the

Employer; (e) Upload of drawings / designs created by the Contractor as per the classification and

on the software platform defined by the Employer; (f) Key contract related communication and progress related data as per processes

defined on the software platform deployed by the Employer (g) Asset details need to be updated in the system in the format prescribed by the

Employer;



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Employer, his IT Project Team and IT Implementation Agency shall render necessary assistance (including providing trained IT staff with requisite skills at Contractor’s cost) and handhold the Contractor for usage of the IT system. The Contractor should actively participate in implementing 5D BIM system by MAHA-METRO. The contractor shall provide inputs i.e. Drawings in 3D BIM format, if applicable. The other detail 5D BIM requirement shall be finalised during Interface management Planning/detail design stage.

CONTRACTOR’S PROJECT ORGANISATION (1) The Contractor shall have a competent team of Managers, Engineers, Technical staff etc so as

to complete the work satisfactory as per various requirements of the contract. (2) A control room with round the clock radio communication or telephone switch board links

with all safety offices, works sites, site offices, batching plants, casting yards, workshops, fabrication yard, off site offices, Engineers site office, Resident Engineer’s office, testing labs etc shall be maintained and manned round the clock. Residences of all senior project team members shall also be linked with the control room. Vehicles for emergency use should be on stand-by at the control room around the clock.

(3) The designations of the various project organisations team members shall be got approved by the Engineer before adoption so as to avoid any duplication of the designations with those of the Employer or the Engineer.

22. TECHNOLOGY TRANSFER (1) The Contractor shall ensure that all local contractors and sub-contractors engaged in the

works are given training, guidance and the necessary opportunity for transfer of technology in various areas of construction such as instrumentation, safety, quality assurance, viaduct and station etc.

23. MAINTENANCE REPORT (1) The Maintenance Report shall be submitted as part of the Definitive Design and shall include

full details of the long-term inspection & maintenance operations for each major component of viaduct, station, water supply, sewerage system, water treatment & ETP cum STP plants etc.

(2) The Contractor shall provide inspection and maintenance manuals for the civil, structural and building works covering the viaduct and station areas.

(3) For each area an inspection checklist shall be supplied giving inspection frequency, items to be inspected, criteria for acceptance, criteria for remedial works and details of the remedial works, including proposed materials and method statements. The recommended regular maintenance regime of each area shall also be given including cleaning methods & frequency for different surfaces; removal of leakage borne salts from concrete surfaces; cleaning of drainage channels, sumps and pipes; repainting of metallic items;

(4) A long-term monitoring regime shall also be included covering items such as Viaduct/station water leakage Differential movement at viaduct / station junctions or other areas identified in the design

(5) All instruments necessary to carry out the inspections and monitoring that are identified in the report shall be provided by the Contractor within the lump sum tender price.

(6) Additional technical details and requirements.



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2. FUNCTIONAL

Objective The objective of the contract is the construction completion, testing and commissioning of the

permanent works by the Contractor (including without limitation, the design, construction and removal of the Temporary Works) and the rectification of defects appearing in Permanent Works in the manner and to the standards and within the time stipulated by the Contract. In full recognition of this objective and with full acceptance of the obligations, liabilities and risks which may be involved, the Contractor shall undertake the execution of the Works.

1. GENERAL 1) The Specification shall in any case not specify standards which, in the Engineer's opinion, are less

than or inferior to those described in the Design Basis Report (Design Criteria) and Technical Specifications contained in the Tender Documents. Construction shall be carried out employing the procedures established by the Contractor in his Quality, Safety Health and Environmental management plans.

2) The Contractor shall be responsible for obtaining all necessary approvals from the relevant Public/Government/Local/Statutory or any agencies in the design and construction of the works.

2. SCOPE OF WORKS 2.1 Scope of Work: 2.1.1 The scope of work in brief is given below but the scope includes all other requirements stipulated

in various parts/volumes of the contract document including appendices and annexure thereto. Entire scope of work shall be included in Schedule A, C, D, E, F, G and H (Schedules of BOQ) described in clause 2.9 of Employer’s Requirements- Functional

2.1.2 Stations: Detailed investigation of the site for station execution of the work in station area and also as detailed in the scope of work given below should be included in contract value rate.

(i) Foundation structures on piles by hydraulic rigs or open footing as the case may be. (ii) Station structure including commercial area, column, Pre-cast and Cast in-situ beams, slabs,

staircases, parapets, canopies, gutters, facades, RCC Water Tank (Underground/Overhead), Entry-Exit Structures, Steel Roof with Roofing Sheet and other structures at all levels as shown in the elevations, cross sections and all floor plans and other tender drawings. (Successful bidder

note that - Detailed structural plans and sections for all respective stations in the scope of work shall be

provided during construction stage) (iii) Structural Roof shall be Pre Engineered Building Structures. The detailed design and drawings of

roof portals, roof columns, roof sheeting, purlins and other members of roof structure shall be provided by MAHA-Metro through its Detailed Design consultant. Proof checking of the same along with the preparation of shop drawings shall be done by the Contractor at its own cost through a separate consultant, the appointment of which shall be done after approval of Maha-Metro.

(iv) Lift shafts and escalators pits and other fixtures in stations subject to coordination with respective system contractors including water proofing of lift pit/escalator pits.

(v) MS powder coated Gavalume sheets and Zincalume sheets for roofing as specified. (vi) Expansion joints including at the track bed and at other floor levels as per the specifications. (vii) Providing and fixing GI brackets with suitable covering arrangement on both sides of the parapet

walls of viaduct / station for electrical cables & Signaling as per site requirement and as directed by Engineer in charge. Providing cutouts, concealed pipes, raceways etc. required for various services and systems as per co-ordination with employer and also the service providers and the other system contractor.

(viii) Underground water tank and pump house, D.G. room, bore wells 2 nos. at each station and connection from bore wells to the underground water tanks, water proofing in the underground structure, terrace and Overhead Tanks.

(ix) Drainage arrangements of station, including laying of pipes, construction of Man Hole, Sump, Drain in Basement and outlet Sump including connection to existing municipal drainage line as required.

(x) Masonry works with bricks confirming to IS 12894:2002 of class designation 100 lintel, ties, Mullions & Bands, Tie Beam etc including earthquake resistance provisions in the detailing etc. at various level in the structures as shown in the Tender Drawings & detailed in the Scope of Work.

(xi) Earth filling with compaction with Contractor’s own good earth up to plinth level wherever required. For the area falling on the road, backfilling shall be done with sand.

(xii) Foundations for the system equipment etc. as per co-ordination with various service provisions and system contractors engaged by MAHA-METRO.



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(xiii) Elastomeric bearings on standard spans including bearing pedestals, seismic devices. (xiv) Ground water recharging arrangements one at each station. (xv) Public toilets one number at station in circulating area as per standard drawing with septic tank-

soak pit/sewer connection with municipal. (xvi) Crash barriers as per drawing. (xvii) Inserts for track plinth (Track plinth is not in the scope of this work) (xviii) For stations located over road, temporary arrangement is to be made for providing working

platform at suitable height so that traffic run below it unhindered. This arrangement shall be maintained till completion of exterior finishing work. The working platform has to be covered with suitable material so that nothing falls on the road. A detailed scheme is to be submitted for approval before start of work.

(xix) Grooves on Parapet as approved, if any. (xx) Provisions for cutouts in the station required for various services in coordination with various

system contractors. (xxi) Earthing arrangement for station and ancillary building as per requirement of system contractor.

The contractor has to get necessary permission/ NOC from the railway, road and other concerned regulatory authorities for block and working in such locations. MAHA-METRO will assist for getting them permission from concerned regulatory authorities for working in such locations. The proceeding for such permission shall be initiated by contractor. MAHA-METRO will recommend, co-ordinate and assist for obtaining such permission from concerned regulatory authorities.

(xxii) Special Conditions for use of PSC structural members in station design and construction

a) MAHA-Metro in its endeavor for Green and Sustainable construction methodology in the heart of the city, intends for use of precast technology. This will reduce onsite work volume and activities apart from traffic congestion due to supply material vehicle like RMC transit mixers or dumpers. The other advantages shall be reduction in noise pollution during day and night shifts, dust control, controlled reduction in city electrical & water supplies, lesser onsite establishments, reduced manpower movements, reduced construction periods and reduced conventional construction safety requirements for labourers and general public.

b) Station Designers shall develop the station concept in such a way that, maximum structural elements or members maybe designed and constructed by use of precast or pre-stressed concrete techniques.

c) This is desirable to ensure the speedy construction, excellent quality of concrete in controlled environment for RCC & PSC elements and least inconvenience to general public by avoiding major in-situ construction activities. Efforts should be made for design of precast pre-tensioned elements such as beams, slabs, girders, columns, slab panels, lift shafts, escalator supports, staircases, ducts etc. For this purpose, the standardization of station and its various structural components is essential. Efforts should be made to emphasize more on pre-tensioned elements rather than post tensioned elements. However, in unavoidable conditions and requirements of structural design; post tensioned structural solutions may also be adopted.

d) Structural connections/ joints apart from its detailing between various members in this case will be a critical part of the design, which Designers shall ensure special attention. Structural designers, Architects and MEP experts shall extensively coordinate with Maha-Metro design team, site officers, General Consultant experts, Proof Consultants and Contractors who are involved in construction of stations and viaduct.

e) Approval of shapes and sizes of the members along with framing plan shall be obtained by the DDC before starting detailed design. The DDC shall check in detail about the compatibility between structural members and their structural efficiency.

f) Contractor(s) shall establish casting yard(s) for casting of various PSC members depending upon the design, requirements and quantum of work. Station designer and Contractors shall closely liaison to ensure design feasibility, constructability, transportation and erection of various structural members and to sort out design and construction complications, if any. For this purpose, DDC may/ shall be required to visit the casting yard for inspection.



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2.1.3 There is possibility of some of the items not getting mentioned in the above list of works of stations. Contractors are requested to go through the tender drawings also in details as the works mentioned above as well as indicated in the tender drawings would be considered inclusive in the scope of work under quoted price. Employer decision shall be final in this regard in case of dispute. Some of the major utilities cannot be diverted. Contractor shall take into consideration the existence of these utilities and design the foundations at these locations accordingly.

2.1.4 Deleted 2.1.5 The scope of work shall also include but not limited to the following:

a) Though Alignment plans (both vertical and horizontal) and obligatory pier locations are provided by the Employer to the Contractor. Utility identification at all the foundation locations will be done by the Contractor before starting piling/excavation and in case utility(s) is encountered or obligatory requirements of Local Authorities are to be met out, the Contractor would modify the span configuration at such locations to save the utility(s) or to meet out the obligatory requirements within the accepted price. (Utility drawings are not

available with Maha-Metro. Utility shifting as and when required shall be under the scope of the

bidder and shall be payable under Schedule-G) The shifting of the utility(ies) would be undertaken only in exceptional circumstances where in the opinion of the Engineer no other option is available. (Utility shifting approval – The employer shall seek necessary permission

from appropriate local authority / service provider in case shifting of utilities becomes

essential) Cost of such utility shifting will be paid separately under relevant item of BOQ. No claim as regard to delay in execution of utility diversion will be entertained.

b) Site clearance and dismantling of obstructions etc., before commencement of work as specified or as directed;

c) True and proper setting out & layout of the Works, bench marks & provision of all necessary labour, instruments and appliances in connection therewith as specified or as directed.

d) Widening of the road to maintain existing facility of two lane traffic on either direction after occupying 8m space on center of the road. The construction of the road shall be in accordance with the MORTH Specification. The payment for this work shall be paid as per relevant item of BOQ. The traffic movement / diversion planning shall be done by successful bidder in coordination with local Traffic Police department & MAHA-METRO in such a way that the existing traffic accommodated in available space and no extra land is required,

e) However, in exceptional locations/ cases, suitable proposal from the contractor may be considered subjected to concurrence of Traffic Police Department

f) Existing street lights on the median of the road shall be dismantled as and when required for the work and temporary lighting arrangement shall be provided along the barricading line at a regular interval to give sufficient illumination level to the carriageways and foot paths. The cost for installation and dismantling of temporary lighting arrangement including availing of connection form Electricity board and the energy charges during the currency of the contract or until a permanent arrangement is made shall be borne by the contactor.

g) The lighting shall be uninterrupted throughout the night using alternative source such as DG set in case of power failure. The temporary lighting arrangement shall be dismantled only after a permanent arrangement for street lighting is made.

h) There may be possibility that the location of the electrical posts/structures become close to the carriage way. To maintain better visibility to vehicle etc these structures near to the carriage way are to be painted with reflective paint or provided with reflective tape. The cost on account of this shall be included in the overall quoted rate.

i) The area beyond the carriage way shall be maintained with proper slope so as to flow the rain water to drain smoothly.

j) OHE & signalling structures themselves are excluded from the scope of the work, but civil works required for fixing the structures such as strengthening of structures and providing inserts are included. These shall be finalized and provided in co-ordination with the OHE/ signalling Contractor and the Engineer. The necessary coordination with system contractors and engineer shall form a part of the work.

k) Conducting load test on piles as per BIS-2911- Part IV and on girders as per IRC-SP-37. Conducting load test on completed span (numbers of span to be tested will be as per relevant item of BOQ) shall be done as per IRC-SP-37.

l) All aspects of quality assurance, including testing of materials and other components of the work, as specified or as directed. The payment shall be included in quoted price.

m) The Contractor has to ensure cleanliness of the roads and footpaths by deploying man power for the same. The Contractor shall have to ensure proper brooming, cleaning and washing of



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roads and footpaths at regular interval or as and when required or directed throughout the entire stretch till the currency of the contract including disposal of sewage. Nothing extra shall be payable on this account.

n) Day to day cleaning of worksite throughout the execution period. o) Clearing of site and handing over of all the Works, as specified or as directed. p) Maintenance of the completed Work during the period as specified; q) Submission of completion (i.e. 'As-Built’) drawings and other related documents as specified; r) Barricading: The contractor shall have to provide boundary wall/ barricading as per tender

drawing at all the land to be used for At Grade Stations, store, site office, casting yard etc. The tenderer shall quote his price inclusive of barricading and other requirements of Safety, Health & Environment as specified in condition of contract on SHE version 1.2. This is included in quoted price.

s) Locations where road vehicles / pedestrians are moving, along the Viaduct / Stations / Construction sites as directed by Engineer contractor shall provide & maintain barricading as per the drawing provided in the tender drawing, the payment of the same shall be made as per the relevant head of schedule and the rates of this items include shifting of barricading at new location during the currency of the project.

t) Tree cutting & transplanting after getting permission of forest department / nodal agencies (permission of tree cutting to be arranged by MAHA-METRO). The payment of the same shall be made as per the relevant head of schedule ‘A’

u) Results of sub-surface investigations conducted at project site are enclosed with the tender document. This information about the soil and sub-soil water conditions is being made available to the contractor in good faith and the contractor shall have to obtain the details of sub soil investigation independently. No claim whatsoever on account of any discrepancy between the sub surface conditions that may be actually encountered at the time of execution of the work and those given in these tender documents shall be admissible to the contractor under any circumstances.

v) The platform length of 140m and station length of 140m shown in tender drawing. No claim on account of change in length of platform & station limit will be entertained.

w) The present proposal of Station is based on 25 KV Overhead electric traction systems. Electrical traction system is not in scope of work but may require some modification in the detailing of fixtures for the same.

2.1.6 Any other item of work as may be required to be carried out for completing the construction of elevated structure of specified length and stations including all necessary interfaces works with system-wide Contractors in all respects in accordance with the provisions of the Contract and/or to ensure the structural stability and safety during and after construction Works to be performed shall also include all general works preparatory to the construction and works of any kind necessary for the due and satisfactory construction, completion and maintenance of the works to the intent and meaning of the drawings adopted and technical specifications, to best Engineering standards and orders that may be issued by the Engineer from time to time, compliance by the agency with all Conditions of Contract, supply of all materials, apparatus, plants, equipment, tools, fuel, water, strutting, timbering, transport, offices, stores, workshop, staff, labour and the provision of proper and sufficient protective works, diversion, temporary fencing, lighting and watching required for the safety of the public and protection of works on adjoining land; first–aid equipment, sanitary accommodation for the staff and workmen, effecting and maintenance of all insurances, the payment of all wages, salaries, fees, royalties, duties or the other charges arising out of the execution of works and the regular clearance of rubbish, clearing up, leaving the site perfect and tidy on completion.

2.1.7 E&M Works: Contractor will be responsible for providing a complete workable E&M, Fire Fighting and Fire Suppression system, VAC system, DG Sets and BMS/SCADA systems, as per BOQ and detailed technical specifications enclosed, including necessary Interfacing with the other contractors (Civil works, S&T, Traction and Rolling Stock etc.). Contractor will be responsible preparation of Shop drawings. Obtaining various statutory approvals CEIG (Chief Electrical Inspector to Govt. of India) approval for various Electrical Installations for energizing the system, Local Fire Authority clearance and No Objection Certificate for energizing complete Fire protection system including Fire Fighting, detection and Fire suppression systems and Water supply & sewage with Pune Municipal corporation.



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The work includes providing training of not less than 60 trainer days to MAHA-METRO staff for various E&M Systems, Fire Fighting, Fire Alarm Annunciation system, Air Conditioning system, DG Sets and BMS/SCADA etc. along with training documents / soft copies of training manuals. Contractor will maintain all the systems in a comprehensive manner including all kinds of spares and consumables without any extra cost during Defect Liability period of 2 years from the date of taking over. Equipment/material approval proposals shall be supported with the compliance of Specifications, Standards & BOQ by the Contractor. The proposals shall be submitted with Manufacture drawings bill of material and the G.T.P (Guaranteed Technical Particular) of the equipment/material along with the Type test certificates (not more than 5 years old) of the various equipment/ material, as per requirement. All the material shall be inspected by MAHA-METRO representatives prior to dispatch of material. However, the contractor will be fully responsible for compliance of tender specifications and performance of equipment/systems as per tender conditions. Submittal of Data The Contractor shall submit to the client / consultant complete information regarding details of materials and equipment involved, prior to any purchase or manufacturing operation. Any purchase or manufacturing operations carried out prior to obtaining approval from the client shall be at the Contractor’s sole responsibility. Information of equipment shall be separately submitted by listing all the details and with attached catalogue indicating at least the model, series, size and performance. Such data shall be in sufficient detail to enable the client / consultant to identify the particular product and to form an opinion to its conformity to the Specification. The Contractor shall stamp the name of his company and sign all documents to be submitted for Notice of No objection. Submittal of Materials Only new materials and equipment shall be incorporated in the Works. All materials and equipment furnished by the Contractor shall be subject to inspections and Notice for No Objection of the client / consultant. The materials and equipment used for Works shall be as per approval by the client / consultant. Any materials which, in the opinion of the client / consultant, have lower quality than as per approval by the client / consultant shall promptly be removed from the job site. Whenever requested by the client / consultant, the Contractor shall send materials to be tested by an independent institute selected by the client / consultant without additional cost to the Client. Shop Drawings The Contractor shall prepare shop-drawings comprising complete details of items to be fabricated and works to be installed. The drawings shall be checked by the Contractor for accuracy with regard to dimensions taken in the building(s) and shall closely follow manufacturer’s recommendations. All drawings shall be signed by the Contractor, and shall indicate the date of submission and the date(s) of revision(s). In case shop-drawings require modifications for any reason, the Contractor shall clearly identify the portion that was modified, and shall indicate the running number of revision every time that a revision-drawing is submitted.



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The installation details shall be checked with the building works, the structure and other related trades to prevent conflicts that may cause delay of the project. Size and scale of the shop-drawings shall be at least 1:100 scale except for enlarged scale details done for clarity, which shall be in conformity with international standards or as directed by the Employer / Employer’s Representative Where required by the Employer / Employer’s Representative, the Contractor shall prepare additional drawings, diagrams, etc., which in opinion of the Employer / Employer’s Representative, are considered necessary for a proper execution of the Works. The Contractor shall not proceed with his work for a certain part or section, prior to the Notice of No Objection of the shop-drawings. Therefore, expense incurred because of modifications that have to be made as a result to get the Notice of No Objection of the shop-drawings shall be borne by the Contractor The Notice of No Objection of the shop-drawings by the Employer / Employer’s Representative shall not be construed as a complete check but will indicate only the general method of installation and its details are satisfactory. The Notice of No Objection of the Employer / Employer’s Representative shall not release the Contractor from his responsibility or his liability regarding the exact dimensions and further properties of the installations. Shop-drawings submitted without sufficient detailed shall be rejected & new submission shall be required. The notice to be given to the Employer / Employer’s Representative for the inspection and the documents and drawings format shall be as per the Tender Documents. Transportation of Materials and Equipment The Contractor shall submit in advance a transportation schedule of materials to the Employer’s Representative and prepare passage ways and storage facilities. The Contractor shall be responsible for all expense incurred during shipping and transporting of material and equipment to the job site. The materials and equipment shall be handled in a manner to prevent warping, twisting, bending, breaking, chipping, rusting and any injury, theft of damage or any kind whatever. The shipping documents of particular materials and equipment shall be submitted to the Employer’s Representative as soon as the materials and/or equipment have arrived at the Site. Materials and Equipment Storage The Contractor shall prepare storage areas of sufficient size for all necessary materials and equipment brought to the job site. The storage areas shall be provided with access for inspection and removal of the stored materials and equipment. Materials and equipment delivered to the Site without suitable storage shall not be accepted. Corrosion Protection All ferrous components and fittings exposed to the atmosphere shall be hot-dip galvanized (1000 g/sqm) unless specified otherwise. Acoustic Criteria Noise emanating from the equipment / service installations shall not exceed 55dB for the static machines and 65dB for rotating machinery at a distance of one meter to match or exceed the relevant international standards for each of the equipment.



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Tools and Appliance The Contractor shall provide, unless otherwise stipulated and pay for all tools and other facilities necessary for the execution to completion of the works. If tools, equipment and materials appear to be insufficient at any time prior to commencement or during the progress of works, in the opinion of the Employer’s Representative, of inappropriate to secure the required quality of works or proper rate of progress. The Employer’s Representative may order the Contractor to increase their efficiency, improve their character, augment their number or replace with new tools, equipment and materials as required. Execution Responsibility The Contractor shall connect electrical wires, telephone wires and water pipe for his own use at suitable connection points, for temporary site work use, and shall bear the expense of usage, which shall be removed upon completion of sections of the Works. The Contractor shall establish, maintain, and supervise all precautions and programs for safety and provide protection to prevent damage, injury or loss to:

(1) All workmen on the worksite and other persons who may be affected thereby. (2) All works and all materials or equipment to be incorporated herein, whether in storage on or off the site.

As the work proceeds, the Contractor shall progressively remove rubbish and surplus materials away from the construction site or to a space indicated by the building contractor and shall maintain his working area in a clean and tidy condition as far as is practicable. Upon completion of the Works he shall, without delay, remove all his temporary works and buildings, all tools, equipment and surplus materials, and shall clean the whole area affected by his work and leave it ready for immediately occupation. All materials, equipment and finished works shall be kept in good condition. The completed work shall be the Contractor's property until handed over to the Employer’s Representative. Procurement, Manufacturing and Delivery Plan The Contractor shall prepare procurement, manufacturing and delivery plans in respect of all items a nd goods. Separate parts of the plan shall be prepared for Contractor or sub-contractor off-Site activities. Each plan shall identify the scope of work to be applied. In relation to such scope of work, it shall, without limitation, define:

(1) The organization of the Contractor's staff directly responsible for the day-to-day management of the manufacturing activity on or off the Site;

(2) The specific allocations of responsibility and authority given to identified personnel for the day-to-day management of the work with particular reference to the supervision, inspection and testing of the work;

(3) The interfacing or co-ordination required with the Contractor's other related plans; (4) The specific methods of manufacture to identify any relevant method statements and

develop those method statements to a degree of sufficient detail reviewed by the Engineer; and

(5) The list of procedures and work instructions to manage and control the quality of work during purchasing, manufacturing and delivery, including without limitation: a. The purchasing of items and goods and ensuring they comply with the requirements of

the Specification, including (without limit) purchasing documentation and specific verification arrangements for Contractor / Engineer’s inspection of material or manufactured product prior to release for use;

b. The manufacturing process so as to ensure compliance with the design; c. The manufacturing process so as to ensure clear identification and traceability of

material and manufactured parts;



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d. The inspection and testing of incoming materials, in process and final product so as to ensure specified requirements for the material and/or manufactured product are met;

e. The identification of the inspection and test status of all material and manufactured products during all stages of the manufacturing process to ensure that only products that have passed the required inspections and tests are dispatched for use and/or installation;

f. Review and disposal of non-conforming material or product so as to avoid unintended use;

g. The assessment and disposal of non-conforming material and manufactured product and approval for reworking or rejection as scrap;

h. The identification of preventive action so as to prevent recurrence of similar non-conformance; and

i. The handling, storage, packaging, preservation and delivery of manufactured product. 1. The Contractor shall propose a structured set of inspection hold points. The hold

points shall be structured such that a formal hold point is allowed for each significant element of the manufacturing process. At each hold point, the Engineer shall hold a formal inspection or advise that the inspection has been waived.

2. Once the inspection and any required remedial actions are completed to the satisfaction of the Engineer, the Engineer shall give a notice of no objection for unit shipment. The Engineer will not withhold his notice of no objection for shipping unreasonably, provided all pre-delivery assembly and testing has been successfully completed.

3. Any unit delivered without the Engineer’s notice of no objection shall be rejected at the Site and all expenses thereby incurred shall be borne by the Contractor.

Factory Testing Plan

The Contractor shall prepare and submit for review by the Engineer the Contractor’s Factory Testing Plan detailing and explaining how the Contractor will plan, perform, and document all inspections and tests that will be conducted to verify and validate the Works prior to delivery to the Site. The plan shall consist of a narrative description supported by graphics, diagrams and tabulations as required.

The plan shall contain but not be limited to the following topics: (1) The Contractor’ s strategy for inspection and Factory Acceptance Tests of all constituent

parts of the Works and how this relates to the sequence of delivery; (2) The sequencing and interrelationships of the inspections and tests including: (a) all Quality Hold Points; and (b) all Quality Control Points; (3) The type and extent of inspection and Factory Acceptance Tests to be undertaken and the

parts of the Works to be proven by that testing; (4) The objective of each inspection or test, what particular design and operating criteria the

test or inspection will prove and how the success of the test or inspection will be demonstrated or measured;

(5) Organization chart and CV of key personnel in inspection and test team; (6) The plan for the production and submission of the inspection and test procedures to the

Engineer for review including the submission of the inspection and test reports and records; and

(7) Type Tests, Routine Tests, First Article Inspections and any other tests constituting the Factory Acceptance Tests wherever applicable.

The Contractor shall arrange for all equipment and systems manufactured for incorporation into the Permanent Works to undergo a Factory Acceptance Test (FAT) before shipment from the place of manufacture. Any particular requirements for inspection and testing at the place of manufacture are prescribed in the PS.

The Contractor shall be responsible for re-inspecting and re-testing any failed inspection and Factory Acceptance Test including regression testing on previously passed items.

Inspections and tests that are to be witnessed by the Employer or the Engineer shall be sensibly grouped and scheduled so that as many inspections and tests as possible may be witnessed during a single visit.

Routine production testing methods shall be detailed for review by the Engineer. Routine testing shall ensure that all samples of a production item are within the tolerances required for complete interchangeability.



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The Contractor shall prepare two copies of an inspection or test report immediately after the completion of each inspection or test whether or not witnessed by the Employer or the Engineer. If the Employer or the Engineer has witnessed the inspection or test, he will countersign the inspection or test report to indicate his review of the information and conclusions (i.e. whether or not the equipment being inspected or tested has passed satisfactorily) contained therein. If the Employer or the Engineer has not witnessed the inspection or test (i.e. if a waiver has been granted, or the Employer or the Engineer has not witnessed the inspection or test for some other reason in accordance with the Contract), the Contractor shall forward two copies of the inspection or test report without delay to the Engineer. The Engineer will countersign the report to indicate his review of the information and conclusions (i.e. whether or not the equipment being inspected or tested has passed satisfactorily) and return one copy to the Contractor. Where the results of the inspect ion or test do not meet the requirements of the Specification, the Employer or the Engineer may call for a re-inspection or re-test.

For standard equipment which is serial or bulk manufactured, manufacturer’s type test certificates (or equivalent) may, subject to review by the Engineer, be accepted. It is to be ensured that type test should not be more than 5 years old.

Test equipment and instrumentation shall be subject to approved calibration tests within a properly controlled calibration scheme, and signed calibration certificates shall be supplied to the Engineer in duplicate. Such calibration checks shall be undertaken prior to testing and, if required by the Engineer, shall be repeated afterwards.

Materials and equipment shall not be released for shipment until all applicable inspect ions and tests including Factory Acceptance Tests have been satisfactorily completed Field Testing

Testing of all electrical equipment shall be required upon completion of installation to ensure that the equipment operates satisfactorily and conform to Contract requirements.

Field testing shall be required for all cables and electrical equipment furnished, installed and/or connected by the Contractor to ensure proper installation, setting, connection, and functioning in accordance with the plans, specifications and manufacturer's recommendations.

Testing shall be conducted in the presence of the Employer’s Representative and, when necessary, under the supervision of equipment manufacturer's field engineer.

All tests recommended by the equipment manufacturer whether specified in these Specifications or not, shall be included, unless specifically waived by the Employer’s Representative.

Testing shall include any additional test asked by the Employer’s Representative to determine the conditions of that equipment, material and system to meet requirements of this Specification

The Contractor shall maintain in quadruplicate a written record of all tests showing date, personnel making test, equipment or material tested, tests performed and results. Two copies of test records shall be given to the Employer’s Representative.

The Contractor shall notify the Employer’s Representative two weeks prior to commencement of any testing.

Contractor shall be responsible for any damage to equipment or material due to improper test procedures or handling test apparatus, and shall replace or restore any damaged equipment or material to original condition.

Safety devices such as rubber gloves and blankets, protective screens and barriers, danger signs, etc. shall be provided by the Contractor and shall be used to protect and warn adequately all personnel in the vicinity of the tests.

The Contractor shall furnish all testing equipment and proper temporary power source for testing purpose when normal supply is not available at the time of testing.

Conduit and wiring system shall be checked to ensure that the system has been installed in safe and reliable way.

The lighting system shall be checked at night to ensure that illumination levels as specified have been met.

Operation of all interlocks, control and alarm circuits shall be tested (if any).

The Conductor’s insulation value shall not be lower than the accepted level as required by concerned Authority.

The grounding system test shall be done as per local standards and regulations.

Test all miscellaneous equipment as recommended furnished by the equipment manufacturer i.e., circuit breaker, low voltage switchboard, motor (if any) etc unless specifically waived by the Employer’s Representative.



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Include all additional tests deemed necessary by the Employer’s Representative that he deems necessary because of field conditions, to determine that equipment, material and systems meet requirements of these Specifications. Commissioning Plan The Commissioning Plan is the Employer and the Engineer’s tool for managing and coordinating the Testing, Commissioning, and Training and Service Trial activities. The Commissioning Plan will be divided into the following sub-plans:

(1) Factory Testing Plan (2) On-Site Testing and Commissioning Plan

Testing and Commissioning Phases Testing and commissioning activities shall be undertaken in the following phases:

(1) Factory Acceptance Test; (2) Installation Tests; (3) Partial Acceptance Tests; (4) System Acceptance Tests;

Operation and Maintenance Instructions Manual The manual shall be prepared in hard cover binding in sets to be submitted to the client / consultant for approval of the completed work. (1) Section 1 Comprises submittal data of all equipment and materials that have been approved, (2) Section 2 Comprises catalogues, categorized in groups, complete with Installation operations and the maintenance manuals from the manufacturers, (3) Section 3 Comprises filled out test reports in the field, (4) Section 4 comprises spare parts list and recommended spare parts, (5) Section 5 Comprises maintenance and services schedule, and service and maintenance procedures for individual equipment listed daily, weekly, monthly, quarterly and yearly, (6) Section 6 Comprises system operations manual; A draft copy of the manual shall be submitted to the client / consultant for approval first. (7)Training shall be provided for the operation and maintenance of all the equipment installed. Works to Completion

The Contractor shall commission, clean down & leave in full working order the works as specified. As the installation proceeds the Contractor shall prepare as built drawings‟. It shall

be sufficient to modify the approved construction drawings showing any amendments to the service which have taken place & submit the marked-up prints to the client / consultant for approval.

The Contractor shall deliver to the client/consultant on completion of the works, manufacturer's literature, specifications, technical information and “as built drawings‟ for all equipment installed.

2.1.8 Interface Works 2.1.9.1Co-ordination/co-operation with other Contractors & Agencies (External/Internal)

i. In addition, the Contractor shall be required to carry out various miscellaneous works as per interfacing requirements. The contractor shall carry out necessary co-ordinations with various system contractors pertaining to insert for street light, lift, escalator, traction power supply, signaling, telecommunication, AFC etc. for keeping provisions pertaining to cut outs, shafts, raceways, concealed conduits, other conduits, fixtures, inserts clearances etc. all complete for the scope of work.

ii. Earthing and lighting protection wherever required. iii. The track supporting structure will support ballast less track (long welded rail) which will be laid

later by a separate contractor. Arrangements required for provision of such ballast less track will have to be incorporated in the deck, in consultation with the Engineer. Where the ballast less track concrete is to be laid the top of the deck slab, as directed by the Engineer, the contractor will make suitable arrangements for proper keying up further concrete layers and/ or casting blocks which will from part of track work to be done by a separate contractor.

iv. The contractor shall cooperate with the other contractors appointed by the employer so that the work proceeds smoothly to the satisfaction of engineer. The contractor shall plan & execute the works with proper interfacing with other contractors.

v. NOC / permission for diversion of utilities is in the scope of MAHA-METRO. However, all necessary documentation/details plan of diversion required, including duration etc. will be submitted by the contractor. The contractor shall attend regular coordination meetings



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convened by the employer/engineer for interface and adhere to the decisions taken in the meeting.

vi. Access will be provided to the staff of the other Contractor appointed by the employer for carrying out their works and bringing materials and equipment at the site. However, the security of materials and Equipment brought at the site will be the responsibility of the respective Contractors.

vii. The contractor shall, in carrying out his coordination responsibility, raise in good time and provide sufficient information for the employer to decide on any disagreement with other contractor. If the contractor despite having taken all reasonable efforts cannot resolve such disagreement, then the decision of the Engineer shall be final and binding on the contractor.

2.1.9.2 Interface with E&M Works E & M construction works of station are to be executed by a separate E & M Sub-Contractor separately appointed by the Contractor. The Civil Contractor shall ensure efficient Interface and Coordination with E & M Sub-Contractor concerning Electrical, Fire Fighting, and Hydraulics works etc. on site. Such coordination responsibility of the contractor shall include the following: i. To obtain from the E & M Contractor information reasonably required to meet the

construction target dates. ii. The Civil Contractor will be the coordinating entity and play major role in the interface with

E & M Contractor. iii. E & M Contractor will make sure that he provides the updated valid documents, for the

reference of the Civil Contractor in time, where E & M Contractor requires the Civil Contractor to executive work as his requirements. These documents will be the reference documents for the Interface Management being carried out by the Civil Contactor.

iv. Where the execution of the Civil Contractor depends upon the Site management or information to be given by the E & M Contractor, the E & M Contractor shall provide correct and accurate information in time so as to enable them to meet their respective programs.

v. It is to be ensured that all provisions for access and delivery of plant is coordinated with and reflected in the coordinated drawings for Delivery Routes. The E & M Contractor shall also ensure that all plants and equipment are delivered at mutually agreed time to allow openings to be left in the structure for such delivery in accordance with the Civil Contractor’s Programmed.

vi. E & M Contractor will ensure that the production of Working Drawings for Services to be provided in the base slab, other slabs, tunnels and structures such as earth mats, electrodes, provision of conducting, cable support, brackets, cable trays / cable ladders, cable routing, fixture mounting, DB mounting, lighting protection, piping, firefighting system and other works included in E & M tender in carried out in time and approval obtained from the Employers Representative. Civil Contractor shall obtain Copy of Drawings along with schedule for execution of such works including information required for any concreting/other works where electrical works is involved.

vii. The Civil Contractor shall conduct regular meetings with the E & M Contractor as necessary to clarify particular aspects of the interfacing requirements of the works. He will also attend regular coordination meetings convened by the Employer / Engineer for Interface.

viii. The Civil Contractor, shall in carrying out his coordination responsibilities, raise in good time and provide sufficient information for the Employer to decide on any disagreement with E & M Contractor. If the contractor despite having taken all reasonable efforts cannot resolve such disagreement, then the decision of the Engineer shall be final.

ix. The E & M Contractor shall ensure that the presence of his qualified and experienced engineer (Chief – Co - coordinator) during Civil construction of the station to enable proper interface with Civil Contractor so as to ensure smooth completion of works.

x. Access will be provided to the staff of the E & M Contractor for carrying out their works and bringing materials and equipment at the site. However, the security of a materials and Equipment brought at the site will be responsibility of the E & M Contractor.

xi. Construction of Plant rooms, Ancillary building, Cable duct, sumps for seepage and sewage, provision of slope in slabs as per drainage requirements, shall be the responsibility of the Civil Contractor. Civil Contractor shall interface with E & M Contractor / other contractors regarding this.

xii. Civil Contractor shall interface with E&M Contractor regarding cut-outs to be made in structures for routing E&M services. The Civil Contractor shall provide these cut-outs.

2.1.9.3 Interface with Elevator/escalator contractor



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i. Provide Shaft structure ii. Provide lifting beams at the top of shafts and sumps in pits iii. Provide Head room structure iv. Providing lifting hooks at the top of lift shafts and escalator if required. v. Providing Intermediate support structures for escalators

2.1.9.4 Interface with Traction Power Supply Contractor Civil Contractor shall construct appropriate passages/ trenches, ducts, cable shaft and also keep provision of crossing of various cables in the station along with walls, central column, under the platform in interface with Power Supply Contractor.

i. Civil Contractor shall coordinate with Power Supply Contractor in order to maintain specific Static and Dynamic clearances.

ii. Provide earthing arrangements in viaduct segments, Pier and pier caps, railing etc. 2.1.9.5 Interfaces Work with System Contractor

1. The contractor will be required to have a close interface with the civil contractor, S&T, ASS and Power supply contractor. In addition the contractor shall have a close interface with Detailed Design consultants (DDC).

2. In addition the Contractor shall be required to carry out various miscellaneous works as per interfacing requirements.

3. The Scope of Work for various interfacing works for other Contracts e.g. Signaling and Telecommunication, Traction Power & Power Distribution, Track work, Rolling Stock etc. shall be but not limited to as described below:

- Cable ducts/hangers/trays/Raceways for routing all type of cables.

- Earthing and lightning protection as required. 4. Supply of relevant documentation mainly including:

- Installation, execution, and as-built drawings,

- Test procedures,

- Maintenance & operation manuals 5. The contractor is required to submit soft copies of all the documents,

- On-site and off-site training sessions of MAHA-METRO staff.

- Maintenance during DLP. The work shall include all activities to make the units fully functional and other works complete as required.

2.1.9 Traffic Management The Contractor shall make the detailed traffic diversion plans in consultation with Traffic Police. The work is to be executed with proper liaison with Traffic Police. Necessary assistance will be given by MAHA-METRO. The scheme should be such that minimum of two lane of traffic on each direction of the road should be available for the smooth flow of traffic. The Contractor should inspect the site. The Contractor shall also strengthen the road where the diversions are planned by widening, repairing to the road surface. The Scope of work (2.1 to 2.8) unless specified otherwise shall be included in overall quoted price.

2.1.11 any other item of work as may be required to be carried out for completing the construction of elevated structure of specified length including all necessary interfaces works with station and system Contractors in all respects in accordance with the provisions of the Contract and/or to ensure the structural stability and safety during and after construction.

2.2 Structures The construction of structures will have to be planned in such a manner that they do not obstruct or interfere with the existing roads/railways and other utilities. Where work is required to be carried out at locations adjacent to such roads/railways, utilities, structures, monuments etc. suitable safety and protection arrangements including sheet pilling wherever required will have to be ensured for which nothing extra will be payable. It should be ensured that no damage is caused to any such element and Engineer/ Employer shall be indemnified against such damage at no extra cost.

2.3 Deleted 2.4 Reference to the Standard Codes of Practice 2.4.1 All Standards, Technical Specifications and Codes of practice referred to shall be latest editions

including all applicable official amendments and revisions. The Contractor shall make available at site all relevant Indian Standard Codes of practice and IRSC & TRC Codes as applicable.



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2.4.2 Wherever Indian Standards do not cover some particular aspects of design/ construction, relevant British German Standards will be referred to. The Contractor shall make available at site such standard codes of practice.

2.4.3 In case of discrepancy among Standard codes of practice, Technical Specifications and provisions in sub clauses of NIT, the order of precedence will be as below:

i) Provision in NIT ii) Technical Specifications, iii) IRS Concrete Bridge Code iv) MORTH Specification for road & Bridges v) CPWD specifications vi) Standard Codes of Practice

In case of discrepancy among Standard Codes of Practice, the order of precedence will be IRS, IRC, IS, BS, DIN

2.5 Dimensions 2.5.1 As regards errors, omissions and discrepancies in Specifications and Drawings, relevant clause of

Special Conditions of Contract will apply. 2.5.2 The levels, measurements and other information concerning the existing site as shown on the

conceptual / layout drawings are believed to be correct, but the Contractor should verify them for himself and also examine the nature of the ground as no claim or allowance whatsoever will be entertained on account of any errors or omissions in the levels or strata turning out different from what is shown on the drawings.

2.6 Associated Works Works to be performed shall also include all general works preparatory to the construction and works of any kind necessary for the due and satisfactory construction, completion and maintenance of the works to the intent and meaning of the drawings adopted and technical specifications, to best Engineering standards and orders that may be issued by the Engineer from time to time, compliance by the agency with all Conditions of Contract, supply of all materials, apparatus, plants, equipment, tools, fuel, water, strutting, timbering, transport, offices, stores, workshop, staff, labour and the provision of proper and sufficient protective works, diversion, temporary fencing, lighting and watching required for the safety of the public and protection of works on adjoining land; first –aid equipment, sanitary accommodation for the staff and workmen, effecting and maintenance of all insurances, the payment of all wages, salaries, fees, royalties, duties or the other charges arising out of the erection of works and the regular clearance of rubbish, clearing up, leaving the site perfect and tidy on completion

2.7 CASTING YARD Land for casting yard, batching plant and other activities shall be identified by the contractor and cost towards it shall be borne by contractor. In case land is made available by MAHA-METRO, contractor shall pay the rent for the same. This land shall be made good for such offsite activities as needed by the Contractor at no extra cost to the employer. The land shall be cleared from debris, all structures made by the contractor including, RCC footings and rafts etc. and reinstated to the line and level and to the same conditions as existed before the work started before handing over back to the Employer within 90 days after completion of work without any extra cost to MAHA-METRO. The final bill shall be released to the contractor after all structures are removed & clearance of site. A mechanical tyre washing plant shall have to be installed by the contractor for the vehicles leaving the depot to avoid the spillage on the connecting roads.

2.8 TIME SCHEDULE & MONITORING OF PROGRESS (i) The agency shall submit with the tender “Time Schedule” for completion of various

portions of works. This schedule is to be within the overall completion period of 110 weeks. The detailed programme in the form of a quantified bar chart or CPM network shall include all activities starting from design to completion.

(ii) In compiling its Works Programme and in all subsequent updating and reporting, the Contractor shall make provision for the time required for coordinating and completing the design, testing, commissioning and integrated testing of the Works, including, inter alia, design co-ordination periods during which the Contractor shall co-ordinate its design with those of Designated Contractors, the review procedures, determining and complying with the requirements of all Government Departments and all others whose consent, permissions, authority or license is required prior to the execution of any work.



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(iii) The Contractor shall submit to the Engineer Four copies of a Monthly Progress Report (MPR), describing the progress and current status of the Works. The MPR shall address the matters set out in the Works Programme.

(iv) The MPR shall be submitted by the end of each calendar month. It shall account for all works actually performed from twenty sixth day of the last month and up to twenty fifth day of the current month.

(v) A monthly / biweekly meeting to monitor the progress of the project shall be convened by the Engineer, Contractor’s site agent and site agent of all interfacing contractors shall attend the meeting. The Employer may also be present in the meeting.

2.9 SCOPE OF WORK UNDER BOQ ITEMS 2.9.1 Tree cutting and (or) transplantation along the alignment after getting permission from forest

department/nodal agency. Permission for cutting/transplantation will be arranged by MAHA-METRO. The payment of the same shall be made as per Schedule-A

2.9.2 Traffic barricade with blinker, reflective tapes, illumination and other necessary traffic signage should be provided wherever required as per detailed plan. Temporary traffic diversion for smooth flow of traffic will be provided during construction including necessary traffic signs, repairs to diverted route/services lanes if required. Traffic marshals shall be deployed for the period of diversion to guide the road users and to avoid traffic congestion. Restoration of diverted route in original condition etc. shall be done by Contractor. Contractor shall be paid under relevant item under Schedule ‘A’ items.

2.9.3 The shifting of the utility(s) would be undertaken only in exceptional circumstances where in the opinion of the Employer no other option is available. The utilities are to be diverted with proper liaisoning and approval of the utility owning agencies. For the utilities which are not to be diverted proper supporting shall be done to prevent any damage. Contractor shall be paid for diverting the utilities under relevant item heads. No payment shall however be made for supporting and protecting the utilities during course of the work.

2.9.4 Maintaining Road & Footpaths etc. during the contract period / handing over to road owing agencies which is earlier, is included in the scope of this contract. Dismantling of any road & footpaths etc. for construction purpose including its restoration after completion of work is included in overall quoted price. Any road work i.e. widening / diversion required to facilitate the movement of traffics shall be paid separately under BOQ item subhead. However maintenance of road along alignment, diversion road and widened road during currency of contract included in overall quoted price. Final carpeting of road within barricading areas i.e. areas affected by construction to be done before handing over to road owing agencies is included in overall quoted price. Contractor has to maintain a minimum clearance of 5.5 m from road surface to bottom of structure. Final carpeting beyond the barricading areas i.e. areas affected by Construction shall be paid separate under relevant schedule.

2.9.5 Utility diversions and other miscellaneous works to be paid under relevant heads of Schedule F & G of BOQ

2.9.6 Inserts/Fixtures/Supports/Hangers for system contractor. 2.9.7 Scope of Architectural Finishing Works (General)

The work includes architectural finishes comprising of flooring, finishing, wood works, stone/ granite/marble works, stainless/mild steel railing, glass mosaic tiles, aluminium door & windows, steel doors, plumbing, drainage, water supply, sanitary installation & fixtures glass & Glazing works etc. complete. The work under this contract shall consist of, but not limited to all materials, labour, equipment, tools, plants and necessary machinery as required to completely execute all the works relating to Architectural finishes and shall be paid on item rate basis under relevant heads of schedule of BOQ. i. All wall treatments including plastering, cladding, tiling and painting. ii. Flooring work with Kota stone/marble/granite & ceramic/vitrified tiles etc. as specified at

various locations. iii. Cavity flooring on pedestal supports as specified. iv. Veneering to walls and columns using Kota stone/marble/granite/ceramic tiles/glass

mosaic tiles in columns and walls as specified. v. Aluminum/ pre-laminated particle bounded doors with aluminum frames, aluminum

windows with glazing and steel doors with steel frames. vi. Railings, handrails, glass hand railings, balustrades in mild steel/stainless steel as

specified.



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vii. Gates – Rolling shutters and steel gates with architectural elements e.g. fins etc. viii. False ceiling works, Aluminum perforated, MS. Perforated, MS sheet, interlocking MS

strips as specified. ix. Paints shall be synthetic enamel, distemper, texture paint; oil bound distemper, plastic

/acrylic emulsion and any other as specified. x. ACP cladding, perforated metal cladding, Aluminum sheet cladding, SS cladding,

Aluminum Louvers, as specified. xi. Structural glazing, toughened glass panels on SS railings as specified. xii. Sandstone Louvers as specified. xiii. Glass door on SS frame, hemispherical structure as specified. xiv. Tensile structure as specified. xv. Public health engineering works like water supply, sanitary and drainage. Plumbing &

sanitary works for toilets and drinking water coolers for staff and handicaps including provision of water tanks, treatments, boosting and installation of various sanitary fixtures and appliances as per requirement, soil & waste pipes and disposal of sewage into city main sewer line or by other alternative method as per BOQ.

xvi. Site development works including grading, precise concrete/interlocking tiles, paver blocks, Kerb stones, bituminous road, water bodies, mounds etc.

xvii. Architectural detailed drawings for finishing, plumbing, drainage including all shop drawings shall be developed by the contractor’s architect and submitted to MAHA-METRO for approval prior to commencement of finishing work at site. The Architect / DDC shall be engaged by the contractor subject to the same having relevant experience. All documentation pertaining to the DDC/Architect having the relevant experience shall be submitted to MAHA-METRO prior to engagement for approval.

xviii. Masonry works with bricks confirming to IS 12894:2002 of class designation 7.5 MPa are included in the lump sum quoted price. This work shall be taken up at site only after approval of drawings from all relevant departments of MAHA-METRO.

2.9.8 Any other item of work as may be required to be carried out for completing the construction of elevated structure of specified length including all necessary interfaces works with station and system Contractors in all respects in accordance with the provisions of the Contract and/or to ensure the structural stability and safety during and after construction.

2.10 UTILITIES Utility identification at foundation locations will be done by the contractor and in case utility(s) is encountered or obligatory requirement is to be met out; the contractor shall modify the span configuration at such location out of the standard spans configuration provided in the tender drawing to save the utility (i.e.) or to meet obligatory requirements within the accepted price. Shifting of utility (i.e.) would be done only in exceptional cases where in the opinion of the Engineer no other option is available. Contractor shall be paid for diverting the utilities under relevant Schedule. No payment shall however be made for supporting the utilities during course of work. The utilities are to be diverted with proper liaison and approval of the utility owning agencies. The utilities which are not be diverted but require supporting, proper supporting is be done so that they are not damaged along their branches. Precautions to be taken while handling the utilities are mentioned as under; (i) Utilities must not be damaged at any cost. If due to some or the other reason, mis-

happening occurs, it should be rectified immediately by the Contractor at his own cost under intimation of MAHA-METRO.

(ii) Till rectification of the damaged trunk sewers, the Contractor shall arrange substitute arrangement for sewer pumping and its disposal as per directions of Engineer/ MWA (Maharastra water Authority). The similar arrangement is done for other utilities.

(iii) The manholes of Trunk/Sewers should not be covered under the foundation as these may create hindrances to the annual de-silting/cleaning of sewer lines.

(iv) sufficient distance of foundation from outer edge of Trunk / Sewers is kept in view of further maintenance/Safety of Trunk /Sewers.

(v) The covers of manholes are to be saved from heavy machinery movement to avoid any accident/Slippage of malba in manholes etc into the Trunk /Sewers which may cause blockage of lines. In case of damage of manhole cover & frame the same shall be replaced immediately by the Contractor at his own cost.

(vi) Manholes of the trunk sewer should be kept freely accessible for cleaning and removal of blockages and malba should not be dumped over these manholes.



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(vi) Branch sewer connections which are connected with the trunk sewers should also be taken care of. If the same are damaged, the same should be restored immediately on priority.

(vii) NOC & Approval of schemes of Diversion of Utilities from the concerned regulatory / statutory / Local Authority is the responsibility of the Contractor and nothing extra is payable on this account.

These are only indicative for one of the utility. Similarly, necessary precautions which are specified from time to time by the utility owning agencies shall also be followed. The Central verge/footpath furnishings which are to be dismantled be handed over to the concerned department in their stores at his own cost. Contractor should make his own survey for identification of underground/above ground utilities.

2.11 INSPECTION MAHA-METRO may appoint an independent agency to ensure the quality checking of design,

supply, fabrication, erection and construction of all works under scope of work. The Contractor shall ensure the complete co-operation with the agency to perform their work satisfactorily. In addition MAHA-METRO also reserves right to undertake quality check and inspection directly by itself.

2.12 DELETED 3. ALIGNMENT OF TRACKWAYS (1) The alignment shall be as shown in the tender drawings. The alignment has been developed by

the Employer to meet operational and technical criteria. The Contractor is not required to evaluate the alignment for compliance with these criteria, but shall review it with respect to his own design and construction proposals and shall satisfy himself that there is no conflict with existing structures which are to be preserved.

(2) The Contractor is permitted to propose minor deviations in alignment to suit his construction proposals, but he must demonstrate that any such deviations shall comply with good design practice and the alignment requirement of the Design Criteria. Such deviations shall require prior approval of the Employer subject to following conditions:-

i. There is no extra cost to the employer ii. Changes proposed are essentially required to suit the contractor’s specific design iii. There is no change at the contract boundaries or if there is any, the same is agreed by

the contractor of the adjoining section without any extra cost to the employer. 4. CLEARANCES

1) The Permanent Works shall not infringe the Structure Gauge as shown on the drawings. Extra clearance shall be provided on curved alignment as per the Schedule of Dimensions.

2) The Permanent Works shall provide for the installation by the Designated Contractors of operating equipment for the railway and without infringement of the Structure Gauge.

Railway clearances:- Various clearances shall be provided as per the schedule of dimensions approved for the Pune Metro Rail. Construction limits: (a) The limits of land for the Works are shown on the Worksite Drawings. The Contractor shall

design the Works to be contained totally within these limits, respecting the regulations concerning construction and property boundaries of the local authorities. In the event that the Contractor, having used its best endeavours, is unable to design the permanent works and utilities to be contained totally within these limits, then the Employer will obtain the necessary additional land or the Contractor may be required to redesign the structure as instructed by Engineer

(b) The limits of land as shown in the right of way survey drawings may undergo changes after final survey and the Contractor shall make any adjustments necessary to the design to acknowledge the changes to the limits as then defined.

5. DESIGN LIFE The design life of all the Permanent Works shall be 120 Years

6. DURABILITY AND MAINTENANCE 1) The Permanent Works shall be designed and constructed such that, if maintained reasonably

and in accordance with the Contractor's statement of maintainability contained in the Contract, they shall endure in a serviceable condition throughout their minimum lives

2) The Permanent Works shall be designed and constructed so as to minimise the cost of maintenance whilst not compromising the performance characteristics and ride quality of the railway.



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3) Restoration of roads, utilities and other services dislocated during construction. 4) Survey, Instrumentation, ground treatment, ground and building monitoring, risk analysis,

settlement prediction, preventive and corrective actions. 5) Traffic management along the worksite including works connected with traffic management. 6) Reinstatement of services (such as street lighting, signalling system, bus stand, footpath

including kerb stone, boundary wall, horticulture work and any other work to bring the site to original position) within barricading area as per current standards with new materials (except electrical/signal post which may be reused).

7) The contractor shall be responsible for obtaining relevant certificates or clearance from local civic authorities.

8) The contractor shall be responsible for obtaining approval by all relevant civic authorities having jurisdictional authority wherever required.

7. OPERATIONAL REQUIREMENTS 1. The Permanent Works shall be designed to permit the railway to operate satisfactorily at a

maximum design speed of 80 km/hr where applicable. 2. The vertical and horizontal alignments for the main line track work shall comply with the

conditions laid in para 3. (1) & (2) of this document. 3. Particular attention shall be paid to locations where flooding could enter the tunnel or

underground structures or otherwise damage the railway. In particular, 4. Construction of surface water drainage systems including plinths and ducts shall be avoided

in the vicinity of traction substations to obviate any risk of flooding of electrical equipment areas.

5. Entrances and all other points of access to the underground stations and tunnels shall be adequately protected against flooding.

6. During construction the contractor shall be responsible for providing and maintaining adequate flood protection to ensure protection of the works.

7. In the construction of the Works, the Contractor shall, as a fundamental objective and as a priority, ensure that passengers, staff and the public will, throughout the operational period of the Pune Metro Rail, and within the confines thereof, be provided with as safe an environment as is reasonably possible. The Contractor's attention is directed to Clause 12 of these Employer's Requirements - Functional, concerning the role of the Commissioner of Metro Railway Safety.

8. Deleted. 9. Escalator pits shall be constructed to enable drainage by gravity flow system. However,

where length of the drainage is exceptionally long, the pumping system may be considered subject to approval of Employer. Installation of pumps is not in the scope of this contract.

8. FUNCTIONAL REQUIREMENTS OF PUMPING INSTALLATIONS 1. Water pump installations shall be designed for unmanned operation, controlled through

liquid level controllers, capable of pumping the requisite amount of water to the utility or to the ground / over-head tanks.

2. The pumping installation shall withstand the corrosive effects of normal water supply, seepage water and sewage and serve for the anticipated life of the equipment. The discharge velocity for sewage / seepage pumping shall not be less than 0.75 l/sec.

3. The pipe line size should be such that the velocity head does not exceed the normal static head except for the fire pump which is governed by separate criteria. The valve controls and regulating mechanisms shall be designed for automatic operation.

9. ENVIRONMENTAL CONSIDERATIONS All provisions and conditions contained in the conditions of contract on Safety, Health & Environment, and Section XI shall be strictly complied with.

10. URBAN PLANNING FUNCTIONAL REQUIREMENTS 1. The Station Site Plans are based on the urban planning design carried out by the Employer

and specific land acquisition plans have been submitted to the Government of Maharastra and to the concerned land owning agencies of Govt. of Maharastra, for approval. The land acquisition initiated to date is therefore based on the entrance, ventilation shafts, ancillary buildings and redevelopment of the site areas as shown on the site plans. The Contractor must therefore, if revising the tender drawings for any reason, develop his layouts to suit the available land provided for the metro works.

2. Deleted 3. Deleted



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4. Requests for temporary power supplies for the construction of the works must be submitted by the contractor to the concerned authorities. Alternatively, separate power supplies may be arranged by the Contractor independent of concerned electricity distribution/ transmission authority subject to compliance with all necessary statutes.

5. In addition a number of agencies are involved in the reinstatement works, permanent road accesses, temporary road accesses, refuse collection accesses, street lighting, traffic management and fire hydrant positions. As per tender condition Contractor is responsible for obtaining the approvals for these other works.

6. The Contractor is responsible for obtaining the approval of applications from the above authorities for the construction of works. The Employer may provide assistance in order to obtain any permission on clearances.

11. TRAFFIC MANAGEMENT The Contractor shall carry out the Works so as to minimise disruption to road and pedestrian traffic. The Contractor shall prepare his traffic management plan based on his proposed construction methodology in co-ordination with Engineer and in conjunction with Pune Traffic Police. He shall comply strictly with the approved plan during construction of his works. He shall provide for temporary road deckings wherever necessary to provide minimum no. of traffic lanes as agreed with Pune Traffic Police. The traffic movement / diversion planning shall be done by successful bidder in coordination with traffic department & MAHA-METRO, in such a way that the existing traffic can be accommodated in available space and no extra land is required, However, in exceptional locations/ cases, if opined by Traffic Police of Pune, the extra space/land required may be arranged by MAHA-METRO in co-ordination with local administration.

12. MISCELLANEOUS The Contractor shall note that the Commissioner for Metro Railway Safety (CMRS) will inspect the Works from time to time for the purpose of determining whether the Metro Corridor Project complies in terms of operational and infra structural safety in accordance with the Laws of India. The contractor shall note that CMRS approval is mandatory for commissioning the system. Notwithstanding other provisions of the Contract, the Contractor shall ensure that the Works comply with the requirements CMRS in terms of construction to the drawings, and shall assist the representatives of CMRS in carrying out their inspection duties and also comply with their instructions regarding rectifying any defects and making good any deficiencies.

13. STANDARDS 1. Equipment, materials and systems shall be designed, manufactured and tested in accordance

with the latest issue of International and/or National codes and standards. The Contractor shall submit hard copies in original to the Engineer of all codes & standards used for the work.

2. Reference to standards or to materials and equipment of a particular manufacturer shall be regarded as followed by the words “or equivalent”. The Contractor may propose alternative standard materials, or equipment that shall be equal to or better than those specified. If the Contractor for any reason proposes alternatives to or deviations from the specified standards, or desires to use materials or equipment not covered by the specified standards, the Contractor shall apply for the consent of the Engineer. The Contractor shall state the exact nature of the change, the reason for making the change and relevant specifications of the materials and equipment in the English language. The decision of the Engineer in the matter of quality will be final.

MAHA-METRO Tender No. P1C-06/2018 Part-II: Work Requirement Section VII-A: General Specifications

- Construction (Stations)

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3. CONSTRUCTION 1. CONTRACTOR'S SUPERINTENDENCE (1) The Contractor shall submit a Staff Organisation Plan in accordance with the GCC.

This plan shall be updated and resubmitted whenever there are changes to the staff. The plan shall show the management structure and state clearly the duties, responsibilities and authority of each staff member.

(2) The site agent and his associates/supervisors shall have experience and qualification appropriate to the type and magnitude of the Works. Full details shall be submitted of the qualifications and experience of all proposed staff to the Engineer for his approval.

(3) DELETED 2. CHECKING OF THE CONTRACTOR'S TEMPORARY WORKS DESIGN

The Contractor shall, prior to commencing the construction of the Temporary Works, submit a certificate to the Engineer signed by him certifying that the Temporary Works have been properly and safely designed and checked and that the Contractor has checked the effect of the Temporary Works on the Permanent Works and has found this to be satisfactory.

3. THE SITE (1) Works Areas are those areas identified in Appendix 2A to these Employer's

Requirements and on the Drawings. USE OF THE SITE (2) The Site or Contractor's Equipment shall not be used by the Contractor for

any purpose other than for carrying out the Works in the scope of this contract, except that, with the consent in writing of the Engineer, the Site or Contractor's Equipment such as batching and mixing plants for concrete and bituminous materials may be used for the work in connection with other contracts under the Employer.

(3) Rock crushing plant shall not be used on the Site. (4) The location and size of each stockpile of materials, including excavated

materials, within the Site shall be as permitted by the Engineer. Stockpiles shall be maintained at all times in a stable condition.

(5) Entry to and exit from the Site shall be controlled and shall be only available at the locations for which the Engineer has given his consent.

ACCESS TO THE SITE (6) The Contractor shall make its own arrangements, subject to the consent of

the Engineer, for any further access required to the Site. (7) In addition, the Contractor shall ensure that access to every portion of the

Site is continually available to the Employer and Engineer. (8) Following the handover of the Railway Envelope, (as defined in the

Employer's Requirements- General), to the Employer, the Employer will control the Railway Envelope and will be responsible for all matters relating to security and safety therein. Access to the Railway Envelope by the Contractor shall be in accordance with any procedures, requirements and conditions defined in the tender document.

ACCESS TO OUTSIDE THE SITE (9) The Contractor shall be responsible for ensuring that any access or egress

through the Site boundaries are controlled such that no disturbance to residents or damage to public or private property occur as a result of the use of such access or egress by its employees and sub contractors.

SURVEY OF THE SITE (10) A survey shall be carried out of the Site to establish its precise boundaries

and the existing ground levels within it. This survey shall include a photographic survey sufficient to provide a full record of the state of the Site before commencing the work with particular attention paid to those areas where reinstatement will be carried out later on. The survey shall be carried out before the site clearance wherever possible and in any case prior to the commencement of work in any Works Area. The survey shall be carried out by the Contractor and agreed with the Engineer.

BARRICADES AND SIGNBOARDS (11) The Contractor shall erect barricades as per Tender Drawing and gates

around its areas of operations to prevent entry by unauthorised persons to



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his Works Areas and necessary identity cards /permits should be issued to workers and staff by the contractor. The Contractor shall submit proposal for barricades of the complete perimeter of all works areas to the Engineer. Painting of the barricades shall be carried out to the design and colours as directed by the Engineer and the Contractor shall carry out re-painting of the entire barricades on an annual basis. No work shall be commenced in any Works Area until the Engineer has been satisfied that the barricades installed by the Contractor are sufficient to prevent, within reason, unauthorised entry. The cost of all this barricade is included in quoted price.

(12) Project signboards shall be erected not more than four (4) weeks, or such other period as the Engineer has given his consent, after the date of commencement of the Works. The types, sizes and locations of project signboards shall be agreed with the Engineer before manufacture and erection. Other advertising signs shall not be erected on the Site.

(13) The consent of the Engineer shall be obtained before hoardings, fences, gates or signs are removed. Hoardings, fences, gates and signs which are to be left in positions after the completion of the Works shall be repaired and repainted as instructed by the Engineer.

(14) Hoardings, barricades, gates and signs shall be maintained in clean and good order by the Contractor until the completion of the Works, whether such hoardings, fences, gates and signs have been installed by the Contractor or by others and transferred to the Contractor during the period of the Works. All the fencing, hoardings, gates and signs etc. shall be mopped minimum one in a week and washed monthly.

(15) All hoardings, barricades, gates and signs installed by the Contractor shall be removed by the Contractor upon the completion of the Works, unless otherwise directed by the Engineer.

(16) Hoarding/ barricades can be reused after removing from one place to other locations / sites provided they are in good condition and approved by Engineer.

(17) Damage/worn-out barricades /hoarding shall be replaced by contractor within 24 hours. Engineer ‘s decision regarding need for replacement shall be final and binding and if no action is taken by contractor, the Engineer may get it repaired through other agency and the cost of any repairs will be deducted by the Engineer from any payment due to the Contractor.

CLEARANCE OF THE SITE (18) All Temporary Works which are not to remain on the Site after the

completion of the Works shall be removed prior to completion of the Works or at other times instructed by the Engineer. The Site shall be cleared and reinstated to the lines and levels and to the same condition as existed before the Works started except as otherwise stated in the Contract.

4. SURVEY (1) The Contractor shall relate the construction of the Works to the Site Grid.

To facilitate this, survey reference points have been established and the Engineer will provide benchmarks in the vicinity of the Site.

(2) Before the Contractor commences the setting out of the Works, the Engineer will provide a drawing showing the position of each survey reference point and bench mark, together with the co-ordinates and/or level assigned to each point. The Contractor shall satisfy itself that there are no conflicts between the data given and shall establish and provide all subsidiary setting out points, monuments, towers and the like which may be necessary for the proper & accurate setting out and checking of the Works.

(3) The Contractor shall carefully protect all the survey reference points, bench marks, setting out points, monuments, towers and the like from any damages and shall maintain them and promptly repair or replace any points damaged from any causes whatsoever. The Contractor shall regularly recheck the position of all setting out points, bench marks and the like to the satisfaction of the Engineer.

(4) Upon handover to the Contractor, the survey reference points will become the responsibility of the Contractor. The Contractor shall, by annual or



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more frequent review, ensure that these survey points continue to remain consistent with the bench marks.

5. SAFETY, HEALTH AND ENVIRONMENTAL REQUIREMENTS The Contractor shall comply with in the conditions stipulated in the Conditions of contracts on Safety, Health & Environment (SHE).

5.1 Training of Contractor’s Employees/Staff/Workers: - Contractor shall provide a training/workshop on safety, Health & Environment (SHE) to all its workers/staff/employees/subcontractors of at least 2 weeks (96hrs.) at the time of induction. Before postings of any his workers /staff /employees /subcontractors, the contractor shall give a certificate that the said person had undergone the requisite SHE training. Non-compliance of the above will invoke penalties as per condition of contract on SHE, Section XI of Tender Document. In case of any mishap/ accident causing death/injury to public or damage to public/private property or damage to public/private vehicles or damage to railway property, the employer, will impose a penalty to the contractor as deemed fit and appropriate in addition to the cost of damage caused due to the mishap/accident.

5.2 Use of “Tractor Transmission type” Pick and Carry Hydra Crane :- “Tractor Transmission type” Pick and Carry Hydra crane – 1st Generation model is prohibited at MAHA-METRO works. Contractor shall mobilize “Truck Transmission type” pick and carry hydra crane – 2nd Generation model only.

6. OTHER SAFETY MEASURES Site Safety, Health & Environment Plan

(1) The Contractor shall, within 60 days of the date of Notice to Proceed, prepare and submit to the Engineer for review his proposed safety, Health and Environment plan which shall contain as a minimum those items set out in Conditions of Contract on Safety, Health & Environment Plan.

Fire Regulations and Safety (2) The Contractor shall provide and maintain all necessary temporary fire protection and

fire fighting facilities on the Site during the construction of the Works, and shall comply with all requirements of the Pune Fire Services Department. These facilities may include, without limitation, sprinkler systems and fire hose reels in temporary site buildings, raw water storage tanks and portable fire extinguishers suitable for the conditions on the Site and potential hazards.

(3) The Contractor shall submit details of these facilities to the Engineer for review prior to commencement of work on the Site.

(4) If, in the Engineer's opinion, the use of naked lights may cause a fire hazard, the Contractor shall take such additional precautions and provide such additional fire fighting equipment (including breathing apparatus) as the Engineer considers necessary. The term "naked light" shall be deemed to include electric arcs and oxyacetylene or other flames used in welding or cutting metals.

(5) Oxyacetylene burning equipment will not be permitted in any confined space. Burning equipment of the oxypropane type shall be used.

Hazard and Risk Assessments (6) The Contractor shall, prior to the commencement of any operation carry out a detailed

hazard and risk assessment. The results of such assessments shall be recorded and the records kept for inspection by the Engineer.

(7) The Contractor shall produce detailed method statements for all medium and high risk operations and shall submit them to the Engineer for his consent prior to commencement of any task to which they relate.

(8) The Contractor shall produce and implement a Permit to Work system for all high risk operations. The Permit to Work system shall be submitted to the Engineer for consent before application.

Explosives (9) Explosives shall not be used without prior written consent of the Engineer. Before

consent to blasting is granted, the Contractor shall prepare a Specification as to the size of charge, the method of firing and any other restrictions that may be imposed from time to time.

(10) Where the Engineer has consented to the use of explosives, the Contractor shall be responsible for obtaining the requisite licences and permits for complying with all statutory requirements for blasting.



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(11) The storage, transportation and use of explosives shall at all times be governed by the Explosives Acts and such other statutory regulations which may be applicable and as imposed by the Statutory Authorities.

Launching Girder (12) No Launching Girder shall be used without the prior written consent of the Engineer. (13) The Contractor shall prepare a detailed specification for the operation of Launching

Girder and submit it to the Engineer for review. Standby Equipment (14) The Contractor shall provide adequate stand-by equipment to ensure the safety of

personnel, the Works and the public. These measures shall include as a minimum the following:- (a) stand-by pumping and generating equipment for the control of water; (b) stand-by equipment and spares for illumination of the Works; and (c) Stand-by generating equipment and equipment for the lighting for the works.

Co-operation (15) The Contractor shall provide full co-operation and assistance in all safety surveillance

carried out by the Engineer or the Employer. Any breaches of the Site Safety Plan or the statutory regulations or others disregard for the safety of any persons may be the reason for the Engineer to exercise his authority to require the site agent’s removal from the Site.



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7. CARE OF THE WORKS (1) Unless otherwise permitted by the Engineer all work shall be carried out in dry

conditions. (2) The Works, including materials for use in the Works, shall be protected from damage

due to water. Water on the Site and water entering the Site shall be promptly removed by temporary drainage or pumping systems or by other methods capable of keeping the Works free of water. Silt and debris shall be removed by traps before the water is discharged and shall be disposed of at a location or locations to which the Engineer has given his consent.

(3) The discharge points of the temporary systems shall be as per the consent of the Engineer. The Contractor shall make all arrangements with and obtain the necessary approval from the relevant authorities for discharging water to drains, watercourses etc. The relevant work shall not be commenced until the approved arrangements for disposal of the water have been implemented.

(4) The methods used for keeping the Works free of water shall be such that settlement of, or damage to, new and existing structures do not occur.

(5) Measures shall be taken to prevent flotation of new and existing structures. PROTECTION OF THE WORKS FROM WEATHER

(6) Work shall not be carried out in weather conditions that may adversely affect the Works unless proper protection is provided to the satisfaction of the Engineer.

(7) Permanent Works, including materials for such Works, shall be protected from exposures of weather conditions that may adversely affect such Permanent Works or materials.

(8) During construction of the Works storm restraint systems shall be provided where appropriate. These systems shall ensure the security of the partially completed and on-going stages of construction and in all weather conditions. Such storm restraint systems shall be installed as soon as practicable and shall be compatible with the right of way, or other access around or throughout the Site.

(9) The Contractor shall at all times programme and order progress of the work and make all protective arrangements such that the Works can be made safe in the event of storms. PROTECTION OF THE WORK

(10) The finished works shall be protected from any damage that could arise from any activities on the adjacent site/ works.

8. DAMAGE AND INTERFERENCE (1) Work shall be carried out in such a manner that there is no damage to or

interference with: a. watercourses or drainage systems; b. utilities; c. structures (including foundations), roads, including street furniture, or other

properties; d. public or private vehicular or pedestrian access; e. monuments trees, graves or burial grounds other than to the extent that is

necessary for them to be removed or diverted to permit the execution of the Works. Heritage structures shall not be damaged or disfigured on any account. The Contractor shall inform the Engineer as soon as practicable of any items which are not stated in the Contract to be removed or diverted but which the Contractor considers need to be removed or diverted to enable the Works to be carried out. Such items shall not be removed or diverted until the consent of the Engineer to such removal or diversion has been obtained.

(2) Items which are damaged or interfered with as a result of the Works and items which are removed to enable work to be carried out shall be reinstated to the satisfaction of the Engineer and to at least the same condition as existed before the work started. Any claims by Utility Agencies due to damage of utilities by the Contractor shall be borne by the Contractor.

UTILITIES (3) Please refer Employer’s Requirement - Functional STRUCTURES, ROADS AND OTHER PROPERTIES (4) The Contractor shall immediately inform the Engineer of any damage to structures,

roads or other properties. ACCESS



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(5) Alternative access shall be provided to all premises if interference with the existing access, public or private, is necessary to enable the Works to be carried out. The arrangements for the alternative access shall be as agreed by the Engineer and the concerned agency. Unless agreed otherwise, the permanent access shall be reinstated as soon as practicable after the work is complete and the alternative access shall be removed immediately as it is no longer required, and the ground surfaces reinstated to the satisfaction of the Engineer. Proper signage and guidance shall be provided for the traffic / users regarding diversions.

TREES (6) The felling of trees in Pune District is governed by the THE MAHARASHTRA

(URBANAREAS) PROTECTION AND PRESERVATION OF TREES ACT, 1975. The Contractor is not permitted to cut any trees without the permission of the Employer. The Employer has assessed the number of trees existing within the right-of-way and has arranged permission from Forest Department cutting back or removal of trees which are deemed to be affected by the right of way (ie. within the limits of permanent works) construction works. The trees requiring to be felled will be removed from ground level up by the Contractor prior to commencement of the works. The Contractor will not be permitted to cut or remove any further trees. If for the purposes of the works additional trees are required to be cut/trimmed or removed, the Contractor must notify the Engineer of further tree felling requirements. Subject to compliance with the aforementioned act, arrangements for permission from Forest Department for tree felling may be made by the Employer. The payment of tree cutting, removal, transportation required in this item shall be paid as provided in relevant schedule of BOQ.

REMOVAL OF GRAVES AND OTHER OBSTRUCTIONS (7) If any graves and other obstructions are required to be removed in order to execute

the Works and such removal has not already been arranged for, the Contractor shall draw the Engineer's attention to them in good time to allow all necessary arrangements and authorisations for such removal, and it shall not itself remove them unless the Engineer has given consent.

PROTECTION OF THE ADJACENT STRUCTURES AND WORKS (8) The Contractor shall take all necessary precautions to protect the structures or

works being carried out by others adjacent to and, for the time being, within the Site from the effects of vibrations, undermining and any other earth movements or the diversion of water flow arising from its work.

9. WORK ON ROADS (1) Traffic Management Plan

The Contractor shall develop a detailed Traffic Management Plan for the work under the contract. The purpose is to develop a Traffic Management Plan to cope with the traffic disruption as a result of construction activities by identifying strategies for traffic management on the roads and neighbourhoods impacted by the construction activities. The Contractor shall implement the Traffic Management Plan throughout the whole period of the Contract. Principles for Traffic Management The basis for the Plan shall take into consideration four principles:

to minimise the inconvenience of road users and the interruption to surface traffic through the area impacted by the construction activities;

to ensure the safety of road users in the impacted area;

to facilitate access to the construction site, and to maintain reasonable construction progress.

to ensure traffic safety at each construction site. Integrated Traffic Management Plan The Contractor shall prepare an integrated plan showing the arrangements to be made for accommodating road and pedestrian traffic, at individual construction sites and continuously along the alignment, to smooth traffic operations and for the safety of both construction workers and road users. The Plan shall consider different measures such as:

proper phasing and timing of traffic signals;

modifications to intersection geometry;

changes in lane usage;

parking prohibitions;

re-location of bus stops;



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reducing width of footpaths and median;

right-turn prohibition;

work site access management;

minimising the duration of any road closure;

reversible lane operations;

modification of roadway alignment affected by the construction, which shall be in conformance with the requirements and regulations defined by the relevant authorities; and may include widening of roads, Construction of temporarily new road etc.

other traffic engineering measures as may be applicable.

(2) Mitigation of Traffic Disturbances The Contractor shall manage the vehicular and pedestrian right of way during the period of construction. The Contractor shall take account of the need to maintain essential traffic requirements, as these may influence the construction process. The Contractor shall include local traffic diversion routes and assess traffic impacts caused by the construction in the affected areas. Signage layout shall be included to ensure that adequate motorist information will be provided for traffic diversions. Where it becomes necessary to close a road or intersection, or supplementary lanes are required to satisfy the traffic demands, traffic diversion schemes to adjacent roadways shall be developed with quantitative justifications. The Contractor shall co-ordinate with all relevant authorities. Other considerations include:

The minimum lane widths for fast traffic and mixed traffic shall follow the regulations of the different authorities.

Any roads or intersections that have no alternative access shall not be fully closed for construction.

Emergency access to all properties shall be maintained at all times.

Access to business premises and property shall be maintained to the extent that normal activities are not seriously disrupted.

Minimum footpath width shall be 1.5 m, unless otherwise indicated. The footpath shall be separated from vehicle traffic and not necessarily immediately adjacent to vehicle traffic;

Where existing footbridges and underpasses are demolished or closed, provisions shall be made for pedestrian crossing to minimise the conflicts between a traffic lane.

Construction traffic shall be separated from other traffic wherever possible;

Any traffic related facilities (bus stops, parking, etc.) which are affected by the construction works shall be maintained or relocated to appropriate locations;

Motorists, pedestrians, workmen, plant and equipment shall be protected from accident at all times;

Roadway designs, traffic management schemes, and installation of traffic control devices shall be in conformance with the requirements and regulations defined by the relevant authorities; and

Where applicable, utility diversions shall be incorporated in the traffic management plan.

APPROVAL FOR TEMPORARY TRAFFIC ARRANGEMENTS AND CONTROL (3) The Contractor shall make all arrangements with and obtain the necessary approval

from the transport authorities and the Police Department for temporary traffic arrangements and control on public roads. In the event that the Contractor, having used its best endeavours, fails to secure the necessary approval from the transport authorities and the Traffic Police Department for temporary traffic arrangements and control on public roads, then the Employer will use its best endeavours to assist the Contractor to secure such approval but without responsibility on the part of the Employer to do so.

TEMPORARY TRAFFIC ARRANGEMENTS AND CONTROL (4) Temporary traffic diversions and pedestrian routes shall be surfaced and shall be

provided where work on roads or footpaths obstruct the existing vehicular or pedestrian access. The relevant work shall not be commenced until the approved temporary traffic arrangements and control have been implemented.



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(5) Temporary traffic arrangements and control for work on public roads and footpaths shall comply with the requirements of the Traffic Police. Copies of documents containing such requirements shall be kept on the Site at all times.

(6) Temporary traffic signs, including road marking, posts, backing plates and faces, shall comply with the requirements of the Traffic Police and should be in accordance with the requirements of Ministry of Surface Transport. All overhead traffic management signs that are fixed to bridges and gantries shall be illuminated at night. Pedestrian routes shall be illuminated at night to a lighting level of not less than 50 lux.

(7) Adequate number of traffic marshals shall be deployed for smooth regulation of traffic.

(8) Temporary traffic arrangements and control shall be inspected and maintained regularly, both by day and night. Lights and signs shall be kept clean and legible. Equipment which are damaged, dirty, incorrectly positioned or not in working order shall be repaired or replaced promptly.

PARTICULARS OF TEMPORARY TRAFFIC ARRANGEMENTS AND CONTROL (9) The following particulars of the proposed temporary traffic arrangements and

control on public roads shall be submitted to the Engineer for consent at least 28 days before the traffic arrangements and control are implemented:

(a) details of traffic diversions and pedestrian routes; (b) details of lighting, signage, guarding and traffic control arrangements and

equipment; (c) any conditions or restrictions imposed by Traffic Police or any other relevant

authorities, including copies of applications, correspondence and approval. (10) Where concrete barriers are used to separate flows of traffic, the barriers shall be

in a continuous unbroken line. No gaps shall be left between any section of the barrier.

(11) Site perimeter fencing and barriers along the roadway, shall have flashing amber lights positioned on the top of them every 50 metres apart and at every abrupt change in location. Directly below the flashing light shall be fixed, in the vertical position, a white fluorescent light with a waterproof cover.

USE OF ROADS AND FOOTPATHS (12) Public roads and footpaths on the Site in which the work is not being carried out

shall be maintained in a clean and passable condition. (13) Measures shall be taken to prevent the excavated materials, silt or debris from

entering gullies on roads and footpaths; entry of water to the gullies shall not be obstructed.

(14) Surfaced roads on the Site and leading to the Site shall not be used by tracked vehicles unless protection against damage is provided.

(15) Contractor's Equipment and other vehicles leaving the Site shall be loaded in such a manner that the excavated material, mud or debris will not be deposited on roads. All such loads shall be covered or protected to prevent dust being emitted. The wheels of all vehicles shall be washed when necessary before leaving the Site to avoid the deposition of mud and debris on the roads.

REINSTATEMENT OF PUBLIC ROADS AND FOOTPATHS Temporary diversions, pedestrian access and lighting, signing, guarding and traffic control equipment shall be removed immediately when they are no longer required. Roads, footpaths and other items affected by temporary traffic arrangements and control shall be reinstated to the same condition as existed before the work started or as permitted by the Engineer immediately after the relevant work is complete or at other times permitted by the Engineer. The cost of same shall paid as per BOQ. The Contractor shall submit his design for the reinstatement to the relevant authorities and obtain their prior approval to carrying out the work. Reinstatement works shall include:

Parking bays

Footpath and kerbs

Road Signage

Street Lighting

Landscaping

Traffic Lights and Control Cable

Road painting 10. SITE ESTABLISHMENT



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SITE LABORATORIES (1) The Contractor shall provide, erect and maintain in a clean, stable and secure

condition a laboratory, equipped for the routine testing of concrete, soil and rock samples and for the storage and curing of concrete cubes or cylinders only. This laboratory shall be located at the Contractor's principal work site or at a location agreed to by the Engineer. Detailed requirements for this laboratory are set out in Appendix 7 to these Employer's Requirements.

CONTRACTOR'S SITE ACCOMMODATION (2) The Contractor shall provide and maintain its own site accommodation at locations

consented to by the Engineer. Offices, sheds, stores, mess rooms, garages, workshops, latrines and other accommodation on the Site shall be maintained in a clean, stable and secure condition. Living accommodation shall not be provided on the Site. The Contractor shall comply with the requirements of Appendix 8 to the Employer's Requirement.

LATRINES AND WASHPLACES (3) The Contractor shall provide latrines and wash places for the use of its personnel

and all persons who will be on the Site. The size and disposition of latrines and wash places shall accord with the numbers and dispositions of persons entitled to be on the Site, which may necessitate their location on structures and, where necessary there shall be separate facilities for males and females. The capacities and layout shall be subject to approval of the Engineer. The Contractor shall arrange regular disposal of effluent and sludge in a manner that shall be in accordance with local laws/ regulations. The Contractor shall be responsible for maintaining all latrines and wash places on the Site in a clean and sanitary condition and for ensuring that they do not pose a nuisance or a health threat. The Contractor shall also take such steps and make such provisions as may be necessary or directed by the Engineer to ensure that vermin, mosquito breeding etc. are at all times controlled.

SITE UTILITIES AND ACCESS (5) (a) The Contractor shall be responsible for providing water, electricity, telephone,

sewerage and drainage facilities for contractors site offices, structures and buildings and for all site laboratories in accordance with Appendix 14 to these Employer's Requirements and all such services that are necessary for satisfactory performance of the Works. The Contractor shall make all arrangements with and obtain the necessary approval from the relevant civil and utility authorities for the facilities. The contractor shall be responsible for provision of power supply for his works including for launching girder and the like. The Employer can not guaranty provision of adequate, continuous power supply however assistance will be given in obtaining the necessary permissions for site generators and the like.

(6) Access roads and parking areas shall be provided within the Site as required and shall be maintained in a clean, acceptable and stable condition. For lengths of roadway longer than 100 m and where vehicle movements exceed one hundred (100) movements/day and heavy commercial vehicle are to ply the Contractor shall provide paved surfacing of adequate thickness and quality to the satisfaction the Engineer.

ASSISTANCE TO ENGINEER - Deleted (7) Any operation of the Works that interferes with the checking of lines and levels

shall be temporarily suspended at the request of the Engineer until the checking is complete.

SUBMISSION OF PARTICULARS (8) The following particulars shall be submitted to the Engineer for his consent not

more than fifty-six (56) days after the date of commencement of the Works: (a) drawings showing the formation works and the layout within earmarked area for the Contractor's offices, project signboards, principal access and other major facilities required early in the Contract, together with all service utilities; (b) drawings showing the details to be included on the project signboards and diversion boards.

(9) Drawings showing location of stores, storage areas, concrete batching plants and other major facilities +and their access roads/paths shall be submitted to the Engineer for his consent as early as possible but in any case not less than twenty-



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eight (28) days prior to when such facilities are intended to be constructed on the Site.

11. SECURITY The Contractor shall be responsible for the security of the Site for the full time the

Site is in its possession, except for the specific case of the Railway Envelope after handover to the Railway Operator It shall set up and operate a system whereby only those persons entitled to be on the Site can enter the Site. To this end, the Contractor shall with the consent of Engineer provide the specific points only at which entry through the security fence can be effected, and shall provide gates and barriers at such points of entry and whereby maintain a twenty-four (24) hours security guard, and such other security personnel and patrols elsewhere as may be necessary to maintain security. The Contractor shall maintain all site boundary fences in first class condition, and shall so arrange site boundary fences at all access drainage points of work areas that it’s use of such access points etc., are not restricted by the system or method of achieving the required security measures. Notices shall be displayed at intervals around the Site to warn the public of the dangers of entering the Site. During the progress of the Works the Contractor shall maintain such additional security patrols over the areas of the Works as may be necessary to protect its own and its sub-contractor's work and equipment and shall co-ordinate and plan the security of both the work under this Contract and the work of others having access to and across the Site and the Works. In order to operate such a security system, it will be necessary to institute the issue of unique passes to personnel and vehicles entitled to be on the Site, and which may need to be separately identifiable according to the shifts being worked on Site. The Contractor shall at the outset determine, together with the Engineer, a system and the design of passes to suit the requirements of the foregoing and to suit the methods of work to be adopted by the Contractor. The Contractor shall at all times ensure that the Engineer has an up to date list of all persons entitled to be on the Site at any time. The contractor shall also introduce a system of issue passes to any outsider or person/vehicles belonging to agencies other than employer/ Engineers who may have to visit the site in connection with work The Contractor shall liase with the Designated Contractors and the contractors responsible for the adjacent and other interfacing contracts and ensure that co-ordinated security procedures are operated, in particular in respect of vehicles permitted to pass through the Site and/or the adjacent sites in the latter periods of the Contract. Security and checking arrangements as felt necessary shall be provided with advise and help of Police.

12. TESTING GENERAL (1) The Contractor shall provide and perform all forms of testing procedures applicable

to the Works and various components and the interfacing of the Works with the other Contract works and shall conduct all necessary factory, site and acceptance tests.

(2) Deleted (3) All testing procedures shall be submitted at least thirty (30) days prior to

conducting any Test. The Testing procedures shall show unambiguously the extent of testing covered by each submission, the method of testing, the Acceptance Criteria, the relevant drawing (or modification) status and the location.

(4) The testing Procedures shall be submitted, as required, by the Contractor during the duration of the contract to reflect changes in system design or the identification of additional testing requirements.

(5) The Engineer shall have the facilities for monitoring all tests and have access to all testing records. Ample time shall be allowed within the testing programmes for necessary alterations to equipment, systems and designs to be undertaken, together with re-testing prior to final commissioning.

(6) The Contractor is reminded that at some point, the High Voltage Power Supply system will be energised and the additional precautions for the safety of staff and co-ordination of activities after power-on shall be anticipated in its testing and commissioning programmes.

(7) All costs associated with the Testing shall be borne by the Contractor, unless otherwise specified, including the services of any specialised personnel or



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independent assessors. The Contractor shall also bear any expenses incurred due to resetting caused by defects or failure of equipment to meet the requirements of the Contract in the first instance.

(8) Unless agreed in writing by the Engineer, the personnel engaged on testing shall be independent of those directly engaged in the design or installation of the same equipment.

(9) All testing equipment shall carry an appropriate and valid calibration labels. BATCHES, SAMPLES AND SPECIMENS (10) A batch of material is a specified quantity of the material that satisfies the

specified conditions. If one of the specified conditions is that the material is delivered to the Site at the same time, then material delivered to the Site over a period of a few days may be considered as part of the same batch if in the opinion of the Engineer there is sufficient proof that the other specified conditions applying to the batch apply to all of the material delivered over the period.

(11) A sample is a specified quantity of material that is taken from a batch for testing and which consists of a specified amount, or a specified number of pieces or units, of the material.

(12) A specimen is the portion of a sample that is to be tested. SAMPLES FOR TESTING (13) Samples shall be of sufficient size and in accordance with relevant Standards to

carry out all specified tests. (14) Samples taken on the Site shall be selected by, and taken in the presence of, the

Engineer and shall be suitably marked for their identification. An identification marking system should be evolved at the start of works in consultation with the Engineer.

(15) Samples shall be protected, handled and stored in such a manner that they are not damaged or contaminated and such that the properties of the sample do not change.

(16) Samples shall be delivered by the Contractor, under the supervision of the Engineer, to the specified place of testing. Samples on which non-destructive tests have been carried out shall be collected from the place of testing after testing and delivered to the Site or other locations instructed by the Engineer.

(17) Samples which have been tested may be incorporated in the Permanent Works provided that: (a) the sample complies with the specified requirements; (b) the sample is not damaged; and (c) the sample is not required to be retained under any other provision of the Contract.

(18) Additional samples shall be provided for testing if in the opinion of the Engineer: (a) material previously tested no longer complies with the specified requirements; or (b) material has been handled or stored in such a manner that it may not comply with the specified requirements.

TESTING (19) The Contractor shall be responsible for all on-site and off-site testing and for all in-

situ testing. All appropriate laboratory tests shall be carried out in the Contractor's laboratory, unless otherwise permitted or required by the Engineer. Where the laboratory is not appropriately equipped and/or staffed for some tests, or if agreed to by the Engineer, tests may be carried out in other laboratories provided that: (a) they are accredited for the relevant work to a standard acceptable to the Engineer; and (b) particulars of the proposed laboratory are submitted to the Engineer for his consent.

(20) In-situ tests shall be done in the presence of the Engineer. (21) Equipment, apparatus and materials for in-situ tests and laboratory compliance

tests carried out by the Contractor shall be provided by the Contractor. The equipment and apparatus shall be maintained by the Contractor and shall be calibrated before the testing starts and at regular intervals as permitted by the Engineer. The equipment, apparatus and materials for in-the situ tests shall be removed by the Contractor as soon as practicable after the testing is complete.



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(22) The Contractor shall be entitled in all cases to attend the testing carried out in the Employer's or other laboratories, to inspect the calibration certificates of the testing machines and to undertake the testing on counterpart samples. Testing of such samples shall be undertaken in laboratories complying with Clause 12(19)(a) above and particulars of the laboratory proposed shall be submitted to the Engineer for consent prior to the testing.

(23) Attendance on tests, including that by the Engineer, Contractor and Designer, shall be as laid down in the Quality Assurance procedures.

COMPLIANCE OF BATCH (24) The results of tests on samples or specimens shall be considered to represent the

whole batch from which the sample was taken. (25) A batch shall be considered as complying with the specified requirements for a

material if the results of specific tests for of the specified properties comply with the specified requirements for the properties.

(26) If additional tests are permitted or required by the Engineer but separate compliance criteria for the additional tests are not stated in the Contract, the Engineer shall determine if the batch complies with the specified requirements for the material on the basis of the results of all tests, including the additional tests, for every properties.

RECORDS OF TESTS (27) Records of in-situ tests and laboratory compliance tests carried out by the

Contractor shall be kept by the Contractor on the Site and a report shall be submitted to the Engineer within seven (7) days, or such other time stated in the Contract or in the Quality Assurance Programme, after completion of each test. In addition to any other requirements, the report shall contain the following details: (a) material or part of the Works tested; (b) location of the batch from which the samples were taken or location of the

part of the Works; (c) place of testing; (d) date and time of tests; (e) weather conditions in the case of in-situ tests; (f) technical personnel supervising or carrying out the tests; (g) size and description of samples and specimens; (h) method of sampling; (i) properties tested; (j) method of testing; (k) readings and measurements taken during the tests; (l) test results, including any calculations and graphs; (m) specified acceptance criteria; and (n) other details stated in the Contract.

(28) Reports of tests shall be signed by the site agent or his assistant, or by another representative authorised by the Contractor.

(29) If requested, records of tests carried out by the Employer's staff or by the Engineer shall be given to the Contractor.

13. RECORDS DRAWINGS PRODUCED BY THE CONTRACTOR Drawings produced by the Contractor including drawings of site layouts, Temporary Works, etc. for submission to the Engineer shall generally be to ISO A1 size. They shall display a title block with the information as detailed in Appendix 7 to these Employer's Requirements. The number of copies to be submitted to the Engineer shall be as stated in the Contract, or as required by Engineer. PROGRESS PHOTOGRAPHS The Contractor shall provide monthly progress photographs which have been properly recorded to show the progress of the works to the Engineer. The photographs, of not less than 72 in number, shall be taken on locations agreed with the Engineer to record the exact progress of the Works. Two sets of photographs shall be provided on CD ROM format with two sets of colour prints of 175 mm x 125 mm size. The Contractor shall mount each set of each month's progress photographs in a separate album of a type to which the Engineer has given his consent, and shall provide for each photograph two typed self-adhesive labels, one of which shall be mounted immediately below the photograph and one on the back of the photograph. Each label shall record the



Maha-Metro June-18

location, a brief description of the progress recorded and the date on which the photograph was taken. All photographs shall be taken by a skilled photographer whose name and experience shall be submitted to the Engineer for consent and approval received. Processing shall be carried out by a competent processing firm to the satisfaction of the Engineer. The Contractor shall ensure that no photography is permitted on the Site without the agreement of the Engineer. Contractor should be aware of the local regulations and conditions with regard to Photography in some “RESTRICTED AREA’ in Nagpur. RECORDS OF WAGE RATES The Contractor shall keep monthly records of the average, high and low wage rates for each trade/tradesman employed on the Site and records shall be made available to the Engineer during inspection.

14. MATERIALS (1) Materials and goods for inclusion in the Permanent Works shall be new unless the

Engineer has consented otherwise. Preference shall be given to local materials where available. Approved Manufacturers/Suppliers of few important items have been given in Appendix 10 of this document. These materials shall be procured only for these manufacturers/Suppliers.

(2) Certificates of tests by manufacturers which are to be submitted to the Engineer shall be current and shall relate to the batch of material delivered to the Site. Certified true copies of certificates may be submitted if the original certificates could not be obtained from the manufacturer.

(3) Parts of materials which are to be assembled on the Site shall be marked to identify the different parts.

(4) Materials which are specified by means of trade or proprietary names may be substituted by materials from a different manufacturer which has received the consent of the Engineer provided that the materials are of the same or better quality and comply with the specified requirements.

(5) Samples of materials submitted to the Engineer for information or consent shall be kept on the Site and shall not be returned to the Contractor or used in the Permanent Works unless permitted by the Engineer. The samples shall be used as a mean of comparison which the Engineer shall use to determine the quality of the materials subsequently delivered. Materials delivered to the Site for use in the Permanent Works shall be of the same or better quality as the samples which have received consent.

PROVISION AND DISPOSAL OF EARTHWORKS MATERIAL The Contractor shall be responsible for the provision of all classes of earthworks material required for the Works, whether sourced from the excavations within the Contract or obtained from any other sources, which are located outside the Site, for which the Engineer has given the consent. For fill or dumping sites, the Contractor shall prepare a land plan with details of surface drainage requirements, final formation levels, spreading and compaction of the fill during dumping acceptable to the Engineer. The Contractor shall also provide security for such sites. The dumping sites to be used by the Contractor shall be as directed by the Engineer. All excavated material, excluding waste material, bentonite fluid and bentonite contaminated material shall be disposed of at the appointed site only. This material shall be placed and compacted in accordance with the Construction Specification for Earth Works or as otherwise directed by the Engineer's Representative. The disposal of waste material, bentonite fluid and material contaminated with bentonite shall be the full responsibility of the Contractor and these materials shall be disposed of by the Contractor at an approved location. The dumping sites provided by the Employer shall not be used for disposal of waste material, bentonite fluid or material contaminated with bentonite. Rock deposited as fill material at the dumpsites shall be capable of compaction with single pieces no larger than 300mm.

15. PROVISIONS FOR DESIGNATED CONTRACTORS -DELETED 16. RESTORATION OF AREAS DISTURBED BY CONSTRUCTION.

Unless otherwise directed by the Engineer, any areas disturbed by the construction activity, either inside or outside the Project Right of Way, shall be reinstated as follows: All areas affected by the construction work shall be reinstated to their original condition, with new materials, including but not necessarily limited to, sidewalks, parking lots, access



Maha-Metro June-18

roads, adjacent roads properties and landscaping. Grass cover shall be provided for any bare earth surface areas, along with proper provisions for surface drainage.

17. LANDSCAPING Landscaping design must be submitted to the relevant authorities and match the remaining areas. In addition, the Contractor shall carry out the design and construction of landscaping for all works areas and will submit his proposals to the relevant authorities for approval before commencement of landscaping works.

18. CONTRACTORS LABOUR CAMPS

(1) The employer will not provide living accommodation for use of the contractor or any of his staff or labour employed on the works. Living accommodation shall not be established on any land provided to the contractor by the employer for the works.

(2) Provisions of Labour Camps. The contractor, shall, at his own expense make adequate arrangements for the housing, supply of drinking water and provisions for bathrooms, latrines and urinals, with adequate water supply for his staff as well as for workman employed on the works directly or through subcontractors at the locations authorized by engineers. No labour camp shall be allowed at work site or any unauthorized place. The contractor at his own cost shall maintain all camp site in a clean and sanitary conditions, the contractor shall obey all health and sanitary rules and regulations and carry out at his cost all health and sanitary measures, that may from time to time be prescribed by the local/medical authorities and permit inspection of all health and sanitary arrangements at all times by the employer, the employer and the staff of the local municipality or the other authority concerned. Should the contractor failed to provide adequate health and sanitary arrangement these shall be provided by the Employer and the cost recovered from the contractor.

The contractor shall, at his own cost, provide first-aid and medical facilities at the labour camp and at work sites on the advice of the medical authority consistent with the strength of the contractor’s staff and workman, employed directly or through subcontractors. The contractor shall at his own cost, provide the following minimum requirements for meeting the fire hazards.

Portable fire extinguishers

Manual fire alarms

Water supply for use by the fire service.

The contractor at his own cost shall provide necessary arrangements for keeping the camp area sufficiently lighted to avoid accidents to the workers. He should also ensure that electrical installations done by trained electricians. These installations shall be maintained and daily maintenance record must be made available for inspection by the engineer.

(3) CAMP DISCIPLINE



Maha-Metro June-18

The contractor shall take requisite precautions, use his best endeavours to prevent any riotous or unlawful behaviour by or amongst his workmen, others, employed directly or through sub- contractors. These precautions shall be for the preservation of the peace and protection of the inhabitants and the security of the property in the neighbourhood of the Works. In the event of the Employer requiring the maintaining of a Special Police Force at or in the vicinity of the site, during the tenure of the work, the expenses thereof shall be borne by the contractor and if paid by the Employer, shall be recoverable from the contractor.

The sale of alcoholic drinks or other intoxicating drugs or beverages upon the work, in any labour camp, or in any of the buildings, encampments or tenements, own or occupied by, or with the control of, the contractor or any of his personnel employed on the work directly or through sub-contractors shall be forbidden, and the contractor shall exercise his influence and authority to secure strict compliance with this condition. The contractor shall also ensure that no labour or employees are permitted to work at the site in an intoxicated state or under the influence of drugs. The contractor shall remove from his camp such labour and their families, as refuse protective inoculation and vaccination when called upon to do so by the Engineer on the advice of his Medical Authority. Should Cholera, Plague or any other infectious disease break out, the Contractor shall at his own cost burn the huts, bedding, cloths and other belongings of or used by the infected parties. The contractor shall promptly erect new heads on healthy sides as required by the Employer. Within the time specified by the Employer, failing which the work may be done by the Employer and the cost recovered from the Contractor.

(4) LABOUR ACCOMODATION The contractor shall provide living accommodation that is equal to or exceeds the minimum criteria established in the following sub-sections, needed to house his staff as well as workers employed directly or through sub-contractor. The buildings shall be constructed so as to have a minimum life of not less than the length of contract.

(a) The roof shall be watertight and laid with suitable non-flammable materials permissible for residential use under local regulation and for which the consent of the Engineer has been obtained.

(b) Each hut shall have suitable ventilation. All doors, windows, and ventilators shall be provided with security leaves and fasteners. Back to back units may be avoided.

(c) The minimum height of each unit shall be 2.1m and shall have separate cooking place.

(d) Suitable number of common toilets/bath shall be provided.

(5) WATER SUPPLY The contractor shall provide an adequate supply of water for the use of labours in the camp. The provisions shall not be less than two gallons of pure and wholesome water per head per day for drinking purposes and three gallons of clean water per head per day for bathing and washing purposes. Where piped water supply is available, supply shall be at stand post and where the supply is from wells or river, tanks that may be of metal or masonry shall be provided. The contractor shall also at his expense make arrangements for the provision and laying of water pipe lines from the existing mains wherever available and shall pay for all the fees and charges thereof.

(6) Drainage The contractor shall provide efficient arrangements for draining away sullage water so as to keep the camp neat and tidy. Surface water shall be drained away from the paths and roads and shall not be allowed be allowed to accumulate into ditches or ponds where mosquitoes can breed.

(7) Sanitation The contractor shall make arrangements for conservancy and sanitation in the labour camps according to the rules and regulations of the Local Public Health and Medical Authorities. The contractor shall provide a sewerage system that is adequate for the number of the residents in the camp and which meets the requirements of the Municipal Authorities.

MAHA-METRO Tender No. P1C-06/2018 Part – 2: Work Requirement Section VII-B: Particular Specification

MAHA-METRO June-18 Section VII-B: Page 1


BID DOCUMENTS

FOR



MAHARASHTRA METRO RAIL CORPORATION LTD

(A joint venture of Govt. of India & Govt. of Maharashtra) 101, The Orion, Opposite Don Bosco Youth Centre,

Koregaon Park, Pune- 411001 E-mail: mahametrorail.etenders.in Website: www.punemetrorail.org

Telephone: 020-26051072

PART II: WORK REQUIREMENT

SECTION VII-B: Particular Specifications

(Station)

Tender No.

P1C-06/2018



MAHA-METRO Tender No. P1C-06/2018 Part – 2: Work Requirement Section VII-B: Particular Specification


Contents of Section VII-B: (Station)

Particular Specifications

General Specification - Construction

Structural

Architectural

Public Health Engineering

Electrical, HVAC & Fire Fighting

IGBC Scope


Section VII-B: Particular Specification

- Construction (Station)


PARTICULAR SPECIFICATION –CONSTRUCTION

(STATION)





1 GENERAL REQUIREMENTS – CONSTRUCTION 1.1 Any error in the execution of work leading to redesign work shall be duly compensated by

the Contractor as per the decision of Engineer. Any error attributable to the construction including Failure to locate underground utilities shall attract penalties.

1.2 Unless otherwise permitted by the Engineer all works shall be carried out in dry conditions. 1.3 The Works, including materials for using in the Works, shall be protected from damage due

to water. Water on the Site and water entering the Site shall be promptly by temporary drainage or pumping system or by other methods capable of keeping the Works free of water. Silt and debris shall be removed by traps before the water is discharged and shall be disposed of at a location or locations to which the Engineer has given his consent.

1.4 The discharge points of the temporary systems shall be as per the consent of the Engineer. The Contractor shall make all arrangements with and obtain the necessary approval from the relevant authorities for discharging water to drains, watercourses etc. The relevant work shall not be commenced until the approved arrangements for disposal of the water have been implemented.

1.5 The methods used for keeping the Works free of water shall be such that settlement of, or damage to, new and existing structure does not occur. Measures shall be taken to prevent flotation of new and existing structures.

2 PROTECTION OF THE WORKS FROM WEATHER 2.1 Work shall not be carried out in weather conditions that may adversely affect the Works

unless proper protection is provided to the satisfaction of the Engineer. 2.2 Permanent Works, including materials for such Works, shall be protected from exposures of

weather conditions that may adversely affect such Permanent Works or materials. 2.3 During construction of the Works storm restraint systems shall be provided where

appropriate. These systems shall ensure the security of the partially completed and on-going stages of construction in all weather conditions. Such storm restraint systems shall be installed as soon as practicable and shall be compatible with the right of way, or other access around or throughout the Site.

2.4 The Contractor shall at all-time programme and carry out the work duly ensure protective arrangements such that the Works can be made safe in the event of storms.

3 PROTECTION OF THE FINISHED WORK 3.1 The finished Works shall be protected from any damage that could arise from any activities

on the adjacent site / works. 4 DAMAGE AND INTERFERENCE 4.1 Work shall be carried out in such a manner that there is no damage to or interference with:

a. Watercourses or drainage systems: b. Utilities c. Structures(including foundations)roads, including street fixtures, or other properties: d. Public or private vehicular or pedestrian access: e. Monuments, temples, graves or burial grounds other than to the extent that is

necessary for them to be removed or diverted to permit the execution of the Works. Heritage structures shall not be damaged or disfigured on any account.

The Contractor shall inform the Engineer as soon as practicable of any items which are not stated in the Contract to be removed or diverted but which the Contractor considers necessary to be removed or diverted to enable the Works to be carried out. Such items shall not be removed or diverted until the consent of the Engineer to such removal or diversion has been obtained.

4.2 Items which are damaged or interfered with as a result of the Works and items which are removed to enable the Works to be carried out shall be reinstated to the satisfaction of the Engineer and to at least the same condition as existed before the Work started. Any claims by Utility Agencies due to damage of utilities by the Contractor shall be borne by the Contractor.

5 STRUCTURES, ROADS AND OTHER PROPERTIES 5.1 The Contractor shall immediately inform the Engineer of any damage to structures, roads or

other properties. 6 ALTERNATIVE ACCESS 6.1 Alternative access shall be provided to all premises if interference with the existing access,

public or private is necessary to enable the Works to be carried out. The arrangements for the alternative access shall be as agreed by the Engineer and the concerned agency. Unless agreed otherwise, the permanent access shall be reinstated as soon as practicable after the





work is complete and the alternative access shall be remove immediately it is no longer required, and the ground surfaces reinstated to the satisfaction of the Engineer. Proper signage and guidance shall be provided for the traffic / users regarding diversions.

7 TRANSPLANTED / CUTTING OF TREES 7.1 The felling of trees in the Pune District is governed by THE MAHARASHTRA (URBAN AREAS)

PROTECTION AND PRESERVATION OF TREES ACT, 1975. The Contractor is not permitted to cut any tree in terms of the provisions of the aforementioned Act. The Employer has assessed the number of trees existing within the right-of-way and has arranged for cutting and removal of trees, which are likely to be affected by the right of way (i.e., within the limits of permanent works) construction works. The trees requiring to be felled will be removed from ground level up by the Employer prior to commencement of the works. However, if the need arises, the Contractor may have to cut and remove the trees as directed by the Employer. Payment shall be made according to item regarding Tree Cutting in BOQ item 7 Schedule-A

7.2 The Contractor shall carefully survey the site and identify the additional trees, if any which are coming within the footprints of the permanent structure / building and within the space required for forming slopes / benching etc., for excavation of the basements and are required to be cut / trimmed. The Contractor must notify the Engineer of such requirements well in advance.

7.3 On receipt of the submission by the Contractor giving such details, the Engineer shall arrange to verify the requirement of additional tree cutting / removal and identify the trees, which can be transplanted subject to compliance with the aforementioned Act. These requirements and details will be forwarded to Forest Department for getting the permission. Contractor shall liase with the Forest Department for getting the permission. The Contractor shall also submit a detailed procedure approved by the Engineer for such transplantation duly assisted by competent horticulturist. The trees shall be transplanted at the site as directed by the Engineer. If the Contractor is able to obtain permission for tree cutting from the concerned authority, then such trees can be cut / transplanted by the Contractor and any replacement carried out by the Contractor. Alternatively, arrangements for tree felling / transplantation of the additional trees may be made by the Employer under separate contract and compensatory replacement of felled trees will also be made by the Employer.

8 REMOVAL OF GRAVES AND OTHERS OBSTRUCTIONS 8.1 If any grave and other obstructions are required to be removed in order to execute the

Works and such removal has not already been arranged for, the Contractor shall draw the Engineer's attention to them in good time to make necessary arrangement for authorizations for such removal. The Contractor shall not himself remove them unless the Engineer has given consent.

9 PROTECTION THE ADJACENT STRUCTURES AND WORKS 9.1 The Contractor shall be take all necessary precautions to protect the structures or works

being carried out by others adjacent to and, for the time being, within the Site from the effects of vibrations, undermining and any other earth movements or the diversion of water flow arising from its works

10 WORK ON ROADS 10.1 Traffic Management Plan

The Contractor shall develop a detailed Traffic Management Plan for the work under the contract in consultation with the Traffic Police and Engineer. The purpose is to develop a Traffic Management Plan to cope with the traffic disruption as a result of construction activities by identifying strategies for traffic management on the roads and neighbourhoods impacted by the construction activities. The Contractor shall implement the Traffic Management Plan, as approved, throughout the whole period of the Contract.

10.2 Principles for Traffic Management The basis for the Plan shall take into consideration four principles

To minimize the inconvenience of road users and the interruption to surface traffic through the area impacted by the construction activities

To ensure the safety of road users in the impacted area

To facilitate access to the construction site and to maintain reasonable construction progress.

To ensure traffic safety at each construction site.





11 SITE ESTABLISHMENT 11.1 Site Laboratories :- The Contractor shall provide. Erect and maintain in a clean, stable and

secure condition a laboratory, equipped for the routine testing of concrete, soil and rock samples and for the storage and curing of concrete cubes or cylinders. The laboratory shall be located at the Contractor's principle work site or at a location agreed to by the Engineer. Detailed requirements for this laboratory are set out in Special specifications.

11.2 Contractor's Site Accommodation :- The Contractor shall provide and maintain its own site accommodation at locations consented to by the engineer. Officers, sheds, casting yards), stores, mess rooms, garages, workshops, latrines and other accommodation on the Site shall be maintained in a clean, stable and secure condition. Living accommodation shall not be provided on the Site.

11.3 Latrines Wash places 11.3.1 The Contractor shall provide latrines and wash places for the use of its personnel and all

persons who will be at the above site establishments. The size and disposition of latrines and wash places shall accord with the numbers and dispositions of persons entitled to be on the Site. There shall be separate facilities for males and females. The capacities and layout shall be subject to approval of the Engineer. The Contractor shall arrange regular disposal of effluent and sludge in a manner that shall be in accordance with local laws/ regulations.

11.3.2 The Contractor shall be responsible for maintaining all latrines and wash places on the above site establishments in a clean and sanitary condition and for ensuring that they do not pose a nuisance or a health threat. The Contractor shall also take such steps and make such provisions as may be necessary or directed by the Engineer to ensure that vermin, mosquito breeding etc., are all time controlled.

11.4 Site Utilities and Access 11.4.1 The contractor shall be responsible for providing water, electricity, telephone sewerage &

drainage facilities & all such services that are necessary for satisfactory performance of the Works for all site accommodation, structures & buildings and for all site laboratories in accordance with Appendix V herein above. The contractor shall make all arrangements with & obtain the necessary approval from the relevant civic utility authorities for the facilities.

11.4.2 The Contractor shall be responsible for provision of power supply for his works. The Employer cannot guarantee to the Contractor provision of adequate, continuous power supply. However, assistance will be given by the Employer in obtaining the necessary permissions for installation of site generators and the like.

11.4.3 Access roads and parking areas shall be provided within the Site as required and shall be maintained in a clean, acceptable and stable condition. For lengths of roadways longer than 100m and heavy commercial vehicle are to play the Contractor shall provide paved surfacing of adequate thickness and quality to the satisfaction of the Engineer.

12 SUBMISSIONS OF PARTICULARS 12.1 The following particulars shall be submitted to the Engineer for his consent not more than

Thirty (30) days from the date of issue of Letter of Acceptance. Successful bidder shall note that Drawings shall be provided progressively in a timely manner.

Drawings showing the formation works and the layout within the Site of the Engineer's accommodation, the Contractor's officers, project signboards, principle access and other major facilities required early in the Contract, together with all service utilities

Drawings showing the layout & the construction details of the Engineer’s accommodation, and Drawing showing the details to be included on the project signboards and diversion boards

Drawings showing locations of stores, storage areas, concrete batching plants and other major facilities.

12.2 Drawings showing access roads/paths shall be submitted to the Engineer for his consent as early as possible but in any case, at least twenty eighty (28) days prior to the date when such facilities or intended to be constructed on the Site.

13 SECURITY 13.1 The Contractor shall be responsible for the security of the Site for the full times the site is

in his possession. The contractor shall set up and operate a system whereby only those persons entitled to be on the Site could enter the Site. To this end, the Contractor shall with the consent of Engineer provide the specific entry points only at which entry through the security fence can be effected, and shall provide gates and barriers at such points of entry & maintain a twenty-four(24) hours security guard. The Contractor shall also arrange





for such other security personal & patrols elsewhere as may be necessary to maintain security.

13.2 Contractor’s as well as his Sub Contractor’s employees and representative shall wear Identification Badges (cards), uniforms, helmets, safety: shoes/gum boots & other safety/ protection wear as directed by Engineer, and to be provided by the Contractor. Badges shall identify the Contractor/ Sub Contractor and show the employee's name and number and shall be worn at all times while at site.

13.3 All vehicles used by the Contractor/ Sun Contractor shall be clearly marked with the Contractor's / Sub Contractors name or identification mark.;

13.4 The Contractor shall maintain all site boundary fences in first class condition, and shall so arrange site boundary fences/ barricading and security measures that the drainage arrangement is not affected. Notices shall be displayed at intervals around the site to warm the public of the dangers of entering the Site during the progress of the Works. The contractor shall maintain such additional security patrols ever the areas of the Works as may be necessary to protect its own and its sub- Contractor's work and equipment.

13.5 The Contractor shall co-ordinate and plants the security of both the works under this Contract and the works of other encaged in adjacent and interfacing contractor's and requiring access to the site. In order to operate such a security system, it will be necessary to institute the issue of unique passes to personnel and vehicles entitled to be on the Site, system of separately identifiable according to the shifts being worked on Site. The Contractor shall at the outset determine, together with the Engineer, a system including the design of passes to suit the requirements of the foregoing and to suit the methods of works to be adopted by the Contractor. The Contractor shall at all times ensure that the Engineer has an up to date list of all persons entitled to be on the Site at any time. The Contractor shall also introduce a system for issue of passes to any outsider or persons/ vehicles belonging to agencies other than Employer/ Engineer who may have to visit the site in connection with work. The Contractor shall liase with the Designated Contractors and the contractors responsible for the adjacent and other interfacing contracts and ensures that co-ordinated security procedures are operated, in particular in respect of vehicles permitted to pass through the Site and/ or the adjacent sites.

13.6 Security and checking arrangements, as felt necessary shall be provided with advice and help of the Police.

14 RECORDS OF WAGE RATES 14.1 The Contractor shall keep monthly records of the average, high and low wage rates for each

trade/ tradesman employed on the Site and records shall be made available to the Engineer during inspection.

15 MATERIALS 15.1 Material and goods for inclusion in the Permanent Works shall be new unless the Engineer

has consented otherwise. 15.2 Certificates of tests by manufactures, which are to be submitted to the Engineer, shall be

current and shall relate to the batch of material delivered to the Site. Certified true copies of certificates may be submitted if the original certificates could not be obtained from the manufacturer. Parts of the materials, which are to be assembled on the Site shall be marked to identify the different parts.

15.3 Materials which are specified by means of trader or propriety names may be submitted by materials from a different manufacturer which has received the concerned of the Engineer provided that the materials are of the same or better quality and comply with the specified requirements.

15.4 Samples of materials submitted to the Engineer for information or consent shall be kept on the Site and shall not be returned to the Contractor or used in the Permanent Works unless permitted by the Engineer. The samples shall be used as a means of comparison, which the Engineer shall be used to determine the quality of the materials subsequently, delivered. Materials delivered to the Site for use in the Permanent Works shall be of the same work better quality of the samples, which have received consent.

16 PROVISION AND DISPOSAL OF EARTHWORKS / MATERIALS 16.1 The Contractor shall be responsible for the provision of all classes of earthworks material

required for the Works, whether sourced from the excavation within the Contractor obtained from any other source located outside the Site, for which the Engineer has given the concerned. For fill or dumping sites, the Contractor shall prepare a land plan with the details of surface drainage requirement, final formation levels and arrangement for





spreading and comparison of the filled during dumping as acceptable to the Engineer. The Contractor shall also provide security for the Site. The dumping site to be used by the Contractor shall be as directed by the Engineer.

16.2 All excavated material, excluding waste material,bentonite fluid & bentonite contaminated material shall be disposed of at the designated site only. This material shall be placed and compacted in accordance with the Construction specification for Earthwork or as otherwise directed by the Engineer's Representatives, the disposal of waste material, bentonite fluid and material contaminated with bentonite shall be the full responsibility of the Contractor and these materials shall be disposed of by the Contractor at an approved location in an approved manner. The dumping sites provided by the Employer shall be not be used for disposal of waste material, bentonite fluid or material contaminated with the bentonite.

16.3 Rock / Dismantled Concrete deposited as fill material at the dumpsites shall be capable of compaction with the single pieces no larger than 300mm

17 PROVISION FOR DESIGNATED CONTRACTORS 17.1 The Contractor shall carry out all reasonable civil, structural & building works necessary for

the Designated Contractors. These works shall include but not be limited to forming holes, casting plinths and trenches, casting in components and leaving holes in pre-cast elements.

17.2 The Contractor shall make all reasonable provision to accommodate the fastenings and fixings of the Designated Contractors. Such provisions will be notifies by the Designated Contractors during design interface stage. The Contractor shall take a lead in developing the interface Management Plan (IMP) with respect to the other contracts having interfacing with the works under the scope of present Contract. The IMP will be prepared in conjunction with the other Designated Contractor to cover all aspects of the implementation of the interface works required. The IMP will define the interface works necessary to complete all the works under this Contract.

18 RESTORATION OF AREAS DISTURBED BY CONSTRUCTION 18.1 Unless otherwise directed by the Engineer, any area disturbed by the construction activity,

either inside or outside the Project Right of Way, shall be reinstated as follows: All areas affected by the construction work shall be reinstated to their original condition, with new materials, including but not necessarily limited to, sidewalks, parking lots, access roads, adjacent roads, properties and landscaping. Grass cover shall be provided for any bare earth surface areas, along with proper provisions for surface drainage.

19 CONTRACTOR'S LABOUR CAMPS 19.1 The Employer will not provide living accommodation for use of the Contractor or any of his

staff or labour employed on the works. Living accommodation shall not be established on any land provided to the Contractor by the Employer for the Works.

19.2 Provision of Labour Camps :- The Contractor, shall, at his own expense, make adequate arrangements for the housing, supply of drinking water and provision of bathrooms, latrines and urinals, with adequate water supply, for his staff as well as for workmen employed on the Works directly or through sub-contractors at the location authorized by Engineer. No labour camp shall be allowed at work site or any unauthorized place. The Contractor at his own cost shall maintain all campsites in a clean and sanitary condition. The Contractor shall obey all health & sanitary rules & regulations, and carry out at his cost all health & sanitary measures that may from time to time be prescribed by the Local/ Medical Authorities & permit inspection of all health and sanitary arrangements at all times by the Employer, the Engineer and the staff of the local municipality or other authorities concerned. Should the Contractor fail to provide adequate health & sanitary arrangements these shall be provided by the Employer and the cost recovered from the Contractor. The Contractor shall at his own cost, provide First Aid and Medical facilities at the Labour Camp and at work sites on the advice of the Medical Authority consistent with the strength of the Contractor's staff and workmen, employed directly or through sub-contractors. The Contractor shall at his own cost, provide the following minimum requirements for meeting the fire hazards

Portable Fire Extinguishers

Manual Fire Alarms

Water Supply for use by the Fire Service





The Contractor at his own cost shall provide necessary arrangements for keeping the camp area sufficiently lighted to avoid accidents to the workers. He should also ensure that electrical installations are done by Trained Electricians. These installations shall be maintained and daily maintenance records must be made available for inspection by the Engineer.

19.3 Camp Discipline :- The Contractor shall take requisite precautions, and use his best endeavours to prevent any riotous or unlawful behaviour by or amongst his workmen, and others, employed directly or through sub- contractors. These precautions shall be for the preservation of the peace and protection of the inhabitants and security of property in the neighbourhood of the Works. In the event of the Employer requiring the maintenance of a Special Police Force at or in the vicinity of the site, during the tenure of the work, the expenses thereof shall be borne by the Contractor and if paid by the Employer, shall be recoverable from the Contractor. The sale of alcoholic drinks or other intoxicating drugs or beverages upon the work, in any labour camp, or in any of the buildings, encampments or tenements, owned or occupied by, or with the control of, the Contractor or any of his personnel employed on the work directly or through sub- contractors shall be forbidden, and the Contractor shall exercise his influence and authority to secure strict compliance with this condition. The Contractor shall also ensure that no labour or employees are permitted to work at the site in an intoxicated state or under the influence of drugs. The Contractor shall remove from his camp such labour and their families, as refuse protective inoculation and vaccination when called upon to do so by the Engineer on the Advice of the Medical Authority. Should Cholera, Plague or any other infectious disease break out, the Contractor shall at his own cost burn the huts, bedding, cloths and other belongings of or used by the infected parties. The Contractor shall promptly erect new heads on healthy sides as required by the Employer. Within the time specified by the Employer, failing which the work may be done by the Employer and the cost recovered from the Contractor.

19.4 Labour Accommodation :- The Contractor shall provide living accommodation that is equal to or exceeds the minimum criteria established in the following sub-sections, needed to house his staff as well as workers employed directly or through sub-contractor. The buildings shall be constructed so as to have a minimum life of not less than the length Contract

The roofs shall be watertight & laid with suitable non-flammable materials permissible for residential use under local regulation and for which the consent of the Engineer has been obtained.

Each hut shall have suitable ventilation. All doors, windows, and ventilators shall be provided with security leaves and fasteners. Back to back units may be avoided.

The minimum height of each unit shall be 2.10m and shall have separate cooking place.

Suitable number of common toilet/bath shall be provided. 19.5 Water supply :- The Contractor shall provide an adequate supply of water for the use of

labours in the camp. The provision shall not be less than two gallons of pure and wholesome water per head per day for drinking purposes and three gallons of clean water per head per day for bathing and washing purposes. Where piped water supply is available, supply shall be at stand post and where the supply is from wells or river, tanks that may be of metal or masonry shall be provided. The contractor shall also at his expense make arrangements for the provision and laying of water pipe lines from the existing mains wherever available and shall pay for all the fees and charges thereof.

19.6 Drainage :- The Contractor shall provide efficient arrangements for draining away sullage water so as to keep the camp neat and tidy. Surface water shall be drained away from paths and roads and shall not be allowed to accumulate into ditches or ponds where mosquitoes can breed.

19.7 Sanitation :- The Contractor shall make arrangements for conservancy and sanitation in the labour camps according to the rules, and regulations of the Local Public Health and Medical Authorities. The Contractor shall provide a sewerage system that is adequate for the number of residents in the camp, and which meets the requirements of the Municipal Authorities.



- Structural (Station)


PARTICULAR SPECIFICATION – STRUCTURAL

(STATION)





1 GENERAL 1.1 General 1.1.1 These Specifications contained herein shall be read in conjunction with other tender

documents. Generally, the work shall be carried out as per the latest edition of “Specifications for Road and Bridge works” of Ministry of Road Transport & Highways (MORTH) as published by Indian Roads Congress and CPWD latest specifications with correction slips & amendments up to date to the extent they are applicable to the works covered under scope of works. However, the provisions of MORTH specifications take precedence over CPWD specifications. Further the specifications contained herein will supersede the provisions of the MORTH & CPWD specifications to the extent of their applicability.

1.1.2 The Work shall be carried out in accordance with the "Good for Construction" drawings and designs as would be issued to the Contractor by the Engineer duly signed and stamped by him. The Contractor shall not take cognisance of any drawings, designs, specifications, etc. not bearing Engineer's signature and stamp. Similarly, the Contractor shall not take cognisance of instructions given by any other authority except the instructions given by the Engineer in writing.

1.1.3 The work shall be executed and measured as per metric units given in the Schedule of Quantities, drawings etc. (FPS units where indicated are for guidance only).

1.1.4 Absence of terms such as providing, supplying, laying, installing, fixing etc. in the descriptions does not even remotely suggest that the Contractor is absolved of such providing, supplying etc. unless an explicit stipulation is made in this contract. The Employer / Engineer shall bear no costs of materials, labour, equipment, duties, taxes, octroi, cess, royalties etc.

1.1.5 The specifications have been divided into different sections / sub-heads for convenience only. They do not restrict any cross-references. The Contractor shall take into account inter-relations between various parts of works/trades. No claim shall be entertained on the basis of compartmental interpretations.

1.1.6 The classification of various items of works for purposes of measurements and payments shall be as per Bills of Quantities (BOQ). Except where distinguished by BOQ, the rates apply to all heights, depths, leads, lifts, sizes, shapes and locations. They also cater for all cuts and wastes. No height wise / floor wise separation shall be made for the rates. Likewise, all heights of centring, shuttering, staging, formwork and scaffolding, launching trusses and other launching methods are covered by the quoted rates including multi stage propping for heights greater than one lift / floor as per drawings.

1.1.7 Reference to the Standard Codes of Practice 1. The contractor shall make available at site all relevant Codes of practice as

applicable. 2 Legend:

ASCE American Society of Civil Engineers ASME American Society of Mechanical Engineers ASTM American Society for Testing Materials BS British Standard CPWD Central Public Works Department DIN Deutsches Institut für Normung e.V. IRC Indian Road Congress IRS Indian Railway Standards IS Indian Standards JIS Japanese Industrial Standard MORTH Ministry of Road Transport and Highways UIC International Union of Railways IRCEM Institution de Retraite Complementaire des Employes de

Particular 1.1.8 Contractor to Provide

The Contractor shall provide and maintain at site throughout the period of works the following at his own cost and without extra charge, except for the items specified in the Bill of Quantities the cost being held to be included in the Contract Rates





1. General works such as setting out, site clearance before setting out and on completion of works. All weather approach roads to the site office should also be constructed and maintained in good condition.

2. All labour, materials, plant, equipment and temporary works, overhead charges as well as general liabilities, obligations, insurance and risks arising out of GCC, required incompletion and maintenance the works to the satisfaction of the Engineer.

3. Adequate lighting for night works, and also at other times whenever and wherever required by the Engineer.

4. Continuous & Rigid temporary fences, barricades/hoardings on both sides of the site occupied by the contractor including, guards, lights and protective work necessary for protection of workmen, supervisors, engineers, General public and any other persons permitted access to the site as approved by the Engineer. Contractor shall provide proper signage as directed. All fences, barricade/hoardings shall be as per approved drawings and painted with colour shades as specified by the Engineer. The barricading/hoardings should be of adequate height to ensure visual obstruction of work from public view.

5. All equipment, instruments, labour and materials required by the Engineer for checking alignment, levels, slopes and evenness of surfaces measurements and quality etc.

6. Design mixes and testing them as per relevant clauses of specifications giving proportion of ingredients, sources of aggregates and binder along with accompanying trial mixes. Test results to be submitted to the Engineer for his approval before adoption on works.

7. Method Statements, for each main activity of the work (temporary and permanent) to be executed detailing the purpose, scope, resources required, sequence / procedure of execution, persons responsible, time frame, safety requirements & measures, risk analysis, Inspections, and Test Procedures along with standard values / acceptable criteria etc. duly approved by the Engineer before start of that particular activity at site.

8. Contractor shall also prepare / approve and make available to the Site Engineer the work procedure for each sub-activity to be done at the site, detailing the procedure / process to be followed including work sequence, safety measures, to be followed, level of quality to be maintained, type of material to be used, type of finishing required and responsibility assigned etc.

9. Preparation and compliance with provision of a quality assurance control programme as per Appendix II of Special Conditions of Contract.

10. Prepare and submit Standard Quantities for the purpose of billing based on the approved drawings.

11. Safe guarding the environment as per Section V- Eligibility criteria and Social & Environment Responsibility.

12. Cost of safety measures and requirements of site safety plan as per Appendix VI of Special Conditions of Contract.

13. A testing laboratory as specified by the Engineer equipped with the following minimum apparatus, materials and competent trained staff required for carrying out tests, as specified in the relevant sections of the specifications/Codes:-

i. 1 Set of standard sieves for testing grading of sand with mechanical sieve shaker. ii. Sieves with openings respectively of 4.75mm, 10mm, 20mm, 25mm, 30mm for

testing and grading of aggregates. iii. Weighing Balance of capacity up to 10 Kg. reading up to 5 gm. iv. Electric Thermostat controlled oven and pans for drying of sand and aggregates. v. Glass measuring flasks of 1/2, 1 litre& 2 litre capacity. vi. Flask for determining moisture content of sand. vii. Slump cone with rod and V B Apparatus, flow table to measure slump or DIN

Specifications (separate sets for laboratory and at Site). viii. Apparatus to measure permeability of concrete as per Appendix 1700/II of MORTH

Specifications. ix. Minimum 24 Nos. steel moulds for 150mm x 150mm x 150mm concrete test cubes. It

may be necessary to provide more steel cube moulds depending upon concreting programme.

x. 25mm dia. vibrator for compaction of concrete in test cubes and also vibrating table.

xi. Concrete cube testing machine of 200 tonnes capacity with 3 dial gauges electrically operated.





xii. Work benches, shelves, desks, sinks and any other furniture and lighting as required by the Engineer.

xiii. Abrasion, Flakiness & Impact testing Equipment for testing coarse aggregates. xiv. Silt Testing Equipment. xv. Any other equipment specified by Engineer.

1.1.9 Quality Assurance & Quality Control i. The work shall conform to high standards of design and workmanship, shall be

structurally sound and aesthetically pleasing. The Contractor shall conform to the Quality standards prescribed, which shall form the backbone for the Quality Assurance and Quality Control system.

ii. At the site, the Contractor shall arrange the materials, their stacking/storage in appropriate manner to ensure the quality. The Contractor shall provide all the necessary equipment and qualified manpower to test the quality of materials, assemblies etc., as directed by the Engineer. The tests shall be conducted at specified intervals and the results of tests properly documented. The cost of all such testing shall be included in the quoted rates and nothing extra shall be paid for in this regard. In addition the Contractor shall keep appropriate tools and equipment for checking alignments, levels, slopes and evenness of the surfaces.

iii. Testing of Materials (a) The Engineer shall be free to carry out such tests as may be decided by him

at his sole discretion, from time to time, in addition to those specified in this document as per provisions of Clause 48 of General Conditions of Contract. The Contractor shall provide the samples and labour for collecting the samples. Nothing extra shall be payable to the Contractor for samples, or for the collection of the samples. The test shall be conducted at the Site laboratory that may be established by the Contractor or at any other Standard Laboratory having NABL certification.

(b) The Contractor shall transport the samples to the laboratory for which nothing extra shall be payable. In the event of the Contractor failing to arrange transportation of the samples in proper time the Engineer shall have them transported and recover two times the actual cost from the Contractor's bills.

(c) All testing shall be performed in the presence of Engineer or his authorised representative. Testing may be witnessed by the Contractor or his authorised representative if permitted by the Test House. Whether witnessed by the Contractor or not, the test results shall be binding on the Contractor.

(d) Cost of all such tests shall be borne by the Contractor and nothing extra shall be payable on this account.

iv. The Engineer shall have the right at all times to inspect all operations including the sources of materials, procurement, its transportation, layout and storage of materials, all equipment including the concrete batching and mixing equipment, and the quality control system. Such an inspection shall be arranged and the Engineer's approval obtained prior to starting of the particular item of work. This shall however, not relieve the Contractor of his responsibilities. All materials which do not conform to these specifications shall be rejected. In the event of contractor not being able to arrange the material conforming to these specifications or in the event of failure of the contractor to get the sources approved within the agreed schedule submitted by contractor, the Engineer shall have the powers to cause the Contractors to purchase and use such materials from any particular source, as may, in the Engineer's opinion, be necessary for the proper execution of work. Nothing extra shall be payable to the contractor on this account.

v. Dimensions 1 Figured dimensions on drawings shall only be followed and drawings to a large scale

shall take precedence over those to a smaller scale. Special dimensions or directions in the specifications shall supersede all others at tender stage where as those mentioned in the construction drawings supersedes all others. All dimensions shall be checked at site prior to execution.





2 The dimensions where stated do not allow for waste, laps, joints, etc., but the Contractor shall provide at his own cost sufficient labour and materials to cover such waste, laps, joints, etc.

3 The levels, measurements and other information concerning the existing site as shown on the drawings are believed to be correct, but the Contractor should verify them for himself and also examine the nature of the ground as no claim or allowance whatsoever will be entertained on account of any errors or omissions in the levels or the description of the ground levels or strata turning out different from what was expected or shown on the drawings.

1.1.10 Setting out of Works The Contractor shall set out the Works indicated in the Conditions of Contract. The Contractor shall provide suitable stones with flat tops and build the same in concrete for temporary bench marks. All the pegs for setting out the Works and fixing the levels required for the execution thereof shall, if desired by the Engineer, likewise be built in masonry at such places and in such a manner as the Engineer may direct. The Contractor shall carefully protect and preserve all bench marks and other marks used in setting out the works. The contractor will make overall layout of complete work and get it checked from engineer. The cost of all operations of setting out including construction of bench marks is deemed to be included in the quoted rates as per Bill of Quantities.

(a) All the survey work except levelling shall work shall be carried out using total stations with one second accuracy. The levelling work shall be carried out using Auto level.

(b) The triangulation points given by Employer/Engineer before start of work shall be maintained during execution and handed over back to Employer/Engineer after completion of work.

1.1.11 Materials 1 Source of Materials

It shall be the responsibility of the contractor to procure all the materials required for construction and completion of the contract. The contractor shall indicate in writing the source of materials well in advance to the Engineer, after the award of the work and get it approved from the Engineer before commencing the work. If the material from any source is found to be unacceptable at any time, it shall be rejected by the Engineer.

2 Quality All materials used in the works shall be of the best quality of their respective kinds as specified herein, obtained from sources and suppliers approved by the Engineer and shall comply strictly with the tests prescribed hereafter, or where tests are not laid down in the specifications, with the requirements of the latest issues of the relevant Indian & other Standards.

3 Sampling and Testing All materials used in the works shall be subjected to inspection and test in addition to test certificates. Samples of all materials proposed to be employed in the permanent works shall be submitted to the Engineer at least 45 days in advance for approval before they are brought to the site. Samples provided to the Engineer for their retention are to be labeled in boxes suitable for storage. Materials or workmanship not corresponding in character and quality with approved samples will be rejected by the Engineer. Samples required for approval and testing must be supplied sufficiently in advance in required quantity and number to allow for testing and approval, due allowance being made for the fact that if the first samples are rejected further samples may be required. Delay to the works arising from the late submission of samples will not be acceptable as a reason for delay in completion of the works. Materials shall be tested before leaving the manufacturer’s premises, quarry or source, wherever possible. Materials shall also be tested at site and they may be rejected if not found suitable or in accordance with the specifications, notwithstanding the results of the tests at the manufacturer’s works or elsewhere or test certificates or any approval given earlier. The contractor will bear all expenses for sampling and testing, whether at the manufacturer’s premises at source, at site or at any testing laboratory or institution





as directed by the Engineer subject to the provisions of Clause 1.1.9 above. No extra payment shall be made on this account.

4 Dispatch of materials Materials shall not be dispatched from the manufacturer’s works to the site without written authority from the Engineer.

5 Test certificates All manufacturer’s certificates of test, proof sheets, etc showing that the materials have been tested in accordance with the requirement of these specifications and of the appropriate Indian Standards are to be supplied free of charge on request to the Engineer.

6 Rejection Any materials that have not been found to conform to the specifications or otherwise not acceptable to the Engineer will be rejected forthwith and shall be removed from the site by the Contractor at his own cost within three days or as instructed by the Engineer.

1.1.12 Storing of Materials at site All materials used in the works shall be stored on racks, supports, in bins, silos, godowns, under cover etc. as appropriate to prevent deterioration or damage from any cause whatsoever to the entire satisfaction of the Engineer. The storage of materials shall be in accordance with IS 4082 “Recommendation on stacking and storage or construction materials on site” and as per IS 7969 “Safety code for handling and storage of building materials”. The materials shall be stored in a proper manner at places at site approved by the Engineer. Should the place, where material is stored by the Contractor, be required by the Employer for any other purpose, the Contractor shall forthwith remove the material from that place at his own cost and clear the place for the use of the Employer with in the time as communicated by the Engineer and at no extra cost to the Employer.

1.1.13 Water 1 Water from approved source

Potable water only shall be used for the works. Contractor shall have his own source of water required for the works including curing duly approved by Engineer. However, the contractor will have to obtain necessary permission for use of such water, if any, from concerned authorities. The water shall be free from any deleterious matter in solution or in suspension and be obtained from an approved source. The quality of water shall conform to IS 456. Recycled water may be used with prior permission of the Engineer-in-Charge if the quality of recycled water conforms to IS-456 and shall be free from deleterious matter.

2 Storage The Contractor shall make his own arrangements for storing water, if necessary, in drums or tanks or cisterns, to the approval of the Engineer. Care shall be exercised to ensure that water is not contaminated in any way.

3 Testing Before starting any concreting work and wherever the source of water changes during the currency of works, the water shall be tested for its chemical and other impurities to ascertain its suitability for use in concrete and other works including curing for approval of the Engineer. No water shall be used until tested and found satisfactory.

4 Cost of arranging, storing and testing of water shall be deemed to be included in the quoted rates in the Bill of Quantities and nothing extra shall be payable in this regard.

1.1.14 Cement: The grade of cement shall be as specified and confirming the relevant IS code and shall be purchased from the approved manufacturers. Separate go-downs shall have to be provided for different grades of cement. The fresh cement should be used. The cement older than 3 months will not be allowed to use at site. The cement should be stored in a water tight shed and on wooden planks giving sufficient gaps between walls floors and cement piles. The actual issue and consumption of cement in works shall be regulated and proper accounts maintained as provided in the relevant clause of the contract. The theoretical





consumption of cement shall be worked out as per procedure prescribed in relevant clause of the contract and shall be governed by conditions laid therein. Cement (OPC of 43/53 grade and Portland Slag Cement (PSC) as specified in documents in paper bags or any suitable packing shall be arranged by the contractor.

1.1.15 Coarse Aggregate: Coarse aggregate in size and quality shall be conforming to the relevant IS code and as specified in the documents. The nominal maximum size of aggregate (MSA) to be used in RCC and PSC work shall be 20mm. The other requirement shall be as per CPWD specification. The aggregate shall be stored in such a way as to prevent mixing with foreign materials. Different sizes of coarse aggregate shall be stored in separate stock piles sufficiently away from each other in order to prevent intermixing the materials at the edges of the stock piles.

1.1.16 Fine Aggregate: The quality, tests and acceptance criteria for fine aggregates shall be same as per CPWD specifications. The fine aggregate shall conform to Zone II or Zone III of CPWD specifications as per requirement of trial mix design (or any combination of the two as approved by Engineer and the decision of Engineer in this respect shall be final). The silt content of fine aggregate used for trial mixes shall be recorded & the silt content in fine aggregate used shall neither exceed 8% nor 1% more than that of the fine aggregate used in the trial-mix.

1.1.17 Other Materials: All other materials not specifically mentioned above shall be of best quality and shall conform to manufacturer’s specification. Wherever, no specific code of practice of IRS/IRC/BIS is applicable, the decision of Engineer shall be final and binding.

1.1.18 Workmanship 1 All works shall be true to level, plumb and square and the corners, edges and rises in all

cases shall be unbroken and neat. 2 Any work not to the satisfaction of the Engineer or his representative will be rejected

and the same shall be rectified, or removed and replaced with work of the required standard of workmanship at no extra cost.

1.1.19 Load testing on Completed Structures 1.1.19.1 During the period of construction or within the defect liability period the

Engineer may at his discretion order the load testing of any completed structure or any part thereof if he has reasonable doubts about the adequacy of the strength of such structure for any of the following reasons :

a) results of compressive strength on concrete test cubes falling below the specified strength.

b) premature removal of formwork. c) inadequate curing of concrete. d) over loading during the construction of the structure or part thereof. e) carrying out concreting of any portion without prior approval of the Engineer. f) honey-combed or damaged concrete which in the opinion of the Engineer is

particularly weak and will affect the stability of the structure to carry the design load, more so in important or critical areas of the structure.

g) any other circumstances attributable to alleged negligence of the contractor which in the opinion of the Engineer may result in the structure or any part thereof being of less than the expected strength.

1.1.19.2 All the loading tests shall be carried out by the contractor strictly in accordance with the instructions of the Engineer, IS:456 and as indicated hereunder. Such tests shall be carried out only after expiry of minimum 28 days or such longer period as directed by the Engineer.

1.1.19.3 The structure shall be subjected to a super-imposed load equal to the specified superimposed load assumed in the design. This load shall be maintained for a period of 24 hours before removal. During the test, struts strong enough to take the whole load shall be placed in position leaving a gap under the members as directed. The deflection due to the superimposed load shall be recorded by sufficient number of approved deflectometers capable of reading up to 1/500 of a cm and located suitably under the structure as directed by the Engineer.





The structure shall be deemed to have passed the test if the maximum deflection at the end of 24 hours of loading does not exceed the deflection given by the following expressions: D = 0.001 L2/25 T, where, D = max deflection due to imposed load only L = span of the member under load test (the shorter span in case of slabs). The span is the distance between centres of the supports or the clear distance between the supports plus the depth of the member, whichever is smaller. In case of cantilever, this shall be taken as twice the distance from the support to the end and deflection shall be adjusted for movement of the support. T = depth of member. If within 24 hours of the removal of the superimposed load, the structure does not recover at least 75% of the deflection under the superimposed load, the test loading shall be repeated after a lapse of 72 hours. If the recovery after the second test is less than 80% of the maximum deflection shown during the second test, the structure shall be considered to have failed to pass the test and shall be deemed to be unacceptable.

1.1.19.4 In such cases the portion of the work concerned shall be taken down or cut out and reconstructed to comply with the specifications. Other remedial measures may be taken to make the structure secure at the discretion of the Engineer. However, such remedial measures shall be carried out to the complete satisfaction of the Engineer.

1.1.19.5 All costs involved in carrying out the test ordered on the grounds as mentioned in Cl. 1.1.20.1 (a) to (g) above, (except load and integrity test for piles) and other incidental expense thereto shall be borne by the contractor regardless of the result of the test. In case of failure of the test the contractor shall take down or cut out and reconstruct the defective work or shall take the remedial measures, as instructed, at his own cost.

If the load testing is instructed on any ground other than mentioned in para a) to g) of clause 1.1.20.1 above, then the cost of the same shall be reimbursed if the test results are found to be satisfactory.

1.1.19.6 In addition to the above load tests, non-destructive tests on various elements (except on piles) such as core test and ultrasonic pulse velocity test shall be carried out by the contractor at his own expense if so desired by the Engineer. However, non-destructive testing of piles will be paid as per BOQ. Such tests shall be carried out by an agency approved by the Engineer and shall be done using only recommended testing equipment. The acceptance criteria for these tests shall be as specified by the testing agency or good engineering practice and as approved by the Engineer.

1.2 Preliminary Work 1.2.1 Survey Work

The said work involves at the very start of work taking-over of reference point from the Engineer, establishment of control points, triangulation points, bench marks, grid layout for all the piers and other structures maintaining horizontal and vertical control within the permissible limits, incorporating changes (if any), submission of full data in the tabulation form and survey drawings. The item is lump sum and shall be including setting and layout of various works during the progress of work and matching of the station area track alignment with the alignment of the approaches at station ends and incorporating the changes (if any). The payment for the item shall be on pro-rata basis and will be spread over the duration of the contract.

1.2.2 Barricading The work covers barricading for the work done along the median and areas affecting road traffic. Barricading for the other areas like casting yard, batching plant, storage and other working area shall be done at own cost by the contractor. The detailed scope of work is as follows: i) Providing and installing the barricade of the design and type as shown in the typical

sketch furnished as per the approved plan firmly to the ground and maintaining it during the during the progress of work.

ii) Providing adequate road safety devices. A tentative list given hereunder identifies minimum items, which may be required. However, actual numbers required will be as per approved plan by the Engineer and clearance from the traffic department, Nagpur. The contractor shall not be paid extra for any addition to this list if required during the execution of works.





iii) Dismantling of barricading and other temporary installations from the site and cleaning the site as per direction of Engineer upon completion and acceptance of work.

1.2.3 Tentative Road Safety Devices are mentioned below:

S.No. Brief Description

1. Supply of Red portable traffic cones of 750 mm height with white reflective tape bands on min. 100 mm width all around

2. Hazard warning light flasher with rechargeable. Maintenance free battery & Charging system

3. Safety light island post with 11 nos. parallel reflector

4. Red reflective arrow fitted on enamelled mild steel board of 360 x 220 mm size

5. Traffic Triangular Tripod made of fluorescent cloth fitted on steel frame

6. Retro-reflective tape (I) 50 mm width

7. Fluorescent Jackets with reflective tape all around

8. Yellow reflective cat eyes of size 115 x 11 x 22 mm made of ABS material having 19 glass beads on each side.

9. Metal Tubular Delineator of 610 mm height with reflective tapes

10. Retro-reflective arrows diversion board 450 x 900 mm with crystal clear protective transparent coat to avid damage on 14 gauge Mild Steel sheet with and without pole

11. Retro-reflective “Men at work” triangular board of size 900 mm with crystal protective transparent coat to avoid damage on 14 gauge Mild steel board with and without poles

12. Retro-reflective board for “Go Slow Work in progress” of size 1200 x 750 mm with crystal clear protective transparent coat to avoid damages to the Mild Steel sheets with and without pole.

13. Retro-reflective advance direction sign cum Diversion Boards of size 1200 x 900 mm with crystal clear protective transparent coat to avoid damage to the 14 gauge Mild Steel sheet with and without pole.

14. Retro-reflective speed limit circular sign Boards of 600 mm Diameter with crystal clear protective transparent coat to avoid damage to the 14 gauge sheet (without pole).

15. ‘SORRY FOR INCONVENIENCE’ Retro-reflective Boards of size 900 x 300 mm size with crystal clear protective transparent coat to avoid damage to the 14 gauge Mild Steel Sheet (without pole).

16. HAZARD MARKERS (Yellow & Black) must be put all over the construction sites. This Retro-reflective board is of size 300 x 900 mm with crystal clear protective transport coat to avoid damage and the 14 gauge Mild Steel Sheet with or without pole.

17. ‘CAUTION’ tape which is normally yellow tape of special Polythene Material having 75 mm width `CAUTION’ is written all over with Black colour in rolls of 300 metres.

Measurement The barricading including all the required safety devices as listed under the above table shall be measured in running metre up to two decimal places. (Payment of the item shall be made on monthly basis over contract period. Payment shall be deducted for the period during which the barricading and arrangements for traffic diversion are not satisfactory to the Engineer. The payment and deduction (if any) for the item shall be on pro-rata basis.

1.2.4 Supply of Progress Photographs and Album The work covers the supply of colour photographs along with negatives in an album to serve as a permanent record of various stages/facets of work needed for an authentic documentation as approved by the Engineer. The photographs shall be of acceptable quality and they shall be taken by a professionally competent photographer will camera having the facility to record the date of the photographs taken in the prints and negative. The camera reel, type and quality of photo paper shall be of standard make approved by the Engineer. Each photograph in the album shall be suitably captioned and dated.





The frequency, time and extent of coverage for each work shall be as decided by the Engineer. The rate for the supply of record photographs shall include the cost of taking the photographs, developing and obtaining the colour prints, cost of albums, mounting and captioning the photographs. The photographs and materials including negative shall form a part of the records of MAHA-METRO and the prints cannot be supplied to anybody else or published without the written permission of MAHA-METRO.

1.2.5 Supply of Video Cassette of Works The work consists of taking video film of important activities of the works as directed by the Engineer during the currency of the project and editing them to a video film of the duration as indicated in the item. The cassette shall be of approved make and of specified duration. It shall contain narration of the activities in English by a competent narrator. The edition of the film and script of the narration shall be approved by the Engineer.

1.2.6 Transplantation of Trees The item shall be carried out as per the approved plan by the Engineer after the identification of the trees to be transplanted. The actual number of trees shall be finalised after the necessary clearances by the concerned departments. The item is complete and including all expenditures for carrying out all operations i.e. excavation, watering, feeding of chemicals, back filling, lifting of trees by crane and transporting to the designated site where it is to be transplanted and all necessary care to be taken for the specified initial period till the tree gets settled at new site and up to the full satisfaction of the Engineer. Measurements The item shall be measured in numbers according to size of the tree as specified in the item and the full payment shall be released only when the item is executed fully as per the Scope of Work detailed out in the approved plan for transplantation of trees. The rate shall include all required operations during the transplantation and specified duration afterwards, clearances from the concerned authorities.

1.2.7 Site office for Engineer and Other Supervisory Staff The work covers the construction and provisions of furnished site office accommodation for the supervisory staff of engineer and maintaining the same. The contractor shall arrange to provide fully furnished office accommodation constructed as shown in drawings. Work includes providing electric supply, all electric items, like lights, fans, complete wiring, providing water supply including all pipes, fittings, tanks, valves etc. complete, septic tank, drains, internal surface roads etc. complete as shown in the drawings. The contractor shall provide the Office accommodation within 1 month from the date of issue of the acceptance letter. The site office with all services, furniture and fittings shall be the property of the employer. The land for the site office shall be provided by the Engineer and the location shall be indicated in the drawing. The contractor shall arrange to maintain the site office including day to day upkeep of the building and the surroundings, attending to repairs to various parts of the building, furniture, fittings, office equipment and the connected services as and when necessary, including periodic white/colour washing, painting etc. The contractor shall arrange to provide uninterrupted supply of electricity and water for the office building. In case of failure of main power/water supply, alternate source shall be provided.

1.2.8 Providing and maintaining Radio Communication The work covers provision of maintenance of wireless communication system with necessary mobile/base transceivers and other accessories: The System shall consist of the following (i) Hand held radio sets - 4 nos. The contractor shall arrange to obtain all necessary statutory approvals from various govt. departments and also fulfill requirements for operating the wireless system. The contractor shall arrange to maintain the entire wireless system including all accessories, spares etc. in satisfactory working conditions. The payment will be made on monthly basis and commence after commissioning of the system. The system should be commissioned by the contractor within three months of date of issue of acceptance letter.





If the contractor fails to maintain the system as required, a sum of Rs. 5,000/- per month or part thereof will be debited to the contractor and also for the month(s) during which the Contractor fails to carry out the required maintenance shall not be measured for the payment. If the Contract works are not completed with the stipulated period of within the granted extended time of completion the maintenance shall be carried out by the contractor at his own cost and as such no payment shall be made for the same. In case of any failure of contractor to do so, an amount of Rs. 6000/- per month or part there of shall be debited to the contractors account.

1.3 Structural Work 1.3.1 Unless otherwise specified, only controlled concrete with design mix and weigh batching is

to be used for the work. 1.3.2 Minimum cement content for various grades / elements of concrete as specified in MORTH

Specifications in CPWD specification 1996 / 2002 is purely from durability point of view. Larger content of cement shall have to provide if demanded by mix design or as per the requirement of relevant codes.

1.3.3 Provision of cement slurry to create bond between plain / reinforced concrete surface and subsequent applied finishes shall not be paid extra.

1.3.4 Mix design using smaller aggregates of 10mm down shall also be done in advance for the use in the junction having congested reinforcement.

1.3.5 Procedure of mixing the admixtures shall be strictly as per the manufacturer’s recommendations or as directed by the Engineer.

1.3.6 All the water tanks and other liquid retaining concrete structures shall undergo hydro-testing.

1.3.7 Special benches shall be provided at site for stacking reinforcement bars of different sizes. 1.3.8 Formwork for beams of RCC works shall be designed in such a way that the formwork of

the adjacent slabs can be removed without disturbing the props / supports of the beams. 1.3.9 Wherever there are tension / suspended concrete members which are suspended from

upper level structural members, the shuttering / scaffolding of such members at lower level shall have to be kept in place till the time the upper level supporting members gain minimum required strength. Cost of such larger duration of keeping in place the shuttering/scaffolding shall be deemed to be included in the price quoted for respective structural members.

1.3.10 The Contractor shall incorporate seismic considerations of anchoring and isolation in the design and detailing of the finishes as directed by the Engineer. The element to be anchored shall have its motion suitably restrained whilst at the same time it shall be suitably isolated so as not to be affected by the deformations/ vibrations of the building during Construction.

1.3.11 Formwork shall be provided for full height at all locations. Special precautions for such tall formwork shall be taken to ensure its safety. Extra costs for providing such formwork shall be deemed to have been included in the prices quoted against relevant items.

1.3.12 The contractor shall carry out expeditiously and without delay the following works with in the mobilization period itself:

a. Identify and get approved the sources of various major constitution materials. b. Material testing and mix designs of concrete as contemplated in the specifications. c. Setting up of full-fledged site laboratory as per the requirements of these specifications. d. Setting up concrete batching & mixing plant. e. Site office for the use of the Engineer’s staff. f. Contractor’s site office setup. g. Casting yard with complete facilities. h. Any other pre-requisite items required for final execution.

1.3.13 Casting yard shall have following minimum facilities: a. Casting beds as required. b. Sets of form work / moulds as required. c. All handling facilities for precast elements. d. Curing arrangements as required. e. Stacking arrangements for material and precast elements. f. Storing arrangement of materials. g. Proper drainage and all weather approach roads.





1.3.14 The load testing of spans / piles etc. shall be done using certified and calibrated dial gauges only. Use of levelling instruments for measuring deflections shall not be allowed

1.4 Sub-Contractor Works as listed below and those dealing with proprietary materials/ products may be carried out by the Contractor through the Sub-Contractors as may be approved by the Engineer in writing. All sub-contractors shall satisfy the specifications/requirements for their specific works. The Sub-Contractors must be firms of repute and long standing, having adequate experience and complete facilities to carry out all items of work required for completion as per Specifications and expected quality to the satisfaction of the Engineer. The Sub-Contractor must also have personnel experienced in preparing shop drawings. All such works shall be carried out under the direct supervision of the manufacturers of the proprietary materials/ products or their trained and accredited licensee.

(a) Fire fighting / safety equipment/accessories and setup (b) Landscaping (c) Waterproofing (d) Caulking & Sealants (e) Painting and Polishing (where proprietary product or material or a specialised process/

technique is required) (f) Roof sheeting (g) Structural Glazing / cladding

1.5 Guarantees and Building Maintenance for Finishes: The Contractor shall guarantee and undertake to maintain and rectify the various components of the Civil Works for their successful performance for the periods as specified below. The Contractor shall indemnify the Engineer for a similar period against any damage to property and injury to persons on account of any defective work or maintenance carried out by the Contractor. The format and text of the Guarantee and the Indemnity Bond shall be as followed in CPWD or as approved by the Engineer.

a. External/Internal cladding of Stone, Marble and Granite shall be guaranteed for 5 years.

b. All Fire Rated Door sets shall be guaranteed to remain integral and absolutely stable in the event of a fire. All moving parts of the Fire Rated Door sets shall be guaranteed to give trouble free service for 5 years and the finish shall be guaranteed to last for at least 5 years.

c. Waterproofing for basements (which include raft, retaining walls, and expansion/ separation joints in retaining walls) and roofs shall be guaranteed for 15 years. The waterproofing shall include all allied works on the roof such as concrete screed and the China Mosaic roof finish/ stone cladding on the parapet between which the waterproofing treatment shall be sandwiched.

d. Waterproofing for the other areas such as toilets, kitchens, chhajjas etc. shall be guaranteed for 15 years. The waterproofing shall include all allied works on the slab etc. such as concrete/ mortar screeding, if any, floor finish between which the waterproofing treatment shall be sandwiched.

e. The manufacturer / Supplier / fabricator/ contractor of the roofing system shall give a guarantee for 15 years with regarding to its composition, surface and tensile strength.

1.5.1 Responsibility for Shop drawings, Samples and Mock-ups: Approval of shop drawings, samples and mock-ups for the various components shall not absolve the Contractor of his responsibility of completing the work to the specifications, standards, tests for performance and guarantees given in these documents and to a quality of finish as desired by the Engineer.





1.5.2 Cleaning: Surfaces on which finishes are to be provided shall be cleaned with water jets or oil free compressed air or power tools with wire brushes and detergents all as approved by the Engineer.

1.5.3 Expansion bolts/ fasteners: 1 Unless specified otherwise all expansion bolts/ fasteners shall be fabricated from

austenitic stainless steel sheet, strip or plate conforming to ASTM A 240 Gr 304 or bar to ASTM A 479 Gr 304 of approved make and design. The material of the bolt shall not cause any bimetallic corrosion with the reinforcing bars of the RCC/ brickwork or with any other fixings or doors or windows or skylights etc.

2 For steel backings the fasteners shall be prevented from contact with other metals which would lead to bimetallic corrosion.

3 For brick masonry backing the sleeves of the expansion bolts shall be fixed in wedge shaped pockets having an area of 75mm x 75mm at the surface and 100mm x 100mm at the inner surface and shall be 125mm deep. The wedge could also be as a truncated cone of 75mm dia. / 100mm dia. The dimensions shall be reviewed by the Engineer during execution of the work. The wedge shall be filled with PCC 1:1:2 (1: Cement, 1: Sand and 2: Coarse Aggregate) mixed with non-Shrink Compound in the proportion as recommended by the manufacturer.

4 The holes drilled for the expansion fasteners shall be cleaned of all ground material, dust, etc. before inserting the expansion sleeves.

5 All expansion bolts fixed into soffits shall be bonded to the backing with epoxy/ polyester resin of approved make.

6 All expansion bolt fixings shall be tightened in accordance with the recommended torque figures by the manufacturer. Where such values are not available the Contractor shall test at least 6 samples to determine the safe torque values. All bolts shall be tightened using torque spanner/ wrenches. All bolts shall be checked 24 hours (minimum) after installation and retightened if necessary.

1.5.4 No walls, terraces shall be cut for making any opening after water proofing has been done without written approval of the Engineer. Cutting of water proofing when authorised by the Engineer in writing shall be done very carefully so that no other portion of the water proofing is damaged. On completion of the work at such places, the water proofing membrane shall be made good and ensured that the opening / cutting is made fully water proof as per specifications and details of water proofing approved by the Engineer at no extra cost. No structural member shall be cut or chased without the written permission of the Engineer.

1.5.5 Provision of grooves in plaster, drip courses etc, if directed, at junction of walls-ceilings, columns-walls, frames-plaster and such other generally typical locations shall not be paid extra, including grooves in concrete, masonry, stonework.

1.6 Applicable Codes, Standards & Publications For Structural & Architectural Work The important Codes, Standards and Publications to Contract are listed here under : A General IS:875 (Part 3) Code of practice for design loads (other than earthquake) for

buildings and structures IS:1322 Bitumen felts for water proofing and damp-proofing IS:1893 Criteria for earthquake resistant design of structures IS:2572 Code of Practice for construction of hollow concrete block

masonry IS:3414 Code of practice for design and installation of joints in buildings IS:6408 (Parts 1,2)

Recommendations for modular co-ordination in building industry – tolerances

IS:10958 General check list of functions of joints in building IS:11817 Classification of joints in buildings for accommodation of

dimensional deviations during construction IS:11818 Method of test for laboratory determination of air permeability of

joints in buildings IS:12440 Precast concrete stone masonry blocks CPWD Specifications 1996. BS:476 (Part 7) Method for classification of the surface spread of flame of

products





BS:476 (Part 20)

Method of determination of the fire resistance of elements of construction (general principles)

BS:476 (Part 22)

Methods for determination of the fire resistance of non-load bearing elements of construction

BS:5215 Specification for one-part gun grade polysulphide-based sealants BS:5606 Guide to accuracy in building BS:6093 Code of practice for the design of joints and jointing in building

construction BS:8200 Code of practice for the design of non-load bearing external

vertical enclosure of building ASTM C 332 Specification for light weight aggregate for insulating concrete SP 7 National Building Code of India SP 23 (S&T) Hand Book on Concrete Mixes B Bitumen IS:702 Industrial Bitumen IS:3384 Specification for bitumen primer for use in waterproofing and

damp-proofing C Building Construction Practices IS: 1838 Parts I and II.

Specifications for preformed fillers for expansion joint in concrete pavements and structures.

IS:1946 Code of Practice for use of fixing devices in walls, ceilings, and floors of solid construction.

IS:6509 Code of Practice for installation of joints in concrete pavements. IS:11134 Code of Practice for setting out of buildings. IS:11433 Parts I and II. Specifications for one part Gun grade polysulphide

based joint sealant. IS:12200 Code of Practice for provision of water stops at transverse

contraction joints in masonry and concrete dams D Cement IS:269 33 grade ordinary Portland cement IS:455 Portland Slag Cement IS:650 Specification for standard sand for testing cement. IS:1489 (Part 1)

Portland pozzolana cement: Flyash based

IS:1489 (Part 2)

Portland pozzolana cement: Calcined clay based

IS:3535 Method of Sampling Hydraulic Cements IS:4031 (Parts 1 to 13) Methods of physical tests for hydraulic cement. IS:4032 Method of chemical analysis of hydraulic cement. IS:6925 Methods of test for determination of water soluble chlorides in

concrete admixtures. IS:8042 White Portland Cement IS:8112 Specification for 43 grade ordinary Portland cement. IS:12269 Specification for 53 grade ordinary Portland cement. IS:12330 Specification for sulphate resistant Portland cement. E Concrete IS:456 Code of practice for plain and reinforced concrete. IS:457 Code of practice for general construction of plain and reinforced

concrete for dams and other massive structures. IS:460 (Parts I to III)

Specification for Test Sieves

IS:516 Methods of test for strength of concrete. IS:1199 Methods of sampling & analysis of concrete. IS:1200 Method of measurement of building and civil engineering IS:1343 Code of practice for prestressed concrete IS:1607 Method of Test Sieving IS:2386 Parts I-VIII. Methods of tests for aggregates for concrete. IS:2430 Methods of Sampling of Aggregates of Concrete IS:2438 Specification for roller pan mixer IS:2514 Specification for concrete vibrating tables





IS:2571 Code of practice for laying in-situ cement concrete flooring IS:2645 Specifications for integral cement water proofing compounds IS:2722 Specifications for portable swing batchers for concrete (double

bucket type) IS:2770 Methods of testing bond in reinforced concrete part I pull out test IS:3025 Methods of sampling and test (physical and chemical) for water &

waste water IS:3370 Code of practice for concrete structures for storage of liquids IS: 3935. Code of practice for composite construction IS:4326 Code of practice for earthquake resistant construction of building IS: 6925. Methods of test for determination of water soluble chlorides in

concrete Admixtures IS:7242 Specifications for concrete spreaders IS:7251 Specifications for concrete finishers IS:7861 Parts I & II. Code of practice for extreme weather concreting. IS:7969 Safety code for handling and storage of building materials IS:8989 Safety code for erection of concrete framed structures IS:8142 Methods of test for determining setting time of concrete by

penetration resistance IS:9103 Specifications for admixtures for concrete IS:9013 Method of making, curing and determining compressive strengths

of accelerated cured concrete test specimens IS:9284 Method of test for abrasion resistance of concrete IS:10262 Recommended guidelines for concrete mix design. MORTH Specifications for Road and Bridge Works, Ministry of Road

Transport and Highways (Roads Wing) IRS Concrete Bridge Code IRC 21-2000 Standard Specifications and Code of Practice for Road Bridges

Section III – Cement Concrete (Plain & Reinforced)(First Revision) IRC:18-2000 ASTM - C - 94 IS 4926:2003

Design criteria for Prestressed Concrete Road Bridges (Post –Tensioned Concrete) Ready Mix Concrete Ready Mixed Concrete – Code of Practice (Ready Mix Concrete - Crushed sand is permitted but extent will

depend on mix design considering workability, slump and other

parameters) ASTM – C - 1240

Specifications for Silica Fume for use in Hydraulic Cement and Mortar

F Construction Plant and Machinery. IS:1791 Specification for batch type concrete mixers. IS:2505 General requirements for concrete vibrators: Immersion type. IS:2506 General requirements for screed board concrete vibrators. IS:3366 Specification for pan vibrators. IS:3558 Code of Practice for use of immersion vibrators for consolidating

concrete. IS:4656 Specifications for form vibrators for concrete. IS:4925 Specification for concrete batching and mixing plant. IS:11993 Code of Practice for use of screed board concrete vibrators. G Formwork IS:4990 Specifications for plywood for concrete shuttering work. IRC:87 Guidelines for the design and erection of false work for road

bridges. IS:806 Code of practice for use of steel tubes in general building

construction. IS:1161 Specification of steel tubes for structural purposes. IS:1239 Specification for mild steel tubes. Tubulars and other wrought

steel fittings. H Gypsum and Gypsum Board IS:2095 Gypsum plaster boards IS:2542 (Part Methods of test for gypsum plaster, concrete and products: plaster





1/Sec 1 to 12) and concrete IS:2542 (Part 2/Sec 1 to 8)

Methods of test for gypsum plaster, concrete and products: Gypsum products

IS:2547 (Part 1)

Gypsum building plaster: Excluding premixed lightweight plaster

IS:2547 (Part 2)

Gypsum building plaster: Premixed lightweight plaster

I Handling and Storage IS:4082 Recommendation of Stacking and Storage of construction materials IS:8348 Code of practice for stacking and packing of stone slabs for

transportation J Instruments For Testing Cement and Concrete IS:5513 Specification for vicat apparatus. IS:5514 Specification for apparatus used in Le-Chaterlier test. IS:5515 Specification for compaction factor apparatus. IS:7320 Specification for concrete slump test apparatus. IS:7325 Specification for apparatus to determine constituents of fresh

concrete. IS:10080 Specification for vibration machine. IS:10086 Specification for moulds for use in tests of cement and concrete. IS:10510 Specification for vee-bee consistometer. K Joint Fillers IS:1838 (Part 1)

Preformed fillers for expansion joint in concrete pavements and structures (non-extruding and resilient type): Bitumen impregnated fibre

L Paints and Coatings IS:102 Ready mixed paint, brushing, red lead, non-setting, priming IS:109 Ready mixed paint, brushing, priming, plaster, to Indian Standard

Colour No. 361 and 631 white and off white. IS:347 Varnish, shellac, for general purpose. IS:2074 Ready mixed paint, air drying, red oxide-zinc chrome, priming BS:6496 Specification for powder organic coatings for application and

stoving to aluminium alloy extrusions, sheet and preformed sections for external architectural purposes, and for the finish on aluminium alloy extrusions, sheet and preformed sections coated with powder organic coatings

BS:EN:10152 Specification for electrolytically zinc coated cold rolled steel flat products. Technical delivery conditions

ASTM A 164-71 Specification for electrodeposited coatings of zinc on steel M Pigment for Cement

BS:1014 Specification for pigments for Portland cement and Portland cement products

N Reinforcement & Structural Steel IS:280 Mild steel wire for general engineering purposes IS:432 Part I. Mild steel and medium tensile steel bars. Part II Hard drawn

steel wire. IS:814 Parts I & II. Electrodes for metal arc welding of structural steel. IS:815 Classification coding of covered electrodes for metal arc welding

of structural steels IS:816 Code of Practice for use of metal arc welding for general

construction in mild steel. IS:1566 (Part I) Specifications for hard-drawn steel wire fabric for concrete

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

concrete reinforcement. IS:2502 Code of Practice for bending and fixing of bars for concrete

reinforcement. IS:2629 Recommended practice for hot-dip galvanising of iron and steel.





IS:2751 Code of Practice for welding of mild steel plain and deformed bars for reinforced concrete construction.

IS:4759 Hot-dip zinc coating on structural steel and other allied products. IS:5525 Recommendations for detailing of reinforcement in reinforced

concrete works IS:9417 Recommendations for welding cold-worked steel bars for

reinforced concrete construction. IS:14268 Uncoated stress relieved low relaxation steel class 2 for Pre-

stressed concrete IS:226 Structural steel (Standard Quality) IS:800 Code of practice for use of structural steel in general building

construction. IS:813 Scheme of symbols for welding. IS:814 Covered electrodes for metal arc welding of structural steel. (Part

I & Part II) IS:816 Code of practice for use of metal arc welding for general

construction in mild steel. IS:822 Code of practice for inspection of welds. IS:961 Structural steel (High Tensile) IS:1024 Code of practice for use of welding in bridges and structures

subject to dynamic loading. IS:1161 Steel tubes for structural purposes. IS:1182 Recommended practice for radiographic examination of fusion

welded butt joints in steel plates. IS:2062 Structural steel (Fusion welding quality) IS:3757 Specification for high tensile friction grip bolts. IS:5624 Specification for foundation bolts. IS:3600 Code of practice for testing of fusion welded (Part I) joints and

weld metal in steel. IS:4923 Hollow steel sections for structural use. IS:6227 Code of practice for use of metal arc welding in tubular structure. IS:801 Code of practice for use of cold formed light gauge steel structural

members in general building construction. IS:811 IS:8500 IS:8910 IS:9595 IS:7205

Specifications for cold formed light gauge structural steel sections. Structural Steel Micro alloyed (Medium and high strength qualities) General requirements of supply of weldable structural steel Recommendations for metal arc welding of carbon & carbon-Manganese steels Safety Code for erection of Structural Steel Works

O Aggregates IS:383 Coarse and fine aggregates from natural sources for concrete. P Scaffolding IS:2750 Specification for steel scaffoldings IS:3696 (Part 1)

Safety Code of scaffolds and ladders: Scaffolds

IS:3696 (Part 2)

Safety Code of scaffolds and ladders: Ladders

IS:4014 (Part 1)

Code of practice for steel tubular scaffolding: Definition and materials

IS:4014 (Part 2) IRC:87

Code of practice for steel tubular scaffolding: Safety regulations for scaffolding Guidelines for the design and erection of falsework for road bridges

Q Sealants IS:10959 Glossary of terms for sealants for building purposes IS:11433 (Part 1)

One part grade polysulphide base joint sealant: General requirements





IS:11433 (Part 2)

One part grade polysulphide base joint sealant: Methods of test

IS:13055 Methods of sampling and test for anaerobic adhesives and sealants

BS:5889 Specification for one part gun grade silicone-based sealants.

R Wood

IS:303 Plywood for General Purposes

IS:848 Synthetic resin adhesives for plywood (phenolic and aminoplastic)

IS:1141 Seasoning of Timber - Code of Practice

IS:1328 Veneered decorative plywood

IS:1659 Block Boards

IS:2046 Decorative thermosetting synthetic resin bonded laminated sheets

IS:2202 (Part 1)

Wooden flush door shutters (solid core type): Plywood face panels

IS:2202 (Part 2)

Wooden flush door shutters (solid core (type): Particle face panels and hardboard face panels

S IRC:83Part-II IRC:83 Part-III T IS 4985 U IS :2911 PART-I IRC:78

Bearings Standard specifications and code of practice for road bridges Elastomeric Bearings Standard specifications and code of practice for road bridges Pot Bearings UPVC Pipe For Drainage Unplasticized PVC Pipes for portable water supplies PILING Bored Cast in-situ Concrete Piles Standard specifications and code of practice for road bridges Foundation And Substructure

V All Indian Railway Standards

W MOST Specifications for Road and Bridge works (latest Revision)

X CPWD Specifications (latest Revision)

1.7 Temporary Work 1.7.1 All designs for temporary work shall conform to and comply with all the requirements

given in the latest editions of the relevant Indian Standard specifications and codes of practice and other technical Specifications as detailed in this tender.

1.7.2 For all work for which the contractor has to submit design for approval of the Employer, the same shall be got prepared by the contractor from approved consultants who are specialised in this field. For particular item of scaffolding, staging and shuttering, use of any proprietary method of staging should be supplemented with proper designs of such system after getting approval from the Engineer.

1.7.3 The contractor shall assess with due care the supplementary site investigations needed to verify all topographical, hydrological and other site data indicated in the tender and also





collect such additional site data/geo-technical data as may be necessary for doing the job and safety of structure.

1.7.4 The Engineer at his discretion may order any supplementary site geo technical investigation after award of the contract for verification and evaluation of any relevant data including geo technical data, and no claim for extra payment on this account of variation of site data so evaluated shall be tenable subject to other relevant provisions of the tender elsewhere.





2 EARTHWORK 2.1 These specifications shall be read in conjunction with the MORTH and CPWD specifications

1996/2002 with latest edition and correction ships upto date and other relevant specifications described in the section 1 of these specifications.

2.2 Results of the sub-surface investigations conducted at the Project Site are enclosed with the tender document. This information about the soil and sub-soil water conditions is being made available to the Contractor in good faith and the Contractor is advised to confirm / obtain details independently as may be considered necessary by him before quoting rates in the tender.

No claim whatsoever on account of any discrepancy between the sub-surface conditions that may be actually encountered at the time of execution of the work and those given in these Tender Documents shall be admissible to the Contractor under any circumstances whatsoever.

2.3 Excavation of rock may be carried out by chiselling, jack hammers, crowbars, wedging and using cutting machine or by any other method approved by the Engineer. Use of non-explosive demolition compounds shall also be permitted.

Open blasting is not permitted for the works under scope of this contract but at discretion of the Engineer, Controlled blasting may be permitted only in very special cases where all alternative methods have failed to achieve the satisfactory results. The Blasting, if permitted, shall be carried out with in the pre-defined fixed period to be decided in consultation with Traffic Police and approved by Engineer. Contractor shall be responsible for arranging and implementing an effective & approved system for informing the timing of the blasting to the Public including blowing a Siren on a regular basis. Contractor shall take all necessary precautions to prevent flying of blasted stones outside the excavation pit and damage to adjacent structures etc by controlling spacing and quantity of explosive charge and covering the sufficient area of blasting by steel plates loaded with adequate number of sand bags. All operations of controlled blasting shall be carried out under the supervision of a responsible, authorised, competent and experienced blasting agent / foreman. Contractor shall be responsible for any damage arising out of blasting operation to the Employer/Engineer, workmen, public or any property. Contractor shall obtain all necessary permission from Traffic Police and other concerned authorities for blasting as required. Non-granting of permission for blasting by concerned authorities will not be considered as reason for delay or any claim thereof.

2.4 Excavation for all works and for materials required for filling shall be to the exact width, length and depth shown on the drawings or as directed by the Engineer. Where the nature of soil or the depth of the trench and season of the year, do not permit vertical sides, the contractor at his own expense shall put up the necessary shoring, strutting, planking or any other approved protection measures with due regard to the safety of personnel and works and to the satisfaction of the Engineer. The construction barricading/fence in general will have a maximum width of 8.0m (outside to outside of barricading). This can be increased at specific locations with prior approval of Engineer. The Contractor shall submit method statements for approval of Engineer demonstrating how this will be achieved at site. If required, driving of rolled section / sheet pile of suitable size into the soil shall be done to retain earth as directed by Engineer. Measurement of plan area of excavation for payment shall be permitted only up to the end of PCC under foundations. If excavation is carried out to greater depth than required beyond the level specified, for any reason whatsoever, such volume shall be made good by filling with PCC M10 having coarse aggregates 40 mm and below, graded, and brought to level to receive the levelling course below foundations. If excavation is carried out to greater width and length, such extra width and length shall be filled in by well consolidated earth / sand or if the Engineer thinks it is necessary for the stability of the work, by masonry or concrete as he may direct. No extra payment will be made on this account. Propping shall be undertaken when any foundation or stressed zone from an adjoining structure is within a line of 1 vertical to 2 horizontal from the bottom of the excavation. All excavations shall be carried out in conformity with the directions laid hereunder and in a manner approved by Engineer. The work shall be so done that the suitable materials available from excavation are satisfactorily utilised as decided upon, beforehand.





2.5 The last 200mm depth of excavation shall be done not earlier than 36 hours before laying the levelling course below foundations.

2.6 The Contractor shall make provision for all shoring, de-watering, dredging, bailing out or draining water whether subsoil or rain or other water and the excavation shall be kept free of water while concrete work is in progress and until the Engineer considers the work well set (Refer IS:3764 Safety Code for Excavation Work). The sides of trenches shall be kept vertical and the bottom level throughout or properly stepped as directed by the Engineer. No extra payment shall be made on this account.

2.6.1 De-watering shall be carried out by suitable means with adequate stand-by arrangements as may be approved by the Engineer. The level of ground water shall be maintained at least 300mm below the lowest level of excavation during the laying of foundations. The Contractor shall be deemed to have satisfied himself with regard to feasibility of all aspects of de-watering including site constraints due to existing structures. Though the method of de-watering is left to the contractor, he shall be required to submit method statement of de-watering scheme including requisite justifications to the Engineer and seek his prior written approval.

Approval of the Engineer however shall not relieve the contractor of the responsibility of adequacy and appropriateness of de-watering and protection arrangements for the quality and safety of the work. The contractor shall satisfy the Engineer as to the capacity of the drains or disposal site to take the required quantity and flow of water to be pumped out at various stages of excavation. The Contractor shall obtain necessary approvals of local bodies for discharging and disposal of the pumped out water. All the de-watering pumps shall therefore also have dedicated D.G. Power supply which shall start automatically in case of failure of electrical supply. Monitoring of water table shall be done using electronic probes or by other suitable methods.

2.7 The Contractor shall erect and maintain during progress of works temporary fences/ barricading around the work area with all safety measures. The dangerous excavations, excavations near habitations, public movement areas and all works along the roads, shall be, provided with proper caution signs and marked with red lights, reflectors at night to avoid accidents. The contractor shall take all adequate protective measures to see that excavation operations do not affect or damage adjoining structures. Payment for the same shall be made at the quoted rates for the items in the BOQ and nothing extra shall be payable.

2.8 Excavation material required for filling shall be stacked or dumped where indicated by the Engineer. Excavated material not required for filling and any surplus material shall be removed and spread on the site anywhere within the premises and as directed by the Engineer or carted away from the site as directed by the Engineer. Dumping of this surplus material shall be in an environmental friendly manner using dumper with tarpaulin or suitable cover, placer etc. and according to the levels/grades as indicated by the Engineer. Levelling and Compaction, if required, at the dumping ground shall also be carried out. The cost of such removal and spreading shall be borne by the Contractor and deemed to be included in the Contract Rates. Necessary approval from the local authorities for carting and dumping surplus material is to be obtained by the contractor at his own cost.

2.9 The Contractor shall notify to the Engineer when the excavation is completed and no base or Concrete or Masonry shall be laid until the Engineer has inspected and approved of the soil conditions obtained for each individual footing or the full raft area.

2.10 The Contractor shall ensure the stability of the excavation so that the surrounding ground and all adjoining structures and plants will be safe against settlement, subsidence and damage and that there is no risk of injury to personnel.

2.11 In case any underground structures/ utilities that need to be protected (like underground sewer lines etc.) are encountered, the Contractor shall bring the same to the notice of the Engineer immediately and shall take all such steps as the Engineer may instruct for protection of such structures. Such protective measures shall be done at the Contractor’s cost If any damage occur to such structures/utilities which were required to be protected during execution, the same shall be made good by contractor at his own cost otherwise client will arrange to make it good at the risk and cost of Contractor.

2.12 The Contractor is free, within the framework of rules and regulations of the local authorities, to deal with the surplus earth in any manner suitable to him. The Contractor may dispose-off the surplus earth from the project site to a place/ places as may be permitted by the Engineer/ appropriate authority/ body. The transportation of the surplus





earth shall be done by mechanical means only. The Contractor shall at his own cost obtain necessary clearances/ permissions statutory or otherwise needed for the purpose. Dumpers may be used for transporting slushy, material excavated from pile boring / well boring / pile cap / Open Foundation with precautions for non-spillage of muck.

2.13 In case earth is used for backfilling in foundation and plinth, it shall be got approved from the Engineer. In the foundation the backfilling shall be done in layers not more than 200mm thick and shall be thoroughly watered and consolidated by approved method. The rate for backfilling in foundation using earth is deemed to have been included in the excavation rate even when dewatering may be required to be carried out.

2.14 In case sand is used for backfilling in foundation and plinth, it shall be got approved by the Engineer. In the foundation the backfilling shall be done in layers not more than 200mm thick and shall be thoroughly watered and consolidated by approved method. The rate for backfilling using sand in foundation is deemed to have been included in the excavation rate.

2.15 For open foundation resting on rock, if sound rock is located at shallow depths, the contractor is required to cut the rock (of all type or strength) to a depth so that open foundation with a minimum earth cushion of 500mm can be accommodated.

2.16 Measurements & Payment Payment for excavations in soil and/or rock, including providing and installing shoring / strutting, dewatering, pumping and bailing out water shall be made as per the quoted rate of the respective items of excavation as specified in BOQ. However unless stated otherwise, the quoted rates for concrete in foundation (upto ground level) shall be deemed to include the cost of shoring, strutting, dewatering and backfilling using earth or sand wherever required with compaction of the same. Measurements of excavation shall be solid measurements or actual volume of the materials prior to its removal. Measurements shall be of the exact length, width as indicated in the drawings and depth, measured vertically according to the Engineer's drawing or his instruction. No separate payment shall be made for shoring, dewatering, dredging, bailing, extra excavation required for side slopes and/or benching, ramps, space for providing side shutters and props etc. The measurements for the removal of the excavated material shall be recorded at site of work before it is loaded in trucks and admissible deductions, if any, shall be made depending upon the type of material. For excavation of existing road maximum limit of measurement for payment shall be from the existing ground level to the bottom of rubble soling. Measurement shall be those for the minimum works as ordered/plan dimensions as shown in the drawing and actual depth measured at site. All excavation shall be measured net and rate shall not allow for any additional for working space. The measurement for backfilling shall be based on actual difference of levels before filling and after levelling.





3 STRUCTURAL CONCRETE: PLAIN, REINFORCED & PRESTRESSED These specifications shall be read in conjunction with the MORTH and CPWD specifications 1996/2002 with correction ships / amendments upto date, and other relevant specifications described in the Section 1 of these Specifications.

3.1 Materials Before bringing to the site, all materials for concrete including their source shall be approved by the Engineer. All approved samples shall be deposited in the office of the Engineer before placing orders for the materials with suppliers. The materials brought on to the works shall conform in every respect to the approved samples. In case of change in type and/or source of any approved material, the contractor shall inform the Engineer and fresh samples shall be deposited with Engineer. Prior approval of Engineer will have to be obtained before using such material at site. The contractor shall check fresh consignment of materials as it is brought on to the works to ensure that they conform to the specifications and/or approved samples. The Engineer shall have the option to have any of the materials tested at any time to find out whether they are in accordance with specifications at the contractor's expense. All bills vouchers and test certificates which in the opinion of the Engineer are necessary to convince him as to the quality of materials or their suitability shall be produced for his inspection when required. Any material which has not been found to conform to the specifications and not approved by the Engineer shall be rejected forthwith and shall be removed from the site by the contractor at his own cost within the time stipulated by the Engineer. In the event of contractor not being able to arrange the material conforming to specifications or in the event of failure of the contractor to get the sources approved within the agreed schedule submitted by contractor, the Engineer shall have the powers to cause the Contractors to purchase and use such materials from any particular source, as may, in the Engineer's opinion, be necessary for the proper execution of work. Nothing extra shall be payable to the contractor on this account. Contractor shall also ensure that all constituents of exposed concrete shall be taken from same sources to achieve a uniform colour and texture.

3.1.1 Cement 3.1.1.1 The cement used shall be of the following types:

a) 43 grade Ordinary Portland Cement conforming to IS: 8112. b) 53 grade Ordinary Portland Cement conforming to IS:12269. For piling and foundation work, type of cement shall be as mentioned in section S-08 on Pile Foundations.

3.1.1.2 Whenever possible all cements of each type shall be obtained from one constant source throughout the contract. Cement of different types shall not be mixed together. Different brands of cement, or the same brand of cement from different sources, shall not be used without prior approval of the Engineer.

3.1.1.3 Packaged cement shall be delivered to the site in original sealed bags which shall be labelled with the weight, name of manufacturer, brand and type including date of manufacture. Cement received in torn bags shall not be used. Contractor may obtain cement in bulk and store it in suitable silos of adequate capacity. Each type of cement shall be stored in a separate silo and it shall be ensured, that cements of different quality are not mixed up.

3.1.1.4 All cement shall be fresh when delivered. Cement older than 3 months from the date of manufacture shall not be used.

3.1.1.5 In fair faced elements, the cement used in the concrete for any complete element shall be from a single consignment. All cement for exposed concrete shall be from the same approved source and uniform in colour.

3.1.1.6 With each and every delivery of cement consignment, the contractor shall provide manufacturer’s certificate that the cement conforms to the relevant Indian standard. The contractor shall provide complete facilities at site for carrying out the following tests:

a) Setting time by Vicat's apparatus as per IS:4031 and IS:5513. b) Compressive strength of cement as per IS: 4031, IS:650, IS:10080.

3.1.1.7 Total chloride content in cement shall in no case exceed 0.05 % by mass of cement. Also, total sulphur content calculated as sulphuric anhydride (SO3), shall in no case exceed 2.5%





and 3.0% when tri-calcium aluminate per cent by mass is upto 5% or greater than 5% respectively.

3.1.2 Aggregates Aggregates from natural sources shall be in accordance with IS:383. The contractor shall submit to the Engineer certificates of grading and compliance for all consignments of aggregate. In addition at site from time to time, the contractor shall allow for carrying out such tests and for supplying test records to the Engineer. The aggregates shall be procured from approved sources only as directed by the Engineer from time to time.

For fair faced concrete, the contractor shall ensure that aggregates are free from iron pyrites and impurities, which may cause discoloration. Aggregates shall be stored on paved areas in different compartments according to their nominal size.

3.1.2.1 Fine Aggregates The contractor shall provide complete facilities at site for determining grading of aggregates by sieves as per IS:383, IS:460, IS:1607, and IS:2386. The fine aggregate shall be river sand, pit sand, stone dust or other approved sand subject to their conformity to the specifications. It shall be free from clay, loam, earth or vegetable matter and from salt or other harmful chemical impurities. It shall be clean, sharp, strong,angular and composed of hard siliceous material. The grading of fine aggregate when determined as described in IS:2386 (part I), shall be within the grading zones I, II, III. The contractor shall provide complete facilities at site for carrying out the following tests:

A) Proportion of clay, silt and fine dust by sedimentation method as per IS:2386 part II. B) Moisture content in fine aggregate as per IS: 2386 Part III. C) Bulk density/Bulkage.

3.1.2.2 Coarse Aggregates The coarse aggregate shall be crushed stone. Coarse aggregate obtained from crushed or broken stone shall be angular, hard, strong, dense, non-porous, durable, clean and free from soft, friable, thin plate, elongated or flaky pieces and any deleterious material. Except where it can be shown to the satisfaction of the Engineer that a supply of properly graded aggregates of uniform quality can be maintained over the said period of the works, the grading of aggregates shall be controlled by obtaining the coarse aggregates in different sizes and blending them in correct proportions as and when required. All coarse aggregates shall conform to IS:383 and tests for conformity shall be carried out as per IS:2386,Parts I to VIII. The maximum size of coarse aggregates shall be such that the concrete can be placed without difficulty so as to surround all reinforcement thoroughly and fill the corners of formwork. Unless otherwise permitted by the Engineer the nominal maximum size shall not exceed 20 mm.

3.1.3 Water 3.1.3.1 Water used in the works shall be potable water and free from deleterious materials.

Water used for mixing and curing concrete as well as for cooling and/or washing aggregate shall be fresh, clean and free from injurious amounts of oil, salts, acids, alkali, other chemicals and organic matter.

3.1.3.2 Water shall be from the source approved by the Engineer and shall be in accordance with clause 5.4 of IS: 456. However, chloride content in water shall not exceed 500 mg/litre.

3.1.3.3 Whenever the source of water changes, the water shall be tested for its chemical and other properties or impurities to ascertain its suitability for use in concrete with approval of the Engineer. No water shall be used until tested and found satisfactory. Cost of all such Tests shall be borne by the contractor.

3.2 Blending Of Aggregates In order to obtain optimum workability, individual aggregates of nominal size 20mm, 10mm, 4.75mm and 2.36mm will be blended in such a way that the grading curve for all in aggregates will be a smooth curve from size 0.15mm to 20mm falling within the established envelope grading curve. Contractor shall establish envelope grading curve for each grade of concrete for given maximum size of aggregates and get it approved by Engineer before finalising the mix design.

3.3 Admixtures





3.3.1 Chemical admixtures are not to be used until permitted by the Engineer. In case their use is permitted, the type, quantity/dosage and method of use of any admixture proposed by the Contractor shall be submitted to the Engineer for approval. The minimum cement content specified shall not be reduced on account of the use of the Admixtures.

3.3.2 The contractor shall further provide the information concerning each admixture to the Engineer as per para 1012.1 of MORTH Specifications.

3.3.3 In reinforced concrete works, the chloride content of any admixture used shall not exceed 2 percent by weight of the admixture as determined in accordance with IS:6925 and the total chloride and sulphate contents in concrete mix shall not exceed 0.15 and 4.0 percent respectively by weight of cement.

3.3.4 The admixtures when used shall conform to IS:9103. The suitability of all admixtures shall be verified by trial mixes.

3.3.5 The addition of calcium chloride to concrete containing embedded metal will not be permitted under any circumstances.

3.3.6 Retarding admixtures when used shall be based on lingosus-Phonates with due consideration to clause 5.2 and 5.3 of IS:7861.

3.3.7 The following admixture shall replace the use/ requirement of inhibitor solution as mentioned in clause 5.5 of Structural Specification:

Bipolar Concrete Penetrating Corrosion Inhibiting Admixture: Bipolar Concrete Penetrating Corrosion Inhibiting Admixture of approved make and required specifications shall be used in the concrete. The requirements of ASTM G1, IS 9103 – 1999, ASTM G3, ASTM G-109-2005, AASHTO 259, IS 456-2000 and ASTMC 1202-1997 must be met. The test for the admixture shall be conducted at IIT Bombay at the cost of contractor. The application shall include adding Corrosion Inhibiting Admixture based on BIM mechanism at a dosage of minimum 2 kgs per cubic meter of concrete, exhibiting a noble free corrosion potential (FCP) of 200 mV compared to control concrete and being free from nitrites, chromates and non-migrating types. It should be able to form impermeable film on surface of rebar after migration upto 12cm as evaluated with advance methods including SEM & XPS & having a bond energy (Fe-N) 396.6 ev & 399.9 ev & bond Energy (Fe-Ca): 355.6 ev & 359 ev as per evaluation by CSIR-CECRI & Evaluated at RDSO & Specified under M&C/PCN/126-08. It should exhibit Corrosion inhibition efficiency of minimum 80% even in the presence of severe chloride attacks. As per RDSO technical literature (BS -88), it shall be essential to carry out trial mix with desired admixtures along with Bipolar Concrete Penetrating Corrosion Inhibiting Admixture. In addition, modified accelerated corrosion test (based on Japanese Standard JIS Z1535) shall be carried out preferably at NCCBM, Ballabgarh at the cost of contractor.

3.4 Batching Plants, Mixers and Vibrators 3.4.1 Unless otherwise specified in the schedule of items, for all structural concreting work the

Contractor shall provide automatic weigh-batching plant of suitable capacity. The plant used shall conform to IS:4925. The batching plants should have printing facilities to printout records of each batch in the format approved by the Engineer.

3.4.2 The Contractor shall provide Concrete mixers (IS:1791 – Batch type concrete mixers, IS:2438 – Roller Pan Mixer) and Vibrators (IS:2505 – Concrete Vibrators Immersion Type, IS:2506 – Screed board concrete vibrators, IS:4656 – Form Vibrators for Concrete) supplied by recognized manufacturers.

3.5 Grade of Concrete The concrete is designated as follows: Concrete M 25 / 20





The letter M refers to the mix The number 25 represents the characteristic compressive strength of 15cm cubes at 28 days in MPa (Mega Pascals : 1 MPa : 10 kg/cm2 approximately). M25 concrete thus has a characteristic strength of 250 kg/cm2. Other mix design will also be denoted in same way. The number 20 represents the nominal size of the coarse aggregates in mm.

3.6 Mix Design It is the complete responsibility of the Contractor to design the concrete mixes by approved standard methods and to produce the required concrete conforming to the specifications and the strength, workability requirements approved by the Engineer. Mix Design once approved must not be altered without prior approval of Engineer. However, should the contractor anticipate any change in quality and/or change in source of future supply of materials than that used for preliminary mix design, he should inform the Engineer quite in advance and bring fresh samples sufficiently in advance, to carry out fresh trial mixes. Design mix will indicate by means of graphs and curves etc., the extent of variation in the grading of aggregates which can be allowed. Limits of Water and Cement Contents Maximum water/cement ratio

a) For RCC members including piles - 0.40 b) For PSC members - 0.40

Cement Content Notwithstanding to the stipulations in any code, Cement content in concrete shall not be less than 380 kg/ cum for RCC work and 400 kg/ cum for PSC work under normal exposure. In case of piling work minimum cement content shall be as specified under the section “Pile Foundations”. However, maximum cement content shall be limited to 540 kg/ cum of concrete. Ordinary Portland Cement (OPC) of 43 and 53 grade conforming to IS: 8112 and IS: 12269 respectively shall be used. For pre-stressed concrete, cement conforming to OPC 53 grade cement shall be used. However for nominal mixes, CPWD specifications will be followed. “Cement” means Ordinary Portland Cement and excludes the additions as mentioned in para 5.2 of IS 456. As regards trial mixes, acceptance criteria, acceptance specification, lot size, sampling and testing and sampling size for piling work, PSC girders (cast-in-situ and pre-cast post-tensioned) and general work, the requirement of the relevant codes, standards and directions of the Engineer shall be followed.

3.7 Additional Tests for Concrete As frequently as the Engineer may require, additional tests shall be carried out of concrete in addition to mandatory test specified in MORTH Specifications, CPWD specifications 1996/ relevant IS Code.

3.7.1 Permeability test for Concrete: The concrete will be verified for permeability by the following procedure and shall confirm to IS:3085-1965 – ‘Permeability of Cement Mortar & Concrete’. Section 1716.5 of MORTH Specifications and DIN 1048. 1 The Engineer shall select random batches of concrete for examination at his discretion and sampling will generally be done at the point of discharge from the mixer and at placing point. 2 From the batches thus selected two concrete cylinders shall be made in accordance DIN 1048. 3 At least two cylinders shall be made on each day’s concreting until 60 cylinders have been made for each grade of concrete. 4 All cylinders shall be made, cured, stored, transported and tested in accordance with clause 1716.5 of MORTH Specifications. The tests shall be carried out in a laboratory having NABL certification. 5 Test Procedure The permeability of concrete will be verified by the following procedure: i. Prepare a cylindrical test specimen 150 mm dia. and 160mm high. ii. After 28 days of curing, test specimen will be fitted in a machine such that the

specimen can be placed in water under pressure up to 7 bars. The typical machine shall be similar to one shown in Appendix 1700/II of MORTH.

iii. At first a pressure of one bar is applied for 48 hours, followed by 3 bars for 24 hours and 7 bars for next 24 hours.





iv. After the passage of the above period, the specimen is taken out and split in the middle by compression applied on two round bars on opposite sides above and below.

v. The water penetration in the broken core is measured with scale and the depth of penetration assessed in mm (max permissible limit 25 mm).

6 Acceptability Criteria The concrete shall pass the permeability test if it is properly compacted and is not considered permeable when tested as above. No extra payment shall be made for this test and cost of the same should be included in the quoted rate for concrete work.

3.8 Batching Of Concrete Ingredients Unless permitted by the Engineer, all concreting shall be produced in computerised automatic weigh batching plant having printing facilities to print out records of each batch and installed at site. Under exceptional circumstances Ready Mixed Concrete (RMC) manufactured in computerised automatic weigh batching plant (as per specifications described above) by the approved agencies using the constituent materials from approved sources and approved mix design may also be used with prior approval from Engineer. Nothing extra shall be paid for such RMC used in the work including transportation, placing in position etc. However, in such cases the RMC production & transportation will have to be directly supervised by the qualified personnel of the contractor.

3.9 Placing Temperatures During extreme hot or cold weather, the concreting shall be done as per procedures set out in IS:7861, Parts I & II. The placing temperature of concrete shall be as low as possible in warm weather and care shall be taken to protect freshly placed concrete from overheating by sunlight in the first few hours of its laying. The time of day selected for concreting shall also be chosen so as to minimise placing temperatures. In case of concreting in exceptionally hot weather the Engineer may at his discretion specify the use of ice either flaked and used directly in the mix or blocks used for chilling the mixing water. In either case, the Contractor shall not be paid extra for cost of ice, additional labour involved in weighing and mixing etc. All salt and saw dust shall be removed from ice before use. Quality of water used for making ice shall confirm to IS:456.

3.10 Transporting, Placing, Compacting and Curing Transporting, placing, compacting and curing of concrete shall be in accordance with IS: 456.

3.10.1 Transporting The method of transportation used should efficiently deliver the concrete to the point of placement without significantly altering its desired properties with regard to water-cement ratio, slump, segregation and homogeneity. The mix after discharging from the automatic computerized weigh batching plant/mixer shall be transported by agitating transit mixers, buckets, pumps etc. or as approved by the engineer without causing segregation and loss of cement slurry and without altering its desired properties with regard to water cement ratio, slump, air content, cohesion and homogeneity. It should be ensured that the concrete is moved to its final destination before it attains the initial set. The revolving-drum truck bodies of approved make shall be used for transporting the concrete. The number of revolutions of mixing, speed, during transportation, and prior to discharge shall be specified and agreed upon. Reliable counters shall be used on revolving-drum truck units. Standard mixer uniformity tests, conforming to ASTM standards C 94 “Standard Specifications for Ready Mix Concrete”, shall be carried out to determine whether mixing is being accomplished satisfactorily.

3.10.2 Water, Admixtures and Slump The amount of water required for proper concrete consistency shall take into account the rate of mixing, length of haul, time of unloading, and ambient temperature conditions. Additions of water to compensate for slump loss should not be resorted to nor should the design maximum water-cement ratio be exceeded. Additional dose of retarder be used to compensate the loss of slump at contractor’s cost, when permitted by Engineer. Retempering water shall not be allowed to be added to mixed batches to obtain desired slump.

3.10.3 Placing





The method of placing shall be such as to prevent segregation by providing windows in the formwork for pouring concrete or by Tremie pipe. The thickness of horizontal layers shall not exceed 300mm. High velocity discharge of concrete causing segregation of mix shall be avoided. The concrete shall be placed in the forms gently in such a way that the segregation does not take place. The concrete shall not be dropped from a height exceeding 2.0m. Each layer of concrete shall be compacted fully before the succeeding layer is placed and separate batches shall follow each other close enough to ensure that the succeeding layer shall be placed and fully compacted before the layer immediately below has taken initial set. For piers and pier heads, portal columns, concreting is to be carried out in single stage i.e in first stage concreting will be from kicker to just below pier head bottom and second stage of concreting will be pier head including shear key and cross girder (for all heights by using tremie/ pumps at the rate not more than 1.5m / hror as approved by the Engineer). Concreting of any portion or section of the work shall be carried out in one continuous operation and no interruption of concreting work will be allowed without approval of the Engineer.

3.10.4 Compaction Internal (needle) and surface (screed board) vibrators of approved make shall be used for compaction of concrete. Internal vibrators shall be used for compaction of concrete in foundations, columns, buttresses arch section, slabs etc., and if required surface vibrators shall also be used. Depending on the thickness of layer to be compacted, 25 mm, 40 mm, 60 mm and 75 mm dia. internal vibrators will be used. The concrete shall be compacted by use of appropriate diameter vibrator by holding the vibrator in position until: i. Air bubbles cease to come to surface. ii. Resumption of steady frequency of vibrator after the initial short period of drop in

the frequency, when the vibrator is first inserted. iii. The tone of the vibrated concrete becomes uniform. iv. Flattened, glistening surface, with coarse aggregates particles blended into it

appears on the surface. v. After the compaction is completed, the vibrator should be withdrawn slowly from

the concrete so that concrete can flow in to the space previously occupied by the vibrator. To avoid segregation during vibration the vibrator shall not be dragged through the concrete nor used to spread the concrete. The vibrator shall be made to penetrate, into the layer of fresh concrete below if any for a depth of about 150mm. The vibrator shall be made to operate at a regular pattern of spacing. The effective radii of action will overlap approximately half a radius to ensure complete compaction.

vi. To secure even and dense surfaces free from aggregate pockets, vibration shall be supplemented by tamping or rodding by hand in the corners of forms and along the form surfaces while the concrete is plastic.

vii. A sufficient number of standby vibrators shall be kept readily accessible to the place of deposition of concrete to assure adequate vibration in case of breakdown of those in use.

viii. Form vibrators whenever used shall be clamped to the sides of formwork and shall not be fixed more than 450 mm above the base of the new formwork and concrete shall be filled not higher than 230mm above the vibrator. The formwork must be made specially strong and watertight where this type of vibrator is used. Care must be taken to guard against over vibration especially where the workability of the concrete mix is high since this will encourage segregation of the concrete.

ix. Plain concrete in foundations shall be placed in direct contact with the bottom of the excavation, the concrete being deposited in such a manner as not to be mixed with the earth. Plain concrete also shall be vibrated to achieve full compaction.

x. Green concrete shall be protected from the direct sun light and hot winds as per the methods approved by Engineer. Such method should be got approved from the Engineer before start of concreting operations.

Concrete placed below the ground shall be protected from falling earth during and after placing. Concrete placed on ground containing deleterious substances shall be kept free from contact with such ground and with water draining therefrom during placing and for a period of seven days or as otherwise instructed thereafter. Approved means shall be taken





to protect immature concrete from damage by debris, excessive loading, abrasion, vibrations, deleterious ground water, mixing with earth or other materials, and other influences that may impair the strength and durability of the concrete.

3.10.5 Field Control Sampling at both, truck discharge and point of final placement shall be employed to determine if any changes in the slump and other significant mix characteristics occur. However, for determining strength of concrete, cubes shall be taken from the placement end of line.

3.10.6 Curing i. Curing of concrete shall be complete and continuous using potable water free from

chlorides and sulphates water that is free of harmful amounts of deleterious materials that may attach, stain or discolour the concrete as per IS 456. Minimum wet curing will be for seven days by ponding water followed by moist curing by spraying water which shall be maintained up to a total period of at-least 21 days from the date of casting.

ii. Immediately after compaction and completion of any surface finishes the concrete shall be protected from the evaporation of moisture by means of polythene sheathing, wet hessian or other material kept soaked by spraying. As soon as the concrete has attained a degree of hardening sufficient to withstand surface damage moist curing shall be implemented and maintained for a period of at least 15 days after casting.

iii. Method of curing and their duration shall be such that the concrete will have satisfactory durability and strength and members will suffer a minimum distortion, be free from excessive efflorescence and will not cause undue cracking in the works by shrinkage.

iv. Steam curing with approved methodology can be adopted if required, for precast segments. No extra payment will be made for adopting steam curing.

v. Water based curing compounds may be permitted with specific approval of Engineer. However it is required to be proved that by using such curing compound, the concrete shall not have less strength than concrete cured by water curing. It shall not leave any discolouration on the structural concrete. It shall be applied as per the provisions of clause 1713.3 of MORTH specifications. No extra payment will be made for the same.

3.11 Construction Joints Construction joints in all concrete work shall be made as directed by the Engineer. Where vertical joints are required, shuttering shall be fixed as directed to ensure that the concrete does not take natural slope. Before fresh concrete is placed against a vertical joint, the old concrete shall be chipped, cleaned and moistened. No separate payment shall be allowed to the Contractor for forming joints or chipping and cleaning them. When a horizontal construction joint is formed, provision shall be made for interlocking with the succeeding layer by the embedment of saturated wooden blocks or wooden strips bevelled on four sides to facilitate their removal. Prior to the next pour the wooden pieces shall be loosened and removed in such a manner as to avoid injury to the concrete. Construction joints in concrete walls and slabs for liquid retaining structures shall be prepared in a similar manner to normal construction joints. If use of metal, rubber or plastic water stops is specified, this shall be cast into joints. Measures shall be taken by the Contractor to ensure that no displacement or distortion of water stops takes place during placing of concrete. The construction joints shall ensure proper bond and leak proof joint.

3.12 Cracks If cracks, which in the opinion of the Engineer may be detrimental to the strength of the construction, develop in concrete construction, the Contractor at his own expense shall test the structure as specified in clause 1.1.16 of ‘Loading Tests’ of these Specifications. If under such test loads the cracks develop further, the Contractor shall dismantle the construction, carry away the debris, replace the construction and carry out all consequential work thereto. If cracks develop in the concrete construction, which in the opinion of the Engineer, are not detrimental to the stability of the construction, the Contractor at his own expense shall





grout the cracks with neat cement grout or with other composition as directed by Engineer and also at his own expense and risk shall make good to the satisfaction of the Engineer all other works such as plaster, moulding, surface finish, which in the opinion of the Engineer have suffered damage either in appearance or stability owing to such cracks. The Engineer's decision as to the extent of the liability of the Contractor in the above matter shall be final and binding. External crack width shall be restricted to 0.2mm on all viaduct structures. If crack width is more than 0.2mm or in the opinion of Engineer may be detrimental to concrete construction, the contractor should test the structure at his own expense.

3.13 Defective Concrete Should any concrete be found honeycombed or in any way defective, such concrete shall be cut out partially or wholly by the Contractor and made good at his own expense. If Engineer feels that repaired structure will not be having same strength or shape or uniformity with other exposed surface as original desired structure / original structure, the same shall be rejected by Engineer and required to be dismantled and disposed-off by contractor at his own cost, as instructed by Engineer. Decision of the Engineer shall be final binding in this regard.

3.14 Exposed Faces, Holes and Fixtures On no account shall concrete surfaces be patched or covered up or damaged concrete rectified or replaced until the Engineer or his representative has inspected the works and issued written instructions for rectification. Failure to observe this procedure will render that portion of the works liable to rejection. Holes for foundation or other bolts or for any other purposes shall be moulded, and steel angles, holdfasts or other fixtures shall be embedded, according to the drawing or as instructed by the Engineer.

3.15 Finishes Unless otherwise instructed, the face of exposed concrete placed against formwork shall be rubbed down immediately on removal of the formwork to remove irregularities. The face of concrete for which formwork is not provided other than slabs shall be smoothed with a float to give a finish equal to that of the rubbed down face, where formwork is provided. The top face of a slab which is not intended to be covered with other materials shall be levelled and floated to a smooth finish at the levels or falls shown on the drawings or as directed. The floating shall be done so as not to bring an excess of mortar to the surface of the concrete. The top face of a slab intended to be surfaced with other material shall be left with a spaded finish. Faces of concrete intended to be plastered shall be roughened by approved means to form of a key.

3.16 Concrete for Flooring on Grade Concrete for flooring on grade shall be placed in alternate bays not exceeding more than 4m x 4m or as specified in the drawings including forming the joints or adjacent bays. The stiff mix shall be thoroughly vibrated and finished to receive the floor finish.

3.17 Grouting Of Base Plates & Bolt Holes 3.17.1 Mixing

Dry grout should be mixed in a mechanical mixer: the conventional 200/400-litre capacity concrete mixer can be used to mix four bags of dry grout; alternatively, paddle type mortar mixers can be used. The quantity of grout to be mixed at one time should not exceed that amount which can be placed in approximately 10 to 15 minutes.

3.17.2 Batching Batching of grout by fraction of a bag is not allowed. The quantity of mixing water should be the minimum commensurate with workability, compaction, and filling of the grout in all corners and crevices. Mixing should be done for a minimum of three minutes to obtain a fluid grout of uniform consistency.

3.17.3 Cleaning and preparation of the surface The base concrete should be clean and strong, and its surface should be properly hacked; all dust should be removed by suction or compressed air. The surface should be thoroughly wetted with water for several hours. Before the grout is poured, all free water should be removed and the flat surfaces coated with a thin cement slurry.

3.17.4 Restraint Heavy back-up blocks of timber or concrete should be fixed on all sides of the base plate to prevent escape of the grout, when poured through the openings provided in the base plate.





Adequate restraint must be ensured on all the sides for a period of 7 days to obtain effective expansion and shrinkage compensation.

3.17.5 Curing The grout should not dry out where external restraint is provided in the form of form-work, the top opening and all stray openings should be covered with wet sack for at least 7 days.

3.17.6 Placing and Compaction The grout should be placed quickly and continuously either through the holes in the base plates or from one side only to ensure complete filling without entrapment of air. Grout should be properly spread and compacted by rodding. Excessive vibration should be avoided. Below the bed plates, the grout should be compacted using long pieces of doubled-over flexible steel strapping or chains. The forward and backward movement of the strap or chain will assist in the flow of the grout into place. Steps must be taken to keep the grout in full contact with the underside of the bedplate until the grout sets; maintaining a small head of fresh grout in the forms.

3.17.7 Shrinkage Compensated Grout Shrinkage compensated grout or non-shrinkable grout of Associated Cement Companies Limited or any other approved manufacturer (Fosroc, Roff, Sikka, etc) should be used. The batching shall be as per the manufacturer's specifications, other procedures being as above.

3.18 Pre-Cast Concrete The provision in this section shall be considered supplementary to general provisions for reinforced concrete works.

3.18.1 Handling and Storage The pre-cast units shall be stored as directed by the Engineer. The area intended for the storage of pre-cast units should be surfaced in such a way that no unequal settlement can occur. To prevent deformation of slender units, they should be provided with supports at fairly close intervals and should also be safeguarded against tilting. Lifting and handling positions should conform to the Engineer's directions and drawings. In addition, location and orientation marks should be put on the members, as and where necessary. During erection the precast units should be protected against damage caused by local crushing and chafing effects of lifting and transport equipment.

3.18.2 Temporary Supports and Connections Temporary supports provided during erection should take into account all construction loads likely to be encountered during the completion of joints between any combination of precast and in-situ concrete structural elements. The supports should be arranged in a manner that will permit the proper finishing and curing of any in-situ concreting and grouting associated with the precast member being supported when the gaps of joints have to be filled with concrete or mortar. They should first be cleaned and faces of the joints should be wetted. The mixing, placing and compacting of cement and mortar should be done with special care. Mortar of a dry consistency should be in the proportion of 1:1½ (1 part of cement to 1½ parts of sand) and should be placed in stages and packed hard from both sides of the joint.

3.18.3 Tolerances The following tolerances apply to finished precast products at the time of placement in the structure. The forms must be fabricated / constructed to give a casting well within these limits:

1 Overall dimensions of members should not vary by more than + 6mm per 3m length with a maximum variation of + 20mm.

2 Cross-sectional dimensions should not vary by more than the following: + 3mm for sections less than 150mm thick + 4mm for sections over 150mm & less than 450mm + 6mm for sections over 450mm to 1000mm + 10mm for sections over 1000mm

3 Deviation from straight line in long sections should not be more than + 6mm up to 3m, + 10mm for 3m to 6m, + 12mm for 6m to 12m.

3.19 Additional Specifications For Pumped Concrete 3.19.1 Coarse Aggregates

The maximum size of coarse aggregate shall be limited to one-third of the smallest inside diameter of the hose or pipe used for pumping. Provision shall be made for elimination of





over-sized particles by screening or by careful selection of aggregates. To obtain proper gradation it may be necessary to combine and blend certain fractional sizes of aggregates. Uniformity of gradation throughout the entire job shall be maintained. The quantity of coarse aggregate shall be such that the concrete can be pumped, compacted and finished without difficulty.

3.19.2 Fine aggregates The gradation of fine aggregate shall be such that 15 to 30 percent should pass the 0.30 mm screen and 5 to 10 percent should pass 0.15 mm screen so as to obtain pumpable concrete. Sands, which are deficient in either of these two sizes, should be blended with selected finer sands to produce these desired percentages. With this gradation, sands having a fineness modulus between 2.4 and 2.8 are generally satisfactory. However, for uniformity, the fineness modulus of the sand should not vary more than 0.2 from the average value used in proportioning.

3.19.3 Pumping of concrete Only approved pumping equipment, in good working condition, shall be used for pumping of concrete. Concrete shall be pumped through a combination of rigid pipe and heavy-duty flexible hose of approved size and make. The couplings used to connect both rigid and flexible pipe sections shall be adequate in strength to withstand handling loads during erection of pipe system, misalignment, and poor support along the lines. They should be nominally rated for at least 3.5 Mpa pressure and greater for rising runs over 30 m. Couplings should be designed to allow replacement of any section without moving other pipe sections, and should provide full cross section with no construction or crevices to disrupt the smooth flow of concrete. All necessary accessories such as curved sections of rigid pipe, swivel joints and rotary distributors, pin and gate valves to prevent backflow in the pipe line, switch valves to direct the flow into another pipe line, connection devices to fill forms from the bottom up, extra strong couplings for vertical runs, transitions for connecting different sizes of pipe, air vents for downhill pumping, clean-out equipment etc, shall be provided as and where required. Suitable power controlled booms or specialized crane shall be used for supporting the pipe line.

3.19.4 Planning Proper planning of concrete supply, pump locations, line layout, placing sequence, and the entire pumping operation for a particular pour shall be made and got approved. The pump should be as near the placing area as practicable, and the entire surrounding area shall have adequate bearing strength to support concrete delivery pipes. Lines from pump to the placing area should be laid out with a minimum of bends. For large placing areas, alternate lines should be installed for rapid connection when required. Standby power and pumping equipment should be provided to replace initial equipment, should breakdown occur. The placing rate should be estimated so that concrete can be ordered at an appropriate delivery rate. As a final check, the pump should be started and operated without concrete to be certain that all moving parts are operating properly. A grout mortar should be pumped into the lines to provide lubrication for the concrete, but this mortar shall not be used in the placement. When the form is nearly full, and there is enough concrete in the line to complete the placement the pump shall be stopped and a go-devil inserted and shall be forced through the line by water under pressure to clean it out. The go-devil should be stopped at a safe distance from the end of the line so that the water in the line will not spill into the placement area. At the end of placing operation, the line shall be cleaned in the reverse direction.

3.20 Additional Specifications for Concrete M60 And Above 3.20.1 Any of the following shall be permitted to be used as part replacement of Ordinary

Portland Cement with the approval from Engineer

Microsilica / silica fume

Fly Ash

Granulated Slag However the cement content excluding any mineral admixtures shall not exceed 450kg / cum except with the prior approval from Engineer Also cement contents + binder should not be less than 380kg / cum of concrete





The water / (cement + binder) ratio should generally not exceed 0.33, but in no case more than 0.40.

3.20.2 In order that the performance of the completed structure be consistent with the requirements and assumptions made during planning and design, stringent quality assurance measures shall be taken. The methods and procedures of Quality System shall follow the guidelines contained in IRC:SP:47 – 1998. Q-4 class of Quality Assurance shall be adopted for the ‘Materials’ and ‘Workmanship’ items.

3.20.3 The temperature of concrete at the time of placement shall not exceed 30 C. The temperature of concrete at the mixing stage should be lower, to allow for rise in temperature during transport. When considerable distance of transport is involved, particular attention should be paid to ensure retention of slump as targeted for placement

3.20.4 Use of Microsilica / silica fume (a) Mineral admixture in the form of microsilica or condensed silica fume shall be

permitted in the design mix. It shall comply with ASTM C 1240 “Specifications for Silica Fume for use in Hydraulic Cement Concrete and Mortar”. It shall be obtained from proven, reliable and approved manufacturer/supplier to the satisfaction of the Engineer.

(b) Adequate and complete dispersal of the micro silica during the concrete mixing shall be ensured.

(c) When microsilica is used in powder form the contractor shall take all precautions against potential health hazards during handling of the material.

(d) Chilled water and/ or ice shall be used in the concrete mix depending on the ambient temperature, dimensions of the concrete element, rate of pouring and design mix constituents.

(e) Special profuse curing arrangements shall be made for dissipation of the heat of hydration. The water curing shall be continued for a period of 21 days.

(f) The concrete design mix and arrangement for mixing, transportation, and curing of concrete shall be subject to the approval of the Engineer.

3.20.5 Use of Fly Ash a) Use of well-graded Fly Ash from an approved source may be permitted subject to

satisfying the design criteria and requirement of mix design. Combination of microsilica / silica fume and fly ash may also be used to improve upon the durability of concrete and getting the early strength as required. However, the contents of fly ash or fly ash + microsilica / silica fumes in the mix shall not be more than 35% of the total cementatious material (cement + fly ash or Cement + fly ash + microsilica / silica fumes as the case may be). The maximum allowable content of the fly ash or fly ash + microsilica / silica fume shall be limited to 150 kg per cum of concrete mix.

b) Saving in the cement contents due to this vis a vis the mix design without the using Fly Ash shall be passed on to the Employer

c) Fly Ash shall be conforming to IS: 3812 (Part – 1):2003 and IS: 269-1989. Contractor shall have to make sure of availability of Fly Ash of consistent quality and in required quantity.

d) The physical requirements for Fly Ash are as under: S.No Characteristics Requirement

1 Fineness-specific surface in m3/kg by Blaine’s permeability method, (minimum)

320

2 Particles retained on 45 microns IS sieve (wet sieving) in percent, (maximum)

34

3 Lime reactivity – Average compressive strength in N/mm2 (minimum)

4.5

4 Compressive strength at 28 days in N/mm2 (minimum)

Not less than 80 percent of the strength of corresponding plain cement mortar cubes

5 Soundness by autoclave test – Expansion of specimen in percent (maximum)

0.8

e) Source of Fly – Ash To ensure the good quality of fly ash for use in concrete, the following sources of ash should be avoided:

i. Ash from plants burning different coal or blends of coal





ii. Ash from plants burning other fuels (wood chips, tyres trash) blended with coal

iii. Ash from start-up or shut down phases of operation iv. Ash from plants not operating at a “Steady State” v. Ash that is handled and stored using a wet system vi. Unprocessed ash from power plant without electrostatic precipitator (ESP) f) Drying and Conditioning of Fly Ash

When used in as a partial replacement for Portland cement in ready mix concrete, fly ash must be in dry form and as such requires no processing, provided above source control is maintained.

g) Quality Control Fly Ash in concrete should be as consistent and uniform as possible. Fly Ash to be used in concrete should be monitored by quality assurance/quality control (QA/QC) programmed on lot basis. These procedures include performing tests for fineness by wet sieving at 45-micron sieve and loss on ignition (LOI) so that the consistency of a Fly Ash source can be certified. Contractor shall have to evolve a suitable mix design on Fly Ash or fly ash + microsilica / silica fume (as the case may be) for the specified compressive/flexural strength and also demonstrate the suitability of the mix by field tests. Concrete mixes are designed by selecting the proportions of the mix components that will develop the required strength, produce a workable consistency concrete that can be handled and paved easily, and attend sufficient durability under exposure to in service environmental conditions. Procedures for proportioning Fly Ash or fly ash + microsilica / silica fume (as the case may be) concrete mixes differ slightly from those called conventional concrete mixes. One mix design approach commonly used in proportioning Fly Ash or fly ash + microsilica / silica fume (as the case may be) concrete mixes is to use mix design with all Portland Cement. Increase the total cementatious materials content (normally by 12%) remove some of the Portland Cement and then add Fly Ash or fly ash + microsilica / silica fume (as the case may be) to compensate for the cement removed. Also, water content should be reduced by 5%. The ACI mix proportioning guidelines recommend a separate trial mix for each 5% increment in the replacement of Portland cement by Fly Ash. When Fly Ash is used as a separately batched material, trial mixes should be made using a water (cement + fly ash) W/C + F) ratio, sometimes referred to as the water cementitious ratio, instead of the conventional W/C ratio. Also relaxation shall be given in such cases from 28 days strengths as 56 days strength shall also be tested for compliance. Minimum cement content should be 250 kg per cum. of concrete.

h) It shall be the responsibility of the contractor to procure and to transport and to store the Fly Ash to batching plant site. Contractor may also have to make necessary modifications in the batching plant to enable use of Fly Ash in the concrete mix.

i) Fly Ash handling and Storage When Fly Ash is used as cementitious material, the contractor should handle Fly Ash in the same manner as Portland cement, except that Fly Ash must be stored separately from the Portland cement. Loading, transportation, unloading including handling of the Fly Ash shall be done in eco-friendly manner so as not to pollute / degrade the atmosphere. The safety of the persons handling the Fly Ash should be ensured as per the approved norms.

j) Curing Slower strength development of concrete containing Fly Ash may require that the moisture is retained in the concrete for a longer period of time than what is normally required for conventional concrete. Proper





application of a curing compound should retain moisture in the concrete for sufficient period of time to permit strength development. Normal curing practices should be adequate for concrete containing Fly Ash. Scheduling of pavement construction should allow adequate time for the desired or specified gain prior to the placement of traffic loads.

3.21 Testing Concrete Structures for Water Tightness & Acceptance Criteria 3.21.1 Underground Tanks, Pump Rooms and Sumps

In the case of structures whose external faces are submerged and are not accessible for inspection, such as underground tanks, the structures shall be filled with water and after the expiry of seven days after the filling, the level of the surface of the water shall be recorded. The level of water shall be recorded again at subsequent intervals of 24 hours over a period of seven days. Backfilling shall be withheld till the tanks are tested. The total drop in surface level over a period for seven days shall be taken as an indication of the water tightness of the structure. A structure shall be deemed to be water tight if the total drop in the surface level over a period of seven days does not exceed 40 mm.

3.21.2 Roofs The roofs of liquid-retaining structures shall be water-tight and shall be tested on completion by flooding the roof with water to a minimum depth of 25 mm for 24 hrs. Where it is impracticable, because of roof falls or otherwise, to contain a 25 mm depth of water, the roof shall have water applied by a continuous hose of sprinkler system to provide a sheet flow of water over the entire area of the roof for not less than 6 hrs. In either case the roof shall be considered satisfactory if no leaks or damp patches show on the soffit. Should the structure not satisfy either of these tests, then after completion of the remedial work it should be re-tested in accordance with this clause. The roof insulation and covering should be completed as soon as possible after satisfactory testing.

3.21.3 Contractor shall give warranty for leak tightness of joints for 10 years. 3.22 Measurement

Measurement shall be made for the finished volume of reinforced cement concrete (excluding lean concrete) only. All linear dimensions shall be measured correct to 1cm & restricted to design dimensions, and the volume calculation will be correct to two decimal places in cubic metres. No deduction shall be made for volume of steel embedded in concrete or for voids not exceeding 0.03 cum in volume. In case of pile caps, the quantity of concrete of piles, which has gone into the pile caps, shall not be deducted.





4 FORM WORK 4.1 General

These specifications shall be read in conjunction with the MORTH specifications and CPWD specifications 1996/2002 with correction slips/amendments upto date, and other relevant specifications described in the section 1 of these specifications.

4.2 Materials Formwork shall be of timber, plywood (including marine plywood), steel or any other suitable material capable of resisting damage to the contact faces under normal conditions of erecting forms, fixing steel and placing concrete. The selection of materials suitable for formwork shall be made by the Contractor based on the quality consistent with the specified finishes and safety. For designated areas prominently in public view like piers, piers caps, portals, viaduct (cast-in-situ or pre-cast), parapet, columns etc., only steel shuttering shall be used. The material shall be approved by the Engineer before erected at site. However, the entire responsibility of planning, designing, erecting, dismantling, shifting and safety of false work lies with the contractor. All formwork and formwork supports (centring, props, scaffolds, ladders etc.) shall be in structural steel only and preferably of pipes conforming to IS:806, IS:1161, IS:1239, IS:2750. Wooden ballies shall not be permitted as props/formwork supports. All props shall be properly braced using x & k bracings. Ladders to be used at site should have treads and shall be fabricated from structural steel. Wooden / bamboo / aluminium / pipe ladders shall not be permitted.

4.2.1 Timber Timber used for formwork shall be easily workable with nails without splitting. It shall be stable and not liable to warp when exposed to sun and rain or wetted during concreting.

4.2.2 Plywood Plywood used for formwork shall be minimum 12 mm thick. Shuttering quality plywood complying with IS:4990 and of make approved by the Engineer. Suitable stiffeners and walers shall be provided depending on the shuttering design.

4.2.3 Steel Steel formwork shall be made of minimum 4 mm thick black sheets stiffened with angle iron frame made out of M.S. angles 40 mm x 6 mm supported at suitable spacing. Design & Drawings All temporary works such as formwork, falsework, staging, launching girder, cantilever form traveller scheme etc. shall be designed by the Contractor. The permissible stresses in materials of formwork, falsework, staging, launching girder& cantilever form traveller shall be same as for permanent structure. All calculations and drawings of the same including construction sequence shall be checked and verified by independent agency appointed by contractor. Only after the checking of the same, the calculations and drawings (along with soft copy in CD ROM) shall be submitted to Engineer for approval well in advance of work. All temporary works shall be also inspected by the independent agency and independent report shall be submitted to Engineer. All temporary works shall be robust, safe and constructed such a way that the concrete can be properly placed and thoroughly compacted to obtain the required shape, position and level subject to specified tolerance. It is the responsibility of the Contractor to obtain the results required by the Engineer, whether or not some of the work is sub-contracted. Approval of the temporary works by the Engineer shall not diminish the Contractor's responsibility for the satisfactory performance of the same, nor for the safety and co-ordination of all operations. For pier formwork, it shall be ensured that total deflection (taking account of combined deflection of plate, stiffners, walers or any other supporting arrangement) shall not be more than 3mm. All the formwork, launching truss and cantilever form traveller and other selected temporary works shall be tested for the load including factor of safety for which the truss/formwork is designed before use in works at no extra cost The design of false work should be such as to facilitate easy and safe access to all parts for proper inspection. Methodology for removal of form should be planned as a part of total form work design process. In case of pre-stressed concrete work, careful consideration shall be given to re-distribution of loads due to pre-stressing.





4.3 Formwork for Exposed Concrete Surfaces The facing formwork, unless indicated otherwise in drawings, or specifically approved by the Engineer in writing, shall generally be made with materials not less than the thickness mentioned below for different elements of the structure: 1. Plain slab soffit, and sides of beams, girders, joists and ribs and side of walls, fins,

parapets, pardis, sun-breakers, etc shall be made with: a. Steel plates not less than 4mm thick of specified sizes stiffened with a suitable

structural framework and fabricated true to plane b. Timber planks of 20mm actual thickness and of specified surface finish, width

and reasonable length, c. Plywood not less than 12mm thick (IS:4990 - Specification for Plywood for

Concrete Shuttering Work) stiffened with a suitable timber frame work or 3mm thick plywood with a 20mm timber plank backing, of specified sizes stiffened with a suitable timber framework and bracing. At joints 6mm/10mm sponge to be provided.

2. Bottoms of beams, girders and ribs, sides of columns shall be made with a. Steel plates not less than 5mm thick of specified sizes stiffened with a suitable

structural framework, and fabricated true to plane b. Timber planks of 35mm actual thickness and of specified surface finish, width

and reasonable length, c. Plywood not less than 12mm thick (IS:4990), of specified sizes stiffened with a

suitable timber framework. 3. For Precast segments, piers, pier heads, portals etc. suitable steel form work is to be

used unless otherwise specified by Engineer. 4.4 Formwork for Sloped Surfaces

1. Forms for sloped surfaces shall be built so that the formwork can be placed board-by-board immediately ahead of concrete placement so as to enable ready access for placement, vibration, inspection and finishing of the concrete.

2. The formwork shall be built in such a way so that the boards can be removed one by one from the bottom up as soon as the concrete has attained sufficient stiffness to prevent sagging. Surfaces of construction joints and finished surfaces with slopes steeper than 2 horizontal:1 vertical shall be formed as required herein.

4.5 Formwork for Curved Surfaces 1. The contractor shall interpolate intermediate sections as necessary and shall construct

the forms so that the curvature will be continuous between sections. Where necessary to meet requirements for curvature, the form lumber shall be built up of laminated splices cut to make tight, smooth form surfaces.

2. After the forms have been constructed, all surface imperfections shall be corrected and all surface irregularities at matching faces of form material shall be dressed to the specified curvature.

4.6 Erection of Formwork The following shall apply to all formwork: 1. To avoid delay and unnecessary rejection, the Contractor shall obtain the approval of

the Engineer for the design of forms and the type of material used before fabricating the forms. (Ref. ACI 347 Formwork for Concrete or equivalent I.S. Code).

2. All shuttering planks and plates shall be adequately backed to the satisfaction of the Engineer by a sufficient number and size of walers or framework to ensure rigidity during concreting. All shutters shall be adequately strutted, braced and propped to the satisfaction of the Engineer to prevent deflection under deadweight of concrete and superimposed live load of workmen, materials and plant, and to withstand pouring rate and vibration.

3. Vertical props shall be supported on wedges or other measures shall be taken so that the props can be gently lowered vertically during removal of the formwork. Props for an upper level shall be placed directly over those in the level immediately below, and the lowest props shall bear on a sufficiently strong area. Care shall be taken that all formwork is set plumb and true to line and level or camber or better where required and as specified by the Engineer.

4. Provision shall be made for adjustment of supporting struts where necessary. When reinforcement passes through the formwork care should be taken to ensure close fitting





joints against the steel bars so as to avoid loss of fines during the compaction of concrete.

5. If the formwork is held together by bolts, these shall be so fixed that no iron will be exposed on surfaces against which concrete is to be laid and within the concrete cover to the steel reinforcement. In any case wires shall not be used with exposed concrete formwork. The Engineer may at his discretion allow the Contractor to use tie-bolts running through the concrete and the Contractor shall decide the location and size of such tie-bolts in consultation with the Engineer. The tie bolts shall be so designed that their removal on de-shuttering does not leave any embedment with in the concrete cover to steel reinforcement. Holes left in the concrete by these tie-bolts shall be filled by the concrete repair material and the methodology as approved by the Engineer at no extra cost.

6. Provision shall be made in the shuttering for beams, columns, and walls for a port hole of convenient size so that all extraneous materials that may be collected could be removed just prior to concreting.

7. Formwork shall be so arranged as to permit removal of forms without jarring the concrete. Wedges, clamps and bolts shall be used wherever practicable instead of nails. The formwork for beams and slabs shall be so erected that forms on the sides of the beams and the soffit of slabs can be removed without disturbing the beam bottoms or props under beams.

8. Surfaces of forms in contact with concrete shall be oiled with a mould oil of approved quality form releasing agent. If required by the Engineer the contractor shall execute different parts of the work with different mould oils to enable the Engineer to select the most suitable. The use of mould oil which results in blemishes of the surface of the concrete including diesel, burnt oil and any other lubricating oil shall not be allowed. Mould oil shall be applied before reinforcement has been placed and care shall be taken that no oil comes in contact with the reinforcement while it is being placed in position. The formwork shall be kept thoroughly wet during concreting and the whole time that is left in place,. Nothing extra shall be paid to contractor for oiling the moulds.

9. Immediately before concreting is commenced, the formwork and other related arrangements shall be carefully examined to ensure the following : a. Removal of all dirt, shavings, sawdust and other refuse by brushing, washing and

compressed air / vacuum cleaning. b. The tightness of joints between panels of sheathing and between these and any

hardened core. c. The correct location of tie bars, bracing and spacers, and especially connections of

bracing. d. Adequate cover blocks are in place e. Straightness and plumbness of the form work f. Side supports / restraints for the form work are enough and robust g. Construction joint (wherever applicable) is properly prepared h. That all wedges are secured and firm in position. i. That provision is made for traffic on formwork not to bear directly on reinforcing

steel. j. Pouring platform along with its approach from ground is robust and safe for workers

movement. k. Arrangement for vibrators for compaction of concrete l. Sequence of concrete pouring is well defined and is agreed upon by the Engineer

and is explained to concrete pouring team m. The Pouring area is well lit. n. Curing arrangements are well planned and agreed upon by the Engineer. o. The green concrete protection measures from sun & rain etc. are in place.

10. The Contractor shall obtain the Engineer's approval for dimensional accuracies of the work and for the general arrangement of propping and bracing. (IS:3696 - Safety Code of Scaffolds and Ladders, IS:4014 Steel Tubular Scaffolding I & II). All scaffolding and staging shall be either of steel tubes or built up section of rolled steel with adequate bracing at several levels in each perpendicular direction connecting each prop. In addition to this diagonal bracing should be provided in elevation ideally at 45 degrees or between 30 and 60





degree. The Contractor shall be entirely responsible for the adequacy of propping, and for keeping the wedges and other locking arrangements undisturbed through the de-centring period. (IS:8989 Safety code for erection of concrete framed structures)

11. Formwork shall be continuously watched during the process of concreting. If during concreting any weakness develops and formwork shows any distress the work shall be stopped and remedial action as directed by the engineer shall be taken..

12. Staging for portal girder and cross girder (in station zone ) shall be in the form of portal frame. It shall be ensured that minimum two lanes of traffic with a restricted height of 4.5m can ply underneath it with adequate protection to portal legs from moving traffic.

4.7 Concrete Finishes This section deals with the surface of concrete on which forms had been fixed while concreting.

4.7.1 Formed Surface Allowable deviation from plumb or level and from the alignment profile, grades and dimensions shown on the drawings is defined as "tolerance" and is to be distinguished from irregularities in finishes as described herein. Tolerances in concrete construction are specified elsewhere. The classes of finish and requirements for finishing of concrete surface shall be as shown on the drawings or as hereinafter specified. In the event of finishing not being definitely specified herein or in the drawings, finishes to be adopted shall be as directed by the Engineer. Completed concrete surface shall be tested, where necessary to determine whether surface irregularities are within the limits specified hereinafter. Surface irregularities are classified as "Abrupt" or "Gradual". Offsets caused by displaced or misplaced form sheathing, or form sections or by loose knots or otherwise defective timber form will be considered as abrupt irregularities, and shall be tested by direct measurements. All other irregularities shall be considered as gradual irregularities and will be tested by use of template, consisting of a straight edge or the equivalent thereof for curved surfaces. The length of the template shall be 150 cm for testing of formed surfaces and 300 cm for testing of unformed surfaces. The classes of finish for formed concrete surfaces are designated by one of the symbols F1, F2, F3 and F4. Unless otherwise specified or indicated on drawings, these classes of finish shall apply as follows: Finish F1: This finish applies to surfaces where roughness is not objectionable, or surface that will otherwise be permanently concealed. Surface treatment shall be the repair of defective concrete, correction of surface depressions deeper than 25 mm and filling of tie rod holes. Form sheathing will not leak mortar when concrete is vibrated. Forms may be manufactured with a minimum of refinement. Finish F2: This finish is required on surfaces permanently but not prominently exposed to public view for which other finishes are not specified except F1. Forms shall be manufactured in a workmanlike manner to the required offsets or bulges. Surface irregularities shall not exceed 5mm for abrupt and 8mm for gradual irregularities measured with a 1.5 m template. Finish F3: This finish is required for coarse textured concrete surfaces intended to receive plaster, stucco or wainscoting. Surface irregularities shall not exceed 5mm for both abrupt and gradual irregularities. Finish F4: This finish is designated for surfaces prominently exposed to public view where appearance is also of special importance. This shall include piers of bridges, viaducts, beams, parapets, railings and decorative features on the structure and on the bridges. To meet with requirements for F4 finish, forms shall be manufactured in a skilful, workmanlike manner, accurately to dimensions. There should be no visible offsets, bulges or misalignment of concrete. At construction joints, the forms shall be rightly set and securely anchored close to the joint. Abrupt and gradual irregularities shall not exceed 3mm. Irregularities exceeding this limit shall be reduced by grinding to a level of 1:20 ratio of height to length. Jute bag subbing or sand blasting shall not be used.

4.7.2 Unformed Surfaces The classes of finish for unformed surfaces are designated by symbols U1, U2, U3 and U4. Unless otherwise specified or indicated on drawings, these classes of finish shall apply as follows:





Finish U1: This finish applies to unformed surfaces that will be concealed permanently or otherwise where a screeded surface finish meets the functional requirements. Finish U1 is also used as the stage of finishes for U2 and U3. Finishing operations shall consist of sufficient levelling and screeding to produce an even uniform surface. Surface irregularities shall not exceed 10mm. Finish U2: This is floated finish, and used on all outdoor, unformed surfaces. Finish U2 is also used as the second stage of finish for U3. Floating to be performed manually or mechanically on stiffened screed surface shall be minimum to produce textured surface. If finish U3 is to be applied, floating shall be continued till a small amount of mortar without excess water is brought to the surfaces so as to permit effective trowelling. Surface irregularities shall be removed as directed by the Engineer. Finish U3: This is a trowelled finish and shall be used for tops of parapets, etc prominently exposed to view. When the floated surface has hardened sufficiently, steel trowelling shall be started. Steel trowelling on hardened, floated surface shall be performed with firm pressure to produce a dense uniform surface free from blemishes and trowel marks and having slightly glossy appearance. Surface irregularities shall not exceed 5mm. Finish U4: This is a steel-trowelled finish, similar to finish U3, except that light surface pitting and light trowel marks such as obtained from the use of machine trowelling will be acceptable, provided that surface irregularities do not exceed the limits specified for finish U3. Unformed surfaces which are nominally level shall be sloped for drainage as shown on drawings or as directed by Engineer unless the use of other slopes or level surface is indicated on drawings. Narrow surface such as tops of parapets, walls and kerbs shall be sloped approximately 1cm per 30cm of width. Broader surface such as roadways, platform and decks, shall be sloped approximately half centimetre per 30cm of width. Finishes of floor and roof slabs shall be sloped, if required, by the Engineer.

4.8 Exposed Concrete Work Exposed concrete surfaces shall be smooth and even, originally as stripped without any finishing or rendering. Where directed by the Engineer, the surface shall be rubbed with carborundum stone immediately on striking the forms. The Contractor shall exercise special care and supervision of formwork and concreting to ensure that the cast members are made true to their sizes, shapes and positions and to produce the surface patterns desired. No honeycombing shall be allowed. Honeycombed parts of the concrete including the other surface defects in the concrete shall be removed by the Contractor as per the methods, which do not affect the strength of adjoining Concrete and as approved by the Engineer. Part of defective concrete thus removed shall be re-cast using fresh concrete of same grade or approved quality concrete repair material depending upon the size, location, thickness of the defective concrete and structural behaviour of the member having defective concrete as instructed by the Engineer without extra cost,. For the purpose the Contractor shall prepare a comprehensive work procedure and get it approved from the Engineer. Nothing extra shall be paid for repair of the concrete. Contractor shall ensure that no air bubbles are formed on the exposed surface. Concrete pouring sequence, vibration methodology etc. shall be planned to avoid air bubbles. All materials, sizes and layouts of formwork including the locations for their joints shall have prior approval of the Engineer.

4.9 Age of Concrete at Removal of Formwork In accordance with CPWD Specifications 1996 / 2002 or IS:456. The Engineer may vary the periods specified if he considers it necessary. Immediately after the forms are removed, they shall be cleaned with a jet of water and a soft brush.

4.10 Stripping Of Formwork The work of form work removal should be planned and a definite scheme of operation worked out. Formwork shall be removed carefully without jarring the concrete, and curing of the concrete shall be commenced immediately. Concrete surfaces to be exposed shall, where required by the Engineer, be rubbed down with carborundum stone or bush-hammer to obtain a smooth and even finish. Where the concrete requires plastering or other finish later the concrete surface shall be immediately hacked lightly all over using approved methods and as directed by the Engineer. No extra charge will be allowed to the Contractor for such work on concrete surfaces after removal of forms.

4.11 Reuse of Forms





The Contractor shall not be permitted reuse of timber facing formwork brought new on the works for more than 5 times for exposed concrete formwork and 8 times for ordinary formwork. 5 or 8 uses shall be permitted only if forms are properly cared for, stored and repaired after each use. The Engineer may at his absolute discretion order rejection of any forms he considers unfit for use for a particular item irrespective of no of times the shuttering has been used and order removal from the site of any forms he considers unfit for use in the Works. Used forms brought on the site will be allowed proportionately fewer uses depending upon its condition and as decided by the Engineer. Use of different quality boards or the use of old and new boards in the same formwork shall not be allowed. If any other type of special or proprietary form work is used, the number of times they can be used will be determined by the Engineer.

4.12 Formwork for Precast/ Prestressed Concrete 1. The provisions in this section shall be considered supplementary to the general provisions

stated above and additional Technical Specifications for precast segments. Precast concrete members and panels shall be made in accurately constructed moulds, on a properly prepared casting bed. All aspects of the making, curing and erection of precast units shall be subject to the approval of the Engineer. The contractor shall submit detailed drawings of formwork for the approval of the Engineer. Finishing with cement mortar shall not be allowed.

2. The formwork should be so designed that it does not restrain the shrinkage movement and possible shortening due to pre-stress of the concrete. The formwork shall be of sturdy construction with special considerations to shutter vibrators when used. All edges and joints of the formwork should be designed and sealed so that no cement grout can escape and there is no wedging or keying to the concrete. The effect of curing on the formwork should be given special consideration. Depending on care, curing, erection and maintenance of the formwork after stripping, the following number of uses can be made with different types of formwork.

Plywood with timber backed formwork - As per satisfaction of Engineer Steel moulds -do- Number of uses of shuttering to be as per approval of the Engineer

In case concrete moulds can be satisfactorily provided by the contractor, the Engineer's approval shall be obtained before use on the works.

3. Stripping As soon as the pre-cast units have attained sufficient strength, the formwork shall be stripped. The pre-cast unit shall be lifted uniformly out of the formwork without being subjected to tilting or restraint effects.

4.13 Special Architectural Finishes Special approved architectural finishes like grooves, logos, engravings/projections in inset and out set as per the approved design shall be provided by fixing monolithic rubber forms or any other approved material fixed on the entire surface of the form work. The shore hardness of the rubber shall be 600 ± 5A to ensure strength, flexibility and elasticity. The rubber shall be cold cured (preferably polyurethane based) and fixed to the formwork under controlled conditions in shade and air temperature not exceeding 280 C. The form liners should be shrinkage free, solvent free and should be impervious to abrasion by Concrete, resistant to concrete pressure and heat resistant upto 700 C dry heat. Formwork liner fixation should be factory made under close tolerances and stage inspections.

4.14 If proprietary system of formwork is used, detailed information as given in Annexure 4.1 herein shall be furnished to Engineer for approval before use.

4.15 Measurement Unless stated otherwise, the rate for concrete in plain concrete, reinforced concrete or in prestressed concrete shall be deemed to include the cost of all formwork / shuttering, staging, launching etc.





ANNEXURE 4.1 INFORMATION TO BE SUPPLIED BY MANUFACTURERS OF PROPRIETARY SYSTEMS OF FORM WORK 1. GENERAL 1.1 The information which the manufacturer is required to supply shall be in such detail as to

obviate unsafe erection and use of equipment due to the intention of the manufacturer not having been made clear or due to wrong assumptions on the part of the user.

1.2 The user shall refer unusual problems of erection/assembly not in keeping with intended use of equipment, to the manufacturer of the equipment.

2. INFORMATION REQUIRED 2.1 The manufacturers of proprietary systems shall supply the following information;

a. Description of basic functions of equipment. b. List of items of equipment available, giving range of sizes, spans and such like, with

manufacturer’s identification number or other references. c. The basis on which safe working loads have been determined and whether the

factor of safety given applies to collapse or yield. d. Whether the supplier’s data are based on calculations or tests. This shall be clearly

stated as there may be wide variations between results obtained by either method. e. Instructions for use and maintenance, including any points which require special

attention during erection, especially where safety is concerned. f. Detailed dimensional information, as follows :

i. Overall dimensions, depths and widths of members. ii. Line drawings including perspectives and photographs showing normal uses. iii. Self-weight. iv. Full dimensions of connections and any special positioning and supporting

arrangements. v. Sizes of members, including tube diameters and thicknesses of material. vi. Any permanent camber built into the equipment. vii. Sizes of holes and dimensions giving their positions. viii. Manner of fixing including arrangements for sealing joints. ix. Method of de-stripping, storing & shifting.

g. Data relating to strength of equipment as follows: i. Average failure loads as determined by tests. ii. Recommended maximum working loads for various conditions of use. iii. Working resistance moments derived from tests. iv. Working shear capacities derived from tests. v. Recommended factors of safety used in assessing recommended loads and

deflections based on test results. vi. Deflections under load together with recommended pre-camber and limiting

deflections. vii. If working loads depend on calculations, working stresses should be tested. If

deflections depend on theoretical moments of inertia or equivalent moments of inertia rather than tests, this should be noted.

viii. Information on the design of sway bracing against wind and other horizontal loadings.

ix. Allowable loading relating maximum extension of bases and/or heads. x. Any restrictions regarding usage of any component or full assembly with

regard to spans, heights and loading conditions.





5 REINFORCEMENT 5.1 General

These specifications shall be read in conjunction with the MORTH specifications and CPWD specifications 1996/2002 with correction ships / amendments upto date, and other relevant specifications described in the section 1 of these specifications. Any steel specified for reinforcement shall conform in every respect to the latest relevant Indian Standard Specifications and shall be of tested quality under the ISI Certification Scheme. All reinforcement work shall be executed in conformity with the drawings supplied and instructions given by the Engineer and shall generally be carried out in accordance with the relevant Indian Standard Specifications IS:2502- Bending and Fixing of Bars for Concrete Reinforcement. Only TMT reinforcing bars of grade Fe500 (0.2% proof stress / yield stress not less than 500 MPa) confirming to IS:1786 – 1985 shall be supplied and used as reinforcement steel for the permanent work The reinforcement steel shall be from primary producers and no re-rolled steel shall be supplied and used. The contractor will produce copy of original challan / voucher as a proof of having purchased the steel reinforcement from approved manufacturers or their authorised distributors. The steel reinforcement shall be brought to the site in bulk supply of 10 tonnes or more as decided by the Engineer. All reinforcement shall be stored horizontally above ground level on platforms, skids or other approved supports, clear of any running or standing water. Proper drainage of platform shall be provided. Steel reinforcement shall be stored in such a way as to avoid distortion and prevent deterioration by corrosion. Bars of different diameters shall be stored separately. A record shall be kept of the batch numbers of reinforcement deliveries in such a form that the part of works in which particular reinforcement is used can be readily identified.

5.2 Inspection & Testing Every bar shall be inspected before assembling on the works and any defective, brittle, excessively rusted or burnt bars shall be removed. Cracked ends of bars shall be cut out. No work shall be commenced without the Engineer’s approval of the bar bending schedule. Manufacturer's test Certificate shall be supplied for each lot of supply brought at site of work by the contractor. Specimens sufficient for three Tensile Tests for each different size of bar for each consignment delivered shall be sampled and tested by the Contractor before use at site. Test results shall be duly supported by Graph. Batches shall be rejected if the average results of each batch are not in accordance with the relevant specifications / codes and the rejected steel shall be removed from the site of work by the contractor at his own cost within a week’s time from the written order from the Engineer.

5.3 Bar Bending and Bar Bending Schedule All bars will be carefully and accurately bent by approved means in accordance with IS: 2502, and relevant drawings. It shall be ensured that depth of crank is correct as per the bar cutting and bending schedule. Bent bars are not straightened for use in any manner that will injure the material. Prior to starting bar bending work, the Contractor shall prepare bar bending schedule from the structural drawings supplied to him and get the same approved by Engineer. Any discrepancies and inaccuracies found by the Contractor in the drawings shall be immediately reported to the Engineer whose interpretation and decision there to, shall be final.

5.4 Lapping & Couplers As far as possible, bars of the maximum length available shall be used. Laps shown on drawings or otherwise specified by the Engineer will be based on the use by the Contractor of bars of maximum length. Payment for reinforcement shall be made only for reinforcement shown in such drawings. No extra payment shall be made for reinforcement lapping. In case the Contractor wishes to use shorter bars, laps / mechanical couplers shall be provided at the Contractor's cost in the manner and at the locations approved by the Engineer. However use of mechanical couplers shall be subject to acceptance of the quality and test results by the Engineer. Couplers are permitted only for those structures which are





not subjected to dynamic loads such as pile, pile cap of Viaduct portion and for entry/exit structure. Welding in lieu of lap is not permitted unless specified in the drawings or as instructed by the Engineer.

5.5 Spacing, Supporting And Cleaning All reinforcement shall be placed and maintained in the positions shown on the drawings. The Contractor shall provide approved types of supports for maintaining the bars in position and ensuring required spacing and correct cover of concrete to the reinforcement as specified on the drawings. Cover blocks of required shape, size and strength M.S. Chairs and spacer bars shall be used to ensure accurate positioning of reinforcement. Cover blocks shall be cast well in advance and shall consist of approved proprietary pre-packaged free flowing mortars (Conbextra HF of Fosroc or equivalent) having the strength same as that of concrete for the member for which they are to be used. They shall be circular in shape for side cover and square for bottom cover. Cover blocks shall be cast and compacted using plate vibrator or any other approved method and shall be cured so as to achieve the desired strength. The cost of cover blocks and chairs/spacers shall be deemed to have been included in the rates. Bars must be cleaned before concreting commences of all scale, rust or partially set concrete which may have been deposited there during placing of previous lift of concrete. Any reinforcement which is certified as corroded by the Engineer shall be removed from the site. The HYSD bars shall be provided using cement and inhibitor using following procedure: a) Cleaning of steel by wire brush for dust and rust. b) Apply one coat of Cement slurry [1 kg cement & 600 cc of inhibitor solution (Patent

No. 109784/67)] by dipping or brushing. Allow it to dry for 24 hours in shade. The water is not to be used. The inhibitor solution is prepared in ionised water

No extra payment shall be made for the same. 18 Gauge G.I. wires shall be used for binding reinforcement as well as for tying cover blocks with reinforcement.

5.6 Welding 1. Wherever specified all lap and butt welding of bars shall be carried in accordance with

IS:2571. Only qualified welders duly tested and certified by the contractor shall be permitted to carry out such welding.

2. For cold twisted reinforcement welding operations must be controlled to prevent supply of large amounts of heat larger than that can be dissipated. The extreme non twisted end portion shall be cut off before welding. Electrodes with rutile coating should be used.

3. Bars shall be free from rust at the joints to be welded. 4. Slag produced in welding after each run should be chipped and removed by brush. 5. Electrode should not be lighted by touching the hot bar. 6. The welding procedure shall be approved by the Engineer and tests shall be conducted

to prove the soundness of the welded connection. 5.7 Provision of Future Cathodic Protection for Corrosion Control:

In order to provide Cathodic Protection in future, all reinforcement shall be tack welded using electrodes compatible with the types of bars at the specified intervals in the drawings. As a guideline, all reinforcing bars shall be tack welded at each ends or at a distance not more than 6m along length to the bars intersecting in other direction. The tack welding shall be checked for the electrical continuity before concreting. This shall be measured and paid separately.

5.8 Measurement The measurement shall be done by weight in MT based on bar bending schedule using the standard sectional weight of various bars as indicated below:

S. No. Bar Dia (mm) Standard sectional weight in Kg. / m

1 6 0.222

2 8 0.395

3 10 0.617

4 12 0.888

5 16 1.578





6 18 2.000

7 20 2.466

8 22 2.980

9 25 3.854

10 28 4.830

11 32 6.313

12 36 7.990

13 40 9.864

14 45 12.49

Payment of reinforcement steel shall be made for the length of the reinforcement bars of different diameter as per approved bending schedule (to be prepared by the contractor on the basis of approved drawing) including authorised chairs / spacer bars, lap/butt welding wherever required as per Clause 5.4. However, if standard laps are provided, they will be measured separately for the length shown in the drawing or for measured length of bars. In case the actual reinforcement provided in any member is less than the quantity calculated based on drawings/ bar bending schedule (with the approval of engineer), the same shall be adjusted for the purpose of payment. Payments shall not be made for butt welding and reinforcement bars used for lifting, hooks, handling, etc., as cost towards these is deemed to be included in the accepted rate of the item.





6 PRESTRESSING Structural concrete containing prestressed steel reinforcement to introduce precompression is termed as prestressed concrete.

6.1 General The prestressed concrete work shall generally conform to IS:1343 “Code of Practice for Prestressed Concrete” and Section 1800 of MOST Specifications. The Concrete, Formwork and Non- tensioned reinforcement shall conform to relevant clauses in Section 3, 4, and 5 of this specification. The work shall be carried out in accordance with the drawing and these specifications or as approved by the Engineer. The prestressing steel shall be Uncoated stress relieved low relaxation seven-ply strand conforming to IS: 14268. All prestressing steel shall be free from splits, harmful scratches, surface flaws, piping and other surface defects likely to impair its use in prestressed concrete. The prestressing steel shall be stored in a manner such that they do not come in contact with dirt, water, greasy and other harmful materials. The contractor shall furnish the test certificate for each bundle of strands bought if required by the Engineer, he shall get tested at his cost samples of strands in specified bundles in an approved laboratory. Site for casting yard shall be the choosing of the contractor. If the land is made available MAHA-METRO the same shall be on an agreed rental basis OR Successful bidder has to arrange land for the same at his own cost. The precast pretensioned elements shall be cast by the Contractor in the precasting yard. After 28 days of casting, the girders shall be transported to site and erected at appropriate position by the Contractor. The Tenderers are advised to visit the station sites as well as site of proposed precasting yard and assess the physical condition of the route for transportation of the elements. The Department shall allocate the premises of precasting yard for a specific period to the successful bidder on “as is where is” basis. Concrete and untensioned steel for the construction of prestressed concrete members shall conform to the requirements of sections respectively in so far as the requirements of these Sections apply and are not specifically modified by requirements set forth herein. Contractor shall ensure that different components of prestressing such as jacks, bearing plates, wedges, anchorages, strands and HDPE ducts are compatible to one another and the same shall be exchanged in between all the suppliers to ensure the same.

6.1.1 Scope of Work: The general scope of work will include: i. Providing and placing cement concrete with all ingredients and admixtures if and as

required. ii. All arrangements needed to keep the reinforcement bars, pretensioned strands and

sheathing in position with due spacing & cover blocks iii. Providing steel shuttering, staging, scaffolding, erection & eventual removal. iv. Providing and placing in position and fixing permanent specialised bearings with the

super structure, with their anchor bolts as per detailed specifications/instructions as stipulated, supplemented by manufacturer's specifications and directions of Engineer including grouting of holes etc. if any, with suitable grouts as approved by the Engineer.

v. Installation of expansion joints in stages over the viaduct deck as per approved drawings and as per manufacturer's specifications/directions of Engineer.

vi. Fixing/embedding all necessary electrical or other fixtures which shall be supplied by the dept. free of cost at site.

vii. Providing and mixing cement concrete with all ingredients and admixtures if and as required.

viii. Casting, curing, with steam/water as necessary, stacking at casting yard including all handling, rehandling and interim storage operations as required for precast girders.

ix. Loading at casting yard, transportation to site in accordance with the prevailing traffic rules and regulations, unloading and stacking at site for precast girders.





x. Provision of necessary & suitable packing to maintain the required gap between precast girders.

xi. Protection of reinforcement, required to be left for Integration of the precast unit with top deck slab cast in place and bending the reinforcement to required shape after precasting& till their embedment in concrete.

xii. Transporting precast girder to the location of placement, hoisting & placing in correct position, including all handling operations.

xiii. The operation of placing precast I-girders over brackets/pier arms on teflon/neoprene pads/tar paper including the cost of all operations involved, appropriate setting of superstructure.

xiv. Fixing/embedding any fixture supplied by the Employer. xv. The handling, carriage and storage of HT strands as per manufacturer’s specification. xvi. The H.T. strands will be procured by the Contractor. The extra pieces of HT strands

cut after the stressing of the cable will be the liability/property of the Contractor. xvii. Cost of all other items of materials, plants and equipment and works (not specifically

excluded above) for proper prestressing operation of the strands in accordance with the provisions contained elsewhere in the tender documents will be included in the cost of this item.

xviii. Providing/supplying and operating etc. of jacks and power pumps for prestressing, recording of data, tabulating the same in necessary formats for submission. The item will also include corrective measures that may be necessary and required by the Engineer.

6.2 Materials 6.2.1 Sheathing

All prestressing sheathing ducts shall be in the form of corrugated HDPE ducts (102mm ID for 19K15, 85mm ID for 12K15 & 19T13 etc) conforming to IRS Concrete Bridge Code-1997 (Addendum & corrigendum Slip No.5 Dated 19.11.2001 with modifications as stated below). The material for the ducts shall be high-density polyethylene with more than 2 percent carbon black to provide resistance to ultra-violet degradation and shall have the following properties: Density (IS: 2350) 0.94 – 0.96 g/cm3 at 230C Tensile Strength at yield (BS EN ISO 527-3) 20-26 N/mm2 Shore Hardness D (BS EN ISO 2039-1) 3 sec –60 min

15sec –58min Elongation at Yield (BS EN ISO 527-3) 7 % (min) Melt Flow Index (MFI ) ( IS:2530 ) 0.4 - 0.6 g / 10 minutes (Temperature

190 C under a mass of 5 kg.) Charpy Impact strength of notched specimen (BS EN ISO 179) At 23° C 10 kJ/m2 -40° C 4 kJ/m2 Coefficient of Thermal Expansion for 200C – 800C (DIN 53 752

1.50 x 10-4 / oC

Environmental Stress Crack Resistance (ASTM D-1693) at 70o C

192 Hrs

The thickness of the wall shall be 2.3 ± 0.3mm as manufactured and minimum 1.5mm after loss in the compression test, for duct size upto 160mm OD. The ducts shall be corrugated on both sides. The duct shall transmit full tendon strength from the tendon to the surrounding concrete over a length not greater than 40 duct diameters. Material and formulation of sheathing ducts shall conform to test and acceptance criteria of Appendix 1B of IRC:18-2000. These ducts shall be joined by adopting any one or more of the following methods, as convenient to suit the individual requirements of the location, subject to satisfactory pressure tests, before adoption.

Screwed together with male and female threads

Joining with thick walled HDPE shrink couplers with glue. This can also be used for connection with trumpet, etc.

Welding with electro-fusion couplers.





The joints shall be able to withstand an internal pressure of 0.5 bars for 5 minutes as per water loss test procedure given in Appendix-B of IRS Concrete Bridge Code-1997 (Addendum & corrigendum Slip No.5 Dated 19.11.2001). The initial acceptance tests such as bond test , compression test are required to be performed as acceptance criteria for system. In addition to above, friction test as given in FIB bulletinNo-7 are also required to be performed as acceptance criteria. Test conducted by supplier in the past shall not be regarded as acceptance criteria. The routine test such as workability test, transverse load rating test, tension load test and water loss test shall be applicable for both post threading and pre – threading system of cables. Loads to be imparted on the 102mm ID sheathing during transverse load rating test and tension load test shall be extrapolated from values given for smaller dia sheathing. At least 3 samples for one lot of supply (not exceeding 3000 metre length) shall be tested.

6.2.2 Anchorages 6.2.2.1 Anchorages shall be procured from authorised manufacturers only. Anchorages shall

conform to BS:4447. Load transfer test and anchorage efficiency shall be conducted as defined in FIP-1993. Engineer in-charge shall select at random, the required anchorage / wedges sample from completed lots for testing by the manufacturer. The concrete unit of required size/R/F will be made by contractor using same design mix of concrete which will be required for the load transfer test . The load transfer test shall be conducted at the strength of concrete at which stressing are proposed in the drawings. No damaged anchorages shall be used. Steel parts shall be protected from corrosion at all times. Threaded parts shall be protected by greased wrappings and tapped holes shall be protected by suitable plugs until used. The anchorage components shall be kept free from mortar and loose rust and any other deleterious coating. After completion of pre-stressing and grouting of cable in PSC girders, the extra length pre-stressing strands projecting outside the anchorage are required to be cut at the anchor end and anchor end is to be sealed.

6.2.2.2 Swages of prestressing strand shall develop strength of at least 95 per cent of the specified breaking load of the strand.

6.2.2.3 Untensioned Steel reinforcement, around anchorages shall be furnished by prestressing system supplier. Requirement of the same should be job specific and based on edge distance of anchorage and strength of concrete at the time of stressing of cables as defined in drawings. The same R/F shall be provided in unit required for load transfer test. Minimum 3 tests each are required to be conducted for load transfer test and anchorage efficiency test. The manufacturer shall complete the required testing and determine compliance the result with FIP-1993 recommendations before transporting the lot to site.

6.2.3 Prestressing Steel Uncoated stress relieved low relaxation steel conforming to IS: 14268, class – 2 shall be used. Nominal dia. shall be 15.2 mm with minimum breaking strength of 260.7 KN and minimum 0.2 % proof load of 234.6 KN. Various tests as recommended in IS: 14268 shall be conducted before transporting the lot to site. Apart from 1000 hrs relaxation test conducted by manufacturer, at least two such tests are required to be conducted by independent agency in the beginning of the project.

6.2.3.1 Prestressing Strands/Wires Storage All high tensile steel for prestressing work shall be stored about 30cm above the ground in a suitably covered and closed space to protect it from dampness. It shall also be invariably wrapped in gunny cloth or tar paper or any other suitable material, as per approval of Engineer. Even if it is to be stored in an area at the site for the short time during transportation it shall be suitably covered. Protection during storage and repacking or application of washable protective coating to the H.T. steel shall be given by the contractor at no extra cost if the packing of H. T. Strand/wire during unloading and storage / handling in the stores gets damaged. The objectives are to keep the materials clean and free from detrimental corrosion and mechanical damage. Storage facilities and procedures for transporting material on site shall not permit tendons to be kinked or notched. Stock piling of H. T. Steel on the work site shall not be allowed any time, specially before and during the monsoon. Strand shall be stored in large diameter coils. The internal diameter of the coil generally





Engineer-in-Charge or his authorized representative shall always have an easy access to the store-yard for inspecting the H. T. Wire/strands/Bars and satisfying themselves regarding the condition thereof. Any modification regarding storage suggested by Engineer shall scrupulously be followed by the contractor. During monsoon days, H.T wires/strands shall be kept in reasonable air tight store, if required by the Engineer, at no extra cost.

6.3 Testing of Prestressing Steel and Anchorages All materials specified for testing shall be furnished free of cost and shall be delivered in time for tests to be made well in advance of anticipated time of use. All strands to be transported to the site shall be assigned a lot number and tagged for identification purposes. Anchorage assemblies to be transported shall be like-wise identified. All samples submitted shall be representative of the lot to be furnished and in the case of strand, shall be taken from the same master roll. The Contractor shall furnish samples of at least 5.0m length selected from each lot for testing. Also, two anchorage assemblies, complete with distribution plates of each size or type to be used, shall be furnished alongwith short lengths of strands as required. All equipment must be used in accordance with the specification of the manufacturer and must at all times be maintained in good condition. The type of jack used should correspond with the type of strand used. It must also be checked that the jacks have the necessary stroke for the stressing of the strands/wires on the particular job. Pressure tests on jacks must be executed with pressures 10% higher than the maximum operating pressure. The combined jack and pump system should be checked for correct behaviour.

6.4 Workmanship 6.4.1 Concreting for Precast Girders

Unless otherwise mentioned hereunder, the concrete shall be prepared, mixed and placed in position in accordance with the particular specifications given earlier. The Contractor shall maintain a record of the proportions of mix at the batching plant and produce the same for checking by Engineer in Charge whenever required. The contractor shall take care in placing reinforcement cage so that cables/strands are not disturbed and the minimum cover as recommended in the drawing is available. The reinforcement protruding at the ends of each girder shall be bent to the shape so as to match with the reinforcement of end cross diaphragm. The protruding reinforcement shall be coated with cement wash. Finished concrete shall have rough finish on top for proper bond with cast in situ top slab at site.

6.4.2 Forms for Precast Prestressed Girders The pre-tensioned girders shall be cast at casting yard. The contractor shall clean, thoroughly, the steel forms of all dirt, mortar and other matter such as chips, blocks etc. prior to using them. The contractor shall check the accuracy of alignment and rectify the inconsistencies, if any, of the forms and steel casting bed. Contractor shall also take care of bulkheads including positioning of jacks which may become necessary to suit the design requirement of the precast girders or as instructed by Engineer in Charge.

6.4.3 Cleaning Tendons shall be free from loose rust, oil, grease, tar, paint, mud or any other deleterious substance. Cleaning of the steel may be carried out by immersion in suitable solvent solutions, wire brushing or passing through a pressure box containing carborundum powder. However, the tendons shall not be brought to a polished condition.

6.4.4 Straightening High tensile strand shall be supplied in coils of sufficiently large diameter such that tendons shall retain their physical properties and shall be straight as it unwinds from the coil. Tendons of any type that are damaged, kinked or bent shall not be used. The packing of prestressing strand shall be removed only just prior to making of cable for placement. Suitable stands shall be provided to facilitate uncoiling of strands without damage to steel. Care shall be taken to avoid the possibility of steel coming into contact with the ground.

6.4.5 Post-Tensioning Prestressing tendons shall be accurately located and maintained in position, both vertically and horizontally, as per drawings.





Tendons shall be so arranged that they have a smooth profile without sudden bends or kinks. Pull-in or push-in of the prestressing strands shall be mechanised, The location of prestressing cables shall be such as to facilitate easy placement and vibration of concrete in between the tendons. Sheathing shall be placed in correct position and profile by providing suitable ladders and spacers. Such ladders may be provided at intervals of approximately 1.0 m. Sheathing shall be tied rigidly with such ladders/spacer bars so that they do not get disturbed during concreting. The method of supporting and fixing shall be such that profile of cables is not disturbed during vibrations, by pressure of wet concrete, by workmen or by construction traffic. Each anchorage device shall be set square to the line of action of the corresponding prestressing tendon and shall be positioned securely to prevent movement during concreting. The anchorage devices shall be cleaned to the satisfaction of the Engineer prior to the placing of concrete. After concreting, any mortar or concrete, which adheres to bearing or wedging surfaces, shall be removed immediately.

6.4.6 Cutting Cutting and trimming of wires or strands shall be done by suitable mechanical or flame cutters. When a flame cutter is used, care shall be taken to ensure that the flame does not come in contact with other stressed steel. The location of flame cutting of strand shall be kept beyond 75 mm of where the tendon will be gripped by the anchorage or jacks. In post-tensioning, the ends of prestressing steel projecting beyond the anchorages shall be cut after the grout has set.

6.4.7 Protection of Prestressing Steel Prestressing steel shall be continuously protected against corrosion, until grouted. 'The corrosion protector shall have no deleterious effect on the steel or concrete or on the bond strength of steel to concrete. Grouting shall conform to these specifications or as directed by the Engineer. The prestressing steel of the end block will also be protected against corrosion by the method approved by the Engineer. Nothing extra shall be paid for the same

6.4.8 Sheathing The joints of all sheathings shall be water-tight. Special attention shall be paid to the junction at the anchorage end, where the sheathing must tightly fit on the protruding trumpet end of anchorage and thereafter sealed preferably with adhesive water proof tape as per approved manufacturer. The sheathing and all joints shall be water-tight. Any temporary opening in the sheathing shall be satisfactorily plugged and all joints between sheathing and any other part of the prestressing system shall be effectively sealed to prevent entry of mortar, dust, water or other deleterious matter. Sheathing shall be neatly fitted at joints without internal projection or reduction of diameter. Enlarged portions of the sheathing at couplings or anchorages shall be of sufficient length to provide for the extension of the tendons.

6.4.9 Grout Vents Grout vents of at least 20 mm diameter shall be provided at both ends of the sheathing and at all valleys and crests along its length. Additional vents with plugs shall also be provided along the length of sheathing such that the spacing of consecutive vents do not exceed 20m. Each of the grout vents shall be provided with a plug or similar device capable of withstanding a pressure of 1.0 MPa without the loss of water, air pressure or grout.

6.4.10 Anchorages All bearing surfaces of the anchorages shall be cleaned prior to concreting and tensioning. Anchor cones, blocks and plates shall be securely positioned and maintained during concreting such that the centre line of the duct passes axially through the anchorage assembly. The anchorages shall be recessed from the concrete surface as per drawings. After the prestressing operations are completed and prestressing strands are cut, the surface shall be painted with two coats of epoxy of suitable formulation having a dry film thickness of 80 microns per coat and entire recess shall be filled with concrete or non-shrink/pre-packaged mortar or epoxy concrete.

6.5 Post-Tensioning





Tensioning force shall be applied in gradual and steady steps and carried out in such a manner that the applied tensions and elongations can be measured at all times. The sequence of stressing, applied tensions and elongations shall be in accordance with the approved drawing or as directed by the Engineer. It shall be ensured that in no case, the load is applied to the concrete before it attains the strength specified on the drawing or as stipulated by the prestressing system supplier, whichever is more. After prestressing steel has been anchored, the force exerted by the tensioning equipment shall be decreased gradually and steadily as to avoid shock to the prestressing steel or anchorage. The tensioning force applied to any tendon shall be determined by direct reading of the pressure gauges or dynamo-meters and by comparison of the measured elongation with the calculated elongation. The calculated elongation shall be invariably adjusted with respect to the modulus of elasticity of steel for the particular lot as given by the manufacturer. Parallel measurement of prestressing force by load cell in combination with direct reading of pressure gauge shall be preferred. In any case such parallel measurements by load cell shall be made for at least 10% of the cables stressed during any tensioning operation The difference between calculated and observed tension and elongation during prestressing operations shall be regulated as follows: a) If the calculated elongation is reached before the specified gauge pressure is

obtained, continue tensioning till attaining the specified gauge pressure, provided the elongation does not exceed 1.05 times the calculated elongation. If 1.05 times the calculated elongation is reached before the specified gauge pressure is attained, stop stressing and inform the Engineer.

b) If the calculated elongation has not been reached at the specified gauge pressure, continue tensioning by intervals of 5kg/sq. cm until the calculated elongation is reached provided the gauge pressure does not exceed 1.05 times the specified gauge pressure.

c) If the elongation at 1.05 times the Specified gauge pressure is less than 0.95 times the calculated elongation, the following measures must be taken, in succession, to determine the cause of this discrepancy: i) Check the correct functioning of the jack, pump and leads. ii) De-tension the cable. Slide it in its duct to check that it is not blocked by

mortar which has entered through holes in the sheath. Re-tension the cable if free.

iii) Re -establish the modulus of elasticity of steel for the particular lot from an approved laboratory. Contractor may suggest other remedial measure for approval of the Engineer. If the required elongation is still not obtained, further finishing operations as cutting or sealing, should not be undertaken without the approval of the Engineer.

d) When stressing from one end only, the slip at the end remote from the jack shall be accurately measured and an appropriate allowance made in the measured extension at the jacking end. A complete record of prestressing operations along with elongation and jack pressure data shall be maintained in the format given in Appendix 1800/II of MOST Specification.

e) Any breakage of individual strand / groups of strands during tensioning shall require immediate destressing of all strands and replacement of the all the strands by fresh strands.

6.6 Sequence of Operations for Pretensioned Girders For pretensioned girders of standard length, the sequence of operation, starting from erection of formwork, shall be as follows:

i) Erection of formwork ii) Placement of reinforcement cage. iii) Threading of H.T. strands from movable bulkhead to fixed anchor through

individual casting beds, end shuttering and reinforcement cages. De bonding tubes are to be placed in position for strands to pass through. The debonding tubes shall be 25 mm internal dia., hollow, rigid HDPE pipes and





the same shall be provided as per detailed drawings/approval of Engineer-in-Charge without any extra cost.

iv) Removal of initial slackness in the strands by using J 20monostrand jack or equivalent upto 20 KN force.

v) Complete the balance prestressing by using mono-strand jacks of desired capacity and lock individual strands. Locking plate to be inserted between the movable bulkhead and fixed bulkhead. Mark individual strands for checking the slip of strands.

vi) Seal the ends of de bonding tubes and close the formwork to correct dimension.

vii) Pour concrete. Keep test cubes in the same environment as that of the girder concrete.

viii) Allow concrete to set for 3 4 hours before steam curing is started. ix) Once steam curing is over as per direction of Engineer-in charge, remove

covers and allow the girders to cool to ambient temperature. Test the cubes for determining compressive strength of concrete in girders.

x) If adequate compressive strength is obtained, release the strands and check the slip of strands.

xi) Cut the strands, remove the formwork and lift the girders to inspection bay for removal of end plate and bending of projected bars.

xii) Cut the projected strands from girder ends and apply epoxy coating to strands. Mark the girders.

xiii) Transfer the girders to curing bay for wet curing. xiv) Arrange for stacking, local handling and transportation to site.

6.7 Grouting Of Prestressed Tendons Prior to grouting, all cables shall be tested with water pressure of 0.3 MPa for approximately 3 minutes, to investigate leakages and connectivity of ducts. Where directed by the Engineer, the Contractor shall perform full scale site test to determine the adequacy of grout mix, equipment and grouting method. The Contractor shall submit a method statement detailing the test procedure. All other aspects of grouting of cables shall be governed by MORTH Specifications. A record of grouting operations shall be maintained in the format as given in Appendix 1800/IV of MORTH Specifications.

6.8 Supervision All prestressing and grouting operations shall be undertaken by trained personnel only. A representative of supplier of the prestressing system shall be present during all tensioning and grouting operations and shall ensure, monitor and certify their correctness.

6.9 Tensioning Equipment i. All tensioning equipment shall be procured from authorised manufacturers only and

be approved by the Engineer prior to use. Where hydraulic jacks are used, they shall be power-driven unless otherwise approved by the Engineer. The tensioning equipment shall satisfy the following requirements:

ii. Jack & pump shall be got calibrated from a laboratory having NABL certification prior to use and then at intervals not exceeding 3 months.

iii. As one pair of pre-stressing tendon is generally stressed simultaneously, the equipment used should be able to work in tandem.

iv. The means of attachments of the prestressing steel to the jack or any other tensioning apparatus shall be safe and secure.

v. Before initial use & subsequently at suitable intervals the prestressing equipment shall be checked to determine any variation from normal values during use. So far as these variations depend upon external influence (e.g. temperature in case of oil jacks) they shall be taken in to account

vi. The tensioning equipment shall be such that it can apply controlled total force gradually on the concrete without inducing dangerous secondary stresses in steel, anchorage or concrete; and

vii. Means shall be provided for direct measurement of the force by use of dynamo-meters or pressure gauges fitted in the hydraulic system itself to determine the pressure in the jacks. Facilities shall also be provided for the linear measurement of the extension of prestressing steel to the nearest mm and of any slip of the gripping devices at transfer.





All dynamo meters and pressure gauges including a master gauge shall be calibrated by an approved laboratory immediately prior to use and then at intervals not exceeding 3 months and the true force determined from the calibration curve. Pressure gauges shall be concentric scale type gauges accurate to within two per cent of their full capacity. The minimum nominal size of gauge shall be 100 mm. The gauge shall be so selected that when the tendon is stressed to 75 per cent of its breaking load, the gauge is reading between 50 percent and 80 percent of its full capacity. Suitable safety devices shall be fitted to protect pressure gauges against sudden release of pressure. Provision shall be made for the attachment of the master gauge to be used as a check whenever requested for by the Engineer.

6.10 Safety Precautions during Tensioning Care shall be taken during tensioning to ensure the safety of all persons in the vicinity. Jacks shall be secured in such a manner that they will be held in position, should they lose their grip on the tendons. No person shall be allowed to stand behind the jacks or close to the line of the tendons while tensioning is in progress. The operations of the jacks and the measurement of the elongation associated operations shall be carried out in such a manner and such a position that the safety of all concerned is ensured. A safety barrier shall be provided at both ends to prevent any tendon, which might become loose from recoiling unchecked. During actual tensioning operation, warning sign shall be displayed at both ends of the tendon. After prestressing, concrete shall neither be drilled nor any portion cut nor chipped away nor disturbed, without express approval of the Engineer. No welding shall be permitted on or near tendons nor shall any heat be applied to tendons. Any tendon which has been affected by welding, weld spatter or heat shall be rejected.

6.11 Tolerances Permissible tolerances for positional deviation of Prestressing tendons in cast-in-situ construction shall be limited to the following a) Variation from the specified horizontal profile : 5 mm b) Variation from the specified vertical profile : 5 mm c) Variation from the specified position in member : 5 mm

6.12 Tests and Standards Of Acceptance The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance.

6.13 Quality Control and Testing Materials The contractor shall carry out all tests of materials in order to guarantee the specified quality in accordance with the relevant clauses of this specification.

6.13.1 Curing of Precast Girders The pre tensioned girders shall be subjected to steam curing. Temperature gradients within the elements must be minimised as curling, warping and similar defects may be introduced into the concrete by differential thermal movement. The contractor shall maintain steam curing record of the girder in an approved proforma. For the observations of temperature, thermocouples, thermistors, immersion thermometers etc. shall be used by the contractor. The contractor shall observe the following precautions during steam curing process:

i) Rate of rise of temperature in the concrete does not exceed 15 C/hour in the first 3 hours.

ii) Thereafter, the rate of rise and fall of temperature of concrete does not exceed 35 C/hour.

iii) The temperature of concrete does not exceed 80 C. In order to avoid thermal cracking, exposure to ambient temperature should not take place while the temperature of the concrete is more than 40oC above ambient temperature. Wet curing of the above element shall continue constantly for a period of 14 days, after the steam curing is over.

6.13.2 Marking of Precast Elements





Precast Elements shall be marked immediately after removing the side forms with paint of approved quality. The elements shall be marked at minimum four places on outer faces of webs and at the ends with the following details: i) Girder Number. ii) Date of casting the girder.

6.13.3 Tests of Precast Pretensioned Elements One unit of each type of precast element shall be load tested upto to failure but its quantity shall not be measured for payment. Prior to carrying out load tests, if required, the contractor shall submit arrangement of testing, loading etc. and shall carry out any modifications, if needed, on the existing testing arrangement to the satisfaction of Engineer in Charge at no extra cost. The contractor shall submit a report containing test results and observations etc. to the department.

6.13.4 Handling, Stacking, Transportation and Placing of Precast Element All aspects of casting, pretensioning,handling, transportation and erection shall be proposed by contractor in detailand method of statements to be submitted by contractor for approval of engineer. Detailed fabrication drawings of each element to be submitted by contractor for approval of engineer. Handling of precast members shall be allowed only after the same have attained the specified strength. Minimum concrete strength at transfer for precast pretensioned member shall be 35Mpa and for post-tenisoned members it shall be 40Mpa. Minimum age of precast elements is 28 days at the time of incorporation in the structure. The members shall be lifted only from the positions specified for this purpose. Precast members are to be lifted, stacked and/or handle such that self-weight is mobilized and supports are located within 500mm from each end. Lifting inserts are to be proposed by the contractor for approval of engineer. Precast elements will have projecting reinforcement for composite action with cast-in-situ elements. They will also have steel embedments of various types for connection to other structural elements. For precast pretensioned members arrangements would be required for debonding of strands for part length towards end of members. All exposed edges of precast elements should have chamfers of 10mm x 10mm. All necessary safety precautions will be taken to avoid any accident and damage during handling of the precast units. Special precautions areto be taken during and after erection for stability of the precast elements. The contractor shall submit detailed plan showing stacking of precast elements at casting yard and at site and shall obtain approval of the Engineer in Charge. The precast girders shall be stacked on timber or any other suitable supports provided over the firm ground/base. The girders shall be placed side by side on these supports. The girders shall be stacked not more than three in a layer keeping adequate gap between the layers to avoid damage to protruding reinforcement of girders. In no case the layers shall be placed in cross directions to each other. Care shall be taken to avoid any undue loading of girders during stacking. The girders shall be transported in an upright position and points of support and the direction of reaction with respect to the girders shall approximately be the same during storage as when the girder is placed in final position. The transportation and placing of precast units to position shall be done during night unless otherwise permitted by the Engineer in Charge. The contractor shall obtain necessary permission from the concerned department for transporting the precast girders. Mode of transportation, proposed by Contractor, shall be got approved from the Engineer in Charge before commencing the transportation operation. Proper precautions should be taken during handling of precast units during transportation and all traffic safety measures taken. The contractor shall be required to execute all handling and re-handling of girders including interim storages etc., till these are finally erected, within his quoted rate. Contractor can plan the activities in advance to reduce such handling if practicable. The Contractor shall ensure the security of all personnel by avoiding any risk of instability of the members or of the lifting or handling equipment, avoid any unexpected stress and excessive deformation, eliminate every risk of deterioration capable to alter the aspect or the durability of the structure. Care shall be taken to avoid any thermal shock during storage. When placing the precast units in position, care should be taken to place the right unit in the right position with minimum handling of units. Care should also be taken to prevent any





damage to the precast units. Units damaged by improper storing or handling/ rehandling shall be replaced by the contractor at his own expense. The methodology proposed by the Contractor for placing these units, shall be got approved from the Engineer in Charge, before commencement of the work. The rate for the reinforcement in the girders shall also include cutting of temporary handles (rebar), if required. The contractor shall prepare and submit a plan for each span indicating the location and girder number of each girder.

6.13.5 Shop drawings and design calculations for construction procedures The contractor shall submit according to a schedule, complete details and information concerning the method, materials, equipment and procedures he proposes to use. These shall be called “Method statements”. Method Statements shall be submitted sufficiently in advance of the start of superstructure filed construction operations, so as to allow the Employer’s Representative adequate review period, which shall not be less than 30 days. The submittals shall invariably include step-by-step casting, lifting, curing, stacking, transportation and erection procedure. The contractor’s Method Statements shall also include all calculations, drawings and information as may be relevant. The following points are specifically highlighted. - Accommodating block-outs, openings and protrusions. Protruding re-bars may be needed (track starter rebars, for example). Anchorages and inserts for OHE poles, Signalling equipment and cable routing supports shall also be included where needed in precast beams. - Adjusting to changes in girder length, curve, inclination and camber as shown in Detailed Design Drawings issued by Employer. - Adjusting the profile to take into account design camber values - Stripping without damage to the concrete -The design shall provide a tapered portion at both end for bearing of electrometric bearing. - Forms shall not be removed until the concrete has attained adequate strength. Care should be exercised in removing the forms to prevent spalling and chipping of the concrete. - All side, bottom and end forms for precast beams shall be constructed of steel. - Forms shall be of sufficient thickness, with an adequate external bracing and stiffeners, and shall be sufficiently anchored to withstand the forces due to placement and vibration of concrete. No tie bolt is permitted for casting of precast beam. Joints in the forms shall be designed and maintained for mortar tightness. The grade and alignment of forms shall be checked each time they are set and shall be maintained during the casting of concrete.

6.13.6 Post Tensioned Cross Girder Precast post-tensioned girders are to be lowered gradually as proper alignment is necessary so that prestressed bars already threaded into the pier cap and the part of it that is projecting out are properly threaded into the duct specified for each bar in the cross girder. Cranes for lifting and placing of girders shall have a capability of lowering the girders at a rate of 25mm per minute. In case two cranes are proposed to be used for a single component, their movement has to be synchronised. High tensile bar anchor system and components are to be complied and tested in accordance with requirements of BS:4486, ASTM T22-88 and IS:2090. The system shall comply with, “Recommendations for Acceptance and Application of Post-Tensioning Systems,” of FIP. High tensile threaded bars shall be such as manufactured by Macalloy and Dywidag System.

6.14 Measurements for Payment Prestressed Concrete shall be measured in -cubic metres based on theoretical cross-sectional area and length. The volume occupied by mild steel reinforcement / HYSD bars; high tensile steel, sheathing and anchorages shall not be deducted. Measurement for transportation of precast member/segment shall be measured in tonnes based on standard density of concrete equivalent to 2.4 t/cum including the weight of rebars, sheathing ducts, embedments etc. High tensile (prestressing) steel shall be paid for separately and measured as actually incorporated in finished work i.e. end of live end wedges to dead end wedges. (The rate shall include its length including additional length of cables for attaching jacks or additional length at dead end). From the length so measured its weight shall be calculated in tonnes on theoretical basis based on the standard weight per m length and paid for.





Actual length of sheathing provided in permanent works shall be measured and paid for separately. All the accessories required for grouting operations, protection of sheathing, couplers for sheathing, samples for testing including testing shall all be deemed to be included in the item of sheathing and shall not be paid for separately. Actual numbers of anchorages used shall be measured and paid for separately. Making of recess and filling the same, protection by painting with epoxy and furnishing samples for testing including testing shall all be deemed to be included in the item of anchorages and shall not be paid for separately. The rate shall also include payments, if any to be made to the supplier of the prestressing system who has to monitor, ensure and certify the correctness of all the arrangements/operations.

6.15 Rate The contract unit rate for cast-in-situ / precast prestressed concrete shall cover the cost of all materials, labour, tools and plant required for mixing, placing in position, vibrating and compacting, finishing as per directions of the Engineer, curing and other incidental expenses for producing concrete of specified strength to complete the structure or its components as shown on the drawings and according to specifications. The contract unit rate shall also include the cost of making, fixing and removing of all centring and forms required for the work unless otherwise specified in the Contract. The shuttering shall have to be of steel plates and arrangement has to be designed and provided to ensure that there is no obstruction to traffic during construction. Design calculations shall be submitted for approval for all temporary construction which may be required to complete the work. For precast concrete members, the rate shall include the cost of all items as mentioned above and materials, labour, tools and plants required for casting bed, curing (water or steam), handling equipment, steel moulds, transportation of elements within casting yard ( i.e. to curing tank or stacking yard etc.). However, the cost of transporting the segments from casting yard to launching site, launching arrangements, application of epoxy including temporary bar prestressing etc. will be paid separately as per BOQ. The contract unit rate for high tensile steel shall cover the cost of all items as mentioned above including material, labour, tools and plant including plant required for manufacturing, placing, tensioning, anchoring and grouting the high tensile steel in the prestressed concrete as shown on the drawings and as per specifications herein above or as directed by the Engineer.





7 STRUCTURAL STEEL WORKS 7.1 These specifications shall be read in conjunction with the CPWD specifications 1996 and

other relevant reference specifications described in the section 1 of these specifications. The Contractor will provide all materials and equipment required to complete the works in every respect, whether such materials are required as part of the permanent structures or temporary for fabrication or erection or maintenance including specifically structural steel plates, flats, bars, welding rods, rivets, bolts and nuts, paint, welding sets in the shop and at site, all workshop facilities, derricks, cranes, pulley blocks, wire ropes, hemp or manila ropes, winches, erection cleats and temporary braces or supports and all other materials required to deliver the Works complete in every respect. All labour required for fabrication and erection for any cleaning, making good, rectifying, hauling, and painting for any other ancillary work required to complete fabrication and erection. The Contractor shall observe all safety requirements for erection of structural steelwork as covered in IS:7205.

7.2 Drawings: 7.2.1 The Engineer will supply to the Contractor profile drawings showing sizes of all structural

members and typical connection details. 7.2.2 Should there be any discrepancy in the drawings the Contractor is to refer the matter to

the Engineer. The Contractor shall further provide a drawing showing the accurate setting out to line and level of all the anchor bolts intended for the work in sufficient time for their inclusion in the work so as to maintain the building program.

7.2.3 The Contractor is to prepare all the necessary fabrication shop drawings and these shall be submitted to the Engineer in duplicate and be approved by him before fabrication is commenced. All such drawings shall show the dimensions of all parts, method of construction, welding and bolting. A further set of all approved fabrication drawings shall be supplied by the Contractor for use of the Engineer as required.

7.2.4 Approval by the Engineer of drawings or any other particulars submitted by the Contractor shall not relieve the Contractor of full responsibility for any discrepancies, errors or omissions therein. The Contractor shall at his own expense supply such additional copies of his working drawings as are required for the use of the interested parties.

7.3 Material: 7.3.1 Structural Steel

All structural steel shall be of tested quality and shall conform to one of the following standards: IS:226 Structural steel (Standard Quality) IS:2062 Structural steel (Fusion welding quality) IS:961 High Tensile Structural Steel (Ordinary) IS:1161 Steel Tubes for Structural purposes

IS:4923 Hollow Steel Sections for Structural use The Contractor shall supply to the Engineer copies of the manufacturer certificate that the steel brought to the site for incorporation in the works is of a quality fully complying with the specification. If required by the Engineer, the Contractor shall arrange for testing of the steel samples as per IS:1608 - 1599.

7.3.2 Welding Electrodes: Welding electrodes used for the works shall conform to IS:814/latest and shall be supplied by manufacturer approved by the Engineer and shall be of the grade approved by the Engineer. All Electrodes shall be kept under dry conditions. Any electrode which has part of its flux coating broken away or is damaged shall be rejected.

7.3.3 Bolts and Nuts: Bolts and nuts used for the works shall unless otherwise specified be black bolts and nuts supplied by manufacturer approved by the Engineer and shall conform to IS:1367. For the truss hot-dip galvanized (@ 300gm/sqm) bolt sleeve of mild steel grade ‘B’ conforming to IS:2062 and 4 dia 12mm anchor bars welded to same as per detailed drawing and instruction of the Engineer shall be provided. The length and diameter of sleeve shall be 300mm and 60mm respectively. The sleeve shall receive hexagon head bolt IS:1363 (part –I) –ISO 4016-M20x90-8.8. Hexagon head bold shall be provided with galvanized spring washer as per the detailed drawing and instruction of the Engineer.

7.3.4 Washers





Plain washers shall be made of mild steel conforming to IS:5369 (1975), unless otherwise specified. One washer shall be supplied with each bolt and, in case of special types of bolts, more than one washer as needed for the purpose shall be supplied. An additional double coil helical spring washer, conforming to IS:6755 (1980), shall be provided for bolts carrying dynamic or fluctuating loads and those in direct tension. Tapered washers, conforming to IS:5372 (1975) and IS:5374 (1975), shall be used for channels and beams respectively wherever required.

7.3.5 For all other material required for the works, the approval of the Engineer shall be obtained by the Contractor prior to the use of the material in the works.

7.4 Workmanship and Fabrication: 7.4.1 For all the works, workmanship shall be of first class quality, throughout, in conformity

with IS:800-latest, and true to line, level and dimension as shown in the drawings or instructed by the Engineer.

7.4.2 All parts assembled for bolting shall be in close contact over the whole surface and all bearing stiffeners shall bear tightly at top and bottom without being drawn or caulked. The component parts shall be so assembled that they are nottwisted otherwise damaged as specified cambers if any shall be provided. Drilling done during assembling shall not distort the metal or enlarge holes. The butting surfaces at all joints shall be so cut and milled so as to butt in close contact throughout the finished joints.

7.4.3 Cutting shall be done automatically. Hand flame cutting will not be permitted. 7.4.4 The edges and ends of all cut/sheared flange plates, web plates of plate girders, and all

cover plates, and the ends of all angles, tees, channels and other sections forming the flanges of plate girders, shall be planed/ground.

7.4.5 Holes for bolts shall be drilled to confirm to clause 10 of IS:7215 (1974). Punching of holes will not be permitted. All drilling shall be free from burrs. No holes shall be made by gas cutting process.

7.4.6 All welding for the works shall be carried out by first class welders and shall be in

accordance with IS:816, IS:819, IS:1024, IS:1261, IS:1323 and IS:9595. The Engineer may at his discretion order periodic tests of the welder and/or of the welds produced by them. All such test shall be carried out by the Contractor at his cost.

7.4.7 Safety requirements should conform to IS: 7205, IS: 7273 and IS: 7269 as applicable and should conform to safety, economy and rapidity.

7.4.8 As much as possible shall be welded in shops. The pieces shall be manipulated to ensure down hand welding for all shop joints as far as possible. All parts to be welded shall be arranged so as to fit properly on assembly. After assembly and before the general welding is to commence the parts are to be tack welded with small fillet or butt welds as the case may be. The tack welding must be strong enough to hold the parts together but small enough to be covered by the general welding. The welding procedure shall be so arranged that the distortion and shrinkage stresses are reduce to a minimum.

7.4.9 All joints required in structure to facilitate transport or erection shall be shown on the drawings or as specified by the Engineer. Should the Contractor need to provide joints in locations other than those specified by the Engineer he shall submit his proposals and obtain the prior sanction of the Engineer for such joints. The lengths of structural shall be the maximum normally available in the market jointing of shorter length in order to make up lengths required shall not be permitted.

7.4.10 Each piece of steel work shall be marked distinctly before delivery, indicating the position

and direction in which it is to be fixed. Three copies of a complete marking plan are to be supplied to the Engineer before erection commences.

7.4.11 In the case of welded fabrication any distortion remaining in the member after welding operations are completed shall be rectified by and/or at the expense of the Contractor to the approval of the Engineer.

7.4.12 All members of trusses and lattice girders shall be straight throughout their length, unless shown otherwise on the drawings, and shall be accurately set to the lines shown on the drawings. Sheared edges of gussets or other members to be straightened and dressed where necessary.

7.4.13 Templates and jigs used throughout the work shall be all steel. In cases where actual materials have been used as templates for drilling similar pieces, the Engineer shall decide whether they are fit to be used as parts of the finished structure.





7.4.14 Apart from the requirements of welding specified under the above sub clauses, sections above, the Contractor shall ensure the following requirements in the welded joints.

i) Strength-quality with parent metal. ii) Absence of defects iii) Corrosion resistance of the weld shall not be less than that of parent

material in an aggressive environment. 7.4.15 No gasket or other flexible material shall be placed between the holes. The holes in parts

to be joined shall be sufficiently well aligned to permit bolts to be freely placed in position. Driving of bolts is not permitted. The nuts shall be placed so that the identification marks are clearly visible after tightening. Nuts and bolts shall always be tightened in a staggered pattern and, where there are more than four bolts in any one joint, they shall be tightened from the centre of the joint outwards.

7.5 Testing of Welds: 1 Butt welds - Radiographic testing of 5% of welds as per IS 1182. 2 Fillet welds - Ultrasonic testing of 5% of welds. 3 All welded connections shall be inspected as per IS:822 4 All welds shall be tested by "dye penetration test" as per current practices. 5 Agency for testing of weld shall be approved by the Engineer prior to testing. 6 Defected welds shall be repaired or replaced as decided by the Engineer. The

repaired or replaced welds shall be tested using the same methods as above. Additionally, when defective welds are found, the cause of the defective welding shall be determined and the contractor shall institute immediate corrective action.

7 No extra payment shall be made for the tests indicated above. 7.6 Protection of Steel Works (IS:8629):

a) Sand blasting where specified shall be carried out in accordance with IS:1477. b) Painting work shall be carried out in accordance with IS:8629 (Parts I to III).

Painting shall be applied under the temperature requirement specified by the manufacturer.

c) The steel work, prior to delivery, shall be cleaned form scale, rust, dirt and grease etc., but means of chipping, scraping and wire brushing using skilled operators as described in the painting systems below. The cleaning shall proceed each day over the extent of surfaces which can be painted on that day. The paint shall be applied by brushing or spraying as per approval of the Engineer.

d) Paint brushes round/oval and flat shall be conforming to IS:487 and IS:384 codes respectively, if painting with brushing is approved by Engineer.

e) The spraying equipment shall be compatible with the paint material, fitted with necessary gauges and controls and approved by the Engineer.

f) Site weld locations shall be left free from paint within 50mm of the weld position, and contact surfaces in connection using High Strength Friction Grip Bolts shall not be painted. Immediately after completion of erection all damaged paint shall be scraped off and made good to the approval of the Engineer.

g) The Steelwork specialist shall also clean down and apply one coat of primer to all site bolts, site bolted connections and site weld locations and the paint work generally shall be left in sound condition for any subsequent painting.

h) All paints and primers shall be of best quality and in original sealed containers as packed by the paint manufacturer conforming to the relevant Indian Standards and shall be procured directly from the manufacturers. All paint to be used shall be stored under cover in such conditions as will preserve it from extreme of temperature and the paint shall be used and applied strictly in accordance with the manufacturer's instructions.

i) In addition, the following specification shall apply to the shop painting of contact and inaccessible surfaces: a. Surfaces to be painted shall be thoroughly cleaned from scale, rust, dirt, grease

etc. by means of sand/grit/shot blasting or other equivalent means. b. Surfaces which are to be brought permanently into close contact or made

inaccessible either in the shops or upon erection shall, after cleaning, be given two coats of Red Lead Priming Paint. The surfaces shall be brought into contact while the paint is still wet.

c. Contract surfaces in connection using High Strength Friction Grip bolts shall not be painted or oiled and shall be free from dirt, loosed scale, burrs, pits and any





other defects which would prevent the solid seating of the parts and would interfere with the development of friction between them.

d. All enclosed surfaces of box members shall be completely sealed by oilingor by coating with approved bitumen paint and all such members and tubes shall have their ends closed by suitable plates welded in position.

j) Surfaces in contact during shop assembly shall not be painted. Surfaces which cannot be painted, but require protection, shall be given a rust inhibitive grease conforming to IS:958 (1975), or solvent deposited compound conforming to IS:1153 (1975) or IS:1674 (1960), or treated as specified in the drawings.

k) Surfaces to be in contact with concrete shall not be painted. Contractor shall decide such rates accordingly to the definitive paints selected by him for ensuring the specified DFT in Table.

m) The Contractor shall take all precautions to prevent dust and dirt coming in contact with freshly painted surfaces or with surface being painted. The second coat of paint shall only be applied when the first coat has dried.

n) Surfaces not in contact but inaccessible after shop assembly shall receive the specified protective treatments before assembly.

o) Exposed machined surfaces shall be adequately protected. p) A uniform film thickness of paint is to be ensured throughout the work. q) Surfaces, which have not been shop coated, but require surface treatment shall be

given necessary surface preparation and coats at site as specified in the painting system.

7.7 Quality Control & Testing Requirements 7.7.1 General

7.7.1.1 Scope of Specification The scope of work of these specifications is to establish the norms for ensuring the required Quality Control through established the norms of the welded structural steelwork.

7.7.1.2 Codes/ Standards Relevant IS codes for tolerance and tests of welding procedures as specified in the specification for Structural Steelwork.

7.7.1.3 Submittals The contractor shall submit the following:

Proposed overall schedule for documentation of calculations, shop drawings, plan/ procedures and records, submission of procedure of fabrication.

The contractor shall himself inspect all materials, shop work and field work to satisfy the specified tolerance limits and Quality norms before the same are inspected by Engineer or his authorised representative.

7.7.2 Products Not applicable

7.7.3 Execution 7.7.3.1 Tolerances

The contractor shall through appropriate planning and continuous measurements in the workshop and erection at site ensure that the tolerance specified is strictly adhered to.

7.7.3.1.1 Dimensional & weight tolerance The dimensional and weight tolerance for rolled shapes shall be accordance with IS: 1852. The acceptance limits of straightness for rolled or fabricated members as per IS: 7215 are: Struts and columns: L/1000 or 10 mm whichever is smaller Where L is the length of finished member A limit for distortion in transverse direction from the true axis of plate and box girder shall not be more than L/1000 where L is the length of diagonal of profile. Tolerance in specified camber of members shall be 3 mm in 12 m length Tolerance in specified lengths shall be as follows:

Column finished for contact bearing ± 1 mm

Other members (cols.) up to and over 10 m ± 5 mm

Including 10 m L/2000 subject to max of ± 8 mm

Other members (beams) up to 12 m ± 3 mm

Over 12 L/4000 subject to max of ± 5 mm 7.7.3.1.2 End of members





Beam to beam and beam to column connection – Where the abutting parts are to be joined by butt welds, permissible deviation from the squareness of the end is:

Beam up to 600 mm in depth : 1.5 mm

Beam over 600 mm in depth : 1.5 mm for increase in depth of every 600 mm subjected to max of 3 mm.

Where abutting parts are to be joined by bolting through cleats or end plates, the connections require closer tolerance, permissible deviation from the squareness of the end is:

Beam up to 600 mm in depth 1 mm per 600 mm of depth subject to a max of 1.5 mm.

For full bearing, two abutting ends of columns shall first be aligned to within 1 in 1000 of thecombined length and then the following conditions shall be met:

a) Over atleast 80% of the bearing surface the clearance between the surfaces does not exceed 0.1 mm

b) Over the remainder of the surfaces the clearances between the surfaces does not exceed 0.3 mm

Where web stiffeners are designed for full bearing on either the top flange or the bottom flange or both, atleast half the stiffener shall be in positive contact with the flange. The remainder of the contact face could have a max. gap of 0.25 mm Acceptable deviation from the specified overall depth as per IS: 7215 (1974) is:

Up to and including 1000 mm : 1.0 mm

Over 1000 mm : 2.0 mm 7.7.3.1.3 Web Plates

An acceptable deviation from flatness in girder webs in the length between the stiffeners or in a length equal to the girder depth shall be: Up to 500 mm depth : 0.5 mm Over 500 mm & including 1000 mm : 1.0 mm Over 1000 mm : 2.0 mm

7.7.3.1.4 Flange Plates A reasonable limit for combined warpage and tilt on the flanges of a built-up member is 1/200 of the total width of flange or 2 mm whichever is smaller measured with respect to centreline of flange. Lateral deviation between centreline of web plate and centreline of flange plate at contact surfaces measured as the difference between diagonals of nominal length of L shall not be greater than L/1000.

7.7.3.1.5 End Milling Column ends bearing on each other or resting on base plates and compression joints designed for bearing shall be milled true and square to ensure proper bearing and alignment. Base plates shall also have their surfaces milled true and square.

7.7.3.2 Quality Control In order to exercise proper control of the quantity of the welding, Contractor shall enforce methods of control as tabulated below:

Purpose Control Subjects Methods of Control

1. Control of welding materials and basic metal quality

Quality control of electrode, welding wire, flux and protective gases

Weldability test to determine the technological properties if materials. Mechanical test of weld metal Metalographical investigations of welds macro-structure and microstructure Checking of weld metal resistance for intercrystalline corrosion. Study if weld metal solidity by physical control methods

2. Checking of welders qualifications

Welding of specimens for quality determination

Mechanical tests, metalographical investigation & checking of welded joints by physical control methods

3. Control of welded joint quality

Control of assembly accuracy and technological welding

Checking of assembly quality &centering of welded members





process Checking of welding equipment condition. Checking correctness of welding procedure. Visual examination of welds.

7.7.3.3 Tests & Testing Procedures Agency for testing of weld shall be approved by the Engineer prior to testing.

7.7.3.3.1 Visual Examination The contractor shall conduct visual examination and measurement of the external dimensions of the weld for all joints. Before examining the welded joints, areas close to it on both sides of the weld for a width not less than 20 mm shall be cleaned of slag and other impurities. Examination shall be done by a magnifying glass which has a magnification power of ten (10) and measuring instrument which has an accuracy of ±0.1 mm or by weld gauges. Welded joints shall be examined from both sides. The contractor shall examine the following during the visual checks.

i. Correctness and shape of the welded joints ii. Incomplete penetration of weld metal iii. Influx iv. Burns v. Unwelded craters vi. Undercuts vii. Cracks in welded spots and heat affected zones viii. Porosity in welds and spot welds ix. Compression in welded joints as a result of electrode impact while carrying out

contact welding x. Displacement of welded element

The contractor shall, document all data as per sound practices 7.7.3.3.2 Mechanical test

The contractor shall carry out various tests to determine weldability, metal alloyability, nature of break, correct size and type of electrodes, degree of pre-heat and post-heat treatment. The type, scope and sample of various mechanical tests shall be determined in agreement with the purchaser. The number of tests conducted shall depend on the result obtained to satisfy the engineer that the correct type and size of electrode, degree of pre-heating and post- heating and weldability of metal are being followed.

7.7.3.3.3 Dye Penetration Test All welds shall be tested by “Dye Penetration test” as per current practices

7.7.3.3.4 Radiography test Radiography test shall be conducted by the contractor to determine gas inclusion (blow holes, hollows) slag inclusion, shallow welds and cracks for 25 % length all butt joints. Before conducting the examination the welded joints shall be cleaned of slag and scales and visually examined. The welds shall be marked into separate portions depending on the length of photograph. The length of photograph shall be such as to ensure that there are no distortions and shall reveal the defect correctly. The length shall not be more than 0.75 of the focal distance and the width of the photograph would depend on the width of the welded joint plus 20 mm on either side of the weld. The cassette with the film shall be protected by sheet of lead or equivalent of proper thickness against incidental, diffused and secondary radiation. The direction of the ray with relation to the film shall be as specified hereunder. Welds of butt joints without edge slopes with edge processing shall be examined by central ray directed at right angles to the weld. In special cases examination of welds with inclined rays directed along edge slopes may be permitted by the Engineer. Lap joints shall be examined by directing rays at 45 degree to the bottom plate. Welds in T-joints without any edge preparation shall be examined by rays directed at 45 degree to the weld. Angle welds in lap and tee-joints shall be examiner by the rays in opposite direction i.e. the film will be on the side of the weld. Weld in angle joints shall be checked by directing ray along the bisector of the angle between the welded elements. Opposite directing of the ray and location of the film may also be permitted by the Employer.

7.7.3.3.5 Ultrasonic Test Ultrasonic test shall be conducted by the contractor to detect gas inclusion 9pores), slag inclusion, shallow welds, cracks, lamination and friability etc. Prior to starting of ultrasonic





test the welded joint shall be thoroughly cleaned of slag and other material. Surface of the basic metal adjacent to welded joint on both sides shall be mechanically cleaned by the grinder or a metal brush to provide metal adjacent to welded joint on both sides shall be mechanically cleaned by the grinder or a metal brush to provide the contact of the whole ultrasonic probe surface with surface of basic metal. The width of the clean surface shall be as directe4d by the Engineer. The welded joint then shall be covered with a thin coat of transformer oil, turbine or machine oil to ensure acoustic contact. The joints so treated shall be marked and the marks shall be entered in to the documentation, subsequent to this, ultrasonic test shall be carried out as directed by the Engineer. At least 50% of weld shall be tested by ultrasonic testing

7.8 Erection & Site Work: 7.8.1 The Contractor shall be responsible for checking the alignment and level of foundation and

correctness of foundation bolt centres, well in advance of starting erection work, and shall be responsible for any consequences for non-compliance thereof. Discrepancies if any shall immediately be brought to the notice of the Engineer for his advice.

7.8.2 The structure should be divided into erectable modules as per the total scheme. This should be pre-assembled in a suitable yard/platform and its matching with members of the adjacent module checked by trial assembly before erection.

7.8.3 Immediately prior to erection any rust in the paint area shall be removed by power wire brushing to a standard equivalent to SA3.

7.8.4 During erection the rough handling of fabricated materials such as bending, straining or pounding with sledges shall be avoided. Any damage to the structure during transportation or erection shall be immediately rectified by the Contractor at his own cost. The straightening of bend edges of plates, angles and other sections shall be done by methods which will not cause fracture.

7.8.5 Following the completion of the straightening, the surface of the member shall carefully be inspected for damage and got approved by the Engineer before further use.

7.8.6 The Contractor shall be responsible for accurately positioning, leveling and plumbing of all steelwork and placing of every part of the structure in accordance with the approved drawings and to the satisfaction of the Engineer. All stanchion base, beam and girder bearings etc. shall be securely supported on suitable steel packs. All reference and datum points shall be fixed near the work site for facilitating the erection work.

7.8.7 All equipment used by the Contractor shall be sufficient for the purpose and for the erection of the steel work, in the time specified in the contract. Any lifting or erecting machinery shall be to the approval of the Engineer and shall be removed from the site if he considers such appliances dangerous or unsuitable for their functions. The approval of the Engineer shall not relieve the Contractor of the responsibilities for the loads to which the erection equipment shall be called upon to carry. Adequate arrangement shall be made to resist wind loads and lateral forces arising at the time of erection.

7.8.8 The Contractor is entirely responsible for the stability of the structure during erection and shall arrange that sufficient tack bolts, braces or guy ropes are used to ensure that work will remain rigid until final bolting, rivetting or welding is completed. The Contractor shall supply and fix, without extra charge, any temporary bracing which may be necessary.

7.8.9 All steelwork shall be erected in the exact position as shown on the drawings. All vertical members shall be truly vertical throughout and all horizontal members truly horizontal, fabrication being such that all parts can be accurately assembled and erected. No permanent bolting, welding or grouting shall be done until proper alignment has been obtained and checked by the Engineer.

7.8.10 At stanchion splices and at other positions where concrete cover to the steel is liable to be restricted, bolts will be placed with their heads on the outside of the members.

7.8.11 All field assembly bolting and welding shall be executed in accordance with the requirements for shop fabrication excepting such as manifestly apply to shop conditions only. Where steel has been delivered painted the paint shall be removed before field welding for a distance of at least 50mm on either side of the joints. The number of washers on permanent bolts shall not be more than two for the nut and one for the bolt head.

7.9 Rectification of damaged materials: Any error in shop work which prevents the proper assembly and lifting up of the parts by moderate use of drift pins or reaming or cutting shall be immediately reported to the





Engineer and his approval of the method of rectification obtained in writing. Wrongly fabricated material whose erection in the field necessitates extra work shall be the responsibility of the contractor. The entire costs of such operation including the replacement of defective members, if required, shall be borne by the contractor.

7.10 Inspection: 7.10.1 The contractor shall inform the Engineer of the progress in fabrication and as to when

individual pieces are ready for inspection. All gauge templates necessary to satisfy the Engineer shall be supplied by the contractor. The Engineer may at his discretion check the results obtained at the contractor's works by independent tests and should the material so tested be found unsatisfactory, the cost of suchtests shall be borne by the contractor.

7.10.2 Structural steel and components viz. bolts, nuts, washers, welding consumables, etc. should be tested for mechanical and chemical properties as per the requirement of the relevant IS or any other specified codes/standard.

7.10.3 During Inspection, the component/member shall not have any load or external restraint. 7.11 Grouting of steel bases:

Before grouting of stanchion bases, the contractor shall take the following action: a. Inform the Engineer. b. Clean all holes, openings, recesses and the top of foundations of all dirt, mud, water,

oil or other extraneous matter. c. A frame shall be placed in position around the base plate with a provision for placing

or injecting grout. d. The contractor shall provide screed bars or mild steel flats and fix them in mortar. e. Holes shall be provided on the stanchion bases for escape of air.

7.11.1 Grouting of steel beams, steel stanchions, bases and bearings and encasement of steelwork will be carried out by the contractor after the steelwork has been finally aligned and leveled and approval of the Engineer obtained.

7.11.2 The bolt sleeves shall be grouted as a separate operation using neat cement grout of a creamy consistency, which shall be poured in so as to completely fill the holes. "Non-shrink" cements, additives of approved makes shall be used for all grouting operations.

7.11.3 The space between the top of the foundations and the underside of the base plate shall be completely filled with a mix 1:2 cement sand mortar and finished flush with edge of the base plate, either: a. Mixed as a stiff mortar well rammed into place from all sides. b. Mixed as thickly as possible consistent with fluidity and poured under a suitable head

and tamped until the space has been properly filled. 7.12 Holding down and Anchor bolts: 7.12.1 The holding down and anchor bolts should conform to the requirements laiddown in

IS:5624 or as directed by the Engineer. 7.12.2 Installation: Individual bolts in groups of holding down bolts shall be positioned accurately

within a tolerance of +6mm. The bolts shall be set vertically to a tolerance of not more than 1 in 250.

7.12.3 During the casting of concrete the contractor shall ensure that space between the bolt and sleeves is kept clean after removal of shuttering. The contractor shall provide and fix timber plugs to maintain this space in a clean condition. The projecting threads of bolts shall be protected by approved wrapping materials.

7.12.4 Grouting of bolt tubes shall be carried out after the steelwork or equipment have been aligned, plumbed and leveled.

7.13 Tolerances: 7.13.1 All tolerances shall be in accordance with IS:7215 unless otherwise specified. 7.13.2 The maximum deviation for line and level shall be + 3.0mm for any part of the structure

including for location of column centres. 7.13.3 The maximum deviation from plumb for columns shall be +3.0mm in 10.0m height subject

to a maximum of +6.0mm in a total height of 30.0m. 7.13.4 The deviation at the centre of the upper chord member from vertical plane running

through the centre of the bottom chord shall not be more than 1/1500 of span but in no case more than 10.0mm. The lateral displacement of top chord at centre of span form vertical plane running through centre of supports shall not be more than 1/250 of the depth of truss but in no case more than 20.0mm.

7.14 Mode of measurement:





7.14.1 The pricing must include for all rolling margins, extras for length and size, allowance for waste, complete fabrication, delivery and erection, and caulking the gap between base plate and foundation, and painting as specified in the item. Unless otherwise specified, the final coats of paints, however, will be measured and paid separately on the basis of tonnage fabricated and erected.

7.14.2 Any temporary strutting, tying or anchor bolts, black bolts, fasteners, welding required to withstand the stresses of erection and carrying of plant are to be included in the price.

7.14.3 The payment for the steelwork will be for the weight of the steelwork actually erected, i.e. plates, rolled sections, shear connections, cleats, splice plates.

7.14.4 Dimensions of the steelwork will be taken correct to 1 mm and the net weight of metal in the fabricated structure on the basis of unit weight of the steel used in the works approved by the Engineer worked out on site or from the actual shop working drawings as decided by the Engineer. In calculating the weights of gusset plates, payment will be made for the least enclosing parallelogram or triangle. For structural sections the weight will be calculated on lengths actually used with no deduction for splay cut or mitred end. In case of imported sections, the weights chargeable shall be the weight according to the relative standards of the country of origin. Full weight of the bolts and nuts will be paid for as per Indian Standard Codes weights without any deduction for shanks, etc. No account shall be taken of the weight of weld in calculating the weight of steelwork. Erection packing plates bedded in mortar and wedges shall not be measured but shall be included in the rates. No deduction shall be made for openings less than 0.1m2 in area measured in plane for bolt holes. The weight of sheet steel, plate, strips and rolled sections shall be taken from relevant Indian Standards.

7.14.5 Unless otherwise specified, foundation and anchor bolt assemblies shall be measured separately including nuts and washers.

7.14.6 The structural work which is temporary in nature and/or which is required for erection purposes shall not be measured.





8 PILE FOUNDATIONS 8.1 General

The piles shall be cast-in-situ reinforced concrete piles according to the approved drawings and specifications. The method of construction shall be with hydraulic drilling rigs with casing and/or bentonite slurry as decided by the Engineer. The average basic length of the piles mentioned in the drawings is tentative. The final length of the pile shall be decided by the Engineer on the basis of resistance actually observed during initial load test at site. It will be the responsibility of the Contractor to ensure by subsequent routine load tests that the installed length of piles is able to carry the specified safe load and the resulting deflections shall be within permissible limits. In case of failure of any pile in routine load test, the remedial measures shall be provided by the Contractor as directed by the Engineer.

8.1.1 Piling plant and Methods Suggested method for piling is cast in situ-bored piles with hydraulic drilling rigs using partial depth casing by oscillator or vibro hammer arrangement,with or without bentonite and equipments and methodology suitable for the purpose. Bailer and chisel method shall not be used except for socketting of the piles in rock.

1. Not less than 2 weeks before any piling work is commenced the Contractor shall submit to the Engineer for approval full details of his proposed piling plant, bentonite mixing, handling, transporting and disposal scheme and detailed method statements for carrying out the Works. Details of casings and concreting methods in respect of bored cast in place concrete piles are to be provided.

2. The Contractor shall not commence any piling until the plant and methods which he proposes to use including bentonite mixing, handling, transporting and disposal scheme have been approved by the Engineer but such approval shall not relieve the Contractor from any of his obligations and responsibilities under the Contract. If for any reason the Contractor wishes to make any change in the plant and methods of working which have been approved by the Engineer, he shall not make any such change without having first obtained the Engineer approval thereof.

3. List and nos. of equipment& accessories proposed to be used for the present job shall be submitted along with the bid and these should not be less than the list submitted for P.Q. tender. However, Contractor is bound to increase the plant & machinery to complete the work within the stipulated completion period.

8.1.2 Records The Contractor shall keep complete records of all data required by the Engineer covering the fabrication; driving and installation of each pile and shall submit two signed copies of these records to the Engineer not later than noon of the next working day after installation of the piles. The following data shall be recorded during install align of pile along with any other relevant data as directed by the Engineer.

i) Sequence of installation of piles ii) Dimensions of the pile, including reinforcement details and mark of the

pile. iii) Depth bored and founding level along with a bore log indicating nature of

stratum iv) Method of cleaning bottom of hole at founding level before commencing

the concreting. v) Time taken in concreting vi) Cut-off level/working level/RL of top of concrete vii) No. of cement bags consumed. Slump of concrete. viii) Details of insertion and taking out of tremie pipes i.e., their number,

length and sequence. ix) Actual sounding before commencing the concrete.

8.1.3 Programme and Progress Report 1. The Contractor shall inform the Engineer each day of the programme of piling for the

following day and shall give adequate notice of his intention to work outside normal hours and at weekends, where approved.





2. The Contractor shall submit to the Engineer on the first day of each week, or on such other date as the Engineer may decide, a progress report showing the rate of progress to that date and progress during the previous week or period of all main items of piling works, as required by the Engineer.

8.1.4 Setting Out The Contractor shall establish and maintain permanent datum level points, base lines and grid lines to the satisfaction of the Engineer and shall set out, with a suitable identifiable pin or marker, the position of each pile. The setting out of each pile shall be agreed with the Engineer at least 8 working hours prior to commencing work on a pile and adequate notice for checking shall be given to the Engineer Notwithstanding such checking and agreement, the Contractor shall be responsible for the correct and proper setting out of the piles and for the correctness of the positions, levels, dimensions, and alignment of the piles.

8.1.5 After all piles are cast in a pile cap and weak concrete is chipped out, the Contractor shall submit the drawing showing the exact location of piles with respect to the column centre line.

8.1.6 Disturbances and Noise 1. The Contractor shall carry out the piling work in such a manner and at such times as to

minimise noise, vibrations and disturbance. 2. The Contractor shall take precautions adequate enough to avoid damage to existing

services and adjacent structures. Fig.1 of IS:2974 (Part 1) - 1969 may be used as a guide for studying qualitatively the effect of vibration on persons and structures. In case of deep excavation adjacent to buildings/structures, proper shoring or other suitable arrangement shall be done to guard against the lateral movement of soil stratum or releasing the confining soil stress. Any such damage if caused shall be repaired by the contractor at his own cost to the entire satisfaction of the Engineer.

3. The Contractor shall ensure that damage does not occur to completed piling works and shall submit to the Engineer for approval his proposed sequence and timing for driving or boring piles having regard to the avoidance of damage to adjacent piles.

8.1.7 Obstructions If during the execution of the Works the Contractor encounters obstructions in the ground, he shall forthwith notify the Engineer accordingly, submit to him details of proposed methods for overcoming the obstruction and proceed according to the Engineer’s instructions.

8.2 Scope of Work 8.2.1 These specifications cover the works of providing pile foundations. Work included consists

of all necessary services and furnishing of all labour material, tools, plant, equipment and related items for the full and satisfactory performance of the contract, conforming to these specifications and as shown in the Contract Drawings or reasonably implied therein or any authorised conditions or alterations thereof.

8.2.2 The tenderer is advised to visit the site and familiarise himself with the conditions at site. The Engineer shall not be held responsible for the accuracy of the soil data, furnished in good faith with the tender.

8.2.3 The construction of piles shall be in accordance with the following Indian Standard Codes of Practice for Design and Construction of Pile Foundations:

8.2.4 IS:2911-1979 Part I Section 2 Bored Cast in-situ Concrete Piles Or IRC:78 Standard specifications and code of practice for road bridges Foundation And Substructure

8.2.5 With the tender, the Contractor shall submit the detailed method of construction to be adopted. For cast-in-situ concrete piles, the Contractor shall indicate the methods he proposes to concrete the piles in order to prevent necking of piles.

8.2.6 The Contractor shall quote rates as detailed in the Bill of Quantities and Rates. In particular:

a. For piles, the rate quoted shall be for ‘per metre length of pile’ .The actual length of piles will be determined from site conditions and load test results after work begins.

b. In case the load tests and actual site conditions reveal that the piles proposed do not, in the opinion of the Engineer provide a satisfactory and economical foundation, the Engineer at his sole and absolute discretion shall have the powers to revise the pile layout.

8.2.7 The items of work to be carried out in piling will generally be:





a. Boring/drilling including provision of temporary casing (including its withdrawal) empty boring, & bentonite slurry, if required.

b. Supplying, fabrication, tying and placement of all reinforcement. c. Casting of concrete piles as per specifications. d. Integrity and Load testing of piles.

8.3 Materials 8.3.1 General

Unless otherwise specified in this section all materials shall conform to the requirements specified in separate sections for Concrete, Formwork and Reinforcement.

8.3.2 Cement The cement to be used for piling and all foundation work shall be conforming to following Indian Standard Specifications: IS:455 Specification for Portland slag cement Cement shall be free from lumps and caking.

8.3.3 Concrete Mix Design The concrete shall generally be of grade M35. The maximum size of coarse aggregate shall not exceed 20mm. For cast-in-situ piles concrete with a slump of 150 to 175mm (consistent with the method of concreting) will be required. Minimum cement content for design mix shall not be less than 400 kg/m3 of concrete in piling. For piling, qty. of cement to be used shall be as per the design mix or the minimum cement content whichever is greater. The contractor shall submit mix design calculations and get the same approved by the Engineer well before the starting of boring of piles and carry out adequate numbers of tests to ensure the minimum specified strength as indicated in drawings.

8.3.4 Concrete cube tests Concrete cubes shall be cast, tested and evaluated as specified in Section 3.

8.3.5 Reinforcement a. The reinforcement shall conform to the requirements specified in Section 5

extending for the full length of the pile and shall project 60 times bar diameters above the cut off level or as specified in the drawing. Only circular concrete cover blocks threaded on to the helix shall be used for ensuring the specified cover.

b. Joints in main longitudinal bars will be permitted only where, in the opinion of the Engineer, each bar cannot be supplied in one complete length. Where permitted, staggered joints shall be provided at agreed centres, designed to develop the full strength of the bar across the joint, provided with adequate extra links or stirrups in position from those of adjacent longitudinal bars, all to the approval of the Engineer.

c. All main longitudinal bars shall be tack welded at lapping and to the pile cap reinforcement. The last circle of helical stirrups at each end shall be welded to main longitudinal bars Nothing extra shall be payable on account of this. Any extra tack welding required for handling and lowering of cage in borehole shall also be done by the contractor at no extra cost.

8.3.6 Casings and Tremie Pipes The casings and tremie pipes shall be in mild steel. The temporary casing plates and permanent liners shall have adequate wall thickness and strength to withstand driving stresses, stresses due to soil pressure, etc. Without damage or distortion all joints shall be water tight. The internal diameter of the casing shall not be less than the nominal diameter of pile.

8.4 Cast In-Situ Bored Piles 8.4.1 General

a. Diameters of the piles shall be the concrete shaft diameters and shall not be less than the diameters specified in the drawing.

b. These shall be formed by boring to the founding strata specified on the drawings or as directed at site. The sides of the boring shall be prevented from collapse by one of the following methods:

• Providing permanent mild steel liner (cased pile) • Providing removable mild steel casing (uncased pile)

c. Piles shall be constructed in a sequence approved by the Engineer. During boring, the Contractor shall, where required by the Engineer, take soil, rock or ground water samples and transport them to an approved testing laboratory or carry out soil tests as directed.





d. The method adopted shall be chosen giving due consideration to the subsoil data, ground water conditions and to the other relevant conditions at site as well as to the presence of adjacent structures.

e. The bottom of the steel lining shall be sufficiently in advance of the boring tool so as to prevent settlement of outside soil and formation of cavities.

f. Removable mild steel casings shall be used, only with extreme caution. Individual casings shall be joined together by screwing or any other approved method and not by direct butting with external lug connections. The inner surface of casings shall be smooth and free of all internal projections.

8.4.2 Boring a. Boring shall be done using Rotary hydraulic drilling rigs with oscillator arrangement/

equipment and methodology suitable for different kinds of strata encountered. b. As a general guideline, size of cutting tool shall in no case be less than the diameter of the

pile minus 75mm. However the size of cutting tool shall be chosen by contractor depending on the type of substrata and equipment employed by contractor so that executable pile shall not have diameter less than nominal diameter of pile as specified in drawing. The contractor shall also ensure that there is no reduction in poured concrete quantities. These calculations shall be based on consumption of concrete poured in bore (as recorded in pour log) and actual concrete required in bore on theoretical basis i.e. based on nominal diameter of pile and actual bore hole length (based on actual sounding of founding level). More than 5% reduction in consumption of poured concrete quantities in pile may be rejected. In general, piling shall be done by using hydraulic rig with temporary liner. Use of liner for top 6 metres from ground level or upto depth having N. value = 10 or more depth, (to protect loose soil falling in bore hole) as directed by Engineer, is essential. No extra payment shall be made to the contractor for using temporary liner, over the item of piling as in BOQ.

c. Use of drilling mud in stabilising sides of the pile borehole may also be necessary together with temporary or permanent casing wherever sub soil and ground water conditions are likely to cause mud flows or instability of pile bore or sand boiling. However, this will be permitted only when deemed necessary by the Engineer. In such situations the properties of bentonite used & quality control shall be as per requirement given below.

Fresh Bentonite slurry shall satisfy the following properties at all times: • Mud density shall not exceed 1.05 g/cc • pH value 9 to 11.5 • Marsh Cone viscosity 30-40 seconds • The sand content of Size > 0.075mm shall not be more than 1 percent. • Liquid limit of bentonite shall not be less than 400 percent. • Bentonite shall be saturated for minimum 24 hours before use.

When using bentonite mud, flushing shall be done with fresh bentonite slurry after lowering of reinforcement cage and tremie. The bottom of the hole shall be cleaned very carefully before concreting work is taken up. Cleaning / flushing methodology shall be submitted and got approved by the Engineer prior to commencement of piling. Where mud flow conditions exist or the aggressive action of ground water is to be avoided, or in the case of piles built in flowing water or in cases where significant length of piles could be exposed due to scour – the casing should be left permanently in the ground and the permanent liners will be paid separately as per BOQ. The quantum of steel required in permanent liners from the cut off level downwards shall be measured as per drawing. Though the liner might have been provided right from the level of the working platform on practical considerations, the length of the permanent liner above the cut-off level has to be necessarily removed for facilitating chipping of the top portion of the pile and for interlacing its reinforcement bars into the capping slab. There is however, no objection if the surplus pieces (if cut and removed carefully and then found reusable) are joined and are rewelded to required length for reuse in the same contract on some of the other piles. No claim / compensation shall be entertained for such cut pieces if they cannot be reused by the Contractor in the aforesaid manner.

d. Pumping from a bore hole shall not be permitted unless a casing has been driven into a stable stratum which prevents flow of external ground water from other strata in significant quantities.





e. In case of end bearing piles founded on rock, cutting of rock by hydraulic rig using diamond bits / conventional winches with chiseling will be resorted to. Scheme adopted shall be such that noise and vibration parameters specified in tender document /Environment manual are not violated. Drilling in rock shall be carried out by hydraulic rig using diamond bits. No extra payment shall be entertained for socketing in rock except as specified in BOQ.

f. On completion of boring, loose disturbed or remoulded soil shall be removed from the base of bore.

Penalty on mishandling of bentonite Mishandling of bentonite ( like splashing of bentonite outside specified width of barricading or non-cleaning of tyres of dumpers and transit mixers before leaving the piling site thereby making the road dirty etc.) is strictly prohibited . Noncompliance of same shall attract a penalty as follows: I. On first observation – Rs one lac II. On Second observation – Rs two lacs III. On third and each subsequent observation – Rs three lacs

8.4.3 Concreting a. Prolonged delays in the commencement of concreting after the completion of the boring

shall not be permitted. The time interval between the completion of boring and placing of concrete shall not exceed 6 hours.

b. The concrete shall have a minimum slump of 150mm Suitable precautions shall be taken for prevention of segregation. Internal vibrators shall not be used unless the Contractor is satisfied that segregation will not result because of vibration and unless the method of use has been approved by the Engineer.

c. The concrete for piles underwater or in drilling mud shall be placed with a tremie pipe. The tremie pipe shall not be less than 200mm diameter for 20mm aggregate. The joint between the hopper and tremie pipe as well as the joints in the tremie pipe shall be water tight and the tremie pipes shall be thoroughly cleaned after each use. . It is essential that the water level within the pile bore be in equilibrium before commencement of concreting.

d. The Contractor shall ensure that heavily contaminated drilling mud has not accumulated at the base of boring since this could impair free flow of concrete from the tremie pipe.

e. If the specific gravity of the drilling mud at the base of the bore exceeds 1.20 the placing of concrete shall not proceed.

f. The first charge of concrete shall be placed in the hopper over a sliding plate of the bottom of the hopper. The charge should be adequate in volume to ensure flushing action to prevent mixing of water or drilling mud and concrete. Alternatively floating plugs of approved specification may be used before the first charge of concrete.

g. The tremie pipe shall at all times penetrate the previously placed concrete for minimum depth of 2 m as a precaution against accidental withdrawal. The tremie pipe shall not be withdrawn until the completion of concreting. At all times a sufficient quantity of concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that from the seepage water.

h. Spot measurements shall be taken at suitable intervals to check that the tremie pipe has an adequate penetration into previously placed concrete.

i. Concreting of the pile shall be in one single and continuous operation. In case of long piles of large diameter, large size mixers or more number of mixers shall be used so that the entire concreting operation is completed in not more than two hours.

j. The top of concrete in a pile shall be brought above the cut-off level since the top concrete is loose and is weak because of contamination with water/drilling mud. This ensures good concrete at the cut-off level.

k. Cut off level (COL) Cut off level of piles (50mm inside the pile cap) shall be as indicated in working drawings or as indicated by Engineer. The top of concrete in pile shall be brought above the cut off level to remove all laitance & weak concrete and to ensure good concrete at cut-off level. In case of concrete being placed by tremie method and pile cut off level being less than 1.0meter below the ground level, concrete shall be cast to the piling platform level to permit overflow of concrete for visual inspection. In case COL of pile is more than 1.0 meter below working level then concrete shall be cast to a minimum of one meter above





COL. Before concreting contractor shall obtain the approval of the Engineer of the height above COL up to which the concrete is to be cast. In the circumstances where COL is below ground water level, the need to maintain a pressure should be observed & accordingly length of extra concrete above COL shall be determined by the Contractor and approval of Engineer obtained before concreting. Any defective concrete in the head of the completed pile shall be cut away and made good with new concrete.

l. When a casing is being extracted, sufficient quantity of concrete shall be maintained within the bore to ensure the pressure from external ground water and soil is adequately exceeded by the pressure of concrete. Otherwise necking of the pile may result.

m. No concreting shall be placed in the bore once the bottom of the casing has been lifted above the top of concrete.

n. While concreting the pile, the overflowing bentonite slurry from pile should be carefully pumped out to a water tight container/tank so that it does not spill over. The contaminated bentonite should be disposed-off as per the methodology approved by the Engineer.

o. After each pile has been cast any empty bore shall be protected by putting steel cage/Jali over it and carefully backfilled as soon as possible with approved materials.

p. Complete boring and concreting records shall be submitted to the Engineer for each pile. The records shall include the duration of concreting, tremie lengths (individual and cumulative), tremie pipe lengths removed, theoretical sounding, actual sounding, actual lengths of pile concreted and the volume of concrete placed, cut off level, founding levels etc. For piles with temporary casings records of sequence of casing withdrawal and levels of concrete before and after withdrawal shall also be included in the reports.

8.5 Alignment of Piles 8.5.1 Piles shall be installed as accurately as possible according to the drawings either vertically

or to the specified batter. All deviations will be measured at the cut off level of the piles. The deviation from the true axis shall not be more than 1.5% for vertical piles and 4% for raker piles. Piles should not deviate in location by more than 75mm when used in groups. For single or two piles used under piers / columns, deviation shall not be more than 50mm.

8.5.2 The Contractor shall maintain a record of actual pile locations in the form of a drawing and submit the information to the Engineer at suitable intervals.

8.6 Pile Cap Pile caps shall be of reinforced concrete. A minimum offset of 200mm shall be provided beyond the outer faces of the outer most piles in the group. If the pile cap is in contact with earth at the bottom, a leveling course of minimum 75 mm thickness of PCC of grade M15 shall be provided or as shown in the drawings. The attachment of the pile head to the cap shall be adequate for the transmission of loads and forces. A portion of pile top may be stripped of concrete and the reinforcement anchored into the cap. Manual chipping may be permitted after three days of pile casting while pneumatic tools for chipping shall not be used before seven days after pile casting. The top of pile after stripping shall project at least 50mm into the pile cap. Concreting of the pile cap shall be carried out in dry conditions. Nothing extra will be paid for dewatering, etc. for carrying out pile cap excavation or providing concrete leveling course on building up pile cap and further substructure. Cost of all the operations and tools required for making the pile in dry condition is deemed to be included in the item. The excavation area for the Piling / Pile cap shall be back filled and compacted and restored immediately but not later than 7 days after casting of the pile cap. Similarly the road surface should be repaired immediately after casting of column or completion of launching of superstructure (as the case may be but not later than 2 weeks). The payment for the same shall be made as per BOQ. If the area is not back filled and/or road surface is not repaired, with in the time frame as above, penalty will be imposed as decided by the Engineer.

8.7 Testing Of Piles 8.7.1 The load tests shall be in accordance with the Indian Standard Code of Practice for Design

and Construction of Pile Foundations IS 2911 (Part IV) Load Tests on Piles. For initial load test, test load will be 2.5 times the theoretical designed capacity of pile. For initial load, test arrangement to be designed shall also cater for additional 25% above test load and nothing extra will be paid on this account. The payment shall be made based on relevant





item included in BOQ on test load only. Permissible stresses in test arrangement (steel truss or plate girder) to cater for test load plus additional 25% load shall be within permissible stresses as per IS:800 (as for permanent structure). For test frame, steel of Grade –B conforming to IS:2062 shall be used.

8.7.2 Engineer will decide the locations and no. of initial load tests to be performed in different zones depending on variation in substrata but minimum two initial load tests are required to be done for different types of strata. The contractor shall undertake test piles required for initial pile load test in the initial stages of work using the same methodology and equipment’s which will be subsequently used for working piles. These tests shall be undertaken well in advance of working pile. No working pile would be allowed to be undertaken till initial pile load tests have been satisfactorily completed. Non-granting of permission for pile/ pile cap by Engineer in such respect will not be considered as reason for delay or any claim thereof. The test arrangement to be employed shall be of nature which is quick to install and remove and easily transferable. Sufficient no. of test arrangement and resources will be required to be mobilized by contractor so as to conduct required no. of initial load tests simultaneously. Vertical cyclic loading tests shall be carried out where specially needed and specified for separation of skin friction and point bearing components of the load carrying capacity of the piles.

8.7.3 Routine tests are performed as a check on the load carrying capacity and settlements of the pile foundations. At least one routine test shall be performed for every 100 piles unless otherwise specified by the Engineer.

8.7.4 Before commencing the load test the contractor shall prepare the work procedure for the same and shall make it available at site.

8.7.5 The Contractor shall give the Engineer at least 48 hours’ notice of the commencement of construction of these piles which are to be subjected to Initial Tests.

8.7.6 The load tests shall not normally be conducted unless the concrete is at least 28 days old. However in special circumstances, permission can be given by Engineer for prior testing.

8.7.7 All testing shall be done under the direction of experienced personnel conversant with the equipment and the testing procedure.

8.7.8 Before the commencement of the tests all the particulars regarding the test pile including boring data and concrete cube strengths shall be made available at site and shall form a part of the test report.

8.7.9 On completion of each load test the Contractor shall submit a report of the load test which shall include the following information. a. Description of soil conditions, ground water table, actual boring and installation

records, concrete cube test results. b. Method of load application c. Load settlement readings during loading and unloading d. Time load-settlement curve e. All other observations relevant to the test being conducted.

8.7.10 This Dynamic Integrity test using pile driving analyser or approved equivalent for pile integrity shall be performed on the sample of piles selected by the Engineer. The top of the pile shall be made accessible, chipped off up to hard concrete, levelled by trimming it back as far as practicable. The reinforcing bars of the piles tested shall be bent sideways. The test shall be performed after removal of bad/ weak concrete at top so that the wave propagation is steady through hard concrete. The test shall be carried out at minimum 3 locations on each pile in such a way that the entire cross section of the pile is evenly covered. The test shall be conducted with a minimum age of concrete of 15 days. A specialist approved agency shall be employed for the test and the tests shall generally be as per recommendations of the agency unless otherwise directed by the Engineer. A complete report indicating the graphical display of wave propagation under each flow shall be submitted along with interpretation of results showing discontinuities, cross-sectional changes or material changes if any. The results are to be co-related with Site data.

8.7.11 Various utilities/services are running parallel to or crossing the viaduct alignment at different locations. Known utilities enroute have been identified, listed and marked on the GAD. The contractor shall take care that all necessary precautions shall be taken for preventing any damage to it during piling / casting of pile cap. The contractor shall carryout trial probes and trial pits down to depths decided by the Engineer with the objective of locating underground utilities well in advance of the piling. The locations shall be decided by the Engineer after consultation with the contractor.





8.7.12 Any damage done to the utilities / services (charted or un-charted) during piling/casting of pile cap or due to any of the contractor’s operations, shall be made good by the contractor at his own cost. Any demurrage / penalty levied by the utility agency in this regard will also be payable by the contractor and no claim in this regard shall be entertained by Engineer/Employer.

8.7.13 As the work is to be carried out in urban areas, load test by kentalage method is not permitted

8.8 Defective Piles 8.8.1 The Engineer reserves the right to reject any pile which in his opinion has not been

constructed in accordance with the specifications. 8.8.2 The Contractor will not be paid for rejected piles. The increase in cost of the pile caps,

tie beams and other measures adopted for strengthening as a result of rejection of defective piles shall be borne by the Contractor.

8.9 Mode of Measurement of Piles 8.9.1 Piles with casing pipe / Temporary Liners

1. The Contractor shall be paid for the length of each pile as measured from the theoretical founding level (as per drawing) or as per actual whichever is less to the point of the vertical cut-off level. The Contractor's rate shall include all items of work including all temporary/permanent arrangements for boring including usage of Bentonite, chiseling as specified / required, concreting, handling, form-work and grouting for precast piles, including chipping of top weak concrete, cutting off the MS liner / casing as necessary, removal of excavated earth, chipped concrete, casing / liners and bentonite slurry away from site including its treatment & final disposal, and all other items of work for the satisfactory completion of the pile foundations. Reinforcement shall be measured and paid separately.

2. Pile load tests initial and routine shall be measured separately and paid for separately. 3. Each pile integrity test shall be measured and paid for separately. 4. The quoted rate should include costs of tools and plants, cutting, welding MS liner,

cutting shoe etc. complete. Attention is also drawn to Para 8.4 2 (c) above.

8.9.2 Piles with Permanent Liners

The quantity of piles with permanent steel liners required for the job shall be measured as per specifications / detailed in para A above and paid for separately as per the relevant item of BOQ. Attention is also drawn to Para 8.4 2 (c ) above.

8.10 As-Built Drawings On completion of the work, the Contractor will submit a plan showing the exact location and length of each pile as constructed at site, as well as dates of concreting, cube test results etc. The original tracings of these drawings along with soft copies shall be submitted to the Engineer.





9 ROOF SHEETING 9.1 General:

The roofing material shall consist of single skin crimp curved profiled sheeting made up of either of the below mentioned materials:

High tensile SMP galvalume steel

Modified polyester coated GI sheet

Powder Coated MS sheet

Aluminium/Aluminium Alloy sheets

Zincalume sheets The profile and length of sheets shall be commensurate with the design and site requirements and pre-coated with approved colour. The contractor shall prepare shop drawings based on the drawings supplied by the Engineer. These shall be submitted in five sets sufficiently in advance to the Engineer for approval. All manufacturers shall be ISO 9001:2000 accredited.

9.2 Steel Material

High tensile SMP galvalume steel The base material of sheet shall be galvalume high tensile cold rolled steel as per AS 1397, coating class AZ 150 (min. 150 gm/m2 zinc aluminium alloy coating mass, total of both sides) and having a yield strength not less than 550 Mpa.

Modified polyester coated GI sheet The material shall be 0.60 mm TCT (Total Coated Thickness) modified polyester coated Galvanised steel. The sheets shall have a hot-dip metallic coating of Zinc (180 gms/Sq.M. zinc. Coating mass total on both sides) and have a yield strength not less than 240 MPa as per relevant IS codes.

Powder Coated MS sheet The material shall be 0.60 mm TCT (Total Coated Thickness) powder coated mild steel. The sheets shall have a yield strength not less than 240 Mpa as per relevant IS codes.

Aluminium/Aluminium Alloy sheets The External sheet shall be 65/400 profile straight sheets or tapered sheets Aluminium Alloy: EN AW-3004-AIMn1Mg1 (as per DIN 1725)with minimum ultimate tensile strength of 225 N/mm² and 0.2% Proof stress - min 200 N/mm² modulus of elasticity - 70,000 N/mm². Profile reference shall be 65/400 with min 65mm standing seam; 400mm cover width and nominal thickness/gauge: 0.9mm. The roofing system shall comply to the British Board of Agreement and be certified as CLASS 1 roofing by Factory Mutual Research Corporation.

9.2.1 Profile Trapezoidal profile with minimum depth of 30/40 mm with 3 small ribs at the centre to stiffen the profile. The profile shall have the seam and rib height as per the material used, thickness, purlin spacing and profile of the sheeting.

9.3 Coating/ Finishing

High tensile SMP galvalume steel The sheet shall have silicon modified polyester (SMP) coating of approved colour of total thickness of 35 microns exterior coat of SMP over 5 microns polyester back coat over 5 micron primer coats on both surfaces including sides and end laps.

Modified polyester coated GI sheet The sheet shall have modified polyester coating of approved colour of total thickness of 35 microns comprising of 20 microns exterior coat of modified polyester coating over top surface and 5 micron polyester backer coat over 5 micron primer coats on both surfaces

Powder Coated Mild Steel Sheet The sheet shall have powder coating of approved colour of total thickness of 35 microns on both surfaces.

Aluminium /Aluminium Alloy sheeting The outer sheet shall have PVF 2 coat system (non-clad 3004 type) or stucco embossed and colour as per requirements and specifications. The fluorocarbon (PVF2) coating system shall have 2 coats. The first coat shall be of inhibitive primer, with a dry film thickness averaging 5-7 m. Second coat shall have Fluorocarbon colour coat, with a minimum dry film thickness of 20 m.





The exterior finish coat shall be PVF2 paint system containing at least 70% of PVF2 resin in dry paint film, as required by approved licensed coating formulate. The finish coat shall have a dry film thickness of 0.020mm. The paint finish system shall have mica particles to achieve its unique appearance, which result in a visual effect known as geometric metamerism. In order to minimise appearance differences; all requirements shall be processed in one production run using the same batch of paint. Standard colours will have a nominal gloss level of 20 to 35% (60o) - subject to choices of colours. A Backing Coat of nominal thickness of 0.005mm with standard colour coating. The coated finish for flashing and roofing sheet shall have the following properties:

Humidity Resistance Blistering tested accordance to ASTM D 2247 (3000 Hours) with no blistering.

Acid Salt Spray tested accordance to ASTM B117 (3000 Hours) with no creepage sighted.

Formability of 0T to 2T, tested accordance to ASTM D4145.

Pencil hardness conforming to ASTM D3363 with HB to 2T hardness grading.

Reverse Impact tested accordance to ASTM D2794, with no loss of adhesion.

Flame test tested to ASTM E84. Class A coating

Specular gloss of 20 - 35%, measured at 60o and tested in accordance to ASTM D523.

9.4 Fixing If slope of roof is less than 15 degree, the end lap on roof shall be minimum 225mm and single length sheets with joint sealed with double sided self-sticking tapes fixed between two sheets are recommended. The contractor shall ensure that panel erector is familiarised with erection procedure and all the supporting members are straight, level, plumb and true (according to AISC) before starting panel erection. Panels shall be erected according to approved shop drawings. The indicative installation procedure is given below. It shall be suitably adapted based on the cladding/roof system adopted. • Cut sheets and flashings to give clean true lines, with no distortion. Remove burrs

and any lubricant. • Cut openings in sheets for outlets, vent pipes, flues, etc. to the minimum size

necessary and as per the cladding manufacturer’s recommendations. • The sheets shall be laid starting from the eaves, or from bottom upward in case of

cladding (IS:3007). The sheets shall be laid from the end of the building away from prevailing wind so that exposed edges face down wind.

• Ensure that ends of sheets, and end laps are fully supported with fixings at top of lap.

• Ensure that raking cut edges at hips and valleys are fully supported. • Remove dust and any other foreign matter before finally fixing sheets into position. • Protect sheets adequately during fixing and up to Practical Completion against

mechanical damage and disfigurement. Rectify any defects as quickly as practicable to minimise damage and nuisance.

Fasteners • Sheets shall be crest fixed to roof purlins with no. 12-14 x 55 mm long polymer

coated galvanised hex head self-drilling screws with integral washers and EPDM seals (four fasteners per support) per sheet.

• Or drill all holes and install fasteners perpendicular to the surface of the cladding. Position fasteners at regular intervals in straight lines, centred on support bearings.

• Locate fasteners centrally within holes that are oversized. • Install fasteners to correct tightness using any special tools recommended by the

fastener manufacturer. When used, screw guns must be fitted with depth sensitive devices and used at the correct speed.

• Check fastenings on completion and adjust as necessary to ensure that they are watertight and sheeting is secure but not buckled or distorted.

• Paint all cut edges to match face finish. FIXING OF STANDING SEAM SHEETS





• Standing Seam sheets to be installed by mechanically seaming sheets to support clips with electrically operated zipping machine.

• Only roofing contractors approved by the manufacturers should be employed to install Standing Seam roofing system.

STRUCTURAL MOVEMENT JOINTS • Leave space between sheets to coincide with structural movement joints. • Fix movement joint cover to sheets on one side only. • Movement joint flashing details to be in accordance to cladding manufacturers

recommendations. 9.4.1 Jointing Detail:

Trapezoidal profile with atleast one corrugation for side lap. 9.5 Accessories

The specification for capping, flashing and trims materials shall be same as that for sheeting and shall be factory formed to required shape and profile based on shop drawings. Depending on the cladding system adopted and the suitability, the accessories mentioned below shall be used.

Extruded aluminium alloy: EN AW-6061 halters, 85mm long fixed to galvanised steel purlins, 2mm thick, with 25mm long 6.3mm dia stainless steel self-tapping fasteners

Polyamide thermal barrier pads fixed to halter base

Pressed aluminium alloy channel verge cap

Pressed aluminium alloy ridge support

Aluminium alloy Z section ridge closure

Pressed aluminium alloy drip angle 40 x 60mm

The aluminium clip shall be manufactured from extruded Aluminium Alloy 6061T6 with a ultimate tensile strength of not less than 340 MPa and elongation not more than 16% when tested according to ASTM B 557: 1981.

Stainless steel self-tapping screws complete with stainless steel/EPDM bonded washers – thread type, length to suit construction detail. A minimum of 2 numbers of fixings per halter should be used.

9.6 Gutter 9.6.1 Material description:

Outer skin: 2.0mm aluminium, plain mill finish or galvalume, GI or MS powder coated sheet as per the cladding system adopted as per the specifications mentioned above.

9.6.2 Special requirements • Gutter shall be supported by colour matched 2mm thick GI support brackets at every meter and butt jointed at (maximum) every 3 meters. • Gutter fixings: stainless steel bolts, nuts, stainless steel & EPDM washers. • Gutter sealing: All joints to be sealed with suitable sealant and water flow area shall be lined with waterproofed using suitable material.

9.7 Measurement The sheets including special accessories such as gutters, north light curves, flashings, trims, etc. shall be measured and paid per sqm area. No separate payment will be made for laps of sheets and accessories, bolts, nuts, washers, whitewashing, adjustable bolts and supports for gutters and other fixtures. These are assumed to be included in the quoted rates.

9.8 Warranty Period The manufacturer / Supplier / fabricator/ contractor of the roofing system shall give a guarantee for 15 years with regarding to its composition, surface and tensile strength.

10 MISCELLANEOUS 10.1 Bearings 10.1.1 General

This work shall consist of design supply and fixing in position of bearings for bridge / viaduct girders in accordance with details shown on drawings and to the requirements of these Specifications, Codes and Standards quoted therein and as directed by Engineer.

10.1.1.1 Bearing plates, assemblies and other expansion or fixed devices shall be constructed in accordance with details shown on drawings.





When bearing assemblies or plates are shown on drawings to be placed (not embedded) directly on concrete, the concrete bearing area shall be constructed slightly above grade and shall be finished by grinding.

10.1.1.2 It shall be ensured that the bearings are set truly level and in exact position as indicated on drawings so as to have full and even bearing on the seats. This shall be checked with spirit level in both directions. Thin epoxy mortar pads (not exceeding 5 mm) may be made to meet with this requirement. It shall be ensured that the bottoms of girders to be received on the bearings are plane at the location of these bearings and care shall be taken that the bearings are not displaced while placing the girders.

10.1.1.3 When elastomeric bearing pads or preformed fabric pads are to be provided, the concrete surfaces on which pads are to be placed shall be wood float finished to a level plane, which shall not vary by more than 1.5 mm from a straight edge placed in any direction across the area.

10.1.2 Scope of Work The scope of work will include: i) Rendering necessary assistance/coordinate with the manufacturer with regard to

placement/fixing of said bearings. The contractor shall ensure that these bearings are installed in accordance with the specification of the manufacturers so that the bearings perform in the desired manner, in accordance with the forces/ displacements/ rotations for which these bearings have been designed. The contractor shall liaise with the agency and will be responsible for design etc. The contractor shall furnish adequate and proper installation details for these bearings while submitting his design and detailed Engineering Drawings. The design criteria, specifications etc. as mentioned in tender documents are mandatory and no deviation to the same shall be permitted unless otherwise directed by the Engineer.

ii) The contractor shall supply all the bearings in suitable packed condition (for its proper transportation and storage before placement in position) at project site to be identified by the Engineer. The price for such bearings (quoted in Schedule of Quantities) shall include all the accessories/holding down bolts/fixing arrangements (excepting reinforced concrete work in piers and girders, and finishing the surfaces of the pedestal) including grouting of holes with epoxy etc., as required.

A. POT BEARINGS A.1 Material specifications of Pot bearing

The material such as PTFE (Poly Tetra Fluoro Ethylene) and lubrication to be used in Pot bearing should conform to BS:5400 Part-9.2 & BS:3784. The confined elastomer to be used shall conform to IRC:83 with a minimum IRHN of 60 +/- 5. The stainless steel shall conform to AISI: 304. The Pot base,saddle & top plate shall be of Cast steel conforming to IS:1030 Gr 280-520 W. Structural steel shall conform to grade A IS:2062-1992. The POT cylinder shall be made up of cast steel. If POT cylinder is to be made of mild steel, then it shall be made of Mild Steel conforming to Grade A of IS: 2062 – 1992 and without welding, duly certified as lamination free steel from SAIL/TISCO. No building up of thickness shall be permitted for POT cylinder. The anchor bolts shall conform to IS: 1364. All welding will be done by manual arc process and as per approved drawing shall conform to IS:816 & IS:9595 with electrode as per IS:814. Pre-healing and post weld stress relieving shall be done as per IS: 9595. Painting on non-working surface of bearing shall be as per MOST specification, cl 2006.4.5. The mating surface of Piston and cylinder shall be hardened to 350BHN (Min).

A.1.1 ELASTOMER –Only the required type of chloroprene viz. Neoprene – WRT, Bayprene 110 or equivalent as specified in IRC: 83(Part-II) – 1987 shall be used in the manufacture of bearings. The Chloroprene shall either be imported directly from the manufacturers or purchased from their authorised agent in India and shall give a certificate to this effect to the department and the same shall be verified from the documents of purchase. Only fresh chloroprne which has been produced not earlier than one year shall be permitted for manufacture of bearings. No reclaimed rubber or vulcassired wastes shall be used.

A.1.1.1 The confined elastomer inside the POT will have the following properties as per Clause 2006.3(c) of MOST Specifications for Roads and Bridges which is reproduced below (Test method as per IS: 3400). (a) Hardness IRHD 50+5 (b) Tensile strength (minimum) 15.5 Mpa (c) Elongation at break (minimum) 400%





(d) Compression set (maximum) 35% (e) Accelerated ageing (maximum Change from initial value) (i) Hardness (+) 15 IRHD (ii) Tensile Strength (-) 15% (iii) Elongation at Break (-) 40% Other specifications as given in IRC-83 (Part II) for elastomeric bearings will be followed.

A.1.1.2 The elastomer for guide-stopper bearing shall be of synthetic rubber (Chloroprene) and shall conform to all the properties specified in clause 915.2 of IRC: 83 (Part – II) – 1987. Laminates of mild steel conforming to IS: 226 shall only be permitted to be need. Use of any other materials like fibre glass or similar fabric as laminates shall not be permitted.

A.1.2. Accessories other than those mentioned below will be as per IS:2062 – 1992. (a) Sealing ring for POT – Metallic (brass). (b) Wiper seal – elastomer as per IRC: 83 (Part - II) - 1987. (c) Dust seal – elastomer as per IRC: 83 (Part II) - 1987. Guide stop bearings shall be fabricated as per tolerances in Table 2 of IRC:83 (Part-II)-1987. Design of the bearing and all accessories shall be the responsibility of the Contractor and got approved from the Engineer.

A.2. Permissible stresses in steel component of Pot bearing The entire design requirement for Pot bearing as specified in IRC:83 Part-III has to be fulfilled with following modifications. (a) No increase in permissible stresses in any material of bearing or bearing stress

between concrete and bearing is permitted in seismic condition. A.3. Permissible bearing stresses in concrete

The allowable bearing stresses in concrete as defined in IRC:83 Part-III has to be followed with following modifications. (a) No increase in permissible bearing stress between concrete and bearing is

permitted in seismic condition. A.4 Anchor sleeve

All the part of bearing such as anchor sleeves embedded in concrete shall be hot dip galvanized @ 300gm/ m². The anchor sleeves have to be designed taking account of difference in elasticity of steel of sleeve and concrete. The effect of shifting of center of rotation of sleeve should be also taken into account

A.5. The contractor shall furnish along with tender documents in technical bid , the name of the manufacturer of bearings , his qualifications with all details including proof of satisfactory performance, certification and testing facilities of the bearing he proposes to use . Products of reputed manufacturers shall only be used.

A.6 The Bearings shall be measured in numbers according to their capacities. For this purpose Fixed type POT bearings, Free sliding type POT-cum-PTFE bearings, Guided sliding type POT-cum-PTFE bearings, Free or Guided PTFE Sliding Assembly, Pin Bearings or Metallic Guided bearings shall be counted separately. The rate shall include the cost of supplying, fixing, sampling and testing as required and confirming to the specifications





A.7 Testing of Pot Bearing A.7.1 Proof Load Test

A test bearing shall be loaded to 150% of the bearing's rated design capacity and simultaneously subjected to a rotational range of 0.02 radians or design rotation, whichever is greater, for a period of one hour. The bearing will be visually examined both during the test and upon disassembly after the test. Any resultant visual defects, such as extruded or deformed elastomer or PTFE, damaged seals, or cracked steel, shall be cause for rejection. During the test, the steel bearing plate and steel piston shall maintain continuous and uniform contact for the duration of the test. Any observed lift-off will be cause for rejection. All bearings will be applied with a vertical load perpendicular to the plan area of the bearings and on approved system duly approved by Engineer, to subject the bearings to rotation. The minimum load at which the required rotation is achieved is to be determined and this value should be less than the minimum design vertical load as tabulated in the drawing. For guide-stopper bearing, test on specially molded test pieces shall be conducted as per clause 918.4.1.2. of IRC : 83 (Part – II) – 1987 which shall be compared with Test pieces from test bearings. The variation shall be within limits specified herein.

A.7.2 Sliding Coefficient of Friction For all guided and non-guided expansion type bearing, the sliding coefficients of friction shall be measured at the bearing's design capacity. The sliding coefficient of friction shall be calculated as the horizontal load required maintaining continuous sliding of one bearing, divided by the bearing's vertical design capacity. The test result will be evaluated as follows:- (a) The measured sliding coefficients of friction shall not exceed 3%. (b) The bearing will be visually examined both during and after the test. Any resultant visual defects, such as bond failure, physical destruction, cold flow of PTFE to the point of debonding, or damaged components shall be cause for rejection.

A.8 Sampling and Testing A.8.1 Lot Size

Sampling, testing and acceptance consideration will be made on a lot basis. A lot shall be defined as those bearings presented for inspection at a specific time or date. A lot shall be further defined as the smallest number of bearings as determined by the following criteria.

(a) A lot shall not exceed a single contract or project quantity; (b) A lot shall not exceed 25 bearings; (c) A lot shall consist of bearings of the same type regardless of load capacity.

Bearing types shall be fixed or expansion bearings types . Guided and non-guided expansion bearing shall be considered a single type.

A.8.2 Sampling and testing requirements The manufacture shall furnish the required number of samples to perform testing in accordance with Table Given below:

Test Sample Required

Proof load

Coefficient of Friction

Physical Properties of elastomeric rotational elements

Physical properties of PTFE sheet

One production bearing per lot

One production bearing per lot

One elastomeric element per lot

One 10" x 15" sheet of PTFE material per project

A minimum of thirty (30) days shall be allowed for inspection, sampling and testing of production bearings and component materials. All exterior surfaces of sampled production bearings shall be smooth and free from irregularities or protrusions that might interfere with testing procedures.





The manufacturer shall select, at random, the required sample bearing(s) from completed lots of bearings for testing by the manufacturer. He shall complete the required testing and determine compliance with this specification before submitting the lot(s) for inspection, sampling, and acceptance consideration. The Engineer shall select, at random, the required sample bearing(s) from completed lots of bearings. Necessary test certificates for all raw material shall be furnished by manufacturer .Test specified in IS:1030 for cast steel shall be performed . Casting shall be ultrasonically got tested by approved testing agency.

A.9 Fabrication Details The Contractor shall provide the Engineer with written notification thirty (30) days prior to the start of bearing fabrication. This notification shall include all the information shown on the shop drawings which are required as explained in subsequent section. The finish of the mold used to produce the elastomeric rotational element shall conform to good machine shop practice. All steel surfaces exposed to the atmosphere, except stainless steel surfaces and metal surfaces to be welded, shall be shop painted in accordance with the Contract Plans. Prior to painting, the exposed steel surfaces shall be cleaned in accordance with the recommendations of the coating's manufacturer. Metal surfaces to be welded shall be given a coat of clear lacquer, or other protective coating approved by the Engineer, if the time of exposure before welding takes place is to exceed three months, the coating shall be removed at the time of welding. No painting will be done to these surfaces prior to the completion of welding. Stainless steel sheet shall be attached to its steel substrate with an approved epoxy to ensure complete contact and then sealed with a continuous seal weld. The steel piston and the steel pot shall each be machined from a solid piece of cast steel. The outside diameter of the piston shall be no more than 1mm less than the inside diameter of the pot at the interface level of the piston and elastomeric rotational element. The sides of the piston shall be bevelled to facilitate rotation. Except as noted all bearing surfaces of steel plates shall be finished or machined flat in accordance with tolerance given below: Tolerances:- Manufacture tolerance shall be as per IRC:83 Part-III and BS:5400,section 9.2 shall be followed subject to following modification . (a) Plan Dimension: -0 to +5mm (b) Overall height: -0 to +3 mm (c) Height of any steel component

(i) Machined -0 to 0.5mm (ii) Unmachined class 2 of IS:4897

(d) Stainless steel sliding surface a. Flatness 0.0004L, where L= lengthin directionof measurement b. Surface Finish Ra shall be less than or equal to 0.25 pm as perIS: 3073 All the measurements will be taken using dial / height gauges, verniercalipers, surface finish measurement instrument etc. has to be arranged by manufacturer at the workshop. Every bearing shall have the Project Identification Number, Lot Number, and individual bearing number indelibly marked with ink on a side that will be visible after erection. After assembly, bearing components shall be held together with steel strapping, or other means, to prevent disassembly until the time of installation. Packaging shall be adequate to prevent damage from impact as well as from dust and moisture contamination during transportation and storage.

A.10 Shop Drawings Along with detailed design of different types of bearing, shop drawings shall be submitted .The shop drawings shall contain the following information, which is necessary for proper design and detailing of the bearings.

Quantity, type (fixed, guided expansion, non-guided expansion), and location of all bearing units. A table containing maximum and minimum vertical and horizontal loads, design rotation requirements, and magnitudes and directions of movements.





Allowable contact stresses, maximum dimensions, and anchorage requirements at the bearing interfaces; grades, bevels, and slopes at all bearings; and allowable coefficients or friction of all sliding surfaces. The painting system to be used on the steel components to guard against corrosion. Any special consideration such as earthquake requirements, uplift details, or temporary attachments. Installation scheme of pot bearing The Contractor shall submit detailed shop drawings in conformance with the applicable requirements.

A.11 Measurements The bearings will be counted in numbers alongwith bolts & washers.

B. ELASTOMERIC BEARINGS The term “bearing” in this case refers to an elastomeric bearing consisting of one or more internal layers of elastomer bonded to internal steel laminates by the process of vulcanisation. The bearing shall cater for translation and/or rotation of the superstructure by elastic deformation.

B.1 Raw Material The raw material shall confirm to the requirements laid down in clause 2005.1 of MORTH specifications. Chloroprene (CR) only shall be used in the manufacture of bearing. Grades of raw elastomer of proven use in elastomeric bearings, with low crystallization rates and adequate shelf life (e.g. Neoprene with low crystallization rates and adequate shelf life (e.g. Neoprene WRT, Bayprene 110 Skyprene B- and Denka S-40V) shall be used. No reclaimed rubber or vulcanized wastes or natural rubber shall be used. The raw elastomer content of the compound shall not be lower than 60 per cent by its weight. The ash content shall not exceed 5 percent (as per tests conducted in accordance with ASTM D-297, sub-section 10). EPDM and other similar candidate elastomers for bridge bearing use shall not be permitted.

B.2 Properties The elastomer shall conform to the properties specified in Clause 4.3.1 of the IRICEN publication titled "Bearings for Railway Bridges" and those specified in Table 2000-1 of the publication titled "Specifications for Road and Bridge Works", published by IRC on behalf of MORTH (Roads Wing). The design, drawings, detailed method statement for installation & replacement of the bearings including its accessories shall be the responsibility of the Contractor. The design shall be got checked and certified by approved independent agency before submitting to the Engineer for approval

B.3 Fabrication and Tolerances Fabrication and Dimensional tolerances shall be governed by the specifications laid down in Clause 4.3.2 of the IRICEN publication & Clause 2005.2 of the MORTH specifications mentioned above.





B.4 Acceptance Specifications For inspection and testing requirement Clause 4.4 of the above mentioned IRICEN publication shall be referred with modifications of lot size as mentioned below:-

Sampling testing and acceptance consideration will be made on a lot basis. A lot shall be defined as those bearings presented for inspection at a specific time or date. A lot shall be further defined as the smallest number of bearings as determined by the following criteria. (a) A lot shall not exceed a single contract or project quantity; (b) A lot shall not exceed 50 bearings; (c) A lot shall consist of bearings of the same type regardless of load capacity.

Accepting and testing requirements shall also conform to the specifications laid down in Clause 2005.3 of the referred MORTH specifications. In addition to tests mentioned above, all bearings shall also be weighed actually and compared with the theoretical weight. All bearings shall carry a warrantee of not less than 15 years in an approved format. The contractor shall be responsible for immediate repair or replacement of the bearings in case of failure / distress to the satisfaction of the Owner at not extra cost to the Owner within the warrantee period. Criteria for Selection of bearing manufacturer shall conform to requirement of MOST letter No-RW/NH-34057(1) / 95-(S & R) dated 2nd November,2000. It is necessary that all manufacturers of all elastomeric bearings shall have in house facilities for carrying out Infrared Spectro-Photometry as per ASTM D-3677.

B.5 Design The design of elastomeric bearings shall be as per the guidelines laid down in the UIC 772 R. Alternatively, design can also be made with latest version of Euronorm prEN1337-3 Part 3. The design, drawings and detailed method statements for installation and replaceability of the bearings shall be checked and certified by approved independent agency before submitting to the Engineer for approval.

B.6 Storage and Handling Each elastomeric bearing shall be clearly labelled or marked. The bearing shall be wrapped in a cover. They shall be packed in timber crates with suitable arrangement to prevent movement and to protect corners and edges. Care shall be taken to avoid mechanical damage, contamination with oil, grease and dirt, undue exposure to sunlight and weather to the bearings during transport and handling prior to and during installation.

B.7 Installation Installation procedure shall conform to the guidelines listed in Clause 4.5 of the IRICEN publication and Clause 2005.6 of the MORTH specifications. Cost of Non-shrink grout above and below the bearing should be included in the cost of providing and installation of bearing as per BOQ.

B.8 Measurement Measurement shall be done in cu.cm correct to two decimal places. All linear dimensions required to arrive at volume of elastomer shall be measured correct to a mm. Payment shall be made for the volume of bearing as per design.

C. SHEAR KEY DEVICE C.1 General Description of the System C.1.1 General

The shear key is made of concrete cast in place in second pour after concrete decks are assembled. The shear keys shall take all horizontal loads (longitudinal and transverse). It is equipped with a system of fixation with high strength bars to one end of the deck, and with 5 vertical bearings taking the transverse horizontal loads and the rotations.

C.1.2 Description of the proposed system The system of fixation of the shear key to the deck is performed by high strength tensile bars installed on only one horizontal layer. The system shall satisfy with the two main following requirements:

Construction easiness

Maintenance easiness





The high strength tensile bars shall have a good resilience and a good resistance to fatigue because due to the rotation of the deck and the braking/acceleration loads the bars are almost continuously loaded. The elastomeric bearings shall be of sufficient quality to avoid premature ageing. All the external surfaces shall be made of polychloroprene.

C.2 Materials characteristics C.2.1 High tensile bars

Quality of steel: the quality of the raw material steel shall be according to the DIN EN 10083-1 or equivalent. The chemical composition shall be such as to guarantee the following mechanical characteristics:

Yield stress Fy >1050 MPa

Tensile stress Fu >1200 MPa

Elongation at breaking >10%

Resilience at 20°C > 50 Joules; The threading of the bars shall be made by rolling method (cold plastic deformation of the metal between two dies). The threads shall have a triangular profile H7 according to ISO 262 - NFE 03014 and 03053. The tolerance of the length of the bars is +/- 5mm Diameters of bars: the stress in the bar will not exceed 0.85 Fu. The following U.T.S of bar are contemplated, but may be adjusted during detailed design phase: U.T.S of bars is 1420 kN, 1300 kN, 1120 kN, 1000 kN, 900 kN. Due to the repetitive loading that will be applied to the bars, some tests shall be carried out to demonstrate the fatigue resistance of the bars. The test criteria shall be as follows:

mean stress : 0.57 Fy

stress range : +/- 0.03 Fy

millions cycles

after 4 million cycles, no breaking at less than 0.80 Fy. Ultimate tensile strength test shall be conducted at manufacturers or any other approved independent laboratory in presence of Employer’s Representative in charge, same test conducted in the past will not be considered.

C.2.2 Other materials The repartition plates shall be of S355 JO steel quality or equivalent, and each shall include an injection pipe. The bars end shall be equipped with a protection cap filled up with grease and fixed on repartition plate by threading. The nuts at the bars ends shall be spherical in order to ensure that the tensioning is well axed. Sheaths shall be made with 2 mm thick steel / 5 mm thick HDPE pipe. The injection product shall be wax / high-density grease in order to provide a good time-resistance and to provide flexibility under the deck rotations. The product shall be equivalent as for use for protecting stay cables or tension rods.

C.2.3 Elastomeric bearings system On the movable side of deck, one sliding elastomeric bearing shall be installed longitudinally on each side of the shear key. This sliding elastomeric bearing shall be made of one laminated elastomeric pad and of one sliding plate. On the fixed side of deck, one laminated elastomeric bearing shall be installed longitudinally on each side of the shear key. In addition, at the interface between the shear key, one laminated elastomeric with adequate recesses to allow for replacement without taking out the high tensile bars shall be installed transversally. These elastomeric bearings shall be made of polychloroprene, and manufactured according to Euronorm EN 1337-3 or equivalent. The sliding plate shall be PTFE, with elongation at break >300% and tensile strength from 29 to 40 MPa.

C.3 Corrosion Protection C.3.1 High tensile bars

The protection against corrosion of the high tensile bars shall be performed by using wax/ high-density grease injected in tube. So, the bars will be protected against corrosion only for the time of transportation and storage by means of sprayed oil or equivalent system.

C.3.2 Other materials





The upper repartition plate and the protection cap shall be sandblasted and shall receive 3 layers of coating. The articulation room, the coupler and the lower ring shall be sandblasted and shall receive 3 layers of coating and a petrolatum tape. The articulation room and the upper protection cap shall be filled up with grease.

C.4 Transportation & Storage The bars and the accessories shall be transported in wooden cases and in containers, or equivalent. The bar threading shall be temporarily protected against shocks by a greased tape and a steel ring, or equivalent. The protection of the threads shall be taken off only right before the installation of the bars. The bars and accessories shall be carefully stored in the jobsite in the following conditions: They shall be protected from rain, and the storage room shall have ventilation. If the bars have to be kept stored for a long time, it will be necessary to protect them with a layer of solvable oil or equivalent in order to protect them against corrosion. Before installation of the bars, if there is some corrosion, they shall be cleaned up. Acceptance of the bars shall be subject to CMRL approval.

C.5 Installation Procedure The installation procedure is proposed as follows. Alternate methods can be submitted by the contractor, subject to CMRL approval. 1. Shear Key is poured before precast concrete deck segments are installed .The span

must be assembled on higher level to avoid conflicts with already built concrete key. 2. Superstructure should have recess of 20mm for grouting by non-shrinkage grout at later

stage 3. Erect the superstructure on temporary bearings/jacks with sliding surface at top at

both ends 4. Provide some arrangement to prevent deck sliding (e.g. under seismic load). 5. Move the girder by hand screwing/jacking bar be nearly 20mm 6. At this stage vertical faced elastomeric pad is in position (resting on tubes) 7. Replace the temporary bearing with the permanent elastomeric bearing 8. Grout the gap between the girder (with hacked surface at grouting location) and the

elastomeric bearing 9. Bar stressing 10. Wax injection and capping Notes: a) The bars are installed after alignment check, and the bars are installed inside the

spherical nut at movable end. Then the bars are prestressed with jack. The bars are tensioned step by step (50% one bar, then 50% the other, then the remaining 50%).

b) Injection is then made from the movable end, with heated wax through injection tube. C.6 Maintenance Procedure

The system shall be such that any device can be replaced without any destruction of concrete part of the structure. The system shall be such that the maintenance procedures described below can be undertaken. a) Lateral elastomeric bearings

For the lateral vertical bearings, a theoretical gap of 2mm shall be provided on each side of the shear key. If it is needed to change one or all of these lateral bearings, then, as the deck will not be in contact on each side at a time, the lateral bearings on the non-compressed side are taken out first. First the sliding plate is taken out, then the elastomeric bearing. Then the deck may need to be translated laterally to take out the elastomeric bearings on the compressed side. For this, steel angles can be split in the concrete on each side of the elastomeric bearings to provide support for jacks or threaded bars. The needed force to distort the neoprene bearings supporting the deck will be calculated.

b) Transversal elastomeric bearings Thanks to the opening on the bearing, it will only be necessary to un-stress temporarily the tie-bars to take out the bearings and replace it.

c) Prestressed tie-bars Bars will be un-stressed, then simply taken out thanks to the device provided at the movable end. Bars will be taken out easily because the connection between the





spherical nut and the protection cap will not allow the spherical nut to turn. The wax product will come out with bar. New bars are introduced as per first installation, then tensioned and wax is injected.

10.2 Expansion Joints 10.2.1 Scope of Work

The scope of work will include: i) Preparation of detailed engineering and installation drawings, supply and

supervision during fixing of strip seal/compression seal expansion joints conforming to specifications. The expected expansion/contraction of the superstructure at the location of expansion joints are shown in relevant drawings.

ii) Design, manufacture, providing and seating of expansion joints by the specialised agency and approved by the Engineer.

iii) Necessary technical supervision for installation of each and every expansion joint during different stages of installation including rectification of any deficiency or defect attributable to fixing and installation will be provided by the manufacturer/supplier.

iv) The expansion joint shall be provided for the full width of viaduct including the railing.

v) Leak tightness of all joints shall be ensured which shall also carry a warranty of 10 years from the contractor.

10.2.2. The expansion joints provided over elevated structure decks should be so designed as to be compatible with the bearings wherever provided where the structure passes through stations, specially designed completely waterproof expansion joints should be provided.

10.2.3. The contractor shall submit design and drawing of compression seal expansion joints based on design criteria mentioned under “scope of Work” to the Engineer for approval. The design of expansion joint shall be done as per Revised Highways “Interim Specification for expansion joint” issued by Ministry of Road Transport vide No. RW/NH – 34059/1/96 – S & R dated 30th November 2000, IRC Codes and MOST Specification for Roads and Bridges and Sound Engineering practices. Any modification to the design and drawings submitted by the Contractor, if suggested by the Engineer, shall be incorporated without any reservations. The design and drawings including changes approved by the Engineer shall form basis of execution and the Contractor shall undertake all necessary action for ensuring execution of work on that basis. For design, manufacture, testing and supply of strip seal/modular strip seal expansion joints, following will be followed in order of preferences. (a) Details in this chapter and elsewhere in tender documents. (b) “Revised Interim Specifications for expansion joints” issued by MOST vide No.

RW/NH – 34059/1/96/ S & R dtd.30.11.2000. (c) IRC Codes and MOST specifications for Roads and bridges published by Indian Road

Congress. (d) Sound Engineering Practice (Decision of Engineer will be final in this case) which

shall include specialized literature as decided by Engineer-in-Charge.





STRIP SEAL ELEMENT SPECIFICATION Sealing element is made of chloroprene and must be extruded section. The working movement range of the sealing element shall be 70mm.

Property Specified Value

Hardness*

DIN 53505

ASTM D 2240 (Modified)

Tensile Strength*

DIN 53504

ASTM D 412

Elongation at fracture*

DIN 53504

ASTM D 412

Tear Propagation Strength

Longitudinal

Transverse

Shock elasticity

Abrasion

Residual Compressive Strain

(22h/70 deg C/30 per cent Strain))

Aging in hot air

(14days/70 deg C)

Change in hardness

Change in tensile strength

Change in elongation at fracture

Ageing in Ozone

(24 h/50 pphm/25 deg

C/20 per cent elongation)

Swelling behaviour in Oil (168h/25 deg. C)

ASTM Oil No. 1

Volume Change

Change in hardness

ASTM Oil No. 3

Volume Change

Change in hardness

Cold Hardening Point

63+ /-5 Shore A

55 +/- 5 Shore A

.

Min 11 MPa

Min 13 .8Mpa

Min 350 per cent

Min 250 per cent

Min 10 N/mm

Min 10 N/mm

Min 25 per cent

Min 220 Cu.mm

Max 28 per cent

Max + 7 Shore A

Max –20 per cent

Max - 20 per cent

No cracks

Max + 5 per cent

Max –10 Shore A

Max + 25 per cent

Max –20 Shore A

Max –35 deg C

*Only one set of specification viz. ASTM or DIN shall be followed depending on the source of supply.

10.2.4. Building Expansion Joints Specialised expansion joints consisting of aluminium extrusions and / or elastomer suited to building applications shall be used. These will be provided for covering the structural gap at expansion joints along the horizontal faces of slabs and beams, vertical faces of retaining walls, etc. Necessary block-outs as per the manufacturer's recommendations shall be provided in the structure which shall be filled in the approved manner after placing the expansion joints. The base of the expansion joint assembly shall be fixed onto the concrete base using anchor fasteners as per manufacturer’s specifications. All aluminium in contact with concrete shall have zinc chromate finish. The joint assembly shall be capable of accommodating the specified movement without loss of cover. The expansion joint cover assemblies shall withstand a minimum 500lb point load without damage or permanent deformation.





Only proprietary imported expansion joints from reputed manufacturers such as those manufactured by M/s Watson Bowman Acme supplied by Sanfield India Ltd and those manufactured by M/s c/s expansion joint and supplied by Z-Tech India Pvt Ltd and other MORTH approved manufacturers shall be used.

10.2.5. Fabrication (Pre-installation) (a) The strip seal joint system and all its component parts including anchorages shall be

supplied by the manufacturer /system supplier. (b) The width of the gap to cater for movement due to thermal effect, prestress,

shrinkage and creep, superstructure deformations (if any) and sub-structure deformations (if any) shall be determined and intimated to the manufacturer. Depending upon the temperature at which the joint is to be installed, the gap dimension shall be preset.

(c) Each strip seal expansion joint system shall be fabricated as a single entity unless stage construction or excessive length prohibits monolithic fabrication. It shall fit the full width of the structure as indicated on the approved drawing. The system shall be pre-set by the manufacturer prior to transportation. Presetting shall be done in accordance with the joint opening indicated on the drawing.

(d) The finally assembled joint shall then be clamped and transported to the work site. 10.2.6. Handling and Storage

(a) For transportation and storage, auxiliary brackets shall be provided to hold the joint assembly together.

(b) The manufacturer/supplier shall supply all the materials of strip seal joints including sealants and all other accessories for the effective installation of the jointing.

(c) Expansion joint material shall be handled with care. It shall be stored under cover on suitable lumber padding.

10.2.7. Supply/Installation: Components of expansion joint such as edge beam and strip seal shall be imported from the specified foreign manufacturer / collaborator to ensure quality and performance. The joint shall be supplied and installed only by the MORTH approved manufacturer. Contractor shall furnish a warranty of trouble free performance for at least ten years and free rectification of defects / replacement, if any, during this period. The joints shall be installed by the manufacturer/supplier (only MORTH Approved) or their authorised representative who will ensure compliance to the manufacturer’s instructions for installation. Taking the width of gap for movement of the joint into account, the dimensions of the recess in the decking shall be established in accordance with the drawings or design data of the manufacturer. The surfaces of the recess shall be thoroughly cleaned and all dirt and debris removed. The exposed reinforcement shall be suitably adjusted to permit unobstructed lowering of the joint into the recess. The shuttering in the recess will be provided in such a way that dimensions in the joint drawing are maintained. The formwork shall be rigid and firm. Immediately prior to placing the joint, the presetting shall be inspected. Should the actual temperature of the structure be different from the temperature provided for presetting, correction of the presetting shall be done. After adjustment, the brackets shall be tightened again. The joint shall be lowered in a pre-determined position. Following placement of the joint in the prepared recess, the joint shall be levelled and finally aligned and the anchorage steel on one side of the joint welded to the exposed reinforcement bars of the structure. Upon completion, the same procedure shall be followed for the other side of the joint. With the expansion joint finally held at both sides, the auxiliary brackets shall be released, allowing the joint to take up the movement of the structure. High quality concrete shall then be filled into the recess. The packing concrete must feature low shrinkage and have the same strength as that of the superstructure, but in any case not less than M40 grade. Good compaction and careful curing of concrete is particularly important. After the concrete has cured, the movable installation brackets and shuttering still in place shall be removed. The neoprene seal shall be field installed in continuous length spanning the entire carriageway width to ensure proper fit of seal and enhance the ease of installation dirt, spatter or standing water shall be removed from the steel cavity using a brush, scrapper or





compressed air. The seal shall be installed without any damage to the seal by suitable hand method or machine tools. The deck surfacing shall be finished flush with the top of the steel sections. The horizontal leg of the edge beam shall be cleaned beforehand. It is particularly important to ensure thorough and careful compaction of the surfacing in order to prevent any premature depression forming in it.

10.2.8. Acceptance Criteria: (i) All steel elements shall be finished with corrosion protection system. (ii) For neoprene seal, the acceptance test shall conform to the requirements

stipulated in Table-1. The manufacturer/supplier shall produce a test certificate conducted in a recognized laboratory, in India (having NABL certification) or abroad.

(iii) The manufacturer shall produce test certificates indicating that anchorage system had been tested in recognized laboratory having NABL certification to determine optimum configuration of anchorage assembly under dynamic loading.

(iv) Prior to acceptance, 25 percent of the completed and installed joints, subject to a minimum of one joint, shall be subjected to water tightness test. Water shall be continuously ponded along the entire length for a minimum period of 4 hours for a depth of 25mm above the highest point of deck. The width of ponding shall be at least 50mm beyond the anchorage block of the joint on either side. The depth of water shall not fall below 25mm anytime during the test. A close inspection of the underside of the joint shall not reveal any leakage.

(v) As strip seal type of joint is specialized in nature, generally of the proprietary type, the manufacturer shall be required to produce evidence of satisfactory performance of this type of joint.

10.2.9. Test and Standards of Acceptance The materials shall be tested in accordance with these specifications and shall meet the prescribed criteria. The manufacturer/supplier shall furnish the requisite certificates from the recognized testing laboratory in India having NABL Certification or abroad.

10.2.10. Mode of Measurement The measurement for expansion joints as a finished work shall be in running meters nearest to a centimetre.

10.2.11. Rates The contract unit rate shall include the cost of all materials , labour , equipment, cost of transportation (overseas as well as with in country), cost of testing including cost of test samples and other incidental charges for fixing the joints complete in all respects as per specifications

10.3. Sealants 10.3.1. General

Joint sealing compounds shall seal joints in concrete against the passage of water, prevent the ingress of grit or other foreign material and protect the joint filler. The compound shall have good extensibility and adhesion to concrete surfaces and shall be resistant to flow and weathering. Approved Sealant where specified on the drawings shall be provided strictly in accordance with the manufacturer's written instructions, such joints shall be formed to the correct dimensions, thoroughly cleaned and treated with recommended primer strictly in accordance with the manufacturer's written instructions prior to sealing. Wherever width of gap to be sealed is wide enough to necessitate the use of backer rod, the same shall be provided at no extra cost. The contractor shall use only competent personnel experienced in the application of sealant for such work. Where specified in the drawings, silicon/poluurithane/ polysuphide based sealants shall be of an approved manufacture. The treatment of the joint and the use of sealing compound shall be strictly in accordance with the manufacturer's written instructions. The entire work shall be carried out as per IS:3414, IS:6509, IS:11433. Sealants shall be as follows: Silicon sealant shall be one part gungrade type with minimum movement capability of ±25% and elongation at break of 450% confirming to BS 5889 or TTS 001543A. This Sealant shall be of approved color and shall be nonstaining to the parent concrete surface.

10.3.2. Ancillary Materials





The Contractor shall provide all ancillary materials such as cleaning solutions, epoxy mortar, primer, tool cleaner, bond breaker type, filler boards, back up material, backing rods, polyethylene foam, masking tapes, sealant slot former etc.

10.3.3. Primer Primer for sealants shall only be as recommended by the sealant manufacturer, Primer shall have been tested for compatibility and durability with the sealant to be used and on samples of the surfaces to be selected.

10.3.4. Backdrop Material Backdrop material shall be an expanded polyethylene of nominal density 35 kg/cum as recommended by the sealant manufacturer. It shall be of non-absorbent and non-staining material compatible with the sealant used. Tube or rod stock shall be rolled into the joint cavity.

10.3.5. Bond-preventive Materials Bond-preventive materials shall be pressure-sensitive adhesive polyethylene tape or aluminium foil.

10.3.6. Equipment The Contractor shall inter alia provide the following plant and equipment for the work. T-paddle, follower plate, solid barrel gun, plastic nozzle, wire brush, heavy duty 500 rpm electric drill, palette knife, masking tape and paint brush for priming etc.

10.3.7. Working Life Care shall be taken to ensure that material with adequate shell life is provided. Material whose shell life is over shall not be used in the works and shall be removed from the site forthwith. Depending on the storage, temperature and humidity, only one unit shall be drawn from the storage.





10.3.8. Curing Period No portion of the work where sealant has been applied shall be allowed to be submerged or be wetted by any liquid for a period of 7 days after application of the sealant. This period may be modified depending on the temperature and humidity prevalent at the time.

10.3.9. Environmental Requirements The ambient temperature shall be within the limits as given by the manufacturer, when the sealants are applied. The work shall not be carried out in a dusty atmosphere or when it is raining or when the humidity is high. Sealants shall not be applied when the ambient temperature is below 4 degree C. When the ambient temperature is below 10 degree C but greater than 4 degree C, the sealant containers shall be stored for some hours at 21 degree C, to ease mixing and application.

10.3.10. Delivery and Storage Materials shall be delivered to the job site in the manufacturer’s original unopened containers. The containers shall include the following information on the label:

a) Name of supplier, b) Name of material, c) Formula, d) Lot number, e) Colour f) Date of manufacture, g) Mixing instructions h) Shell life and i) Curing time

Materials shall be carefully handled and stored to prevent contamination of foreign materials to exposure to temperatures exceeding 35 degree C.

10.4. Joints The effective width to depth ratio shall be as per the table given below unless directed otherwise by the Engineer.

Surfaces Joint Width Joint Depth

Minimum Maximum

For concrete masonry or stone: 6 mm 6 mm 6 mm

Over 6 mm up to 12 mm

6 mm Equal to width

Over 12 mm ½ of width ½ of width

10.4.1. Surface Preparation General The surface of joints to be sealed shall be clean, dry, sound and free of all release agents, water repellents, laitance, oil, grease, dirt, chalk, particles of mortar, dust, loose rust, loose mill scale and other foreign substances. Oil and grease shall be removed with solvent and the surfaces shall be wiped with clean clothes.

10.4.2. Concrete and Masonry Surfaces Where surfaces have been treated with curing compounds, oil or other such materials, the materials shall be removed by sandblasting or wire brushing, Litance, efflorescence and loose mortar shall be removed from the joint cavity. The surfaces/edges shall be repaired with epoxy mortar to give smooth and even surfaces to correct lines and levels with a uniform gap for the length to be sealed.

10.4.3. Application Masking Tape Masking tape shall be placed on the finished surface on one or both sides of a joint cavity to protect adjacent finished surfaces from primer or compound smears. The masking tape shall be removed within 10 minutes after the joint shall be filled and tolled.

10.4.4. Bond-preventive materials Bond-preventive materials shall be installed on the bottom of the joint cavity and other surfaces to prevent the sealant from adhering to the surfaces covered by the bond-preventive materials. The materials shall be carefully applied to avoid contamination of adjoining surfaces or breaking bond with surfaces other than those covered by the bond-preventive materials.





10.4.5. Backstops The back or bottom of joints constructed deeper than specified shall be packed tightly with an approved backstop material to provide a joint of the depth specified.

10.4.6. Primer The primer shall be used in accordance with the manufacturer’s instructions. The primer shall be applied to the joint surfaces to be sealed only and not spill over or be applied to surfaces adjacent to the joints.

10.4.7. Application of Sealant The sealant shall be gun-applied with a nozzle of proper size to fit the width of the joint indicated and shall be forced into grooves with sufficient pressure to expel air and fill the groove solidly. The sealant shall be uniformly smooth and free of wrinkles. The plastic nozzles shall be inserted on the gun and cut to appropriate size. The sealant shall be gunned into joints using an even trigger pressure. The nozzle shall be cleaned occasionally. The sealant shall be pressed into joints with a wet spatula and tooled within five minutes of application. The jointly shall be tooled slightly concave after the sealant is installed. The tolled joint shall present a smooth and professional joint giving the desired finish and shape. The masking tape shall be removed immediately after tooling. Application equipment shall be cleaned with a tool cleaner, recommended by the manufacturer, after wearing PVC or rubber gloves and whist the sealant is still in an uncured state.

10.4.8. Cleaning The surfaces adjoining the sealed joints shall be cleaned of smears and other soiling resulting from the sealing application as the work progresses. Sealant adhering to, porous surfaces shall be left until is just cured and then removed by abrasion or other mechanical means.

10.4.9. Measurement Measurement shall be made in running metres correct to two decimal places.

10.5. Waterbars / Waterstops Where waterbars/ waterstops are shown on the drawings, the joints shall incorporate PVC waterbar/ waterstop such as "Fixostop" or approved equivalent (conforming to IS:12200). The waterbars/ waterstops shall be complete with all the necessary moulded or prefabricated intersection pieces assembled with bends and butt joints in running lengths made by welding in an electrically heated jig. The fabrication drawing made by the manufacturer shall be submitted by the Contractor for approval of the Engineer Jointing and fixing of waterbars/ waterstops shall be carried out strictly in accordance with the manufacturer's instructions which should be enumerated in a detailed method statement and submitted for approval / comments of the Engineer. The following types of waterbars/ waterstops are proposd to be used in the Work. (a) 'FIXOSTOP' Type 230 KD or equivalent – To be used at construction joint in base slab (b) 'FIXOSTOP' Type 230 KV or equivalent – To be used at expansion joint in base slab (c) 'FIXOSTOP' Type 240 RS or equivalent – To be used at construction joint in between wall

and base slab (d) 'FIXOSTOP' Type 240 H or equivalent – To be used at expansion joint in base slab Waterbars/ waterstops shall be of approved and appropriate type obtained from approved manufacturers. The waterbars/ waterstops shall be installed so that they are securely held in their correct position during the placing and compacting of the concrete. Necessary supporting devices to prevent sagging of the waterbars/ waterstops shall be provided. Where reinforcement is present adjacent to waterbars/ waterstops, adequate clearance shall be left between the reinforcement and waterbars/ waterstops to facilitate compaction of the concrete. Double headed nails maybe used in the edge of the waterbar/ waterstop outside the line of the external grooves for fixing purposes, but no other holes shall be permitted through the waterbar/ waterstop. A representative of the manufacturer shall be present at site during the operations of installing, jointing and embedment of waterbar/ waterstop. He shall monitor and certify that the work is being carried out strictly as per specifications and recommended practices. Waterbars/ Water stops shall be measured and paid for separately as per BOQ.

10.5.1. MEASUREMENT





Waterbars/ Waterstops shall be measured in running meters along the line they are to be laid. Laps and welding etc. shall not be measured separately. The length shall be taken in metres correct to two decimal places. All wastages, laps and variations are deemed inclusive in the item rate quoted by the contractor and nothing extra is admissible on this account. Payment will be made only for the measured quantity incorporated in the work.

10.5.2. RATE The rate quoted shall include the cost of materials all transportation etc. and labour involved in all the operations described above.

10.6. Compression Seal expansion Joint Expansion joint type described here-after is the “Compression seal” type, but alternate designs can be proposed for approval of the Engineer (e.g. elastomeric omega-shape cover joint, or any other suitable joint type.)

10.6.1. Compression seal joint shall consist of steel armoured nosing at two edges of the joint gap suitably anchored to the deck concrete and a preformed chloroprene elastomer or closed cell foam joint sealer compressed and fixed into the joint gap with special adhesive binder.

10.6.2. Material 10.6.2.1.Steel Nosing: The steel nosing shall be of angle section ISA 100 x 100 conforming to

weldable structural steel as per IS:2062. The thickness of legs shall not be less than 12mm. The top face of the angle shall be provided with Bleeder holes of 12mm diameter spaced at maximum 100mm centre so as to ensure that there are no voids in the concrete beneath the angle.

10.6.2.2. Anchorage: The anchorage steel shall conform to IS:2062 or equivalent. The steel nosing shall be anchored to the deck by reinforcing bars or anchor plates cast in concrete or a combination of anchor plates and reinforcing bars, anchor plates and anchor loops. This shall be achieved by passing transverse bars through the loops or plates. The minimum thickness of anchor plates shall be 12mm. Total cross sectional area of bars on each side of the joint shall not be less than 1600sq mm per m length of the joint and the centre to centre spacing shall not exceed 250mm. The ultimate resistance of each anchorage shall not be less than 600 KN/m in any direction. Corrosion Protection: All steel section shall be protected against corrosion by hot dip galvanising or any other approved anticorrosive coating with a minimum thickness of 100micron.





10.6.2.3.Joint Seal The sealing element shall be a preformed continuous chloroprene or closed cell foam seal with high tear strength, insensitive to soil, gasoline and ozone. It shall have high resistance to ageing and ensure water tightness. The seal should be vulcanised in a single operation for the full length of the joint required for carriageway, kerbs and footpaths, if any. The seal shall cater for a horizontal movement up to 40mm and vertical movement of 3mm. The physical properties of chloroprene/closed cell foam sealing element shall conform to the following: (a) Chloroprene Seal

It shall be performed extruded multi-web cellular section of chloroprene of such a shape as to promote self-removal of foreign material during normal service operations. Chloroprene of joint seal shall conform to clause 915.1 of IRC:83 (Part-II) and satisfy the properties stipulated in Table 1 herein above strip seal element specifications of these specifications except in respect of the working movement range of the sealing element which shall be as specified in Cl G.2.4.1 above.

(b) Closed Cell Foam seal: It shall be of preformed non-extruded non cellular section made from low density closed cell, cross linked ethylene vinyl acetate, polyethylene copolymer that is physically brown using nitrogen. The material shall possess properties as indicated in the Table 2 below.

Table-2 Properties of Closed Cell Foam Seal

Property Special Value

(ii) Density 41.7 – 51.3 kg/cum

(iii) Compression set on 25 mm 50% compression samples (ASTM D 3575) for 22 hours at 230 C, 2 hour recovery; 13% set.

(iii) Working temperature -70 to +700C.

(iv) Water Temperature absorptions (total Immersion for 3 months) (ASTM3575)

0.09766 kg/sqm

(v) Tensile strength 0.8 MPa

(vi) Elongation at break (ASTM D 3575) 195+/-20%

10.6.2.4. Lubricant cum Adhesive: The type and application of material used in bonding the preformed joint seal to the steel nosing and concrete shall be as recommended by the manufacturer/supplier of the seal system.

10.6.3. Handling and Storage (i) The expansion joint material shall be handled with care and stored under cover. (ii) All joint materials and assemblies shall be protected from damage and assemblies

shall be supported to maintain true shape and alignment during transportation and storage.

10.6.4. Installation 10.6.4.1. The expansion joint shall be installed by the manufacturer/supplier or their authorised

representative, who will ensure compliance of specified installation procedure and instructions.

10.6.4.2. The dimension of the joint recess and the width of the gap shall conform to the approved drawing.

10.6.4.3. Anchoring steel shall be welded to the main reinforcement in the deck maintaining the level and alignment of the joint.

10.6.4.4. Concreting of pocket/recess shall be done with great care using proper mix conforming to same grade as that of the deck concrete but no less than M30 grade in any case. The water-cement ratio shall not be more than 0.40. If needed, suitable admixtures may be used to achieve the workability. The width of pocket shall not be less than 300mm on either side of the joint. Care shall also be taken to ensure efficient bonding between already cast/existing deck concrete and the concrete in the joint recess.

10.6.4.5. At the time of installation, joint shall be clean and dry and free from spalls and irregularities, which might impair a proper joint seal.

10.6.4.6. Concrete or metal surfaces shall be clean, free of rust, laitance, oils, dirt, dust or other deleterious materials.

10.6.4.7. The lubricant cum adhesive shall be applied to both faces of the joint and joint seal prior to installation in accordance with the manufacturer's instructions.





10.6.4.8. The joint seal shall be compressed to the specified thickness for the rated joint opening and ambient temperature at the time of installation, which shall be between +05 to +35 degree C.

10.6.4.9. The joint seal shall be installed without damage to the seal. Loose fitting or open joints shall not be permitted.

10.6.5. Acceptance Criteria 10.6.5.1. All steel elements shall be furnished with corrosion protection system. 10.6.5.2. For the joint seal the acceptance test shall conform to the requirements stipulated in

para above. The manufacturer/supplier of this type of joint shall produce a test certificate to this effect conducted in a recognized laboratory in India having NABL certification or abroad.

10.6.5.3. Prior to acceptance 25% of the completed and installed joints, subject to a minimum of one joint, shall be subjected to water tightness test. Water shall be continuously ponded along the entire length for a minimum period of 4 hours for a depth of 25mm above the highest point of deck. The width of ponding shall be at-least 50mm beyond the anchorage block of the joint on either side. The depth of water shall not fall below 25mm any time during the test. A close inspection of the underside of the joint shall not reveal any leakage.

10.6.6. Tests and Standards of Acceptance: The materials shall be tested in accordance with these specifications and shall meet the prescribed criteria. The manufacturer/supplier shall furnish the requisite certificates from the recognised testing laboratory of India having NABL certification or abroad. The work shall conform to these specifications and shall meet the prescribed standards of acceptance.

10.6.7. Mode of Measurement The measurement for expansion joints as a finished work shall be in running meters nearest to a centimetre.

10.6.8. Rates The contract unit rate shall include the cost of all materials (including cast–in-situ concrete), labour , equipment,cost of transportation (overseas as well as with in country), cost of testing including cost of test samples and other incidental charges for fixing the joints complete in all respects as per specifications. However the cost of covering plate over shear keys will be measured in MT and paid separately.

10.7. Railings 10.7.1. General

Prefabricated railing as per approved drawings & details shall be erected at site and shall extend all along the full length of the viaduct and as shown in drawing. Fixing arrangements with deck shall be incorporated as per approved design & drawings. Railing on viaduct shall not be constructed until the centering / supporting arrangement form work / supporting arrangement for the span has been released and the span is self-supporting. For concrete and steel, specifications of the items of controlled concrete and reinforcement mentioned under relevant specifications shall be applicable. Railing shall be carefully erected true to line and grade. Posts shall be vertical with a tolerance not exceeding 6 mm in 3 m. The pockets / blockouts left for posts shall be filled up with non-shrinkable mortar. All edges and corners shall be straight and finished to true line and level. Forms shall either be of single width boards/ plates or shall be lined with suitable materials duly approved by Engineer. Form joints in plain surface will not be permitted. All mouldings, panel work and level strips shall be constructed according to the details shown in the drawings.

10.7.2. Metal Railings 10.7.2.1. General

All complete steel/ aluminium railing elements, terminal sections, posts, and other fittings shall be of shape, size and designation of approved material and make as given in the item of work or as directed by Engineer. In case of steel railing all these elements shall be galvanised or painted with an approved paint. If galvanised, all elements of the railings shall be free from abrasions, rough or sharp edges, and shall not be kinked, twisted or bent. If straightening is necessary, it shall be done by methods approved by Engineer. Aluminium sections shall be of approved quality,and make and free from scratches, stains and discoloration.





The Contractor shall take every precaution against damage of the components during fixing in position. Damaged galvanized surfaces shall be cleaned and regalvanised. Special care shall be taken to prevent staining of all products, rust, mortar, etc. before it is put into use.

10.7.2.2. Fixing The railing shall be carefully adjusted prior to fixing in place to ensure proper matching at abutting joints, correct alignment and camber throughout their length. Fixing shall be strictly as per fixing details shown in the drawings or as directed by Engineer. If sections are not galvanised, railing shall be given one shop coat of paint and three coats of paint after erection. All necessary holes, chases, etc., required in fixing shall be made by the contractor and made good after installation, without any extra charge.

10.7.3. Cast-In-Situ Railings 10.7.3.1.The portion of the cement concrete railing or parapet which is to be cast in place shall

be constructed in accordance with the requirements for Cement Concrete described in the respective section of RCC. Forms shall either be of single width boards or shall be lined with suitable material duly approved by Engineer. Form joints in plane surfaces will not be permitted. All mouldings, panel work and bevel strips shall be constructed according to details shown on drawings. All corners in the finished work shall be true, sharp and clean - cut and shall be free from cracks, spalls or other defects.

10.7.4. Precast Railings Precast members for railings shall be of reinforced cement concrete to be constructed in accordance with the requirements of cement concrete described in respective sections of RCC and Pre-cast concrete. The precast members shall be removed from moulds as soon as practicable and shall be kept damp for a period of at least 14 days. During this period they shall be protected from sun and wind. Any precast member that becomes chipped, marred, or cracked before or during the process of erection and fixing shall be rejected.

10.7.5. Measurements for Payment Railings shall be measured as per BOQ as finished work.

10.7.6. Rate Contract unit rate shall include cost of all labour, materials, tools and plant required for doing the work complete in all respects in accordance with above specifications and as shown in the drawings or as directed by Engineer.





11 STRUCTURAL STEEL SPECIFICATIONS - PAINTING WORKS 11.1 General

• Scope of specification This Specification covers the scope of painting, methods for the surface preparation, application of paints and precautions to be taken for the painting of structural steel work. It covers the supply and delivery of all necessary materials, labour, scaffolding, tools, equipment and everything that is necessary for the job completion on schedule.

• Applicable Codes The following Specifications, Standards and Codes are included as part of this Specification. All standards and codes of practice referred to herein shall be the current editions during the currency of project including all applicable official amendments and revisions. In case of discrepancy between this Specification and those referred to herein, this specification shall govern. In case of discrepancy between Contract drawings and this specification, the Contract drawings shall govern.

a). IS: 102 (1962) : Ready Mixed Paint, Brushing, Red lead, Non Setting, Priming.

b). IS: 159 (1981) : Ready Mixed Paint, Brushing, Acid Resisting for Protection against Acid Fumes, Colour as Required.

c). IS: 384 (1979) : Brushes, Paints and Varnishes, Flat. d). IS: 487 (1985) : Brush, Paint and Varnish i) Oval Ferrule Bound ii) Round Ferrule Bound. e). IS: 958 (1975) : Temporary Corrosion Preventive Grease, Soft Film, Cold

Application. f). IS: 1153(1975): Temporary Corrosion Preventive, Fluid, Hard Film, Solvent

Deposited g). IS: 1477(1971): Code of Practice for Painting of Ferrous Metals in Building. Part I –Pretreatment Part II -Painting h). IS: 1674(1960): Temporary Corrosion Preventive Fluid, Soft Film, Solvent

Deposited. i). IS: 2074(1992): Ready Mixed Paints, Red Oxide -Zinc Chromate.

11.2 Products & Materials • Paint

1. All paint delivered to the fabrication shop shall be ready mixed, in original sealed containers, as packed by the paint manufacturers, and no thinners shall be permitted.

2. Paint shall be stirred frequently to keep the pigment in suspension • Storage of Paints

1. LAN paints shall be stored strictly in accordance with the requirements laid down by the paint manufacturers The storage area shall be well ventilated and protected from sparks, flame, direct exposure to sun or excessive heat, preferably located in an isolated room or in a separate building.

2. All paint containers shall be clearly labelled to show paint identification, date of manufacture, batch number, order number and special instructions in legible form. The containers shall be opened only at the time of use. Paints which have liveried, gelled or otherwise deteriorated during storage, shall not be used. Paints for which the shelf life specified by the supplier has expired shall not be used without inspection and approval by the Engineer-in-charge.

• Execution Paint System (High Performance Polysiloxane System) Sand blasting shall be carried out in accordance with IS: 1477

Painting work shall be carried out as follows: Description Surface

Fabrication Shop

External Surfaces Internal Surfaces





Surface Treatment

Abrasive Blast to SA2.5 (ISO 8501-1:1988). If oxidation occurs between blasting and application of paint, the surface shall be re blasted to the specified standard.

Abrasive Blast to cleaning to minimum SA 2.5 (Swedish Standard SIS 055900), Near-White blast cleaning.

1st Coat Providing & applying two components high build Zinc Rich Epoxy Primer Poly amide cured with minimum volume Solids of approximately 60% and a product weight of 2.50 kg/liter, minimum recoat interval of not more three hours at 25 deg C. The primer can be like Interzinc 52 of International Paints or approved equivalents. DFT-75 microns The primer shall be applied by Conventional/ Airless Spray only in Shop.

Surface Tolerant Epoxy with minimum Volume Solids of 80%, minimum overcoat interval of not more than 24 hours at 25 deg C and a product weight of 1.6kg/liter. The primer can be like Interseal 670 HS of international paints or approved equivalent DFT-150 microns

2no Coat Providing and applying two component Hi Build Epoxy intermediate Coat pigmented with Micaceous Iron oxide with approximate Volume Solids of 80%, minimum re-coat interval of 6 hours at 25 deg C and a product weight of approximately 2 kg/liter- like Intergard 475 HS of international paint or approved equivalent. DFT-150 microns The coat shall be applied by Conventional/Airless Spray only in Shop

Erection Site

Touch up Primer

Power Tool Cleaning to ST 2 standards followed by Surface Tolerant Epoxy with minimum Volume Solids of 80%,minimum overcoat interval of not more than 24 hours at 25 deg. C and a product weight of approximately 1.6kg/ litre like Interseal 670 HS of International Paints or approved equivalent. This primer shall be applied as touch up wherever damages have occurred on account of welding or Transportation & Erection.(Stripe Coat)-The DFT shall not be included in the Total DFT of System DFT-75 microns The primer shall be applied by Conventional/ Airless Spray only at site

Finish Paint Providing and applying two components Hi Gloss Acrylic Polysiloxane Finish Paint with approximate Volume solids of 70%, The product shall hard dry in not more than 5 hours at 25 deg C and 50% R.H. like Interfine 878 of International Paints or approved equivalent. This product should exhibit Gloss Retention following 3000 hours to U.V-A florescent lamp when checked as per ASTM-523 DFT-75 microns. The paint shall be applied by Conventional/ Airless Spray only at site.





The total Average DFT of External Surface is 375 microns The total Average DFT of Internal Surface is 150 microns DFT measurements should be done in accordance with Specifications SSPC PA 2. INTERNAL SURFACE =Internal surface are those which will become inaccessible after fabrication and are not prone to humidity and moisture from the atmosphere. EXTERNAL SURFACE = All other surfaces which are prone to humidity and moisture from the atmosphere. The following precautions must be taken:

a) After abrasive blast cleaning, the first undercoat (primer coat) should be applied well before surface deterioration.

b) Over coating intervals, application parameters shall conform to manufacturer’s instruction manual.

c) The DFT (Dry film thickness) shall be measured after completion of each coat. • Surface Preparation

All surfaces shall be cleaned of loose substances and foreign materials, e.g. dirt, rust, scale, oil, grease, welding flux etc so that the primer coat adheres to the original metal surface. The work shall be carried out in accordance with IS: 1477 (1971) (Part I). Any oil, grease, dust or foreign matter deposited on the surface after preparation shall be removed and care shall be taken to ensure that the surface is not contaminated with acids, alkalis or other corrosive chemicals. The primer coat shall be applied immediately after the surface preparation is completed. Before the application of any paint the surfaces to be treated shall be thoroughly cleaned freed from all scale, loose paint, rust and other deleterious matters. Oil and grease shall be removed from the surface by washing with solvents or with a detergent solution before blast cleaning operation of metal polish with metal pellets. If any traces of oil or grease remain after blasting they shall be removed by solvent cleaning and the area will be re-blasted thereafter. All welding areas shall be given special attention for removal of weld flux slag, weld metal splatter weld head oxides, weld flux fumes silvers and other foreign objects before blasting. If deemed necessary by the Engineer in Charge, acid washing and subsequent washing with clean water shall be used. Any rough seams will have to be ground and must be inspected and approved by the Engineer-in-charge before application of the coatings. All structural steel to be painted shall be cleaned using blast cleaning in accordance with SA 2 1/2 Near-White Blast cleaning (equivalent Swedish Standard SIS 055900). For SA 2 1/2 the profile should be in the range of 40-70 microns and shall be measured with comparator. Mill scale, rust and foreign matter shall be removed to the extent that the only traces remaining are light stains in the form of spots or stripes. Finally the surface shall be cleaned with a vacuum cleaner or clean dry compressed air. The blast cleaning shall produce a surface roughness complying with the one specified by the paint manufacturer for the primer concerned. If, cleaned surfaces are rusted or are contaminated with foreign material before painting is accomplished they shall be re-cleaned by the Contractor at his own expenses. Nothing extra shall be paid on this account.

• Mixing of paint All ingredients in a paint container shall be thoroughly mixed to break-up lumps and disperse pigments, before use and during application, to maintain homogeneity. All pigmented paints shall be strained after mixing to remove skins and other undesirable matters.

1. Dry pigments, pastes, tinting pastes and colours shall be mixed and/or made into paint so that all dry powders get wetted by vehicles and lumps and particles are uniformly dispersed.

2. Additives that are received separate such as curing agents, catalysts, hardeners etc. shall be added to the paint as per the manufacturer’s instructions. These shall be promptly used within the pot life specified by the manufacturers and unused paint thereafter shall be discarded.

3. Thinners shall not be used unless essential for proper application of the paint. Where thinners are used, they shall be added during the mixing





process and the type and quantity of thinner shall be in accordance with the instructions of paint manufacturer.

Paint Application General

• Paint shall be applied in accordance with the manufacturer recommendations, as supplemented by these Specifications. The work shall generally follow IS 1477 (1971) Part II. Prior approval of the Engineer-in-charge shall be taken in respect of all primers and/or paints, before their use in the works.

• Paint shall generally be applied by brushing except that spraying may be used for finish coats only when brushing may damage the prime coats. Roller coat or other method of paint application shall not be used unless specifically authorized.

• Paint shall not be applied when the ambient temperature is 10°C and below. For paints, which dry by chemical reaction the temperature, requirements specified by the manufacturer shall be met with. Also, paint shall not be applied in rain, wind, fog or at relative humidity of 80% and above or when the surface temperature is below dew point, resulting in condensation of moisture. Any wet paint exposed to damaging weather conditions shall be inspected after drying and the damaged area repainted after removal of the paint.

• Each coat of paint shall be continuous, free of pores and of even film thickness without thin spots. The film thickness shall not be so great as to detrimentally affect either the appearance or the service life of the paint.

• Each coat of paint shall be allowed to dry sufficiently before application of the next coat, to avoid damages such as lifting or loss of adhesion. Undercoats having glossy surface shall be roughened by mild sand papering to improve adhesion of subsequent coats. Successive coats of same colour shall be tinted. Whenever practical, to produce contrasts and helps in identifying the progress of the work.

Brush Application • Proper brushes shall be selected for a specific work piece. Round or oval brushes

which conform to IS: 487(1985) are better suited for irregular surfaces, whereas flat brushes which conform to IS: 384(1979) are convenient for large flat areas. The width of flat brushes shall not generally exceed 1.25mm.

• Paint shall be applied in short strokes depositing a uniform amount of paint in each stroke followed by brushing the paint into all surface irregularities, crevices and corners and finally smoothening or levelling the paint film with long and light strokes at about right angles to the first short strokes. All runs and sags shall be brushed out. The brush marks left in the applied paint shall be as few as practicable.

Spray Application • The spraying equipment shall be compatible with the paint material and provided

with necessary gauges and controls. The equipment shall be cleaned of dirt, dried paint, foreign matter and solvent before use.

• The paint shall be applied by holding the gun perpendicular to the surface at a suitable distance and moved in a pattern so as to ensure deposition of a uniform wet layer of paint. All runs and sags shall be brushed out immediately. Areas not accessible to spray shall be painted by brush or dauber.

• Water trap acceptable to Engineer-in-charge shall he furnished and installed on all equipment used in spray painting.

Shop Painting • The painting system specified in Table shall be followed. Surfaces, which will be

inaccessible after field assembly, shall receive the full-specified protective treatment before assembly.

• Surfaces in contact during shop assembly shall not be painted. Surfaces which cannot be painted but require protection shall be given a rust inhibitive grease conforming to IS:958-1975 or solvent deposited compound conforming to IS: 1153 (1975) or IS: 1674 (1960) or treated as specified in the drawing.

• The shop coats shall be continuous over all edges, including ends meant for jointing at site by bolting, except where the paint could be detrimental to bolting. In such cases, no paint shall be applied within 50mm, and the unprotected surface shall be given a coat of corrosion inhibitive compound.





• The unpainted area shall be cleaned prior to welding. The welded joint shall be cleaned and deslagged, and immediately after covered by the same paint as has been used for the remaining surface.

Painting at Site • Surfaces which will be inaccessible after site assembly shall receive the full

specified protective treatment before assembly. Surfaces which will be in contact after site assembly shall receive a coat of paint (in addition to any shop priming) and shall be brought together while the paint is still wet. Damaged or deteriorated paint surfaces shall be first made good with the same type of coat as the shop coat. Where steel has received a metal coating in the shop, this coating shall be completed on site so as to be continuous over any welds, bolts and site rivets. Specified protective treatment shall be completed after erection. Protection of Paint work

• The Contractor shall provide measures as necessary to prevent damage to the work and to other property or persons from all cleaning and painting operations. Paint or paint stains, which result in other unsightly appearance on surfaces not designated to be painted, shall be removed or obliterated by the contractor at his cost.

• All painted surfaces that in the opinion of the Engineer-in-charge are damaged in anyway, shall be repaired by the contractor at his cost with materials and to a condition equal to that of the requirements specified in these specifications.

• Upon painted surfaces that in the opinion of any other work that would cause dust, grease or foreign materials to be deposited upon the painted surfaces, the painted surfaces shall be thoroughly cleaned.

• The areas for high-strength bolts shall be protected by masking tape against undercoat application at the fabrication shop. Immediately prior to erection any rust in the paint area shall be removed by power wire brushing to a standard equivalent to SA3.

11.3 STRUCTURAL STEEL WORK-ERECTION 11.3.1 General 11.3.1.1Scope of Specifications

This Specification covers the delivery to site, storage and erection of structural steelwork at site. This includes plant and equipment requirements, installation of fabricated steel work in position and grouting all complete as per drawings, specifications and other provisions of the Contract.

11.3.1.2Submittals A. Ref. Specification for Structural Steelwork Erection-General (Clause 11.1.3 above) B. The contractor shall submit for approval a full description of his proposed erection

method including sequence of erection, use of temporary supports, connection details and erection camber diagram and design calculations covering various stages of erection process.

11.3.2 Execution 11.3.2.1Delivery, Storage & Handling

A. Before the shop assembly is dismantled, all members and sections shall be appropriately marked with paint or grooved with their identification numbers as detailed in shop drawings. The Contractor's representative shall be present during all the shop assemblies (wherever fabrication will be done), its dismantling and marking operations.

B. The Contractor shall deliver the fabricated structural steel materials to site, with all necessary field connection materials, in such sequence as will permit the most efficient and economical performance of the erection work. As per scheduled programme, the Engineer may, at his discretion prescribe or control the sequence of delivery of materials.

C. Fabricated parts shall be handled and stacked in such a way-that no damage is caused to the components. Measures shall be taken to minimize damage to the protective treatment on the steelwork. All work shall be protected from damage in transit. Particular care shall be taken to stiffen free ends, prevent permanent distortion and adequately protect all machined surfaces. All bolts, nuts, washers, screws, small plates and articles shall be suitably packed and identified.

11.3.2.2Plant and Equipment





All erection tools and plant & equipment proposed to be used shall be efficient, dependable duly certified by independent third party and in good working condition, and the suitability and adequacy of such shall be determined by the Engineer. The Contractor shall, in his technical proposal submittal, specify the plant and equipment proposed by him for erection of structural steelwork at Site.

11.3.2.3Storage Materials to be stored shall be placed on skids above the ground and shall be kept clean and properly drained

11.3.2.4Method and Sequence of Erection The method and sequence of erection shall have the prior approval of the Engineer. The contractor shall arrange for the most economic method and sequence consistent with the drawings and Specifications and such information as may be furnished to him prior to the execution of the Contract. The erection of steelwork shall be planned so as to ensure safe-working conditions at all times. The Contractor shall be solely responsible for enhancing the safety of his construction activities at Site.

11.3.2.5Assembly & Erection A. During erection, the members and sections shall be accurately assembled as shown

in the approved shop drawings and by following the match marks. The material shall be carefully handled so that no section will be bent, broken or otherwise damaged. Hammering which will damage or distort the members shall not be done. Bearing surfaces and surfaces to be in permanent contact shall be cleaned before the members are assembled. Splices and field connections shall have 50% of the holes filled with bolts and balance 50% with cylindrical erection pins before bolting with high-strength bolts. Filling-up bolts shall be of the same nominal diameter as the high-strength bolts, whereas the cylindrical erection pins shall be 1 mm or larger in diameter.

B. The correction of minor misfits involving harmless amounts of reaming, cutting and chipping will be considered a legitimate part of the erection. However, any error in the shop fabrication or deformation resulting from handling and transportation which prevents the proper assembling and fitting up of parts by the moderate use of drift pins or by a moderate amount of reaming and slight chipping or cutting, shall be reported immediately to the Engineer and his approval of the method of correction obtained. The contractor shall be responsible for all misfits, errors and injuries and shall make the necessary corrections and replacements.

C. The straightening of plates, angles, other shapes and built-up members, when permitted by the Engineer, shall be done by methods that will not produce fracture or other damages. Distorted members shall be straightened by mechanical means or, if approved by the Engineer, by the carefully planned and well supervised application of a limited amount of localized heat Each application will be subject to the approval of the Engineer.

D. The responsibility in respect of temporary bracing and guys shall rest with the Contractor until the structural steel is located, kept in plumb, levelled, aligned and grouted within the tolerances permitted under the Specifications, and the permanent bracing/framing system has been installed.

E. The temporary guys, braces, false work and cribbing shall not be the property of the Engineer/Employer and will be removed by the Contractor, with the approval of the Engineer, without any charge, once the permanent framing system has been installed to the satisfaction of the Engineer and when the temporary bracing, guys etc. can be removed without any potential danger/damage to the erected structure.

11.3.2.6Setting Out A. Positioning and levelling of all steelwork, keeping in plumb and placing of every

part of the structure, with accuracy, shall be in accordance with the approved drawings and to the satisfaction of the Engineer. The Contractor shall check the positions and levels of the anchor bolts etc. before concreting and ensure that they are properly secured against disturbance during pouring operations. The Contractor shall remain responsible for correct positioning and shall set proper screed bars to maintain proper level. No extra payment shall be made on this account.

B. No permanent field connections by bolting shall be carried out until proper alignment and guides for keeping in plumb have been attached.





11.3.2.7Field Bolting A. Bolts shall be inserted in such a way that they remain in position under gravity,

even before fixing the nut. Bolted parts shall fit solidly together when assembled and shall not be separated by gaskets or any other interposed compressible materials. When assembled all joint surfaces including those adjacent to the washers shall be free of scales. They shall be free of dirt, loose scales, burns and other defects that would prevent solid seating of the parts.

B. Holes for turned bolts to be inserted in the field shall be reamed in the field. All drilling and reaming for turned bolts shall be done only after the parts to be connected are assembled. Tolerances applicable in the fit of the bolts shall be in accordance with relevant Indian Standard Specifications.

C. All high tensile bolts shall be tightened to provide the required minimum bolt tension as per relevant Indian Standards / Specifications when all fasteners in the joint are tight,

D. The manufacture and use of high strength friction grip bolts shall comply with the requirements of IS.3757 (1985).

E. Load indicating bolts or washers may be used, subject to the approval of the Engineer.

11.3.2.8Holes, Cutting and Fitting A. No cutting of sections, flanges, webs, and cleats, rivets, bolts, welds etc. shall be

done unless specifically approved and / or instructed by the Engineer. B. The erector shall not cut, drill or otherwise alter the work of other trades, or his

own work to accommodate other trades, unless such work is clearly specified in the Contract, or directed by the Engineer. Wherever such work is specified, the Contractor shall obtain complete information as to size, location and number of alterations, prior to carrying out any work.

11.3.2.9Drifting A. Correction of minor misfits will be considered as permissible. For this, light drifting

may be used to draw holes together and drills shall be used to enlarge holes, as necessary, to make connections. Reaming, that weakens the member or makes it impossible to fill the holes properly or to adjust accurately after reaming, shall not be allowed

B. Any error in shop work which prevents the proper assembling and fitting of parts by moderate use of drift pins and reamers shall immediately be brought to the attention of the Engineer, and approval of the method of correction obtained. The use of gas cutting torches at the erection site is prohibited

11.3.2.10Grouting A. The positions to be grouted shall be cleaned thoroughly with compressed air jet and

wetted with water, and any accumulated water shall be removed. Grouting shall be carried out under expert supervision, takings care to avoid air locks. Edges shall be finished properly.

B. Whatever method of grouting is employed, the operation shall not be carried out until the steelwork has been finally aligned and levelled. Immediately before grouting, the space under steel is thoroughly cleaned. Where packings are to be left in place, they shall be placed such that they are completely covered with grout.

C. The grout to be used shall be Non-shrink grout conbextra GP-2 of M/S Fosroc or equivalent.

D. All steel in foundations shall be solidly encased in Portland Cement Concrete of minimum characteristic strength at 28 days as specified in the drawings, subject to a minimum of 35 N/mm2. A minimum cover of 100mm shall be provided to all steelwork where surrounding concrete is in contact with soil.

11.3.2.11 Inserts and Embedments Various steel inserts and embedments are required under the contract to be fabricated, positioned and secured firmly into place inside the formwork prior to concrete being poured. There are also requirements of jointing, threading, bolting and welding inserts and embedments of different concrete and structural steel elements in order to establish structural continuity and connection. Great care shall be exercised by the contractor in executing all aspects of the work related to inserts and embedments, including tolerances, so that the final assembly of the





concrete elements can meet satisfactorily the continuity and contiguity requirements intended in the structure.

11.3.2.12Painting after Erection A. The surfaces required to remain unpainted at shop, shall be given a protective

coating after the structure is erected, levelled, kept in plumb, aligned in its final position, and accepted by the Engineer. However, touch up painting, making good any damaged shop painting and completion of any unfinished portion of the shop coat shall be progressively carried out by the Contractor.

B. Painting shall not be done in frost or foggy weather, or when humidity is such as to cause condensation on the surfaces to be painted. Before, commencing painting of steel, which is delivered unpainted, all surfaces to be painted shall be dried and thoroughly cleaned from all loose scale and rust.

C. Surfaces, which will be inaccessible after field assembly, shall receive the full-specified protective treatment before assembly. Bolts and fabricated steel members, which are galvanised or otherwise treated, shall not be painted.

D. The contractor shall be responsible for any damage caused to other components of the structure including the substructure. In particular, he shall take all necessary precautions to minimise concrete splash onto completed steelwork or rust staining of concrete due to erected steel work and clean and/or repair all stains and other damages to completed work prior to tests on completion.

11.3.2.13Final cleaning up Upon completion of erection, and before final acceptance of the work by the Engineer, the Contractor shall remove, free of cost, all falsework, rubbish and all temporary works, resulting from or in connection with the performance of his work.

11.4 ADDITIONAL SPECIFICATIONS FOR LAUNCHING Truss launching for longer spans:

• Preferably no road traffic blocking will be used. Multiple day/night short blocks of 1h to 1h30 maximum are acceptable to ensure safety.

• Launching scheme shown in Tender drawings is suggestive only. Contractor has to provide his own proposed launching scheme and supporting calculations with the offer.

• Contractor has to provide principles of nose/truss connection details in tender. • Truss design composite girder requirements will govern over nose/ launching equipment

requirements. • Contractor will submit and get approval from Engineer of the detailed design of the full

launching equipment and scheme before starting the launching.

Contractor will coordinate with Nagpur Traffic Police and Engineer before and during the launching contractor to develop detailed traffic diversion scheme.

• Tentative allowable bearing pressure for temporary supports foundation concrete blocks shall be assumed at 10 tonnes/sqm.

• For location of storage and fabrication yard relevant clause of N.I.T shall be '-referred. Contractor shall indicate and justify in tender the proposed total needed yard area for the purpose.

• Any necessary precaution by proper and secure fixing shall be taken by the contractor to prevent the fall of any object onto the road below during the whole erection period.

• A minimum 15m •clear width (4 lanes) shall be kept during the whole construction period. These lanes can be obtained as 4 or 2+2.

11.5 MODE OF MEASUREMENT 1 The unit rate shall include the following:

i. Erection of fabricated parts (fabrication and transportation of various parts / components including HSFG bolts/nuts / washers from workshop to storage yard will be done by approved sub-contractors)

ii. Receiving, unloading and keeping in safe custody and upkeep of all fabricated parts including HSFG bolts/nuts / washers at storage yard.

jjj. Loading, transportation and unloading of all fabricated structural steel materials including HSFG bolts/nuts / washers from site storage yard to erection site, handling, assembling, bolting, welding if necessary and satisfactory installation of all fabricated structural steel materials in proper location according to approved erection drawings and/or as directed by the Engineer.





iv. Tightening of HSFG bolts for the field erection of fabricated parts. However supply of HSFG bolts and its compatible nuts and washers will be arranged / supplied at the storage yard by approved sub-contractor.

v. Preparation of complete detailed erection drawings and detailed calculation based on suggested erection sequence and design drawings as given by Engineer or alternative scheme proposed by contractor and approved by Engineer.

vi. Preparation of complete detailed fabrication drawings for all temporary structures such as temporary nose, staging, temporary support, bracing required for all permanent and temporary structures.

vii. All tools, plants and equipment I machinery viii. All other consumables including fuel and lubricants etc. x. All safety and protection arrangements to be made at site I storage yards for road

users, public, and workmen. 2 The payment for the erection work and above mentioned work will be Lump-sum. 3 The procurement and application of all coats of site paints on external surfaces after erection as specified will be measured in sqm and paid separately.





12 FIREPROOFING FOR STRUCTURAL STEEL 12.1 GENERAL 12.1.1 SUMMARY

Section Includes: Provide spray-applied standard fireproofing with primers, hard coats, sealers, and accessories as required for complete finished installation.

12.1.2 REFERENCE STANDARDS American Society for Testing and Materials (ASTM): 1. ASTM E84 Standard Test Method for Surface Burning Characteristics of Building

Materials. 2. ASTM E119 Standard Test Methods for Fire Tests of Building Construction and

Materials. 3. ASTM E 605 Standard Test Methods for Thickness and Density of Sprayed Fire-

Resistive Material Applied to Structural Members. 4. ASTM E 736 Cohesion/Adhesion of Sprayed Fire-Resistive Material Applied to

Structural Members. 5. ASTM E 859 Air Erosion of Sprayed Fire-Resistive Material Applied to Structural

Members. 6. ASTM E 761 Compressive Strength of Sprayed Fire-Resistive Material Applied to

Structural Members. 7. ASTM E 759 Effect of Deflection on Sprayed Fire-Resistive Material Applied to

Structural Members. 8. ASTM E 760 Effect of Impact on Bonding of Sprayed Fire Resistive Material Applied

to Structural Members. 9. ASTM E 937 Corrosion of Steel by Sprayed Fire Resistive Material Applied to

Structural Members. 10. British Standard (BS) 476: Fire tests on building materials and structures, Part

20:1987, Method for the determination of the fire resistance of elements of construction (general principles)

11. British Standard (BS) 476: Fire tests on building materials and structures, Part 21:1987 Methods for determination of the fire resistance of load-bearing elements of construction

12. British Standard (BS) 476: Part 4-11 Product Characteristics for Surface Spread of Flame, Non Combustibility tests.

13. International Standard Organisation (ISO) 834: Fire-resistance tests - Elements of building construction, Part 1 - 1999: General requirements

B. Underwriters Laboratories Inc. (UL): 1. Fire Resistance Directory. 2. Cementitious Mixture as identified by Underwriters Laboratories Inc. in latest

edition of UL Fire Resistance Directory under category CHPX, Spray-Applied Fire Resistive Material.

12.1.3 SYSTEM DESCRIPTION A. Performance Requirements: Provide fireproofing in density and thickness as required to achieve fire ratings for Type 1 Fire Resistive Construction.

1. Fire Resistance Ratings: Comply with required ratings based on tests in accordance with ASTM E119, BS 476 part 20 &21, AS 1530.3.

2. Dry Density: Density shall be in accordance with ASTM Standard E 605 or relevant BS standards. Minimum average density shall be in the range of 240-320 kg/m3, whichever is greater.

3. Deflection: Material shall not crack or delaminate from surface to which it is applied when tested in accordance with ASTM E 759, or Material Tested to BS476 Standards for Deflections up to L/30.

4. Bond Impact: Material subject to impact tests in accordance with ASTM E 760 shall not crack or delaminate from surface to which it is applied.

5. Bond Strength: Fireproofing, when tested in accordance with ASTM E 736, shall have minimum average bond strength of 9.6 kPa and minimum individual bond strength of 7.2 kPa and not less than 20 times fireproofing weight.

6. Air Erosion: Maximum allowable total weight loss of fireproofing material shall be .05 g/m2 when tested in accordance with ASTM E 859 or relevant BS standards.





7. Durability: The material shall be durable for a min time period of 50years and shall have a data of durability in no fire situations in various weather conditions and various corrosion resistance, deflections and vibration conditions over these years. The durability data should be from independent recognized testing laboratories.

8. Compressive Strength: Fireproofing shall not deform more than 10 percent when subjected to compressive forces of 57kPa when tested in accordance with ASTM E 761 or relevant BS standards.

9. Corrosion Resistance: Fireproofing applied to steel shall be tested in accordance with ASTM E 937 and shall not promote corrosion of steel.

10. Surface Burning Characteristics: Material shall exhibit following surface burning characteristics when tested in accordance with ASTM E 84 or BS 476 Part 4-11 for product tests:

a. Flame Spread: 25 or less. b. Smoke Developed: 25 or less. 11. Mold Resistance: Materials to show resistance to mold growth, ASTM C665 or shall

be classified as non-hazardous material. 12. Combustibility: Material shall be Non Combustible and tested to BS 476 Part 4-11.

Material shall have maximum total heat release of 20 MJ/m2 and a maximum 125 kW/m2 peak rate of heat release 600 seconds after insertion when tested in accordance with ASTM E 1354 or relevant BS standards at radiant heat flux of 75 kW/m2 with use of electric spark ignition. Sample shall be tested in horizontal orientation.

12.1.4 SUBMITTALS A. Product Data: Submit manufacturer's literature indicating characteristics,

performance, and limitation criteria of fireproofing. B. Thickness Schedule: Provide schedule indicating material to be used, building

elements to be protected with spray-applied fireproofing, hourly rating and material thickness provided and appropriate references

C. Samples: Submit samples of fireproofing, fireproofing with hard coat finish, and fire proofing with sealer. Size: Submit nominal 300mm by 300mm samples. Number: Submit minimum four samples, three of which will be retained by the Employer's Representative.

D. Test Reports: Submit manufacturer's certified laboratory test report indicating the compliance with performance requirements. 1. Submit fire test reports of fireproofing application to substrate similar to

conditions expected on Contract. 2. Submit reports of independent testing agencies indicating conformance to ASTM

E119 and ASTM E84 or BS 476 Part 4-11, and System Test To BS 476 Part 20& 21 and complying with ASTME 119.

E. Certificates: 1. Submit manufacturer certification indicating installer is approved or licensed by

manufacturer. 2. Submit manufacturer certification materials comply with The Contract and

applicable code requirements. 3. Submit Certificate of Approval from Taiwan Ministry of Interior.

F. Manufacturer Field Reports: Submit manufacturer's representative's field report and certification indicating system has been installed in accordance with manufacturer recommendations and installation instructions.

12.1.5 QUALITY ASSURANCE A. Manufacturer Qualifications: Firm with minimum five years successful experience

manufacturing products similar to those required for Contract. B. Installer Qualifications: Firm with minimum five years successful experience

installing products similar to those required for Contract in similar applications. 1. Installer shall be approved or licensed by manufacturer.

C. Regulatory Requirements: Comply with 1. Products, execution, and fireproofing thickness shall conform to applicable

code requirements for required fire resistance ratings.





D. Mockups: Provide mock-up area at reviewed without objection by the Employer'sRepresentative. Replace unsatisfactory mock-ups. Mock-up will be used as a standardfor judging acceptability of work on Contract. 1. Apply mock-up no less than two weeks before scheduled application.

E. Pre-lnstallation Meeting: Convene not less than one week prior to commencing work of this Section. 1. Require attendance of parties directly affecting work of this Section. 2. Review installation procedures and coordination required with related work.

12.1.6 DELIVERY, STORAGE, AND HANDLING A. Deliver products in original packaging. B. Store materials off the ground, under cover, and in dry location until ready for use.

1. Bags exposed to water before use are unacceptable and shall be discarded. 2. Use material prior to manufacturers listed expiration date where applicable.

12.1.7 SITE CONDITIONS A. Apply fireproofing only when temperature of substrate material, surrounding air,

and dew point are within manufacturer's specified range. B. Provide ventilation in enclosed areas to receive fireproofing during and 24 hours

after application to dry material. C. Provide temporary enclosures to prevent spray from contaminating air. D. Provide temporary barriers to prevent over spray.

12.2 PRODUCTS 12.2.1 MATERIALS

A. Fireproofing: Mill-mixed cementitious formulation for sprayed-on application meeting performance requirements specified and blended for even texture. 1. Manufacturers: Match Southwest Vermiculite Co., Inc./Type 5 Cementitious

Fireproofing; W.R. Grace/Monokote MK-6; Albi Manufacturing Division, Stanchem, Inc./Duraspray; Carboline Corp./Pyrolite I; Isolate Intemational/Cafco 300; LAF (India);. Lasarge (India); Keisca (India).

2. Fireproofing shall be tested to certify manufacturer's published bond strength for primed steel.

3. Provide fireproofing product that contains no asbestos. B. Adhesive/Bonding Agent: Manufacturer's standard material used as required to enhance

the bonding strength to substrate. C. Metal Lath or Wire Mesh: lath with galvanized finish to provide mechanical bond top

rimed steel structure. D. Water: Clean, Potable. E. Hard Coat: Provide manufacturer's standard hard-coat topping system or special hard

system for applications subject to abuse. F. Sealer: Provide manufacturer's standard material recommended for use on applications

of sprayed-on fireproofing exposed to exterior and high humidity, applied topping or integral system, Contractor's option.

12.2.2 MIXES A. Mixing water shall be clean, fresh, and suitable for consumption and free from such

amounts of mineral or organic substances as would affect the set of the fire proofing material.

B. Provide water with sufficient pressure and volume to meet fireproofing application schedule.

12.3 SOURCE QUALITY ASSURANCE A. Manufacturer's Field Service: Provide services of a factory-authorized technical service

representative to inspect and approve substrate before application and to instruct applicator on product and application method to be used for each substrate.

12.4 EXECUTION 12.4.1 EXAMINATION

A. Surfaces to receive spray-applied fireproofing shall be provided free of oil, grease, paints/primers, loose mill scale, dirt, or other foreign substances that may impair proper adhesion of fireproofing to substrate.

B. Where necessary to ensure bonding to substrate clean surfaces to receive fireproofing. 12.4.2 PREPARATION

A. Comply with fireproofing manufacturer recommendations for preparation of substrates to receive fireproofing.





B. Prior to application of fireproofing, apply bonding agent to concrete substrates to receive fireproofing and to other substrates where recommended by fireproofing manufacturer.

C. Allow other trades to install clips, hangers, support sleeves and other attachments required to penetrate fireproofing, prior to application of fireproofing material.

D. Complete fireproofing installation prior to installation of ducts, piping, equipment, and other suspended items. Coordinate with work of other Sections.

E. Allow completion of placing concrete on floor and roof decking prior to application of fire proofing to underside of steel deck and supporting beams and joists.

F. Complete roofing applications and roof mounted equipment installation prior to application of fireproofing to underside of roof decking and supporting beams and joists.

1. Prohibit roof traffic upon commencement of fireproofing and until fireproofing material is dry.

G. Protect permanently exposed walls, floors, and special surfaces: 1. Protect concrete, masonry, and other surfaces subject to overspray and that

will be exposed to view, with masking, drop cloths, and other coverings as required to prevent overspray from bonding to protected item.

H. Post appropriate cautionary signs in areas in contact with wet fireproofing material. I. Erect barriers to prevent entry by non-fireproofing workers into fireproofing spray

and mixing areas and other areas exposed to wet fireproofing material. 12.4.3 INSTALLATION

A. Install fireproofing in accordance with manufacturer recommendations and application instructions and in accordance with requirements of applicable codes and fire rating approval numbers and as required to meet required fire ratings. 1. Equipment and application procedures shall conform to material manufacturer's

application instructions. B. Apply fireproofing in sufficient thickness and density to achieve required fire

ratings. C. Apply fireproofing over substrate, building to required thickness with as many

passes or stages necessary to cover with monolithic blanket of uniform density and texture.

D. Hard Coat Application: Provide protective hard coat or hard system at surfaces subject to damage by abrasion and damage by vandalism.

E. Sealer Application: Provide exterior quality material or sealer at fireproofing exposed to exterior and to high humidity.

F. Perform patching and repairing of spray-applied fireproofing with same materials as required to match original fire ratings and appearance.

12.4.4 FIELD QUALITY ASSURANCE A. Site Tests: Provide site testing to ensure applied thickness and density meet fire

rating requirements and reviewed test reports. 1 Correct unacceptable work and pay for further testing required to prove acceptability of installation 2. Patch test areas as required to re-establish fireproofing integrity.

B. Inspection: Allow for independent field inspections as required by applicable authorities.

C. Manufacturer's Field Services: Provide services of a factory-authorized technical service representative to verify installation is in accordance with manufacturer recommendations and installation instructions.

12.4.5 CLEANING A. After completion of fireproofing work, remove application equipment. B. Remove excess and overspray, droppings, and debris. C. Remove fireproofing from materials and surfaces not required to be fireproofed.

1. Surfaces in exposed areas shall be left clean of fire proofing, surfaces in concealed areas shall be left in a scraped clean condition.

12.4.6 PROTECTION Protect applied fireproofing from damage by subsequent operations; repair damaged fireproofing before fireproofing is enclosed.





SN Item Description

1. 2 Layers Electrical Isolation Membrane

Heave duty, cold applied and self-adhesive membrane with minimum 200 micron 4 ply cross-laminated HDPE film and rubber bitumen compound - with manufacturer's standard primer suitable for the application

2 GRC Angle / Tee

Uncoated GRC angle with a volume resistivity of minimum 1.2 X 1010 ohm-cm, or equal and approved, 4.5 mm thick performed to filleted angle / tee shape as required. Angles and tee to be installed in standard lengths butt joint and fixed to structure by means of epoxy based adhesive or equivalent. Ensure all arises are smooth and unlikely to cause damage to the insulation membrane.

3. Isolation Sealant

Backer Rod Performed, compressible, resilient, non-staining, non-waxing, non-extruding strips of flexible plastic foam of size, shape and density to control sealant depth and otherwise contribute to producing optimum sealant performance. Backing materials to be compatible with joint substrates, sealant, primers and other joint filters; and are approved for applications indicated by manufacturer. Minimum volume resistivity 5 X 1010 ohm-cm.

Sealant Elastomeric one component, non-flammable RTV silicone rubber. Minimum volume resistivity 5 X 1010 ohm-cm. 1000mm x 10mm x 20 mm, sample test, wet 125 Mega Ohms. Size of joints related to resistivity test, preferred dimension 6mm.

4 Platform Floors / walls clad in floor tiles

Tie to be not less than 20mm thick and have a volume resistivity of 1 x 108 ohm-cm.

5 Isolation Grout Isolation grout to be not less than 10mm depth with minimum volume resistivity 2 x 108 ohm-cm.

6 Fixings Fixings to substrate to be resin / chemical anchors compatible with substrate / isolation membrane. And to have full isolation washers and caps to bolts. Minimum volume resistivity 5 x 101 ohm-cm.

7 Wire Mesh 2mm diameter wire in mesh sizes of 50 x 50 mm.





APPROVED MANUFACTURERS/SUPPLIERS All materials and products shall conform to the relevant standard specification, BIS codes and other relevant codes etc. and shall be of make as approved by Engineer. The list of approved makes for products and materials is given below. Other equivalent manufacturers may also be considered with prior approval of the Engineer, if found conforming to all standards. Such requests should be made with all documents to the Engineer at least 45 days before the material is required and any order shall be placed only after receiving the written approval of the Engineer.

List of Approved makes

S.No. Details of Materials/Products Manufacturer’s Name



– Architectural (Station)


PARTICULAR SPECIFICATION – ARCHITECTURAL AND SITE DEVELOPMENT (STATION)





1 GENERAL

1.1 The specifications for the architectural works shall be read in conjunction with other sections of these specifications and other tender documents for this Contract, MAHAPWD Specifications 2007-08 in addition to CPWD Specification 1996 and approvals, instructions given by the Engineer. The general requirements are described in Section 01 herein.

1.2 All proprietary material shall be of approved make and the type as stipulated. Lists of approved makes are given at the end of this book. It will be deemed that the contractor has priced the respective items on the basis of those approved makes. However, it shall be the prerogative of the owner to choose any particular make among the list as the most appropriate one and the contractor shall be bound to provide the same without any variation in the contract rate. The guarantees for various architectural finishes shall be stipulated under clause 1.5 of Special Specifications for this Contract.

1.3 The Contractor shall submit a comprehensive list of all proprietary articles and materials used in the works containing catalogue reference numbers, colour shades, etc. and the manufactures and or supplier's names, addresses and where appropriate, supplier’s names and addresses including a price list CIF to the site of works. This list in approved format shall be complete in all respects and shall be submitted together with the 'As-Built' drawings and operation and maintenance manuals.

1.4 Area statement, list of test materials and details of samples and mock-up required are enclosed vide Annexure A, B and C respectively.

Area Statement

S. No. Description Room size

Min. Area in sq.m

Round off Area in sq.m

Length Breadth

1. Station control room 6 6.25 37.5 40

2. Security 3.6 3 10.8 12

3. Ticketing office 6 3.5 21 25

4. Signalling equipment room 6 10 60 60

5. Telecom equipment room 6 7 42 45

6. UPS room 8.5 6 51 55

7. Store room 6 3.55 21.3 22

8. Mess room 3.6 3 10.8 12

9. Mens toilet 3.6 5.75 20.7 21

10. Ladies toilet 3.6 5.5 19.8 20

11. PWD Toilet 3.6 1.6 5.76 6

12. EFO 2.8 2.8 7.84 8

13. Auxiliary substation 20 12.5 250 250

14. Electrical and DB room - - 60 60

15. DG room - - - -

16. AC Compressor - - 7 7

17. Cleaners room - - - -

18. Solar panel control room - - 30 30

Notes: 1. No separate room for cleaners shall be provided. Spaces under staircase soffit shall be converted as cleaners’ room with partition walls 2. Station manager room shall be converted as security room 3. Solar panel control room area to be confirmed with solar panel consultant 4. DG and Sump Room Area - As proposed by MEP consultant





LIST OF TEST MATERIALS

Material Name of the test Field/ laboratory test

Min. Quantity of material required

Frequency of test/ sampling

Brick / Tile bricks/ Concrete block/ Aerocon Block

Efflorescence Water absorption Compressive Strength d) Dimensional Tolerance

Field Laboratory Laboratory Field

As desired by the Engineer - - 50,000 nos. as required by the Engineer.

20 bricks chosen at random for every 100,000 bricks for each brickfield.

Timber Moisture content (Oven drying method) b) Species

Laboratory Field

1 Cum As reqd. by the Engineer.

From each fresh lot or each 10 cum material one sample.

Flush shutters/ Plywood

Test for end immersion Test for glue adhesion

Laboratory Laboratory

11 Shutters As reqd. by the Engineer

Flooring Test for abrasion Hardening compound

- do - - do -

- do - - do-

Vitrified Tiles

a) Shape & Dimension b) Transverse strength c) Resistance to wear d) Water absorption

- do - - do - - do - - do -

- do - - do - - do - - do -

12 Nos./2000 nos. 6 nos./2000 nos. 6 nos./2000 nos. 8 nos./2000 nos.

Glazed tiles a) Water absorption b) Impact test

- do - - do -

3000 nos. As decided by the Engineer.

* *

Granite marble

Hardness test - do - - do - *

Fire Doors

Fire test Laboratory tested at CBRI

Specified fire rated.

1 Door selected randomly at site.

Steel doors a) Thickness of steel b) Sheets

Field/Lab. - do -

As specified. do –

1 Door

Aluminium Composition of Aluminium. Alloy b) Powder coating

Laboratory Field

As required by the Engineer

1 Sample

* To be decided by the Engineer or his representative in accordance with site conditions.





Major items of work for which samples and mock-ups shall be produced by the Contractor free of cost for approval by the Engineer-in-charge.

S.no Particulars of item Details of sample

1. All Marble, kotah stone and granite stone, sand stone and all other stone flooring, copings

30cm x 30cm size sample and mock-up of each type showing edge rounding, polishing, flamed textures, etc.

2. Mirror, Glass 15cm x 15cm size sample

3. Aluminium doors/windows, glazing

Complete assembly including anodising/powder coating/gaskets/accessories/sealants

4. Hardware Complete set of each type

5. Wall claddings stones Samples of 2m x 2m of each type of finish including cramps, etc.

6. Vacuum dewatering system floor One complete mock-up as required by Engineer in charge

7. Paints All types in various shades and sizes, as directed

8. Stone flooring, Vitrified tile with pattern

1m x 1m approx. laid sample

9. Waterproofing treatment Specialised agency and waterproofing system to be approved by Engineer-In-charge

10. Door frame and shutters Mock-up of each assembly of each type

11. Stone/ceramic jali & screen wall Sample and mock-up of each type

12. Roofing Sample and mock-up of each system

13. False floor Sample and mock-up of each system

14. Ceramic tiles on floors Samples and mock-ups as per the requirement of the Engineer-In-charge 15. PVC tile flooring

16. Acid resistant tile

17. Glass mosaic tiles and other wall tiles

Sample and mock-up 1m x 1m of each type also showing the skirting condition.

18. Structural steel work Mock-up of each element

19. False ceiling (All types) Panel of size 2m x 2m of each finish

20. Trims and corner protections Sample and mock-ups as per the requirement of the Engineer-In-charge

21. All types of railings Mock-up 2m long also showing all bends and turning conditions

22. All types of paving Samples and mock-ups as per the requirement of the Engineer-In-charge.

23. All types of kerbs Mock-ups as per the requirement of the Engineer-In-charge 24. Copings

25. Insulation Sample of glass wool insulation together with false ceiling.

26. Fire check doors Specialised agency and complete set including frame and accessories

27. Metal partitions Sample and mock-up as per requirement of the Engineer-in-charge

28. Treatments on expansion joints Sample on mock-up 1m length for each type

29. Rolling shutter Sample of lath

30. External finish Mock-up of 2m x 2m of each type

31. Any other finishing item Mock-ups as per the requirement of the Engineer In-charge

32 Glass blocks Samples and mock-ups as per the requirement of the Engineer-In-charge 33 Concrete designer Paving tiles

34 Aluminium Composite Panel

2 GENERAL The specifications for the architectural works shall be read in conjunction with other sections of these specifications and other tender documents for this Contract, MAHAPWD Specifications 2007-08 in addition to CPWD specifications 1996 and approvals, instructions given by the Engineer. The general requirements are described in Section 01 herein.





All proprietary material shall be of approved make and the type as stipulated. A list of approved makes is given at the end of this book. It will be deemed that the contractor has priced the respective items on the basis of those approved makes. However, it shall be the prerogative of the owner to choose any particular make among the list as the most appropriate one and the contractor shall be bound to provide the same without any variation in the contract rate. The Contractor shall submit a comprehensive list of all proprietary articles and materials used in the works containing catalogue reference numbers, colour shades, etc. and the manufactures and or supplier's names, addresses and where appropriate, supplier’s names and addresses including a price list CIF to the site of works. This list in approved format shall be complete in all respects and shall be submitted together with the 'As-Built' drawings and operation and maintenance manuals.

2.1 Brick Work 2.1.1 Quality

Bricks shall be of class designation 50 and conform to IS: 1077. Bricks shall be whole, sound, well burnt, and free from cracks, to ring when struck and not to crack or break when soaked in water regular in shape and uniform in size. They shall be of the best of description/class designation obtainable in the market, and of the best quality and color, and in every respect to be approved by the Engineer. Unless otherwise specified they shall be of F.P.S. Bricks of size 22.5 x 11.1 x 7.0 cm. No bricks to absorb water more than one fifth of their own weight when dry for use in load bearing walls. For bricks used in panel walls, the water absorption shall not exceed one fourth of their dry weight. Bricks to be thoroughly cleaned, well wetted or soaked in fresh water before being used on the work, and no broken bricks to be used except as closures. Specified brick quality shall be sampled as per IS: 5454-1978 and tested as per IS: 3495-1976. The bricks shall meet the criteria as per IS: 1077-1976 when tested as mentioned herein.

2.1.2 Brick Bats Brick bats required to be used shall be obtained from well-burnt bricks.

2.1.3 Dimensions Unless otherwise specified, they shall be of F.P.S. bricks of size 22.5 x 11.1 x 7.0 Cms.

2.2 Classification 2.2.1 Compressive strength

The bricks when tested in accordance with the procedure laid down in Annexure 11-A.2 shall have a minimum average compressive strength for various classes as given in Table 1 the compressive strength of any individual brick tested shall not fall below the minimum average compressive strength specified for the corresponding class of brick by more than 20%. In case compressive strength of any individual brick tested exceeds the upper limit specified in Table 1 for the corresponding class of bricks, the same shall be limited to upper limit of the class as specified in Table 1 for the purpose of calculating the average compressive strength.

CLASSIFICATION OF BRICKS Average compressive strength

Table 1

Class Designation

Average compressive strength

Not less than Less than

N/mm² (Kgf/cm²) N/mm² (Kgf/cm²)

10(100) 10 (100) 12.5 125

7.5(75) 7.5 (75) 10 100

(50) 5 (50) 7.5 75

(35) 3.5 (35) 5.0 50

2.2.2 Water Absorption The average water absorption of bricks when tested in accordance with the procedure laid down in Annexure 6-A.3 of MAHAPWD shall be not more than 20% by weight.

2.2.3 Efflorescence The rating of efflorescence of bricks when tested in accordance with the procedure laid in Annexure 6-A.4 of MAHAPWD shall be more than moderate.





The common burnt clay bricks shall be classified on the basis of their minimum compressive strength as given in the table 1.

2.3 Sampling For carrying out compressive strength, water absorption, and efflorescence and dimensional tests, the samples of the bricks shall be taken at random and samples thus shall be stored in a dry place until the tests are made.

2.3.1 Soaking of Bricks Bricks shall be soaked in clean water before use for a period at least 6 hours and until air bubbles ceases to come out. The soaked bricks shall be kept on wooden plank or brick platform to avoid earth being smeared on them. When the bricks are soaked they shall be removed from the tank sufficiently early so that at the time of laying they are skin- dry. Such soaked bricks shall be stacked on a clean place where they are not again spoiled by dirt earth etc. Note 1: The period of soaking be easily found at site by a field test in which the bricks are soaked in water for extent of water penetration. The least period that corresponds to complete soaking will be the one to be allowed for in construction works as decided by the Engineer In charge. Note 2: If the bricks are soaked for the required time in water that is frequently changed the soluble salt in the bricks will be leached out, and subsequently efflorescence will be reduced.

2.4 Mortar All brickwork shall be laid with specified mortar to be prepared in specified proportion described in the relevant items of Schedule of Quantities. It shall be of cement and coarse sand and shall be made in small quantities so as to be used up within 30 minutes. Then it shall be mixed to a sufficiently thick consistency as required by the Engineer. No left-over mortar shall be used. The proportion to be used shall be as specified in the relevant items.

2.5 Laying 2.5.1 General

Brickwork shall be carried out as per IS: 2212. Bricks shall be laid in English bond unless otherwise specified. Half or cut bricks shall not be used except when needed 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. a) 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 surface wetted. Bricks shall be laid on a full bed of mortar when laying each brick shall be properly wetted and set in position by gently pressing with the handle of a trowel. It inside face shall be buttered with mortar before the next brick is laid and pressed against it. Joints shall be fully filled and packed with mortar such that no hollow spaces are left inside the joints.

b) The walls shall be taken up truly in plumb or true to the required batter where specified. All courses shall be laid truly horizontal and vertical joints shall be truly vertical. Each course shall be perfectly straight horizontally and transverse. The walls shall be taken up truly plumb, if battered, the batter is to be truly maintained. The plumb of the brickwork in vertical walls shall be checked up at one metre interval. The bricks shall be laid with frogs upward. While laying brick shall be roughly bedded and flush in mortar and tapped into position with a wooden mallet and the superflus mortar is removed.

c) The brickwork shall be built in uniform layers. No part of the wall during its construction shall raise more than one metre above the general construction level.

All holes and openings left in brickwork shall be closed as directed by the Engineer. 2.5.2 Raking back of walls at angle

Walls of all structures shall be carried up regularly in all cases, leaving no part, one metre lower than another. If this cannot be adhered to, the brick work shall be racked back at an angle not more than 45 degrees so as to maintain a uniform and effectual bond, but raking back should not start within 60 centimetres of a corner.

2.5.3 Buttresses, counter forts, etc., In all cases returns, buttresses, counter forts etc., are to built up coarse by course carefully bound into main walls.





2.5.4 Junctions of walls At all angles forming the junction of any two walls, the brick shall, at each alternate course, be carried into each of the respective walls so as to thoroughly unit the work. The brickwork shall not be raised more than 14 courses per day.

2.5.5 Joints and finishing of joints Joint shall be restricted to 1.0 cms for brickwork with bricks of any class designation (unless any wider vertical joints up to 10 mm are necessary to give the required thickness of the wall). All bed joint shall be normal to that pressure upon them i.e. horizontal in vertical walls, radial in arches and at right angles to the face in battered retaining walls. The vertical joints in alternate courses shall come directly one over the other and shall be truly vertical. Care shall be taken that all joints are fully filled with mortar (proportion as specified in bill of quantities) well flushed up and in case where struck as the work proceeds. The joints in faces which are to be plastered or pointed shall be squarely racked out to a depth of 12 mm while the mortar is still green. The raked joints shall be well brushed to remove loose particles. After the work, the faces of the brickwork shall be cleaned with wire brush so as to remove any splash or mortar during the course of raising the brickwork. Before joining the brick work with new brickwork, old bricks surface shall be raked brushed, cleaned and soaked with water.

2.5.6 Fixtures to be provided All iron fixtures, pipes, conduits, drains, sleeves, bolts, holdfasts, of doors and windows and other inserts of services and all other trades of works etc., which are required to be built in walls, shall be embedded in cement mortar 1:3 (1cement: 3 sand) or in cement concrete 1:3:6 (1cement 3 sand: 6 coarse aggregate) as per requirements to suit site conditions in their correct position as the work proceeds. All brick works shall be provided with seismic reinforcements and restrains as directed by the Engineer. The reinforcements shall be measured and paid for separately.

2.5.7 Brick coping and Cut corners The top courses of all plinth, parapet, steps and top wall below RCC shall be laid with bricks on edge, unless specified otherwise. Care shall be taken that the bricks forming the top courses and ends of walls are properly radiated and keyed into position.

2.5.8 Protection Green work shall be protected from rain by suitable covering. The work shall also be suitably protected from damage, mortar dropping.

2.6 Curing The brickwork shall be constantly kept moist on all faces for a minimum period of seven days. Brickwork done during the day shall be suitably marked indicating the date on which the work is done so as of keep a watch on the curing period.

Brick work as it progresses shall be kept thoroughly well-watered on all faces for at least 10 days after completion. Proper watering cans with nozzles must be used for this purpose. The top of brickwork shall be left flooded at the close of the day by forming fillet of mortar 40mm high round the edges of top courses and filled with water.

2.7 Scaffolding Double scaffolding sufficiently safe and strong so as to withstand all loads likely to come upon it and having two sets of vertical supports shall be provided. When two sets of supports are not possible the inner end of the horizontal scaffolding pole shall rest in a hole provided in the header course only. Only one header for each pole shall be left out. Such holes however shall not be allowed in pillars less than one metre in width or immediately near the skew backs of arches, such holes shall be filled up immediately after removal of scaffolding properly.

2.8 Half Brick Works Bricks used for half brick walls shall be as specified above. It shall be laid in 1:4 cement mortar exactly in the same manner as described earlier except that all courses shall be laid with stretchers. The brickwork shall be reinforced with 2 No 6mm dia bar embedded at every third course for the whole length of the wall as per standard practice. No half brick walls, panels shall be greater than 8 square metres and any side larger than 3.0m. If the panel exceed the parameters mentioned above, the bricks shall be replaced by a RCC column of its same width at 3.0m intervals, which shall be further, tied to the structure by providing 100 x 200mm continuous RCC beams at the lintel level.

2.9 Hollow and solid concrete blocks





Shall conform to the requirements of IS: 2185. Specifications for hollow and solid concrete blocks except with regard to the mix of cement concrete and sizes of aggregates, which shall be as, indicted. Hollow blocks shall be sound, free from cracks, broken edges, honeycombing and other defects that would interfere with the proper placing of block or impair the strength or performance of construction.

2.9.1 Dimensions and tolerances Concrete masonry building units shall be made in sizes and shapes to fit different construction needs. They include stretcher, corner, double corner or pier, jamb, header, bull nose, and partition blocks, and concrete floor units. Concrete block-hollow (open or closed cavity) or solid shall be referred to by its nominal dimensions. The nominal dimensions of concrete blocks shall, as follows: Length: 400,500, or 600mm Height: 200 or 100mm Width: 50, 75, 100, 150, 200, 250 or 300mm In addition, blocks shall be manufactured in half-lengths of 200,250, and 300mm to correspond to the full length. The maximum variation in the length of the units shall be not more than +/-5mm and maximum variation in height and width of unit, not more than +/-3mm.

2.9.2 Classification Hollow (open and closed Cavity) concrete blocks The hollow (open and closed cavity) concrete blocks shall conform to the following three grades: Grade “A”: - These are used as load bearing units and shall have a minimum block –density of 1500kg per CuM. These shall be manufactured for minimum average compressive strength of 3.5,4.5,5.5, and 7.0 N/ Sqmm respectively at 28 days. Grade “B”: - These are also used as load bearing units and shall have a block density less than 1500 kg per CuM but not less than 1000 kg/CuM. These shall be manufactured for minimum average compressive strength of 2.0,3.0, and 5.0N per Sqmm respectively at 28 days. Grade “C”: - These are used as non-load bearing units and shall have a block density less than 500 Kgs per CuM but not less than 1000 Kgs per CuM. These shall be manufactured for minimum average compressive strength of 1.5 N per Sqmm at 28 days. Grade “D”: - The solid concrete blocks are used as load bearing units and shall have a block density less than 1800 Kgs per CuM. These shall be manufactured for minimum average compressive strengths of 4.0 and 5.0N per Sqmm respectively at 28 days. Physical requirements

a) Compressive strength The average crushing strength of eight blocks, when determined in accordance with IS: 2185 shall not less than as specified in Table below

Type

Grade

Density of block

Kg/CuM

Minimum average compressive

strength of units N/Sq.mm.

Minimum strength of

individual units N/Sq.mm

Hollow (open & closed cavity) load bearing unit

A (3.5) Not less than 1500

3.5 2.8

A (4.5) 4.5 3.6

A (5.5) Not less than 1500 but not less than 1000

5.5 4.4

A (7.0) 7.0 5.6

B (2.0) 2.0 1.6

B (3.0) 3.0 2.4

B (5.0) 5.0 4.0

Hollow (Open and closed cavity) no load bearing units

C (1.5) Less than 1500 but not less than 1000

1.5 1.2

Solid load D (5.0) Not less than 1800

5.0 4.0

Bearing Units D (4.0) 4.0 3.2





b) Drying Shrinkage: The drying shrinkage of the blocks (average of three blocks), when unrestrained, shall be determined in accordance with IS: 2185 and shall not be exceed 0.1 per cent.

c) Moisture Movement: The moisture movement (average of three blocks) when determined in the manner described in IS: 2185 shall not exceed 0.09 per cent.

d) Water Absorption: The water absorption (average of three blocks) when determined in the manner described in IS: 2185 shall not be more than 10 per cent by mass.

e) Face shells and webs shall increase in thickness from the bottom to the top of the unit. Depending upon the core moulded, used, the face shells and webs shall flare and tapered or straight tapered, the former providing a wider surface for mortar. The thickness of the face shell and web shell shall not be less than the values given in the MAHAPWD Specifications.

f) Subject to the tolerances specified in 2.9.1 the faces of masonry units shall be flat and rectangular, opposite face shall be parallel, and all arises shall be square. The bedding surfaces shall right angles to the faces of the blocks.

g) Blocks with special faces shall be manufactured and supplied as directed by the Engineer in charge.

2.9.3 Curing and drying The blocks shall be cured in an immersion tank or in a curing yard and shall be kept continuously moist for at least 14 days. When the blocks are cured in an immersion tank, the water of tank shall be changed at least every four days. After curing, the blocks shall be dried in shade before being used on the work. They shall be stacked with voids horizontal to facilitate through passages of air. The blocks shall be allowed to complete their initial shrinkage before they are laid in wall.

2.9.4 Construction of Masonry For single storeyed buildings, the hollow of blocks in foundations and basement masonry shall be filled up with sand and only the top foundation course shall be of solid blocks. But for two or more storied buildings, solid concrete blocks shall be used in foundation courses, plinth, and basement wall, unless otherwise indicated. If hollow blocks are used, their hollows shall be filled up with cement concrete 1:3:6 using 12.5mm nominal size aggregates.

2.9.5 Wetting of Blocks Blocks need not be wetted before or during lying in the walls. In case the climate conditions so require, the top and the sides of the blocks may only be slightly moisturised so as to prevent absorption of water from the mortar and ensure the development of the required bond with the mortar.

2.9.6 Laying Blocks shall be laid in mortar, as indicated and thoroughly bedded in mortar, spread over the entire top surface of the previous course of blocks to a uniform layer of not less than 10mm and not more than 12mm in thickness. All courses shall be laid truly horizontal and all vertical joints made truly vertical. Blocks shall break joints with those above and below for not less than quarter of their length. Precast half-length closures (and not cut from full size blocks) shall be used. For battered faces, bedding shall be at right angles to the face unless otherwise directed. Care shall be taken during the construction to see that edges of blocks are not damaged.

2.9.7 Provisions for Door and window frames A course of solid concrete block masonry shall be provided under door and window openings (or a 10 cms thick precast concrete sill block under windows). The solid course shall extend for at least 20 cms beyond the opening on either side. For Jambs of very large doors and windows either solid units are used, or the follows shall be filled in with concrete mix of 1:3:6 using 12.5 mm nominal size aggregates.

2.9.8 Provisions for Roof The course immediately below the roof slabs shall be built with solid blocks. The top of the roof course shall be finished smooth with a layer of cement and coarse sand mortar 1:3, 10mm thick and covered with a thick coat of white wash or crude oil, to ensure free movement of slab.

2.9.9 Intersecting walls When two walls meet or intersect and the courses are to be laid up at the same time, a true masonry bond between at least 50% of the units at the intersection is necessary. When such intersecting walls are laid up separately, pockets with 20mm maximum vertical





spacing shall be left in the first wall laid. The corresponding course of the second wall shall be built into these pockets.

2.9.10 Piers The top course of block in the pier shall be built in solid blocks. Hollow concrete block shall not be used for isolated piers, unless their hollow is specified to be filled with cement concrete. Fixtures, fittings, etc., shall be built into the masonry in cement and coarse sand mortar 1:3 while laying the blocks where possible. Hold fasts shall be built into the joints of the masonry during lying. Holes, chases, sleeves, openings, etc., of the required size and shape shall be formed in the masonry with special blocks while laying, for fixing pipes, service lines, passage of water etc., After service lines, pipes etc., are fixed, voids, left, if any, shall be filled up with cement concrete 1:3:6 (1 cement: 3 coarse sand: 6 stone aggregate 20mm nominal size) and neatly finished.

2.9.11 Finishes Rendering shall not be done to the walls when walls are wet. Joints for plastering or pointing as specified shall be raked to a depth of 12mm. Joints on internal faces, unless otherwise indicated, shall be raked for plastering. If the internal faces of masonry are not to be plastered the joints shall be finished flush as the work proceeds or pointed flush where so indicated. For other details please refer annexure 5-A.1 of MAHAPWD specification.

2.10 Aerocon Blocks 2.10.1 Aerocon Blocks - Shall conform to the requirements of IS: 2185(part –III) 1984 for

Specifications of AAC, IS 6041, 1985 (Reaffirmed 1990) Code of practice for construction of AAC block masonry and IS: 6441, 1072 (Part 1 to 4): Method of testing for AAC products, Aerocon blocks shall have a minimum compressive strength of 3N/mm^2, the normal dry density shall be in range of 551-600 Kg/m^3.Aerocon blocks should be appropriate for desired fire safety as required by Engineer. Aerocon blocks must have precise edges and shape.

Technical Data

Property Unit Value

Face Size (L x H) mm 600x 200

Thickness mm 75 100 125 150 200 230

Dry weight Kg 5.25 7

8.75 10.5 14

16.10

Compressive strength**mim N/Sqmm 3

Normal dry density** Kg/CuM 551-600

Thermal conductivity W/m-k 0.16

Sound reduction*** Db 37-42

Fire resistance-Load bearing Hrs 4

* Other thickness can be given on request. ** Conforming to IS 2185 (Part 3), 1985- grade 2 *** Depends upon thickness.

2.10.2 Laying The laying procedure is to be carried out as per the manufacturer’s specifications and directions using specified cement mortar proportion. The whole work is to be carried as per the instructions of the Engineer in charge.

2.11 Course Rubble stone masonry Is to be carried out as per Section 5 1.13 of MAHAPWD Specifications 2007-08 in additions to Clause 7.2 of CPWD Specifications 1996 as modified below.





Size stone masonry shall be of hard granite stones obtainable from approved quarry. The stones shall be wetted before they are used. Height of course, shall not be less than 15 cms, and all courses shall be of uniform height. Bond or through stones shall be provided not exceeding 1.50 mtrs apart in each course and shall be staggered., Bond stones shall be from the front to the back of the walls. For walls up to 60 cms thick and under bond stones shall be in one piece and for walls over 60 cms thick they shall either be in one piece (if available locally) or to be in the series of headers, each headed over lapping the adjoining one. Bond or through stones shall be marked as directly to enable their being detected even after having been built in position.

The interior filling shall be with flat-bedded stones laid in mortar. Chips, spalls that be used to avoid thick mortar joints and shall not exceed 10% of the quantity of stones.





3 WOOD WORK

3.1 Scope of Work 3.1.1 The work shall include providing wood work for the building for doors/windows, including

rough grounds, access panels in suspended ceilings, skirting’s, partitions and panelling, sills, counters, handrail, etc., and at any other location and situation as directed by the Engineer, including providing and installation of the hardware/ironmongery complete with finishing, including glazing work in accordance with the design, patterns, shapes, thickness, details all as shown on the approved drawings or as specified or as directed by the Engineer complete in all respects to give the quality of finished work as desired by and to the entire satisfaction of the Engineer. The work shall also include kiln seasoning, impregnation with preservatives and providing all plant, equipment and appliances required to complete the work.

3.1.1.1 The Contractor shall provide all the necessary wood working plant and equipment for use at site for sawing, planning,sanding,rebating, moulding, groove cutting, dovetailing, etc.

3.2 Materials 3.2.1 Plywood and Block Board 3.2.1.1 To Clauses 9.26.2.1 and 9.26.5 of MAHAPWD Specifications 2007-08 in additions to the

clauses of 9.2.2 and 9.2.5 of CPWD specifications 1996 add the following: Plywood shall be first quality, straight grained, light coloured with decorative teak ply, duroply (green marked) or approved equivalent and shall conform to IS: 1328. Plywood shall be BWR Grade. Block board shall be Grade I exterior grade.

3.2.1.2 One sample for every 100 sqm.or part thereof shall be taken and testing done as per IS: 303. All the samples tested shall meet the requirement of physical and mechanical properties of plywood boards.

3.3 Handling and Storing Materials 3.3.1 The contractor shall handle and store the materials such that any particular delivery or

consignment can be identified. Incompatible materials shall be stored separately. All boards shall be stacked on a clean, dry, area so that the materials shall not come in contact with water and extreme weather conditions. The contractor shall take steps to ensure that there is no danger of damages to the boards. The storage areas shall be clear of all other operations.

The storage, handling, lifting and transporting methods shall be subjected to the approval of the Engineer in charge.

3.4 Shop Drawings 3.4.1 Shop drawings with full size details shall be used for execution of the work. These

drawings shall be submitted to the Engineer. All work shall be carried out to the dimensions shown on the drawings. Shop drawings prepared by the Contractor shall show all details of joints, grooves, rebates, mouldings, etc., in all respects and tolerances, hardware, installation of ironmongery, etc., complete.

3.5 Architraves, Mouldings, Beadings, etc. 3.5.1 Architraves, mouldings, beadings shall be provided where called for and shall be of

superior quality teakwood, true to detail (shape, size as required), clear and sharply defined. They shall be securely fastened with finishing nails, screws well set and nail holes puttied with putty coloured to match the trim.

3.5.2 Flush Doors To Clause 9.35 of MAHAPWD Specifications 2007-08 in additions to clause 9.7 of CPWD specifications 1996 add the following.

All flush doors shall be Decorative Duroply (Green marked) or approved equivalent solid core type as specified to conform to IS: 2202 1991 Part -I. The finished thickness of the shutter shall be as shown on the drawings. Face veneers shall be of the pattern and colour approved by the Engineer. The veneers shall be of such thickness that the core construction is not apparent when the doors are decorated. An approved sample shall be deposited with the Engineer for reference.

3.5.3 The solid core shall be prepared from best quality seasoned and treated wood, of one species, having straight grains. The adhesive used for bonding/cross-bonding and





plywood, shall be Phenol Formaldehyde synthetic resin conforming to B.W.R. type specified in IS: 848.

3.5.4 All edges of the core shall be lipped internally with first class teak wood battens of 25mm minimum depth, glued and machine pressed along with the core. The lipping shall not be visible on faces. Samples for approval must have such lipping. The lipping shall not be measured and paid for separately but shall be deemed to be included in the rate for the door.

3.5.5 Flush doors shall have appropriate construction and the depth of top/bottom rail shall be adequate to take concealed door closers/floor springs. The depth of the lock rail shall be appropriate to take the mortise locks. The Contractor shall provide mock-up to demonstrate the above, for approval, before placing order for doors.

3.5.6 No defective door shall be accepted. 3.5.7 Doors having other face veneers or commercial veneers shall be as specified in the

Schedule of Quantities. 3.6 Prelaminated Particle Board 3.6.1 Particle Board shall conform to clause 9.26.3 and 9.26.4 of MAHAPWD specifications

2007-08 in addition to clause 9.2.3 and 9.2.4 of CPWD specifications 1996 and to be further modified as follows.

Prelaminated particleboard shall be of required thickness and shall conform to IS: 12823 exterior grades (Grade – I), type II. Panels made with prelaminated particleboard will have decorative and /or balancing white laminations on one / both sides of the panel. Adhesives used for the bonding shall be BWP synthetic resin conforming to IS: 848. Edges of Prelaminated particleboard shall be sealed with water resistant paint.

3.7 Plastic Laminates 12.7.1 Plastic laminates shall conform to IS: 2046 and shall also satisfy surface flame spread

test as per BS: 476 Part – 7. The laminates shall be 1.5mm thick, having a density of approximately 1383 kg/cum. Laminates shall be of plain matt of approved shade or textured of approved makes – Formica, Neoluxe, Bakelite Hylam or another approved equivalent.

3.8 Holdfasts and Anchor Fasteners 3.8.1 Holdfasts shall be as per IS: 7196. The number of holdfasts used for the doorframes shall

be as approved by the Engineer. 3.8.2 Expansion type anchor fasteners of approved size and manufacturer shall be used in

Locations where holdfasts are not allowed for fixing frames. 3.9 Ironmongery 3.9.1 All ironmongery shall be “Cavalier” or “Godrej” or equal approved make. Ironmongery

shall be made of 316 grade stainless steel, welded, cold drawn, solution annealed and pickled tubes as per ASTM-A-249’95a. The material shall conform to chemical composition and mechanical test as per standard.

3.9.2 All items of ironmongery and fittings, including door locks, hinges, hydraulic door closers,floor springs,sliding mechanism for sliding doors, floor stops, latches, coat hooks, etc.,together with their fixing accessories shall be procured and fixed by the Contractor. The contractor shall supply Catalogues and samples for approval of the Engineer & shall procure the same after obtaining the written approval of the Engineer.

3.10 Protection 3.10.1 The Contractor shall protect the work at all times from any damage. All finished work

including ironmongery shall be protected by polythene-wrap or other approved means. Doors,which are in constant use by work people,shall be kept open by means of a wedge.





4 STONE/GRANITE/MARBLE WORKS 4.1 Scope of Work

The term cladding shall mean veneering, lining, etc., and is used interchangeably with the same in this specification. The work shall include providing stone cladding to internal and external surfaces of the building including pergolas, posts and railings, chhajjas, fascia, sides of beams/lintels/ columns, soffits of slabs/beams/lintels/chhajjas, parapets, copings, balconies, sills, skirting, etc., whether to RCC or concrete or brick masonry or steel/metal all to design, patterns, shapes and thicknesses, details all as shown on the drawings or as specified or as directed by the Engineer, complete in all respects to give the quality of finished work as desired by and to the entire satisfaction of the Engineer. The work shall also include providing stone jalis, screens, balustrades, hand railings, etc.

4.2 Application Specifications All work shall be in accordance with the MAHAPWD Specifications 2007-08 in additions to CPWD specifications 1996 and as detailed in clause 5.1.18 of MAHAPWD in additions to 7.7 of CPWD specifications, Stone Veneering Work and sub-clause there under except as modified hereunder and as per the additional requirements given hereunder. Replace the first clause of 5.1.18 of MAHAPWD specifications 2007-08 in additions to 7.7 of CPWD specifications 1996 to read as follows. Stone cladding work using stone of thickness up to 20cm shall be treated as cladding work. The supply and installation of stone/granite/marble work shall be carried out by approved specialist agency experienced in the trade.

4.3 Materials 4.3.1 Stone

Replace clause 5.1.18.1 of MAHAPWD specifications 2007-08 / 7.7.1 of CPWD specifications 1996 to read as follows: Stones shall be as specified in 5.1.15.1 of MAHAPWD specifications 2007-08 in additions to 7.4.1 of CPWD specifications 1996. Stone shall also not contain crypt, crystalline silica or chart, mica and other deleterious materials like iron oxide, organic impurities etc. All stones used on one face of the work shall be from the same lot and shall be of uniform colour, quality, texture and grain. The Contractor shall provide stones to match approved samples and they shall comply with the following: a) Stone shall be machine cut into slabs of required thickness and to the required sizes.

Hard cutting shall be permitted only for curved pieces. b) Stone shall be properly seasoned and brought to the proper condition for use. c) Each worked stone shall be marked with the natural or quarry bed. d) Stone shall be supplied to the work site with all shaping and matching completed at

the masonry yard. The mortises, sinkings, perforations and notches for cramps, dowels and corbel plates for supporting ribs shall be carefully of stone behind a cramp mortise shall not be less than that specified.

e) Feature stones shall be marked for identification with drawings. f) Stone shall be finished, as specified, for all faces and returns etc., visible in the

finished work. g) Stone shall be worked truly square from all face lines for the full width and thickness. h) The minimum thickness of stone behind a cramp mortise shall not be less than that

specified. i) The compressive strength of common types of stones shall be as per Table – 2.1 and

the percentage of water absorption shall generally not exceed 5% for stones other than specified in Tabular form hereunder:

Table – 2.1

Type of Stone

Maximum Water Absorption Percentage by Weight

Minimum Compressive Strength kg/sqcm.

Granite 3.50 500

Lime Stone 0.15 200

Sand Stone 4.00 300

Marble 0.40 500

Note:





1. Test for compressive strength shall be carried out as laid down in IS: 1121(Part 1 2. Test for water absorption shall be carried out as laid down in IS: 1124.

4.3.2 Materials for Mortar a) Cement: Portland ordinary cement conforming to IS-269 and IS: 8112 shall be used.

The cement shall be non-staining to the stone for cladding. The total chloride content of the cement shall not exceed 0.05%.

b) White Cement: This shall conform to IS: 8042. The cement shall be non-staining to the stone for cladding.

c) Sand: Crushed stone shall be used to match the stonework and shall be graded to comply with the approved sample.

d) Coarse Sand: Shall conform to IS: 383 and shall be used for grouting of the stonework. e) Pigment: Shall conform to BS: 1014 or as per approved sample. f) Water: Shall conform to the requirements of IS: 456.

4.3.3 Ancillary Materials a) Compressible joint filler: Rigid Polyethylene foam or Rigid Polystyrene of 30 kg/cum

density filler sheet or strip. b) Metal Fixings: Dowels, cramps, ties and other metal fixings shall be fabricated from

austenitic stainless steel sheet, strip or plate conforming to ASTM A240 Gr. 304 or bar to ASTM A479 Gr. 304.

c) Expansion Bolts: Unless specified otherwise all expansion bolts/fasteners shall be fabricated from austenitic stainless steel sheet, strip or plate conforming to ASTM A240 Gr. 304 or bar to ASTM A479 Gr. 304 of approved make and design. The material of the bolt shall not cause any bimetallic corrosion with the reinforcing bars of the RCC/brickwork or with any other fixings or doors or windows or skylights etc.

4.3.4 Samples of Stone and Workmanship The contractor shall submit samples of the various stones, in sizes as required by the Engineer for approval. The stones shall be dressed as specified and directed by the Engineer. Decision of the Engineer in regard to the quality of the stone and workmanship shall be final and binding on the Contractor. On approval of the sample the Contractor shall submit three samples in sizes as may be indicated by the Engineer for keeping in the sample rooms. The Contractor shall ensure that the stone procured conforms to the approved samples. The Contractor shall prepare samples of workmanship with stones procured in the first lot, wherein the workmanship of each stone shall be checked and approved, including workmanship of mock-up of stone cladding of various elements. The above sample work shall be to establish besides quality of workmanship, the colour of the stone/mortar, finish, lines, levels, flatness, mortar type, sealing and the like and shall also include samples of fixings, sealant, silicone water repellent application etc. for approval. The work shall be carried out thereafter, wherein the approved mock-up shall form the minimum level of acceptable quality of workmanship.

4.4 Handling and Storing Materials The Contractor shall handle and store materials such that any particular delivery or consignment can be identified. Incompatible materials shall be stored separately. All stone shall be stacked on a clean, dry, free-draining surface, be prevented from contact with soil and shall be protected from extreme weather conditions. The stone shall be covered with non-staining tarpaulins and protected from rain. The Contractor shall take steps to ensure that there is no danger of breaking and damage to the stone. The storage areas shall be clear of all other operations. The Contractor shall prevent damage to the stone due to handling and transport. Handling shall be planned and reduced to a minimum. The storage, handling, lifting and transporting methods shall be subjected to the approval of the Engineer.

4.5 Dressing To clause 5.1.18.2 of MAHAPWD specifications 2007-08 in additions to 7.7.2 of CPWD specifications 1996 add the following: The edge of all stones at corners in junctions soffits, projecting etc. shall be fine chisel dressed with single or double rebate, as shown in the drawings or as directed. The edges of stones shall be fine chisel dressed with chamfer to form V-groove of 6mm or 8mm as shown in drawings or as directed. Machine cutting shall be resorted to instead of hand cutting for all stonework.





4.6 Mortar 4.6.1 Mix Proportions

Mortar for bedding and jointing work shall be made of 1 white cement with pigment (to give desired shade): 2 sand whereas for the grout/backing it shall be made of 1 cement (grey): 3 coarse sand or as specified in the Schedule of Quantities. Only one type of mortar shall be used for any one type of work. The proportions shall be adjusted to suit the sand.

4.6.2 Measuring and Mixing Mortar The materials shall be measured in separate gauge boxes. Mortar shall be mixed by machines. The materials shall be mixed sufficiently to obtain a uniform colour and consistency and to produce consistent batches of mortar. Water shall be added to produce mortar of desired workability.

4.7 Preparation for Stone Cladding Work During the preparation for the stone cladding work the Contractor shall consider the building as a whole while planning, detailing etc. and not treat any face or part thereof in isolation.

4.8 Matching Grains and Colour All stone shall be sorted for colour and grains before laying. The matching of grains/colour shall be carried out as approved by the Engineer. No variation of type of grain or colour shall be allowed in any one area.

4.9 Design and Pattern All work shall be laid as per design, detail, pattern, colours, sizes and dimensions given on the drawings. Any modifications and variations at site shall be reflected in adjustment in design as per the approval of the Engineer. All junctions, rebates, nosings, corners shall have square, curved or shaped mounting as desired and as shown on the drawings.

4.10 Service and Other Outlets Before any work is to be taken up, the sizes and the pattern of stones shall be laid out, together with the location of electrical, sanitary outlets and those of all other services and approval sought from the Engineer. Thereafter the stones shall be laid out on the floor showing pattern of grain, etc. and work shall only be carried out after obtaining approval of the Engineer.

4.11 Setting out The Contractor shall set out the stone cladding work so as to achieve the following: a) Establish a benchmark or datum at each floor level for setting out. b) Establish a vertical centre line in each plain area. c) Establish the positions of movement joints. d) Avoid or minimise unsightly cutting. e) Obtain truly horizontal joint lines. f) Where openings and other features occur the work shall be done as per the detailed

drawings or as directed by the Engineer. 4.12 Laying, Jointing and Grouting

The requirements given under clause 5.1.18.4 laying and 5.1.18.5 joints of MAHAPWD Specifications 2007-08 in additions to 7.7.4 laying and 7.7.5 joints of CPWD specifications 1996 to be superseded. It shall be superseded by the requirements given hereunder. The term laying shall be construed to include bedding where applicable.

4.13 Preliminary a) The Contractor shall undertake everything necessary to obtain a satisfactory bond

between the backgrounds, backings and finishing / cladding. Such work shall include but not be limited to the following:

b) Withholding application until curing and drying shrinkage of the structural backgrounds are achieved.

c) Fungicidal wash as approved to remove any organic growth. d) Removal of any greasy deposits by scrubbing with water and approved detergent. e) Final brushing to remove laitance, efflorescence or loose material. f) Wetting to reduce suction or to obtain uniformity of suction. g) On hard smooth surfaces (such as high grade concrete) or other surfaces presenting an

inadequate key, an adhesive of approved make and brand shall be applied as desired by Engineer in charge. The adhesive shall be applied by spraying and a thin coat of rendering done while the adhesive is still tacky. The provision of the bonding coat shall be deemed to be included in the rate for stonework.





4.14 Laying The stone cladding shall be conducted as follows: a) All stones and all jointing surfaces shall be made perfectly clean and free of dirt,

dust, grease or other deleterious material. b) The stones shall be soaked in clean water for at least 30 minutes. c) The rendering shall be damped just sufficiently to prevent excessive water absorption

from stones. d) The bedding surfaces of small units shall be well wetted and the units stood on a full

bed of mortar and tapped home. e) For every large or heavy units, a mortar bed shall be screeded level and full but kept

back 20mm from the face, before the stone is lowered into place. All joints shall be as completely filled as possible.

f) Only sufficient mortar shall be spread to bed each stone. g) It shall be ensured that there are no hard lumps in the mortar that could prevent

even bedding. h) Spacer dabs: Spacer dabs of appropriate mortar, or, for linings only, Plaster of Paris,

can be used to achieve resistance against inward movement of the stones and shall be of such consistency and size that they will be in permanent contact with the back of the stone cladding and the structure. It is essential that they do not bridge movement joints.

i) It shall be ensured that stones are flat and true by means of a straightedge. Adjustments if necessary shall be made within 10 minutes of fixing.

j) “V” groove of 3 to 5 mm is to be provided as per drawings. 4.15 Jointing

The stone shall be fixed with consistent joint width by correct use of spacer lugs so as to provide hairline (maximum 1 mm thick) joints. All joints shall be filled solid with 1:2 mortar (1 white cement with pigment: 2 sand) except for projecting members of overhanging cornices, which may be provided with hollow bedding where approved by the Engineer. Excess mortar shall be cleaned off immediately so that no mortar is visible on the face of the stone cladding. The stone cladding shall be properly cured for at least 7 days. All stones shall be secured to the backing by means of stainless steel cramps, pins, anchors, fasteners and expansion bolts as shown on the “Good for Construction” drawings and approved shop drawings and as directed by the Engineer. All cramps, dowels etc. shall be fitted and grouted solid as the work proceeds. The fixings shall be secured to concrete backings using expansion fasteners and bolts. No stone shall bridge the expansion / separation gap provided in the structure.

4.16 Grouting The stone joints shall be grouted as follows using 1:3 mortar (1 grey cement: 3 sand) mixed with an approved bonding agent in the proportion as recommended by the manufacturer / as instructed by the Engineer. a) Grouting shall be done at any time after the stones are firmly fixed but before any

dirt or contamination can enter the joints. b) Grouting materials shall be mixed to correct consistency and applied to as large an

area as can be worked before hardening commences. c) The grout shall be worked well into the joints / gaps between the stone and the

backing until they are completely filled. d) When the grout has set, the surplus material shall be removed and the joints tooled

to required profile. When the grout has hardened the stones shall be washed down with water and finally rubbed with a gunny cloth.

If any hollow grounding is detected by tapping the stones, these shall be taken out and re-laidd.

4.17 Attachments / Fixings The Contractor shall ensure that the number of fixings is in accordance with the specifications, drawings and directions of the Engineer, and that the fixings are properly made. Over tightening and bending of fixings to accommodate inaccuracies shall not be allowed. Each vertical unit shall be secured with two supports cum restraint purpose fixings and two restraint purpose fixings plus two pins. Each soffit unit shall be secured with four supports cum restraint fixings or as approved.





The accidental size of a cramp shall not be less than 25mm x 6mm and the pins used for securing adjacent stones shall not be less than 75mm long and 6mm diameter or as approved. The minimum thickness of stone behind a cramp mortise shall be 20mm and the minimum depth of slot for a corbel plate shall also be 20mm or as approved. The minimum depth of the expansion bolt to be considered for effective penetration shall be as given in Table below:

Table – 2.2

Type of Fixing Structural backing material

Concrete Brickwork

Load bearing 75mm 100mm

Soffit 75mm 100mm

Restraint 75mm 100mm

4.18 Movement Joints A clear 10mm wide horizontal joint may be provided at every floor level as shown on the “Good for Construction” drawings. The joints shall be formed using a shelf type stainless steel channel shaped or Z-shaped load bearing fixing. An approved sealant shall be provided in the movement joints. The joint for sealants shall be clean, dry rectangular and formed by means of a removable fillet (such as a premoulded joint filler) for the depth of the stone cladding and backing. The joint shall be later duly sealed after cleaning, drying and placing backing material. The treatment for the horizontal and vertical separation/expansion joints shall be done in a similar manner.

4.19 Ancillary Work 4.19.1 General 4.19.1.1 The Contractor shall:

(a) Form shall chases and fixings, etc. as the work proceeds. (b) Temporary support or brace items liable to distortion. (c) Cut into masonry subject to the following:

1. Delay cutting until the mortar has hardened. 2. Perform cuttings in a manner that involves minimal vibration to the wall.

4.19.2 Sills, Copings, Chhajjas, Projecting Units All sills, copings, chhajjas, projecting units and the like shall be provided with a rebate on the underside/soffit so as to provide a clean fit joint with the vertical facing stone. All sills, copings, chhajjas, projecting units and the like shall be provided with a drip mould cut in chase on one or both sides on the underside and the exposed edge shall be finished as specified or as shown in the drawings.

4.19.3 Circular Columns, Circular Walls Stone facing to circular column/walls shall be provided to match the profile of the columns/walls as specified. The height of the stone shall match that of the course shown in the drawings.

4.19.4 Stone Jalis/Screens/Ceramic Claustra Stone jalis/screens/ceramic claustra shall have a finished thickness as specified in the Good for Construction Drawings. Fine chiselled on all visible surfaces with rebates, grooves etc. as per design in straight rectangular / angular arched pattern all as specified or as directed, duly secured with stainless steel attachments/cement or glue jointed / fixings to RCC, concrete, brick masonry, steelwork etc.

4.19.5 Balustrades and Handrails Balustrades and handrails in rectangular and/or curved shape in plan and/or in elevation shall be fine chiselled on all visible surfaces and duly secured with stainless steel attachments / fixings to adjacent work.

4.20 Scaffolding All scaffolding as required shall be provided till the completion of work.

4.21 Tolerance for Finished Work The finished work shall conform to the following tolerance. (a) All the hairline joints shall be in perfect lines and levels. (b) Plumb.

i. In any 3m + 5mm ii. Maximum per floor + 10mm iii. Maximum for total height + 15mm





(c) Horizontal: i. In any 3m + 5mm ii. Maximum for total length + 10mm

4.22 Cleaning, Completion and Mock-up On completion of the first area of stone cladding, once it is duly cured and dried the Engineer-in-Charge shall examine the same to ascertain whether the quality of workmanship and finish is as desired. If the quality is accepted by the Engineer-in-Charge as the desired finish the same area shall be cleaned of all dust and other deposits by washing together with detergent or other admixtures, with the approval of the Engineer. Upon completely drying, it shall be finished with an application of silicone water repellent solution to seal the surface. Refer specifications for silicone water repellent solution. This area of stone work shall be retained as a sample of finished stonework, wherein the effects of weather, movement and other conditions shall be reviewed over a period not exceeding one month and the effects if found leading to unsatisfactory work, shall be remedied by the Contractor, until a satisfactory sample of finished work is accepted. All subsequent work shall thereafter be completed to the standard and quality as approved for the above mock-up. In case any portion is not done to the desired quality the same shall be deemed to be rejected and shall be removed and replaced at no extra cost.

4.23 Acceptance Criteria 4.23.1 Acceptance of Work at Intermediate Stage

The work executed on any day shall be checked at the end of that day or the next day before commencement of further work. Any work found to be of acceptance quality or not in accordance with the specification should be rejected, removed and replaced before proceeding with further work. Any stones, duly fixed, which are found to have tolerance for surface fine chisel work beyond the limits specified, may be allowed to be chiselled in place to achieve the desired quality of workmanship but acceptance shall be at the sole discretion of the Engineer. This shall not be construed as a means of correcting lines and levels of the joints. Any stones found to have variation in colour with respect to the majority of the stonework shall be removed and replaced, before any further work is taken up.

4.23.2 Final Acceptance of Work Various stages of approval are required to be met by the Contractor. Regardless of the acceptance of work at intermediate stages, the final acceptance shall only be accorded once the entire work is complete in one area of the building; after all other works as per this Contract have also been duly completed and accepted. The Contractor shall ensure that the stone work is so constructed that it prevents rain water from reaching its inside surface and that rainwater falling or running down its external surface does not cause permanent or significant temporary deterioration in its performances. All units and joints between units shall be designed to prevent ingress of water by capillary. The Contractor shall ensure that the risk of attack or infestation by micro-organisms, fungi, insects and other vermin is minimal and also that there is no risk of ingress of vermin into the building.

4.24 Protection The Contractor shall protect all work until handing over. The lower courses shall be protected with heavy polyethylene sheeting, not less than 1000gm/sqm, whilst work is in progress at higher elevations. All cement slurry and droppings shall be washed of daily during work above.

4.25 Shop Drawings The shop drawings shall be prepared on the basis of the “Good for Construction” drawings issued by the Engineer. The shop drawings shall inter alia show the location and type of all attachments. Site variations shall be taken into account while preparing the shop drawings.

4.26 Marble Works 4.26.1 Scope of Work

The work shall include providing prepolished marble for the building in walls, columns, sills, jambs, sides of beams / lintels / columns, soffits of slabs / beams / lintels / chhajjas, façades, floors, staircases, parapets, copings, balconies, jails, skirting, counters, up stands, bands in interior / exterior works and in any other locations and situations, whether to RCC or concrete or brick masonry or steel / metal, all to design, patterns,





shapes and thickness, to details as shown on the “Good for Construction” drawings or as specified or as directed by the Engineer complete in all respects to give the quality of finished work as desired by and to the entire satisfaction of the Engineer.

4.26.2 Applicable Specifications All work shall be done in accordance with section 5.2 of MAHAPWD Specifications 2007-08 in additions to section 8 of CPWD specifications 1996 except as modified hereunder and as per additional requirements given hereunder.

4.26.3 Materials To Section 5.2 of MAHAPWD specifications 2007-08 in additions to Section 8 of CPWD Specifications 2007-08, add the following. For all Marble Works with the following: additional requirements / amendments (a) All stone shall be supplied prepolished, duly table rubbed and polished at the

Contractor’s work, using cutting and polishing stones of different grades (No. 60, 120, 220 and 320) and latter cleaned with oxalic acid applied at 33 mg/sqm. So as to give a plane, true and high-quality mirror polished smooth, even, unwrapped surfaces with square cut edges. In additional to the classification given in clause 5.2.1 of MAHAPWD specifications 2007-08 and clause 8.1 of CPWD Specifications 1996 further classification shall be as mentioned below:

(a) White Indo-Italian marble, selected without pista predominantly white, having light, green grain / brown grain, no blotches or pista.

(b) Rajnagar white, spotless white. (c) Udaipur dark green marble from Khetan mines, without white spots or patches or

black patches. Clause 4.3.2, 4.3.3, 4.3.4, 4.4 shall apply for marble work. All joints in marble work shall either be fit joints or with a V-Groove of 3 mm to 5mm as shown in the Good for Construction Drawings or as directed by the Engineer-in-Charge.

4.26.4 Mortar Clause 4.6 shall apply for marble work.

4.26.5 Preparation for Marble Work Clause 4.7 shall apply for marble work.

4.26.6 Matching Grains and Colour Clause 4.8 shall apply for marble work.

4.26.7 Design and Pattern Clause 4.9 shall apply for marble work.

4.26.8 Service and Other Outlets Clause 4.10 shall apply for marble work.

4.26.9 Marble work Table Rubbed and Polished (Plain Work) 4.26.9.1 Dressing and Rubbing

Replace first Para of clause 5.2.5 of MAHAPWD specifications 2007-08 and Para of clause 8.5.1 of CPWD Specifications 1996 by the following.

(a) Every stone shall be machine cut to the required size and shape, free from waviness and to give truly vertical, horizontal, radial or circular joints as required. All visible angles and edges shall be true, square and free from any chippings. The surfaces of the stones coming in contact with backing shall not be polished.

4.26.10 Laying In clause 5.2.5.3 of MAHAPWD specifications 2007-08 and in clause 8.5.3 of CPWD Specifications 1996 add the following. In case of light coloured stones, the back of the stone shall be buttered with white cement or white cement with pigment as required so as to enhance its appearance aesthetically.

4.26.11 Finishing After the marble work is laid the excess mortar shall be cleaned off immediately so that no mortar is visible on the face of the marble work. Curing shall be done for seven days. The work shall then be dusted over with oxalic acid at the rage of 33 gm/sqm. Sprinkled with water and rubbed hard with a namdah block (pad of woollen rags). The following day the marble work shall be wiped with a moist rag and dried with a soft cloth and finished clean.

4.26.12 Waxing not used 4.26.12.1 Cleaning, Completion and Mock-up





Clauses 4.22 shall apply for marble work. 4.26.13 Acceptance Criteria

Acceptance of work at intermediate stage. Clause 4.23.1 shall apply for marble work. The marble work shall be deemed to be acceptable only if the quality of finish desired by the Engineer is achieved. In case the prepolished work is not to be correct lines and levels the Contractor shall rectify the same by replacing the defective pieces or by repolishing the work in situ at no extra cost.

4.26.14 Final Acceptance of Work Clause 4.23.2 shall apply for marble work.

4.27 Marble work in Wall Lining etc. (Veneer work) 4.27.1 General

All clauses given under Stonework Cladding of these specifications shall apply to Marble Veneer work also in so far as they apply to marble work in wall lining etc. (Veneer work). However, the surface finish shall be as specified or as directed by the Engineer-in-Charge. All clauses under 5.2.6 of MAHAPWD specifications 2007-08 and clause 8.6 of CPWD Specifications 1996 shall apply except for clause 5.2.6.3, 5.2.6.6 and 5.2.6.7 of MAHAPWD specifications 2007-08 and clauses 8.6.3, 8.6.6 and 8.6.7 of CPWD specifications 1996 respectively, which shall be replaced as given hereinafter. Add the following to the clause 4.12 for laying. (a) In case of light coloured marble stones for veneering/cladding the back of the stone

shall be buttered with white cement/white cement with pigment so as to enhance its appearance aesthetically.

4.27.2 Joints Clause 5.2.6.3 of MAHAPWD Specifications 2007-08 and clause 8.6.3 Of CPWD Specifications 1996 shall not apply. All jointing shall be as for stonework.

4.27.3 Tolerances All work shall be done so that all the joints are hairline fit and are to perfect lines and levels. Also refer Stonework.

4.28 Marble Stone Flooring and Marble Stones in Steps and Skirting All the relevant clauses under Marble Work as given above shall apply. The allowance provided for the total thickness of the floor finish over the RCC slabs is 75mm. The base shall be screeded with concrete to make up the levels, for provision of the finishing materials and the specified thickness of mortar. The concrete screed for the base shall be measured and paid for separately. Before commencement of flooring work all the joints of the brickwork shall be raked open to provide good key for the base coat of the plaster. Nothing extra shall be paid for raking the joints. The thickness specified for stonework shall be with a tolerance of + 2mm. However, once one thickness is established or adopted the same shall be followed throughout for the rest of the work.

4.29 Dressing Replace the clause 14.19.1 of MAHAPWD specifications 2007-08 and clause 11.19.1 of CPWD Specifications 1996 by clause 4.26.9.1 of this specification.

4.30 Laying Clause 14.19.3 of MAHAPWD Specifications 2007-08 and in additions to 11.19.3 of CPWD Specifications 1996 shall apply to the extent it is applicable to laying of prepolished marble slabs. The base mortar, comprising Portland cement and coarse sand of mix as specified or directed by the Engineer, shall be laid over the area to be tiled, well compacted and levelled. Thereafter marble shall be laid with a floating coat of white cement slurry with pigment. In specific areas and where directed the marble shall be laid to proper slopes as shown on the drawings.

4.31 Granite Works 4.31.1 General

All the clauses as given under marble work shall apply except that the classification for granite shall be as given below.

a) Red granite – Karnataka. b) Multi-colour granite – Andhra Pradesh c) Grey granite – Karnataka





d) Blue lavender granite – Orissa e) Paradiso granite – Andhra Pradesh f) Hassan green granite – Karnataka g) Black granite – Karnataka h) Raw silk i) Sadharhalli j) Kota Stone k) Cuddapa l) Sira 4.31.2 Finishes for Granite Work

The finishes for granite work shall be either mirror polished, semi-polished (honned finished) or flamed as specified or as directed by the Engineer-ion-Charge.

4.31.3 Flamed finished Granite Work All flamed granite work shall be cleaned with a solution of oxalic acid applied at the rate of 33 gm/sqm. So as to give clear, textured and even surface.

4.31.4 Waxing Granite work shall not be wax polished after finishing.

4.31.5 “V” grooves 5 “V” grooves of 3 to 5mm shall be provided as per drawings.





5 FLOORING 5.1 Scope of Work

The work shall include providing floor finishes for the building all as shown on the drawings or as specified or as directed by the Engineer-in-Charge complete in all respects to give the quality of finished work as desired by and to the entire satisfaction of the Engineer-in-Charge. The work shall be carried out under the supervision of the manufacturer/specialist sub-contractor who shall be appointed only after prior approval of the Engineer-in-Charge.

5.2 Applicable Specifications All work shall generally be in accordance with the section 14 of MAHAPWD specifications 2007-08 in addition to CPWD Specification 96.

5.3 Vinyl Tiles/Sheet Flooring These shall conform to IS: 3462 and BS: 3261 Part-1, Type-B or equivalent European standard norms. These shall be as made by INARCO (Armstrong) or Tarkett or Krishna Vinyl or approved equivalent. The tile/sheet shall be of thickness as specified in the Schedule of Quantities. 2mm thick tiles/sheet weigh not less than 3.8 kg/sqm and 3.0mm thick tiles shall weigh not less than 6.08 kg/sqm. The flooring shall satisfy Class 1 surface spread of flame to BS: 476, Part-7 class 1. The flooring shall be laid on a stable, clean, smooth, level, even and dry sub-base. The sub-base shall be free from oil, grease and dust. The tiles/sheet shall be bonded to the sub-base using an adhesive as recommended by the tile/sheet manufacturer. Lying shall also be done as per the instructions given by the manufacturer and as directed by the Engineer-in-Charge. The moisture content in the sub-base shall not exceed 3% as measured by the Calcium Carbide Hygrometer procedure or 5% by the normal Protimeter. Tiles shall not be laid when the ambient room temperature is less than 18 Deg.C or more than 35 Deg.C IS: 5318 shall also be applied.

5.4 Cavity Floor Type “A” These shall be as made by Hewetson or approved equivalent.

5.4.1 General Flooring is laid with floor panels as specified. It shall be laid on raised framework consisting of pedestal and strings forming laid base finished evenly and smooth. Cavity flooring shall be of approved proprietary make, fully removable, fire resistant floor system and shall be installed by an approved specialist agency. Cavity floor shall be of modular construction having modules of panel dimension as specified/detailed in drawing. The construction method will give complete lateral restraint. There shall not be any gap in the panel joints and each panel shall be removable separately without disturbing adjacent panels. The panels shall be supported on all four edges and capable of sustaining a point load of 4.0KN on 25 sqmm on any part of the panel and uniformly distributed load of 25KN per Sqm with a deflection of not more than 2 mm. Panels will not rock on their supports and tolerances in level between top surfaces of adjacent panels shall not be more than 1 mm. The floor panels shall be leveled to a tolerance not more than 3 mm in 12.0 meters. All exposed steel parts shall be galvanized.

5.4.2 Pedestal Pedestals shall be made out of 20/25 mm dia mild steel zinc electroplated with chromate passivation welded with 100 mm x 100 mm x 8 mm thick base plate with top head attachment made out of pressure die cast zinc Aluminium alloy in shape, thickness and size as per details. The top head attachment shall be adjusted by means of check nuts movable up and down for level adjustment. The pedestal shall have level adjustment of 25 mm up and down for leveling. Pedestal shall be fixed firmly to the floor at 600 mm c/c both ways with Araldite or COACM screw.

5.4.3 Supporting Frame Work Stringers shall be of pressed cold rolled steel channel sections (zinc electroplate) with chromate passivation) and of size 40 mm x 40 mm x 3.15 mm thickness shall be of fixed on the top head attachment in both directions to form grid frame work of 600 mm x 600 mm true to level and alignment to support the false floor panels along all edges.

5.4.4 Floor Panels The floor panels will be generally square of sizes 300mm x 300mm, 600mm x 600mm or 900mm x 900mm made of 31 mm thick high-density Particle Board or approved equivalent faced on top with 2 mm thick fire retarded flooring grade F.R.F.G. or approved equivalent laminate or approved Antistatic Vinyl flooring tiles as required. The floor panel will be laminated on the underside with 0.05 mm thick galvanized steel foil. The edges of panels shall have lipping of hard PVC fixed with adhesives. The finished panels shall be in perfect





size, shape, alignment, free from any undulation/warping and properly numbered and directional arrow marked on the underside for identification. The floor panels and stringers shall be completely removable and shall remain in position without screwing or bolting. The joints between finished floor panels shall be airtight. The floor panels shall be suitable for cutting whenever required for providing suitable outlets for cables, etc. The panels shall be removable by pulling upward with a suction device to be provided.

5.4.5 Tolerance (a) Thickness : + 2.5 percent (b) Width/Length

i. 300mm square panel : + 0.4mm ii. 600mm square panel : + 0.6mm iii. 900mm square panel : + 0.8mm

5.4.6 Laying and Fixing a) Before commencing the laying operations, the sub floor shall be examined for

evenness. The floor shall then be cleaned with dry cloth and dryness should be attained. The concrete sub floor dryness can be determined by relevant tests as approved by Engineer.

b) The layout of flooring should be marked on sub floor with guiding/reference lines. The flooring shall be first laid for trial, without fixing pedestals, according to the required layout.

c) The pedestal shall be securely fixed to sub floor with raw plugs and C.P. brass screws and araldite.

d) The channel stringers shall be placed over top head attachment of pedestal. e) The alignment and level should be checked after fixing of channel stringers is

completed. f) The floor panels shall be carefully taken and placed in position from one end

onwards. The panels should have very little gap between joints. 5.4.7 Measurement:

False flooring/ cavity flooring shall be measured separately and in square meter correct to two places of decimal. Length and breadth shall be measured correct to a cm before laying. Nothing extra shall be paid for laying the floor at different levels in the same room.

5.4.8 Rates: The rate shall include the cost of all the materials and labours involved in all the operations described as above.

5.5 Cavity Floor Type “B”: These shall be as made by United Insulations or approved equivalent conforming to PSA MOB standards. Panel: Unitile ® USF-1500 Access Floor panel of size 600 x 600mm shall be all steel welded construction, with an enclosed bottom pan of 49 hemispherical and 36 reverse cones and top plain sheet which are fuse welded at 124locations to form a panel of an overall depth of 35mm. The inner empty core of the panel is injected with a light weight fire retardant noncombustible cementious compound at high pressure to fill in all the crevices of the panel and ensures support of note less than 85% of the top surface area of the panel. The panel after cleaning, degreasing, phosphating by 7-tank process is coated with 40-60-micron epoxy coat and is heated to achieve maximum adhesion and surface resistance. The panel is then laminated with 1.5mm thick fire-retardant floor grade antistatic laminate (electrical resistance shall be in the range of 1.0 x 10x 6ohms to 2.0 x 10 x 10ohm) on a semi automate lamination line to ensure maximum bonding to the steel surface. The edge of the laminated is protected with a conductive PVC edge profile of the same range of the electrical resistivity as the laminate which is 5mm wide on all sides. This edge trim is mechanically locked and sealed in place to avoid detachment. Panel Loading:

1. Concentrated Point Load: 680 Kgs on a 25 x 25mm square indenter on the center of the panel with a maximum permissible deflecting of not more than 2.5mm as per standards.

2. Uniformly distributed load (UDL): 2300 Kgs per Sqm with a maximum permissible deflection of 2.5mm as per standards.

3. Ultimate load: Should be more than or equal to 2640 Kgs. 4. Rolling load: a. Wheel 1 i.e. 3” dia- 10 passes: 667 Kgs.





b. Wheel 2 i.e. 6” dia- 10000 passes: 556 Kgs 5. Impact Load: 78 Kgs.

Fire Rating: The panels shall confirm to Class 0 and Class 1 Fire Ratings tested as per BS 476 Part 6&7. Sub Structure- Pedestal Assembly: Sub structure installed to support the panel shall be suitable to achieve a minimum finished floor height of 65, to a maximum of 600mm from the existing floor level. Pedestals design shall confirm speedy assembly and removal for relocation and maintenance. The assembly shall provide easy adjustment of levelling and accurately align panels for a maximum of 25mm up and down in the vertical direction. The Pedestal head assembly shall consists of a 90 x 90 x 4mm head mechanically riveted to a 100mm length 19mm dia stud and 2 check nuts for level adjustments and arresting vertical movement. The pedestal head shall consists of an anti-vibration PVC cap, for Panel and stringer location. The pedestal base assembly shall consist of 25mm OD pipe of thickness 2mm projection welded to a base plate of 125 x 125 x 2.5mm thick with stiffening folds. The sub structure assembly shall be suitably anchored to the floor with suitable adhesives of fastener as recommended by the manufacturer. All steel components shall be electroplated. Axial Load: Pedestals shall support an axial load of 2200 Kgs without permanent deflection and an ultimate load of 3500 Kgs. Stringers: The stringers are hot-hipped galvanized steel cold rolled construction specially designed for lateral stability, rolling loads and support the panels on all four sides for alignment. The stringer to have a counter sunk holes at both ends to accommodate bolting of the same to the pedestal head assembly. The top of the stringer shall be fitted with sound retardant gasket achieving noise proof and air leakage proof system. The stringers shall be 21 x 32 x 1.00mm x 570mm length. The other specifications not mentioned here will be the same as specified in Type “A” as far as applicable.

5.5.1 Measurement: False flooring/ cavity flooring shall be measured separately and in square meter correct to two places of decimal. Length and breadth shall be measured correct to a cm before laying. Nothing extra shall be paid for laying the floor at different levels in the same room.

5.5.2 Rates: The rate shall include the cost of all the materials and labours involved in all the operations described as above.

5.6 Non-Metallic Hardening Compound 5.6.1 Scope of Work

The scope of work is to comprise of using non-metallic compound as per manufacturer’s specifications to make the surface hard enough to bear abrasion, improve impermeability, resist weathering. The compound to be used shall be Ashford Formula of J B Associates or equal approved.

5.6.2 Ashford Formula 5.6.2.1 Material

It is a transparent, chemically reactive, water based liquid sealer that penetrates through concrete to make it hard, dense and tough.

5.6.2.2 Application 5.6.2.2.1 Sweep all areas to be treated with a fine bristle broom or scrub, hose off with

water and let dry, to remove surface dust, dirt and contamination. Ashford formula can be applied to damp surfaces as long as all puddle areas are swept away so that the Ashford Formula is not diluted before it is able to penetrate the surface. Spray or pour and broom to saturate the surface. For new Concrete

Step 1 – Apply Ashford Formula immediately following the finishing operation as soon as the surface is firm enough to walk on before hairline checking and temperature cracking begin. Keep the entire surface wet with Ashford Formula for 30 minutes.

Step 2 – As the Ashford Formula becomes slippery underfoot, lightly mist the surface with water.





Step 3 – As the Ashford Formula again becomes slippery underfoot, thoroughly flush the entire surface with water and squeegee the surface completely dry to remove all surface alkali or Ashford formula residue.

On exterior broom finished surfaces, no flushing is required, but any remaining Ashford Formula must be squeegeed or broom from the surface after 30-40 minutes.

5.7 VACUUM DEWATERING SYSTEM 5.7.1 General

The Contractor shall improve the quality of all concrete floor slabs by placing the concrete according to the Tremix Vacuum Dewatering System as specified herein, specifications in this document for concrete and other related work.

5.7.2 Planning The contractor shall submit for review shop drawings for floor slabs detailing the location of all construction joints and the sequence of the slab placement, and manufacturer’s literature describing the equipment to be used. In addition to the shop drawings, the contractor shall indicate the quantity of each piece of dewatering equipment that will be located at the construction site and shall include the dimensions of all suction mats. Before concreting is started the work should be planned with a view to determine areas to be placed daily, the required amount of equipment, size of vacuum mats, length of vacuum hoses, arrangement of rails, if any, or screeds etc. Crew required for the vacuum process is two men to handle the mats and the pump. Note that placing, vibration, vacuum treatment and floating follow immediately behind each other.

5.7.3 Equipment All process equipment to be used shall be of a design representative of the state of the art, and shall be subject to the approval of the engineer. Equipment shall be Tremix or approved equal. System shall have a demonstrated five years history of performing such work. The vacuum pumps shall be able to generate a minimum number and size of suction mats required for this work. The contractor shall have at the job site sufficient equipment (vacuum pumps, mats, filler pads and accessories) to ensure that the vacuum dewatering process continues uninterrupted to completion.

5.7.4 Operators and Workers During the placement of concrete, the contractor shall have a minimum of one person present at all times who has been adequately trained by a representative of the equipment manufacturer. This person shall be experienced in the Vacuum Dewatering process, and in the operation of all related equipment and shall direct all concrete dewatering work performed.

5.7.5 Quality Control The contractor has the responsibility for achieving the quality of concrete specified by controlling the concrete mixes, placing, vacuum process finishing and curing. The concrete technician in charge must be present at the site when work is in progress. The contractor shall be responsible for mix adjustments, performing necessary tests, correcting deficiencies and trouble shooting in general. The contractor shall be required to maintain control showing individual test results for aggregate gradation. Slumps, air content, cement content and compressive strength. Data for slump; compressive strength etc. will be supplied by the engineer.

5.7.6 EQUIPMENT SPECIFICATION FOR TREMIX SYSTEM 5.7.6.1 Vibrators

Poker vibrator with high frequency preferably Hz (20 000 vibr/min) dia 25 to 40 mm. Surface vibrator type double beam with spacing 30 cm. Preferably one piece beam in full length exceeding bay width within 20 cm to 60 cm. Beam should easily be adjusted to absolute straightness and controlled every morning before placing of concrete starts.

5.7.6.2 Vacuum Dewatering Equipment Suction mat type rm 60. 100% tight plastic material weight 650 gram/m2. Width same as bay size and length 6m for capacity and flexibility. Filter pad type RD12 weight 600 g/m2, width 1.2 m, length=bay width-minus 20 cm. Vacuum pump o4001 B with 10 HP engine & specially designed pump unit with heavy duty chrome housing & sealing. Adjustable vacuum by value on top of tank for ease of operation with different mix designs.





5.7.7 Execution of Tremix System 5.7.7.1 General

The work shall be planned and executed so that there is no delay between the placements, screeding, dewatering and floating of the concrete to be vacuum dewatered shall be handled and placed so as to prevent segregation. The concrete shall be internally vibrated prior to screeding.

5.7.7.2 Levelling Immediately following placement, the concrete shall be levelled with a vibrating screed running on a true surface, set at the proper elevation required to provide the specified finished elevation. The concrete surface shall be screeded high by 2% of the slab’s thickness to compensate for the compaction caused by the vacuum dewatering process. The vibrator screed shall be moved forward as rapidly as proper consolidated allows. The proper surcharge of concrete must be maintained in front of the leading edge of the screed.

5.7.7.3 Vacuum dewatering Immediately after levelling, the concrete shall be covered with filter pads and suction mats in strict accordance with the recommendation of the manufacturer to have the slab fully dewatered. The suction mat shall extend 100 mm beyond the edge of the filter pad on all sides. The pads shall extend with 100 mm of the edge of concrete slab, and the mat shall cover entire slab. Before connecting the hose on the suction mat to the vacuum pump, the edges of the mat shall be smoothened to enable and airtight seal to be created. A vacuum shall then be applied to the mat. After a minute the gauge on the vacuum pump should indicate a minimum vacuum of 0.70 atmospheres (24.0 in. Hg) and if not, the mat must be checked for leakage. For concrete that dewaters readily the vacuum should then be maintained at 0.70 - 0.80 atmospheres (24.0 - 25.5 in.hg). for concrete which dewaters less efficiently (e.g. air-entrained concrete) the vacuum shall then be reduced to 0.50 - 0.60 atmospheres (15.0 - 18.0 in. Hg). After approximately 10 minutes the vacuum can then be increased to 0.80 atmospheres. The vacuum shall be maintained for at least 3 minutes per 25 mm of concrete thickness at 0.80 atmospheres. (Where) aggregate hardeners are specified, sufficient moisture shall be maintained to meet manufacturer’s requirements). The suction mats and filter pads shall then be removed and moved to the next suction in a leapfrog manner. Stop the vacuum dewatering when light footprints only are left in the concrete when stepped upon. A suitable suction time can also be checked with a Proctor-apparatus which should show 1.5 - 2 kg/cm2.

5.7.7.4 Floating Upon removal of the suction mats and filter pads the concrete surface shall be power-floated without delay until all imprints from the vacuum process are removed. If crusting occurs, the floating operation must be delayed till the concrete carries the machine. The higher speed is recommended for the floating operation. To avoid cracks, two passes with the floating disc should be made in the junction of two mats.

5.7.7.5 Finishing The waiting time after the floating operation depends on concrete temperature and humidity and varies from 10 minutes to 2 hours. The trowelling operation cannot take place before the concrete has hardened enough to carry the machine, i.e. the trowel ling blades will not leave any marks on the concrete. Repeated trowel ling, with intervals between the passes, which are adapted to the setting of the concrete, greatly improves the surface characteristics. The surface will be more wear resistant and less dusty.

5.7.7.6 Inserts The contractors shall fix all necessary inserts such as steel plates, pipe sleeves, bolts etc. And make provision for holes pockets etc. As indicated on the drawings or as required by the Architect.

5.7.8 Curing Vacuum dewatered concrete should be cured like any other quality concrete in order to achieve a good final result. Use curing compounds, plastic sheets or wet burlap.

5.7.9 Measurements Measurements shall be done in square meter in accordance with the mode of measurements as specified in IS: 1200.

5.8 SPECIFICATIONS FOR CEMENT CONCRETE FLOORING





Generally, all works shall be done in accordance with section 14.2 of MAHAPWD Specifications 2007-08 in additions to section 11.2 of CPWD Specifications 1996.

5.8.1 Cement concrete Cement concrete of specified mix shall be used and it shall generally conform to the specifications described in relevant section.

5.8.2 Base concrete Flooring shall be laid on base concrete where so provided. The base concrete shall be provided with the slopes required for the flooring. Flooring in verandah courtyard kitchens & baths shall have slope ranging from 1: 48 to 1: 60 depending upon location and as decided by the engineer. Floors in water closet portion shall have slope of 1: 30 or as decided by the engineer to drain off washing water. Plinth masonry off set shall be depressed so as to allow the base concrete to rest on it. If the base consists of lime concrete, it shall be allowed to set for seven days and the flooring shall be laid within the next three days. If the base is of lean cement concrete, the flooring shall be commenced preferably within 48 hours of the laying of base concrete. The surface of the base shall be roughened with steel wire brushes without disturbing the concrete. Immediately before laying the flooring, the base shall be wetted and a coat of cement slurry at 2 kg of cement spread over an area of one sqm so as to get a good bond between the base and concrete floor. If the cement concrete flooring is to be laid directly on the RCC slab, the top surface of RCC slab shall be cleaned and the laitance shall be removed and a coat of cement slurry at 2 kg of cement spread over an area of one sqm so as to get a good bond between the base and concrete floor.

5.8.3 Thickness - The thickness of floor shall be as specified in the description of the item. 5.8.4 Laying

Panels - Flooring of specified thickness shall be laid in the pattern including the border/ or as given in the drawings or as directed by the engineer. The border panels shall not exceed 450 mm in width and the joints in the border in line with panel joints. The panels shall be of uniform size and no dimension of a panel shall exceed 2 m and the area of a panel shall not be more than 2 sqm. Laying of flooring with strips - Normally cement concrete flooring shall be laid in one operation using glass / plain asbestos/ aluminium/PVC / brass strips or any other strips as required as per drawing or instructions of the engineer, at the junction of two panels. This method ensures uniformly in colour of all the panels and straightness at the junctions of the panels. 4 mm thick glass strips or 5 mm thick plain asbestos sheet, 2 mm PVC strips or 2 mm aluminium or brass strips, shall be fixed with their tops at proper level, giving required slopes. Concreting - Cement concrete shall be placed in the panels and be levelled with the help of straight edge and trowel. The blows shall be fairly heavy in the beginning but as consolidation takes place, light rapid strokes shall be given. Beating shall cease as soon as the surface is found covered with a thin layer of cream of mortar. The evenness of the surface shall be tested with straight edge and made true to required slopes. While laying concrete, care shall be taken to see that the strips are not damaged/disturbed by the labourers. The tops of strips shall be visible clearly after finishing with cement slurry. Laying of flooring without strips Laying of cement concrete flooring in alternate panels may be allowed by the engineer in case strips are not to be provided. Shuttering - The panels shall be bounded by angle iron or flats. The angle iron/flat shall have the same depth as the concrete flooring. These shall be fixed in position, with their top at proper level giving required slopes. The surface of the angle iron or flats, to come in contact with concrete shall be smeared with soap solution or non-sticking oil (Form oil or raw linseed oil) before concreting. The flooring shall butt against the unplastered masonry wall. Concreting - The concreting shall be done in the manner as described. The angle iron / flats used for shuttering shall be removed on the next day of the laying of cement concrete. The ends thus exposed shall be repaired, if damaged with cement mortar 1: 2 (1 cement 2 coarse sand) and allowed to set for minimum period of 24 hours. The alternate panels shall then be cleaned of dust, mortar, droppings etc. and concrete laid. While laying concrete, care shall be taken to see that the edges of the previously laid panels are





not damaged and fresh mortar is not splashed over them. The joints between the panels should come out as fine straight lines.

5.8.5 Finishing The finishing of the surface shall follow immediately after the cessation of beating. The surface shall be left for some time, till moisture disappears from it or surplus water can be mopped up. Use of dry cement or cement and sand mixture sprinkled on the surface to stiffen the concrete or absorb excessive moisture shall not be permitted. Excessive trowelling shall be avoided. Fresh cement shall be mixed with water to form thick slurry and spread at the rate of 2 kg of cement over an area of one sqm of flooring while the flooring concrete is still green. The cement slurry shall then be properly processed and finished smooth. The edges of sunken floors shall be finished and rounded with cement mortar 12 (1 cement 2 coarse sand) and finished with a floating coat of neat cement. The junctions of floor with wall plaster, dado or skirting shall be rounded off where so specified. The men engaged on finishing operations shall be provided with raised wooden platform to sit on so as to prevent damage to new work.

5.8.6 Curing The curing shall be done for a minimum period of ten days. Curing shall not be commenced until the top layer has hardened. Covering with empty gunnies shall be avoided as the colour of the flooring is likely to be bleached due to the remnants of cement dust from the bags.

5.8.7 Precautions During cold weather, concreting shall not be done when the temperature falls below 4 degree Celsius. The concrete placed shall be protected against frost by suitable covering. Concrete damaged by frost shall be removed and work redone. During hot weather, precautions shall be taken to see that the temperature of wet concrete does not exceed 38 degree Celsius. No concreting shall be laid within half an hour of the closing time of the day, unless permitted by the engineer. To facilitate rounding of junction of skirting, dado and floor, the skirting / dado shall be laid along with the border or adjacent panels of floor.

5.8.8 Measurement Length and breadth shall be measured before laying skirting dado or wall plaster. No deduction shall be made nor extra paid for voids not exceeding 0.20 sqm. Deductions for ends of dissimilar materials or other articles embedded shall not be made for areas not exceeding 0.10 sqm. The flooring done either with strips (in one operation) or without strips (in alternate panels) shall be treated as same and measured together.

5.8.9 Rate The rate shall include the cost of all materials and labour involved in all the operations described above including application of cement slurry on RCC slab or on base concrete including roughening and cleaning the surface. Nosing of steps where provided shall be paid for separately in running metre. Nothing extra shall be paid for laying the floor at different levels in the same room or courtyard and rounding off edges of sunken floors. In case the flooring is laid in alternate panels, nothing extra shall be paid towards the cost of shuttering used for this purpose.

5.9 SPECIFICATIONS FOR CEMENT PLASTER IN RISERS OF STEPS, SKIRTING, DADO Generally all works shall be done in accordance with section 14.5 of MAHAPWD Specifications 2007-08 in additions to section 11.5 of CPWD Specifications 1996.

5.9.1 A band of plaster at the bottom of wall not exceeding 30 cm in height above the floor shall be classified as skirting. It shall be flush with wall plaster or projecting out uniformly by 6 mm from the wall plaster, as specified. The work shall be preferably carried out simultaneously with the laying of floor. Its corners and junctions with floor shall be finished neatly as specified.

5.9.2 Thickness - The thickness of the plaster specified shall be measured exclusive of the thickness of key i.e., grooves or open joints in brick work. The average thickness shall not be less than the specified thickness. The average thickness should be regulated at the time of plastering by keeping suitable thickness of the gauges. Extra thickness required in rounding of corners at junctions of wall shall be ignored.





5.9.3 Preparation of wall surface - The joints shall be raked out to a depth of at least 15 mm in masonry walls. In case of concrete walls, the surfaces shall be roughened by hacking. The surface shall be cleaned thoroughly, washed with water and kept wet before skirting is commenced.

5.9.4 Application - Skirting with specified mortar and to specified thickness shall be laid immediately after the surface is prepared. It shall be laid along with the border or adjacent panels of floor. The joints in skirting shall be kept true and straight in continuation of the line of joints in borders or adjacent panels. The skirting shall be finished smooth and true, with top truly horizontal and joints truly vertical except where otherwise indicated.

5.9.5 Finishing - The finishing of surface shall be done simultaneously with the borders of the adjacent panels of floor. The cement to be applied in the form of slurry for smooth finishing shall be at the rate of 2 kg of cement per litre of water applied over an area of 1 sqm. Where skirting is flush with plaster, a groove 10 mm wide and up to 5 mm deep shall be provided in plaster at the junction of skirting with plaster. Curing - Curing shall be commenced on the next day of plastering when the plaster has hardened sufficiently and shall be continued for a minimum period of 7 days.

5.9.6 Measurement - Length and height shall be measured correct to a cm and its area shall be calculated in sqm correct to two places of decimals stating the thickness. Length shall be measured as the finished length of skirting. Height shall be measured from the finished level of floor correct to 5 mm.

5.9.7 Rate - Rate shall include the cost of all materials and labour involved in all the operations described above.

5.10 SPECIFICATIONS FOR KOTA STONE FLOORING Generally all works shall be in accordance with section 14.20 of MAHAPWD Specifications 2007-08 in additions to section 11.20 of CPWD Specifications 1996.

5.10.1 Kota stone slabs - The slabs shall be of selected quality, hard, sound, dense and homogeneous in texture free from cracks, decay, weathering and flaws. They shall be hand or machine cut to the requisite thickness. They shall be of the colour indicated in the drawings or as instructed by the engineer. The slabs shall have the top (exposed) face polished before being brought to site, unless otherwise specified. The slabs shall conform to the size required. Before starting the work the contractor shall get the samples of slabs approved by the engineer.

5.10.2 Dressing - Every slab shall be cut to the required size and shape and fine chisel dressed on the sides to the full depth so that a straight edge laid along the side of the stone shall be in full contact with it. The sides (edges) shall be table rubbed with coarse sand or machine rubbed before paving. All angles and edges of the slabs shall be true, square and free from chippings and the surface shall be true and plane. The thickness of the slab after it is dressed shall be 20, 25, 30 or 40 mm as specified in the

description of the item. Tolerance of 2 mm shall be allowed for the thickness. In respect

of length and breadth of slabs Tolerance of 5 mm for hand cut slabs and 2 mm for machine cut slabs shall be allowed. OR a machine cut slab as specified below: Every stone shall be machine cut to the required size and shape, free from waviness and to give truly vertical, horizontal, radial or circular joints as required. All visible angles and edges shall be true, square and free from any chippings. The surfaces of the stones coming in contact with backing shall not be polished.

5.10.3 Laying - Base concrete or the RCC slab on which the slabs are to be laid shall be cleaned, wetted and mopped. The bedding for the slabs shall be with cement mortar 1:4 (1 cement, 4 coarse sand). The average thickness of the bedding mortar under the slab shall be 20mm and the thickness at any place under the slab shall not be less than 20mm. The slabs shall be laid in the following manner - Mortar of the specified mix shall be spread under the area of each slab, roughly to the average thickness specified in the item. The slab shall be washed clean before laying. It shall be laid on top, pressed, tapped with wooden mallet and brought to level with the adjoining slabs. It shall be lifted and laid aside. The top surface of the mortar shall then be corrected by adding fresh mortar as hollows. The mortar is allowed to harden a bit and cement slurry of honey like consistency shall be spread over the same at the rate of 4.4 kg of cement per sqm. The edges of the





slab already paved shall be buttered with grey cement with or without admixture of pigment to match the shade of the slabs as given in the description of the item. The slab to paved shall then be lowered gently back in position and tapped with wooden mallet till it is properly bedded in level with and close to the adjoining slabs with as fine a joint as possible. Subsequent slabs shall be laid in the same manner. After each slab has been laid, surplus cement on the surface of the slabs shall be cleaned off. The flooring shall be cured for a minimum period of seven days. The surface of the flooring as laid shall be true to levels, and, slopes as instructed by the engineer. Due care shall be taken to match the grains of slabs which shall be selected judiciously having uniform pattern of Veins / streaks or as directed by the engineer. The slabs shall be matched as shown in drawings or as instructed by the engineer. Slabs which are fixed in the floor adjoining the wall shall enter not less than 12 mm under the plaster skirting or dado. The junction between wall plaster and floor shall be finished neatly and without waviness.

5.10.4 Curing, polishing and finishing The day after the tiles are laid all joints shall be cleaned of the grey cement grout with a wire brush or trowel to a depth of 5 mm and all dust and loose mortar removed and cleaned. Joints shall then be grouted with grey or white cement mixed with or without pigment to match the shape of the topping of the wearing layer of the tiles. The floor shall then be kept wet for a minimum period of 7 days. The grinding shall then be carried out with machine fitted with fine grade grit block (No. 120). The final grinding with machine fitted with the finest grade grit blocks (No.320) shall be carried out the day after the grinding described in the preceding para or before handing over the floor, as ordered by the Engineer overall minimum three coats of polishing is to be done or as directed by the Engineer in charge to give complete mirror finish. For small areas or where circumstances so require, hand polishing may be permitted in lieu of machine polishing after laying. For hand polishing the following carborundum stones, shall be used First grinding – medium grade (No. 80) Second grinding – fine grade (No. 120). In all other respects, the process shall be similar as for machine polishing. After the final polish, oxalic acid shall be dusted over the surface at the rate of 33 gm per square meter sprinkled with water and rubbed hard with a ‘namdah’ block (pad or wooden rags). The following day the floor shall be wiped with a moist rag and dried with a soft cloth and finished clean. If any tile is disturbed or damaged, it shall be refitted or replaced, properly jointed and polished. The finished floor shall not sound hollow when topped with a wooden mallet.

5.10.5 Measurements Kota flooring with different kind of stone shall be measured separately and in square meter correct to two places of decimal. Length and breadth shall be measured correct to a cm before laying skirting, dado or wall plaster. No deduction shall be made nor extra paid for voids not exceeding 0.20 square meters. Deductions for ends of dissimilar materials or other articles embedded shall not be made for areas not exceeding 0.10 square meter. Nothing extra shall be paid for laying the floor at different levels in the same room. Steps and treads of stairs paved with kotah stone slabs shall also be measured under the item of kotah Stone flooring. Extra shall, however, be paid for such areas where the width of treads does not exceed 30 cm. Nosing for treads shall be measured in running meter and paid for extra. The width of treads shall be measured from the outer edge of the nosing, as laid, before providing the riser.

5.10.6 Rate The rate shall include the cost of all materials and labour involved in all the operations described above.

5.11 Kota stone in Risers, of steps, skirting and Dado Generally all works shall be in accordance with section 14.21 of MAHAPWD Specifications 2007-08 in addition to section 11.21 of CPWD Specifications 1996. Kota slabs and dressing shall be as specified above except that thickness of the slabs shall be 25mm or as specified in the description of the items. The slabs may be of informed size if required. Preparation of surface shall be as specified above.





Laying shall be as specified in 5.10.3 except the joints of the slabs shall be set in grey cement mixed with pigments to match the shade of the slabs. Curing, polishing and finishing shall be as specified in 14.10.4 except that the first polishing with coarse grade corborandum stone shall not be done.

5.11.1 Measurements Length shall be measured along with the finished face of riser, skirting or dado correct to a cm. Height shall be measured from finished level of tread of floor to the top (the underside of the tread in case of steps). This shall be measured to a mm in case of risers of steps and skirting and correct to a cm, in case of dado. The area shall be calculated in Sqm. Correct to two places of decimals. Laying of pillars etc., shall also be measured under this item.

5.11.2 Rate: The rate shall include the cost of all the materials and labours involved in all the operations described as above.

5.12 Acid resistant tiles The tiles shall conform to IS: 4457. The tiles shall be free from any stains, cracks, bends, and undulations. The tiles shall be square or rectangular of nominal size such as 300 x 300mm, 200x 100mm, or as directed by Engineer in charge. The thickness of the tiles shall be 7.3mm, 10mm or 12mm as specified.

5.12.1 Laying The tiles shall be laid over a cement mortar as specified by Engineer in charge to a true line and level.

5.12.2 Storage and handling The tiles shall be stored in a dry area so that no damages shall occur. The tiles shall be of same shade and colour. If any damages to the tiles occur or colour not matching with the requirements, then the whole lot to be replaced or returned.

5.12.3 Measurements Tiles flooring shall be measured separately and in square meter correct to two places of decimal. Length and breadth shall be measured correct to a cm before laying skirting, dado or wall plaster. No deduction shall be made nor extra paid for voids not exceeding 0.20 square meters. Deductions for ends of dissimilar materials or other articles embedded shall not be made for areas not exceeding 0.10 square meter. Nothing extra shall be paid for laying the floor at different levels in the same room.

5.12.4 Rates The rate shall include the cost of all the materials and labours involved in all the operations described as above.





6 FINISHING 6.1 Polyurethane Paint

Polyurethane paint shall be MRF or equal approved make and shall be applied as per manufacturer’s printed specifications. Material Aliphatic grade “Metal coat” applicable for metal surfaces shall be used which is comprised or Isocyanate hardener to be used in conjunction with Acrylic Polyol. The colour shall be as approved by the Engineer. Application Surface shall be properly cleaned and applied with suitable primer as per manufacturer’s specifications. If surface is not smooth, it shall be treated with metal putty and primer. Two coat of metal coat of thickness 25 to 30 microns shall be applied by spray and finished smooth.

S.no. Parameter Glossy Matt Remarks

1. Product composition PU PU

2. Pack Two Two

3. Shade As approved

4a. Viscosity by FC B4 at 30 Deg.C (Seconds)

Part – A ii) Mix ii) M

45-50 30--35

45-50 30-35

4b. Application Viscosity 22-25 22-25

5. Specific gravity 0.98-1.2 1.16-1.3

6. Solid content 42-55 55-56

7. Thinner recommended 930/000 930/000 Thinner finish.

8. Thinner intake 10-15% 10-15%

9. Mode of application Spray Spray

10. Curing schedule Surface dry Hard dry

30 Minutes O/N

30 Minutes O/N

11. Mixing Ratio 4:1 6:1

12. Finish Smooth Smooth

13. Recommended DFT (u) 25-30 25-30

14. Gloss (%) 90-95* 15-20* At 60

6.2 Washed Stone Grit Plaster 6.2.1 Scaffolding

For all exposed brick work or tile work, double scaffolding independent of the work having two sets of vertical supports shall be provided. The supports shall be sound and strong, tied together with horizontal piece over which scaffolding planks shall be fixed.

6.2.2 Preparation of Surface The joints shall be raked out properly. Dust and loose mortar shall be brushed out. Efflorescence if any shall be removed by brushing and scrapping. The surface shall then be thoroughly washed with water, cleaned and kept wet before plastering is commenced. In case of concrete surface if a chemical retarder has been applied to the formwork, the surface shall be roughened by wire brushing and all the resulting dust and loose particles cleaned off and care shall be taken that none of the retarders is left on the surface. Preparation of Surface: Projecting burrs of mortar formed due to the gaps at joints in shuttering shall be removed. The surface shall be scrubbed clean with wire brushes. In addition concrete surfaces to be plastered shall be pock marked with a pointed tool, at spacing of not more than 5 cm. centres, the pock being made not less than 3 mm deep. The mortar shall be washed off and surface, cleaned of all oil, grease etc. and well wetted before the plaster is applied.

6.2.3 Materials 6.2.3.1 Stone chippings obtained by crushing hard stone shall be free of dust and deleterious

material. 10 mm nominal size stone chippings, where specified, shall pass 100% through 12.5 mm sieve and fully retained on 6.3 mm sieve. Stone chippings shall be thoroughly washed with water and sieved before use.





6.2.3.2 Mortar: Cement mortar for under coat and cement mortar to be mixed with stone chippings for top coat shall be as specified

6.2.4 Application of Plaster 6.2.4.1 12 mm under coat: Under coat of cement mortar 1:4 (1 cement: 4 coarse sand) shall be

applied as specified, except that the finishing, after the mortar has been brought to level with the wooden straight edge, shall be done with wooden float only. The surface shall be further roughened by furrowing with a scratching tool. Furrowing shall be done diagonally both ways and shall be about 2 mm deep to provide a key for the topcoat. The scratched lines shall not be more than 10 cm apart. The surface shall be kept wet till topcoat is applied.

6.2.4.2 15 mm top coat: Top coat comprising cement mortar and stone chippings shall have an overall proportion of 2.5:1:6 (2.5 white cement: 1 dolomite powder: 6 stone chips 10 mm nominal size) or as specified. Colour of stone chips and finished coat will be decided by the Engineer-in-charge. The topcoat shall be applied a day or two after the under coat has taken the initial set. The surface of the under coat shall be cleaned and a coat of cement slurry at 2 kg of cement per sqm shall be applied before the application of coat. The topcoat shall be applied in uniform thickness on the under coat after the application of slurry and sufficiently pressed with wooden float for proper bonding with the coat. Vacant space, if any shall be filled with the specified mix.

6.2.5 Finish: The topcoat of plaster shall be finished to a true and plumb surface. The surface shall be tested frequently as the work proceeds with a true straight edge not less than 2.5 m long and with plumb bobs. All horizontal lines and surfaces shall be tested with a level and all jambs and corners with a plumb bob as the work proceeds. All the corners angles and junctions shall be truly vertical or horizontal as the case may be. Rounding or chamfering of corners junctions etc. where required shall be true to template. Finished surface of the topcoat after the mix has taken the initial set shall be scrubbed and washed with nylon brushes and plain water. Scrubbing and washing shall continue till the stone chips are sufficiently exposed. Stone chips which may come out while scrubbing shall be replaced using the specified mortar mix. After final curing it should wash again with 2% solution of Hydrochloric acid followed by clean potable water. A sample of the washed stone grit plaster shall be got approved from the Engineer-in-Charge.

6.2.6 Grooves: Grooves of size 20 mm x 15 mm or as specified shall be provided as shown on the drawing or as required by the Engineer-in-Charge. Tapered wooden battens to match the size and shape of the grooves shall be fixed on the under coat with nails before the application of the topcoat and these shall be removed carefully so that the edges of the panels of topcoat are not damaged. Damage, if any, shall be made good by the contractor.

6.2.7 Curing: Curing shall be started 24 hours after finishing the plaster. The plaster shall be kept wet for a period of seven days. During this period, it shall be suitably protected from all damages at the contractor's expense by such means as the Engineer-in-Charge may approve. The dates on which the plastering is done shall be legibly marked on the various sections plastered so that curing for the specified period thereafter can be watched.

6.2.8 Measurements Length and breadth shall be measured correct to the nearest cm and the area shall be calculated in sqm correct to two places of decimal. Shall be taken for the work actually done with deductions for all openings and additions for all jambs soffit and sills. However, no deductions is to be made for the grooves provided as specified in 6.2.6. N separate measurements to be taken for grooves and for any height and levels.

6.2.8.1 Rates: The rates shall include the cost of all labour and materials involved in all operations described above including white cement, pigments, colour stone chips except for grooves at all levels. The groves shall be measured in running meter.

6.3 SPECIFICATIONS FOR CEMENT PLASTERING Generally, all works shall be in accordance with section 15.5 of MAHAPWD Specifications 2007-08 in addition to section 13.5 of CPWD Specifications 1996.

6.3.1 The cement plaster shall be 12 mm, 15 mm or 20 mm thick as specified in the item. 6.3.2 Scaffolding and preparation of surface shall be as specified in 15.2.1 and 15.2.2





6.3.3 Mortar - The mortar of the specified mix using the type of sand described in the item shall be used. It shall be as specified. For external work and under coat work, the fine aggregate shall conform to grading IV. For finishing cost work the fine aggregate conforming to grading zone V shall be used.

6.3.4 Application of plaster: 6.3.4.1 Ceiling plaster shall be completed before commencement of wall plaster. 6.3.4.2 Plastering shall be started from the top and worked down towards the floor. All putlog

holes shall be properly filled in advance of the plastering as the scaffolding is being taken down. To ensure even thickness and a true surface, plaster about 15 x 15 cm shall be first applied, horizontally and vertically, at nor more than 2 metres intervals over the entire surface to serve as gauges. The surfaces of these gauged areas shall be truly in the plane of the finished plaster surface. The mortar shall then be laid on the wall, between the gauges with trowel. The mortar shall be applied in a uniform surface slightly more than the specified thickness and then brought to a true surface, by working a wooden straight edge reaching across the gauges, with small upward and sideways movements at a time. Finally the surface shall be finished off true with trowel or wooden float according as a smooth or a sandy granular texture is required. Excessive trowel ling or over working the float shall be avoided.

6.3.4.3 All corners, arises, angles and junctions shall be truly vertical or horizontal as the case may be and shall be carefully finished. Rounding or chamfering corners, arises, provision of grooves at junctions etc. where required shall be done without any extra payment. Such rounding, chamfering or grooving shall be carried out with proper templates or battens to the sizes required.

6.3.4.4 When suspending work at the end of the day, the plaster shall be left, cut clean to line both horizontally and vertically. When recommencing the plastering, the edge of the old work shall be scrapped cleaned and wetted with putty before plaster is applied to the adjacent areas, to enable the two to properly joint together. Plastering work shall be closed at the end of the day on the body of wall and not nearer than 15 cm to any corners or arises. It shall not be closed on the body of the features such as plasters, bands and cornices, nor at the corners of arises. Horizontal joints in plasterwork shall not also occur on parapet tops and copings at these invariably lead to leakages.

No portion of the surface shall be left out initially to be patched up later on. 6.3.5 Finish - The plaster shall be finished to a true and plumb surface and to the proper degree

of smoothness as required. The work shall be tested frequently as the work proceeds with a true straight edge not less than 2.5 m long and with plumb bobs. All horizontal lines and surfaces shall be tested with a level and all jambs and corners with a plumb bob as the work proceeds. The plastering and finishing shall be completed within half an hour of adding water to dry mortar.

6.3.6 Thickness - Where the thickness required as per description of the item is 20 mm the average thickness of the plaster shall not be less than 20 mm whether the wall treated is of brick or stone. In the case of brickwork, the minimum thickness over any portion of the surface shall be not less than 15 mm while in case of stonework the minimum thickness over the bushings shall be not less than 12 mm.

6.3.7 Curing - Curing shall be started as soon as the plaster has hardened sufficiently not to be damaged when watered. The plaster shall be kept wet for a period of at least 7 days. During this period, it shall be suitably protected from all damages at the contractor’s expense by such means as the Engineer may approve. The dates on which the plastering is done shall be legibly marked on the various sections plastered so that curing for the specified period thereafter can be watched.

6.3.8 Precaution - Any cracks which appear in the surface and all portions which sound hollow when lapped, or are found to be soft or otherwise defective, shall be cut out in rectangular shape and redone as directed by the Engineer.

i. When ceiling plaster is done, it shall be finished to chamfered edge at an angle at its junction with a suitably tool when plaster is being done. Similarly, when the wall plaster is being done, it shall be kept separate from the ceiling plaster by a thin straight groove not deeper than 6 mm drawn with any suitable method with the wall while the plaster is green.

ii. To prevent surface cracks appearing between junctions of column/ beam and walls, 150 mm wide chicken wire mesh should be fixed with U nails 150 mm centre





to centre before plastering the junction. The plastering of walls and beam/column in one vertical plane should be carried out in one go. For providing and fixing chicken wire mesh with U nails payment shall be made separately.

6.3.9 Rates – The rate shall include the cost of all labour and materials involved in all the operations described as above.

6.4 SPECIFICATIONS FOR WHITE WASHING WITH LIME Generally, all works shall be in accordance with section 15.25 of MAHAPWD Specifications 2007-08 in addition to section 13.25 of CPWD Specifications 1996.

6.4.1 Scaffolding 6.4.1.1 Wherever scaffolding is necessary, it shall be erected on double supports tied together

by horizontal pieces, over which scaffolding planks shall be fixed. No ballies, bamboos or planks shall rest or touch the surface which is being white washed.

6.4.1.2 For all exposed brickwork or tile work double scaffolding having two sets of vertical supports shall be provided. The supports shall be sound and strong, tied together with horizontal pieces over which scaffolding planks shall be fixed. Note In case of special type of brickwork, scaffolding shall be got approved from Engineer in dvance.

6.4.1.3 Where ladders are used, pieces of all gunny bags shall be tied on their tops to avoid damage or scratches to walls.

6.4.1.4 For white washing the ceiling, proper scaffolding shall be erected. 6.4.2 Preparation of surface - Before new work is white washed, the surface shall be

thoroughly brushed free from mortar droppings a foreign matter. 6.4.3 Preparation of lime wash 6.4.3.1 The lime wash shall be prepared from fresh stone white lime. The lime shall be

thoroughly slaked on the spot, mixed and stirred with sufficient water to make a thin cream. This shall be allowed to stand for a period of 24 hours and then shall be screened through a clean coarse cloth. 40 gm of gum dissolved in hot water, shall be added to each 10 cubic decimetre of the cream. The approximate quantity of water to be added in making the cream will be 5 litres of water to one kg of lime.

Indigo (Neel) up to 3 gm per kg of lime dissolved in water, shall then be added and stirred well. Water shall then be added at the rate of about 5 litres per kg. of lime to produce a milky solution.

6.4.4 Application The white wash shall be applied with moonj brushes to the specified number of coats. The operation for each coat shall consist of a stroke of the brush given from the top downwards, another from the bottom upwards over the first stroke, and similarly one stroke horizontally from the right and another from the left before it dries. Each coat shall be allowed to dry before the next one is applied. Further each coat shall be inspected and approved by the Engineer before the subsequent coat is applied. No portion of the surface shall be left out initially to be patched up later on. For new work, three or more coats shall be applied till the surface presents a smooth and uniform finish through which the plaster does not show. The finished dry surface shall not show any signs of cracking and peeling nor shall it come off readily on the hand when rubbed.

6.4.5 Protective Measures Doors, Windows, floors, articles of furniture etc. and such other parts of the building not to be white washed, shall be protected from being splashed upon. Splashing and droppings, if any shall be removed by the contractor at his own cost and the surfaces cleaned. Damages if any to furniture or fittings and fixtures shall be recoverable from the contractor.

6.4.6 Measurements Length and breadth shall be measured correct to a cm. and area shall be calculated in sqm correct to two places of decimals. Measurements for jambs, Soffits, and Fills etc. for openings shall be as described. Corrugated surfaces shall be measured flat as fixed and the area so measured shall be increased by the following percentages to allow for the girthed area. Corrugated asbestos cement sheet - 20% Semi corrugated asbestos cement sheet - 10%





Cornices and other such wall or ceiling features shall be measured along the girth and included in the measurements. The number of coats of each treatment shall be stated. The item shall include removing nails, making good holes, cracks, patches etc. not exceeding 50 sq. cm. each with material similar in composition to the surface to be prepared.

6.5 SPECIFICATIONS FOR CEMENT PAINT Generally all works shall be in accordance with section 15.32 of MAHAPWD Specifications 2007-08 in addition to section 13.32 of CPWD Specifications 1996.

6.5.1 Material -The cement paint shall be (conforming to IS: 5410) of approved brand and manufacture. The cement paint shall be brought to the site of work by the contractor in its original containers in sealed condition. The material shall be brought in at a time in adequate quantities to suffice for the whole work or at least a fortnight’s work. The materials shall be kept in the joint custody of the contractor and the engineer. The empties shall not be removed from the site of work till the relevant item of work has been completed and permission obtained from the engineer.

6.5.2 Preparation of surface For new work, the surface shall be thoroughly cleaned of all mortar dropping, dirt dust, algae grease and other foreign matter by brushing and washing. Pitting in plaster shall be made good and a coat of waterproof cement paint shall be applied over patches after wetting them thoroughly.

6.5.3 Preparation of mix Cement paint shall be mixed in such quantities as can be used up within an hour of its mixing as otherwise the mixture will set and thicken, affecting flow and finish. Cement paint shall be mixed with water in two stages. The first stage shall comprise of 2 parts of cement paint of one part of water stirred thoroughly and allowed to stand for 5 minutes. Care shall be taken to add the cement paint gradually to the water and not vice versa. The second stage shall comprise of adding further one part of water to the mix and stirring thoroughly to obtain a liquid of workable and uniform consistency. In all cases the manufacturer’s instructions shall be followed meticulously. The lids of cement paint drums shall be kept tightly closed when not in use, as by exposure to atmosphere the cement paint rapidly becomes air set due to its hygroscopic qualities. In case of cement paint brought in gunny bags, once the bag is opened, the contents should be consumed in full on the day of its opening. If the same is not likely to be consumed in full, the balance quantity should be transferred and preserved in an airtight container to avoid its exposure to atmosphere.

6.5.4 Application The solution shall be applied on the clean and wetted surface with brushes or spraying machine. The solution shall be kept well stirred during the period of application. It shall be applied on the surface, which is on the shady side of the building so that the direct heat of the sun on the surface is avoided. The method of application of cement paint shall be as per manufacturer’s specification. The completed surface shall be watered after the day’s work. The second coat shall be applied after the first coat has been set for at least 24 hours. Before application of the second or subsequent coats, the surface of the previous coat shall not be wetted. For new work, the surface shall be treated with three or more coats of waterproof cement paint as found necessary to get a uniform shade.

6.5.5 Precaution - Water proof cement paint shall not be applied on surfaces already treated with white wash, colour wash, distemper dry or oil bound, varnishes, paints etc. It shall not be applied on gypsums, wood and metal surfaces. The specifications in respect of scaffolding, protective measures, measurements and rate shall be as described in 15.40. The primer is to be used as specified by the manufacturers and approved by the Engineer.

6.6 SPECIFICATIONS FOR WALL PAINTING WITH PLASTIC EMULSION PAINT Generally all works shall be in accordance with section 15.42 of MAHAPWD Specifications 2007-08 in addition to section 13.42 of CPWD Specifications 1996.





The plastic emulsion paint is not suitable for application on external, wood and iron surface and surfaces, which are liable to heavy condensation. These paints are to be used on internal surfaces except wooden and steel.

6.6.1 Materials: Plastic emulsion paint as per IS: 5411 of approved brand and manufacture and of the required shade shall be used.

6.6.2 Painting on new surface 6.6.2.1 Preparation of Surface - The surface shall be thoroughly cleaned and dusted off. All

rust, dirt, scales, smoke splashes, mortar droppings and grease shall the thoroughly removed before painting is started. The prepared surface shall have received the approval of the engineer after inspection, before painting is commenced.

6.6.2.2 Application - The number of coats shall be as stipulated in the item. The paint will be applied in the usual manner with brush, spray or roller. The paint dries by evaporation of the water content and as soon as the water has evaporated the film gets hard and the next coat can be applied. The time of drying varies from one hour on absorbent surfaces to 2 to 3 hours on non-absorbent surfaces.

The thinning of emulsion is to be done with water and not with turpentine. Thinning with water will be particularly required for the under coat which is applied on the absorbent surface. The quantity of water to be added shall be as per manufacturer’s instructions. The surface on finishing shall present a flat velvety smooth finish. If necessary more coats will be applied till the surfaces presents a uniform appearance.

6.6.2.3 Precautions i. Old brushes if they are to be used with emulsion paints should be completely dried

of turpentine or oil paints by washing in warm soap water. Brushes should be quickly washed in water immediately after use and kept immersed in water during break periods to prevent the paint from hardening on the brush.

ii. In the preparation of wall for plastic emulsion painting, no oil base putties shall be used in filling cracks, holes etc.

iii. Splashes on floors etc. shall be cleaned out without delay, as they will be difficult to remove after hardening.

iv. Washing of surfaces treated with emulsion paints shall not be done within 3 or 4 weeks of application.

v. Other details shall be as specified as far as they are applicable. The primer is to be used as specified by the manufacturer and approved by the Engineer.

6.7 SPECIFICATIONS FOR PAINTING WITH SYNTHETIC ENAMEL PAINT Generally, all works shall be in accordance with section 15.44 of MAHAPWD Specifications 2007-08 in addition to section 13.44 of CPWD Specifications 1996.

6.7.1 Materials: Synthetic enamel paint (conforming to IS: 2932) of approved brand and manufacture and of the required colour shall be used as recommended by the manufacturer.

6.7.2 Painting on new surface Preparation of surface a) Wood work: The surface shall be cleaned and all unevenness removed, as specified

knots if visible, shall be covered with a preparation of red lead. Holes and indentations on the surface shall be filled in with glazier’s putty or wood putty conforming to IS: 419 and rubbed smooth before painting is done. The surface should be thoroughly dry before painting.

b) Iron and steel work: The priming coat shall have dried up completely before painting is started. Rust and scaling shall be carefully removed by scraping or by brushing with steel wire brushes. All dust and dirt shall be carefully and thoroughly wiped away.

c) Plastered surface: The priming coat shall have dried up completely before painting is started. All dust or dirt that has settled on the priming coat shall be thoroughly wiped away before painting is started

6.7.3 Application: The number of coats including the undercoat shall be as stipulated in the item. a) First coat: One coat of the specified paint shall be applied and allowed to dry

overnight. It shall be rubbed next day with the finest grade of wet abrasive paper to ensure a smooth and even surface, free from brush marks and all loose particles dusted off.





b) Top coat: Topcoats of synthetic enamel paint of desired shade shall be applied after the first coat is thoroughly dry. Additional finishing coats shall be applied if found necessary to ensure properly uniform glossy surface.

Other details shall be as specified in 15.33 of MAHAPWD S.R. as far as they are applicable. The primer is to be used as specified by the manufacturer and approved by the Engineer.

6.8 Glass Mosaic tiles: The work is to carried out as per Italia / Palladio or approved equivalent.

6.8.1 Composition The Product is made of basic raw materials like silica sand, sand ash, nepheline, flooring, and metallic oxides. The tiles should weight approximately 3 grams for 20 x 20 x 4mm thickness. (Approximately)

6.8.2 Fixing: Glass mosaic tiles should be fixed with cement based adhesives recommended by manufacturers or approved by the engineer in charge and white Cement. a) The surface should be mala plastered, level and without undulations. If fixed with

adhesives and single coat mala plastered which will make rough with help of nails of wires, level and without undulations if fixed with white cement.

b) The surface should be free from any dust, impurities, grease and debris etc., before application.

c) The surface should be damp free if fixing is done by white cement. d) Expansion joints are as per standard or preferred. e) Structural cracks, hollow surfaces, scaffolding holes and gaps must be rectified before

fixing by proper filling with which mortar. In certain specific cases chicken wire mesh is to be used for surface preparation instead of commonly used by “V” cut method.

f) In case of specific requirement, the surface should be made waterproof. g) The minimum radius of the rounded edge should not be less than 14mm. h) New plaster surfaces will be wetted till it gets dry and setting the mortar properly

before application. 6.8.3 Storage

The materials shall be kept in dry and covered place. If any damages to the particular sheet of the tile occurs or not matching with print out, then the sheet is to be returned or replaced.





7 SUSPENDED CEILING 7.1 General

Suspended ceiling shall be of metal suspension system, Aluminium lineal ceiling, G.I. metal tile ceiling, Aluminium metal tile ceiling or Armstrong tile ceiling or equivalent in flat, tapered, curved or circular form both in plan and in section together with cover etc., as per design approved by the Engineer in charge

7.2 Specialized Workmen All work shall be done by the Contractor directly or by an experienced specialist sub-contractor who shall be appointed only after prior approval of the Engineer.

7.3 Checking and Approval before Starting Work of ceiling shall only be started after all major work such as masonry work, plaster, window and door fixing and flooring are complete. Before starting dropped ceiling work, all related work such as ducting, electrical and other work, any painting above the dropped ceiling etc., if required shall be completed and thoroughly checked and approved.

7.4 Coordination & Approval of Shop Drawings The dropped ceiling work in general shall be fully coordinated with light fittings & all other electric fixtures, A.C. ducts and grilles, fire detectors, access panels, pelmets, columns and partitions. Detailed shop drawings on this basis suited to the exact site conditions and dimensions for each separate area shall be prepared by the Contractor and got approved by the Engineer well before proceeding with the work. Samples shall be prepared at the site for each type of false ceiling and got approved before commencing the work.

7.5 Lines & Levels All framing work shall be done with approved wood or with proprietary metal suspension system as required and shown. The wood battens shall be securely fixed to walls and columns by approved heavy duty metal fasteners and to the slab above with M.S. straps or bars of required sections, anchored therein. All wood framing, for ceiling shall be given two coats of wood preservative fire resistant coating. The underside of the framing shall be true to planes and slopes. Bottom of the frames shall be planed true to levels. For bulkheads, the frames with cross runners fixed horizontally shall be truly in plumb and plane. Care shall be taken to see that ceiling, unless otherwise required, are absolutely horizontal, flat and in one level, no waviness being allowed. Grooves, lines and patterns, if any, shall be maintained in straight or curved lines as required accurately as per drawing.

7.6 Metal Suspension System Where specified, the ceilings shall be installed with approved proprietary snap grid exposed grid suspension system recommended by the dropped ceiling tile manufacturer's comprising Tee's with main runners, cross-runners, wall channels, suspension hangers, holding channels and holding down clips. The material of the suspension system shall be of tested special spring grade steel accurately formed and die cut with identical ends. All members shall be vinyl coated fully treated and protected against corrosion. The layout of the grid shall follow the ceiling pattern of the tiles as shown and required.

7.7 Handling and Storage All the components shall be stored under cover in clean and dry conditions in a dust free area and shall not be allowed to come into contact with cement, lime, plaster, mortar etc. which can damage them. Special care shall be taken in stacking Plaster of Paris bags. They shall be kept in dry conditions on a raised platform with wooden planks. The stacks shall be kept away from the walls.

7.8 Cutting Power tools shall be employed for the work. Manual work shall be done only under exceptional circumstances with the prior permission of the Engineer.

7.9 Cavity Barriers and Partitions Cavity barriers shall be provided, to prevent spread of fire, above suspended ceilings in accordance with the details recommended by the manufacturer and as directed by the Engineer. Partitions for isolation of different air conditioning zones/rooms shall be of specifications similar to that of the suspended ceilings. The cavity barriers and the partitions shall be measured in sqm. as for the suspended ceiling and shall be paid at the same rate as that of the suspended ceiling.

7.10 Aluminium Lineal False Ceiling Material 7.10.1 Material





Aluminium ceiling wherever shown shall be Track or Hunter Douglas or equal approved powder coated Aluminium strip dropped ceiling with perforated / plain panels of approved shade. The ceiling shall be supplied and fixed by specialized workmen approved by the manufacturer, strictly as per manufacturers printed instruction. The panel will be 84mm x 16 mm deep with recessed flanges of made out of 0.50mm Aluminium alloy AA3105 with powder coated finish.

7.10.2 Installation The ceiling including suspension system shall be installed as per the material specifications and printed instructions of the manufacturer. Provision for cut outs for lights and air-condition diffusers etc. shall be made as shown in the drawings and as required at site. The entire installation shall meet the approval of the Engineer.

7.10.3 Suspension The ceiling panels shall be fixed at maximum 1500 mm c/c carriers to be suspended from slab/roof by 4 mm dia galvanized wire hangers with special height adjustment clips made out of spring steel including all trims, angles, recessed edges profile (20 mm x 20 mm) screwed to panel carrier 84 R Exterior grade@ 1300 c/c.

7.11 Cement Banded Particle Board Dropped False Ceiling a) Material

The cement particleboard shall conform to IS: 14862: 2000. The thickness of the Panel for false ceiling will be 8mm of Bison or equal approved Grid will be made with Aluminium Tee sections with suitable wall line supports. The suspension arrangement will be with G.I. wires of adequate gauge taken to required level from the soffit. The grid shall be 610 x 610mm or 610 x 1220mm (2’0 x 2’0 or 2’0 x 4’0). Aluminium T-sections for the grid shall be powder coated and the minimum thickness of the section shall be 1.2 mm and size 30 x 35 mm. Suspenders will be 8 SWG G.I. wires.

b) Installation The false ceiling will be `T’ grid type with longitudinal supports spaced at 610mm intervals and cross supports at 610mm or 1220mm centers. The maximum distance allowed between suspenders in longitudinal direction and cross direction is 1220 mm or 4’0. Closer intervals may be adopted depending on the soffit conditions. A turn buckle of GIJ Bolt will be provided in the suspender for leveling of the grid. Wall rests will be fixed perfectly leveled, as the level of the entire grid depends on the level of wall rest. Lock pins on the top of the panels to ensure structural integrity of the grid and the panel will be provided. The lock pin can be either a headless nail or a screw taken across the web of the Tee section. Wherever the lighting points occur, extra suspenders will have to be provided to take the load of the fittings. The panels will have primer in dry condition on one side and the ends in particular before inserting them in the grid. The bottom side of the panel will be painted in approved color. A clearance of 1-2mm shall be given between the board and the grid on all sides for taking care of thermal expansion, if any.

7.12 Aluminium metal tile false ceiling The ceiling shall be of Hunter Douglas make or approved equivalent. Material 600 x600 perforated panels manufactured out of 0.7mm thick Aluminium. The tile will be manufactured an advanced equipment. Tile ends will be raised with pips and stops to ensure positive engagements into the spring to enable for demounting of individual panels. The tile sides will be sufficiently high to ensure a minimum deflection across the length of the tile. All tiles will be beveled edged. The tile shall be polyester based, powder coated in white color. The tile shall be clipped into clip in profile of 0.5mm thick G.I. The clip in profile shall be supported from slab by means of rigid suspension of 4mm G.I. rod, hold on clamp with clip as per manufacturer’s instructions.

7.13 G.I. powder coated tile false ceiling The ceiling shall be of Hunter Douglas make or approved equivalent.





600 x600 perforated panels manufactured out of 0.5m thick GI powder coated. The tile will be manufactured an advanced equipment. Tile ends will be raised with pips and stops to ensure positive engagements into the spring to enable for demounting of individual panels. The tile sides will be sufficiently high to ensure a minimum deflection across the length of the tile. All tiles will be beveled edged. The tile shall be polyester based, powder coated in white color. The tile shall be clipped into clip in profile of 0.5mm thick G.I. The clip in profile shall be supported from slab by means of rigid suspension of 4mm G.I. rod, hold on clamp with clip as per manufacturer’s instructions.

7.14 Polycarbonate sheets 7.14.1 Material

The material is made of 2mm thick polycarbonate sheets of GE plastics make or Tuflite or approved equivalent. The material shall conform IS: 14443: 1997 and ASTM D 792. The polycarbonate sheet should have ultra violet resistance capacity on both the sides and it should be of excellent glazing material. The length of the polycarbonate sheet will be as per the manufacturer’s specifications.

7.14.2 Installation The polycarbonate sheets shall be fixed as per drawings to match the same profile of roof sheeting and fixing all as per following manufacturer’s specifications and approved by the Engineer in charge.

7.14.3 Measurements Length and breadth to the nearest cm and over shall be calculated in Sqm correct to two decimal places.

7.14.4 Rates Rates shall include cost of material, labour, fixing involved in the operation.





8 METAL WORK 8.1 Scope of Work

The work shall include providing metal work in the building for door frames, balustrades, handrails, railings, grill work, frame work of sky lights, inserts, fasteners, lugs using plates, chequered and plain plates, flats, strips, squares, rounds, tubes, pipes, angles, channels, tees, expanded metal, I-sections, etc., including cutting, filing, grinding, drilling, mechanical fastening, welding, etc., at locations and situations as directed by the Engineer in accordance with the design, patterns, shapes, thicknesses, details all as shown on the drawings or as specified or as directed by the Engineer and also as per the Specifications, standards and codes as given herein under, complete in all respects to give the quality of finished work as desired by and to the entire satisfaction of the Engineer.

8.2 Applicable Specifications 8.2.1 All work shall be done as per MAHAPWD Specifications 2007-08 section 7 in addition to

CPWD specifications 1996 except as modified herein under and as per the additional requirements given herein under.

8.3 Shop Drawings 8.3.1 All work shall be executed to approve shop drawings. The shop drawings shall inter alia

show the complete details of the connections including the fixing arrangement to concrete or brick work or flooring, etc., the size of the welds/bolts/nuts/washers/ grinding finish/tolerances, etc.

8.4 Samples 8.4.1 The Contractor shall submit samples of all materials that are called for by the Engineer.

The Contractor shall prepare samples of workmanship and mock-up for approval. 8.5 Protection 8.5.1 The Contractor shall protect the work at all times from any damage. All finished work

shall be protected by polythene-wrap or other approved means. 8.6 Inserts 8.6.1 The Contractor shall fix all necessary inserts such as steel plates, pipe sleeves, bolts etc.

and make provision of holes, pockets, dowels, etc., in the form work to enable subsequent fixing of supports, brackets, ceilings, precast members, etc., as indicated on the drawings or called for in the Schedule of Quantities or as required by the Engineer. Concrete inserts shall be as per IS: 1946 and of a type approved by the Engineer.

8.6.2 Rate quoted for inserts is deemed to be inclusive of placing them in position and nothing extra is payable for the same. Nothing extra over and above the provision as per the priced schedule of quantities shall be paid to the Contractor for placement of inserts in position before concreting.

8.7 Fire Check Door 8.7.1 General

The shutter of the door of approved make conforming to IS: 3614 (Part II) 1966 shall be so designed so as to provide the specified fire resistance when tested as per IS: 3614 (Part 2): 1992 and BS: 476- Part 22 to suit the specified requirement and the manufacturer must produce certificates of a recognized laboratory to the satisfaction of the Engineer.

8.7.2 Frame Door frames of 16 SWG G.I. tube of size 139 x 57mm approximately or as specified by the manufacturer with a tolerance of + 3mm section (nominal) with heat activated intumescent fire seal strips of size 12mm x 4mm (for smoke sealing) mounted in the groove in frame or EPDM gasket to act as smoke seal suitable for mounting 120 minutes fire rated shutters with one coat of anti-termite fire retardant primer.

8.7.3 Sill The sill shall be of 16 SWG G.I. tube.

8.7.4 Panels The shutter of overall thickness 60mm formed out of 2 outer skin panels of 1.25 mm galvanized steel sheets having lock seam joints for locking. Reinforcements shall also be provided at locking / hardware area. The sheet metal used for both the frames and the shutters conform to IS 277: 1992. The shutter shall be free from twist or wrap in its plane. Tolerance on width and height shall be + 3.0mm and tolerance on nominal thickness shall be + 1.2 mm. The thickness of the door shutter shall be uniform throughout with a permissible variation of not more than 0.8mm when measured at any two points. In fill materials shall be proprietary ceramic based infill material with internal reinforcements, infill materials as approved by CBRI.





Two nos. stainless steel ball bearing butt hinges shall be used for each leaf of height not more than 1.2m and three hinges shall be used for each leaf of height more than 1.2m. Butt hinges minimum of 100mm and 75mm shall be used for shutters having height more than 1.2m and height less than 1.2m respectively. For shutter of more than 40mm thickness, butt hinges of size 125 x 90 x 4mm shall be used.

8.7.5 Hardware’s/Fittings All fittings used in the manufacturer of the door shall be heavy-duty type. The doors shall be fitted with heavy-duty concealed type automatic door closers, of approved make. All fittings should also with stand the fire temperature and should not melt during 120 minutes of fire rating.

8.7.6 Panic Bar/Exit Devices These shall be of press type panic bars with 4 point latch system either single or triple latch. The panic bar shall be fire rated of 120 minutes of the fire duration.

8.7.7 Seal A heat activated intumescent seal of approved quality and make conforming to BS: 476 (Part-8) or EPDM gaskets shall be provided on all edges of door to check the spread of smoke in case of fire.

8.7.8 Paint The doorframe and panel shall be primed in stoving grade epoxy zincphophate primer and finished in aliphatic grade UV resistant polyurethane paint. Vision panels wherever required to be fixed with clip on window frames with no screws and fasteners on the surface, fire rated vision glass to be 6mm thick borosilicate float glass/ pyran glass fixed on vision panels with 5mm ceramic fiber tape

8.8 Particle Board Door with Aluminium Stiles and Frame The work shall include providing and fixing of door made with prelaminated particleboard and Aluminium as per drawing. The sample of the door including colour of powder coating is to be got approved by the Engineer before mass fabrication.

8.8.1 Material Prelaminated particleboard shall be as specified in clause 3.6, Section 12. Aluminium frames, stiles, channels etc. will all conform as described in clause 8.11. of this section.

8.8.2 Installation Prelaminated particleboard shall have U-type Aluminium edging on three sides and overlapping rebate type U-edge on vertical edge (on locking side) of the panel. Aluminium frame shall be fixed to wall with non-rusting, coloured screws and raw plugs. Heavy duty hinges will be used which will be inserted through slits made in the frame and U-type edging. The door shall be in true alignment for smooth movement. Provisions for all ironmongery, vision panel air transfer grilles etc. is to be made as required.

8.9 Metal Doors 8.9.1 General

The work shall include providing and fixing metal door including frame of approve make and quality as per specified requirement to the satisfaction of the Engineer. Provisions shall be made in panel / frame for ironmongery, vision panel, air transfer grilles etc. Sample of the door is to be approved by the Engineer.

8.9.2 Material Door panel shall be fabricated from 0.90 mm thick G.I. sheets with infill of honeycomb craft core. Doorframe shall be fabricated from 1.60 mm thick galvanized steel sheet and of required dimensions. Stainless steel hinges of adequate strength to be provided for single / double leaf doors. Double leaf doors will have rebated meeting stile. Installation Door panel shall be minimum 46 mm thick made with press formed G.I. sheet panel will be fully flushed double skin with lock seam joints at stile. Doorframe of required dimension shall be fixed to the wall with M.S. lugs / holdfast. Doorframes shall be filled up with P.C.C., 1:5:10 (1 cement: 5 aggregate: 10 coarse sand). Painting Door shutter and frame shall be primered in stoving grade epoxy zinc phosphate primer and finished in aliphatic grade U.V. resistance polyurethane paint.





8.10 tainless Steel Handrail 8.10.1 Scope of Work

The work shall include providing and fixing of handrail, stainless steel grating, stainless steel plate for expansion joints and other things necessary to complete the work as specified and shown in the drawings complete in all respect to give the quality of finished work as desired by and to the entire satisfaction of the Engineer.

8.10.2 Approvals The sample of the material shall be submitted to the Engineer for approval before fabrication of the work.

8.10.3 Material Handrail shall be made of welded cold drawn solution annealed and pickled; stainless steel tubes grade 304 as per ASTM-A 249-95a. Outer diameter of the tube will be as specified and shown in the drawing. Thickness of wall will be 10 gauge as specified. Finish of the tubes will be matt / buff as specified. Material shall confirm to mechanical test of tensile strength, yield strength, elongation, hardness, flanges, flattening, heat analysis, reverse bending etc. Chemical composition in % will be as follows:

C Si Mn P S Ni Cr. Mo

0.035 Max.

0.75 Max.

2.00 Max.

0.040 Max.

0.030 Max.

10.00 15.00

16.00 18.00

2.00 3.00

8.10.4 Installation G.I. sleeve of 40mm dia will be grouted in the steps / landing of staircases or railing as specified and shown in the drawing. 25mm dia stainless steel baluster will be bolted to the sleeve and lead jointed. The baluster will be welded to 50mm dia stainless steel handrail. Stainless steel round cover will be fixed to the bottom of baluster. Ends of the handrail tube to be capped wherever required. While assembly is to be true in line and upright as per requirement.

8.11 Aluminium work and Glazing 8.11.1 Scope of Work

The work shall include providing aluminium and glazing for the building for doors, windows, glazing, skylights, semi-unitized structural curtain wall system, etc., and at any other locations and situations as directed by the Engineer-in-Charge in accordance with the design, patterns, shapes, thicknesses, details, all as shown on the drawings or as specified or as directed by the Engineer and also as per the specifications, standards and codes as given herein under, complete in all respects to give the quality of finished work as desired by and to the entire satisfaction of the Engineer-in-Charge. The work shall be carried out by an experienced specialist Sub-Contractor who shall be appointed only after prior approval of the Engineer.

8.11.2 Materials 8.11.2.1 Aluminium

Aluminium shall conform to IS: 733-designation HE9-WP or HV9-WP alloy. Aluminium shall be superior quality extruded sections made by Indian Aluminium Co. or Hindustan Aluminium or Jindal or an approved equivalent manufacturer, of a gauge suitable for the work.

8.11.2.2 Glass Glass shall generally conform to the requirements of BS: 952 or JIS: R3203 or equivalent standards. It shall be clean cut without edge faults and free from defects. Glasses shall be tested for critical parameters like flexural bending strength, fragmentation, bow and corrugation as per DIN: 1249 Part-12 with necessary test certificates from the manufacturer for each lot.

a) Float Glass Glass shall be clear Float Glass or Body Tinted Float Glass, conforming to JIS: R3203 manufactured by Saint Gobain glass, Belgium glass, Float Glass India Ltd. or Gujarat Guardian Ltd. or approved equivalent manufacturer.

b) Toughened Glass Clear or Tinted Float Glass shall be toughened (tempered) for applications where specified. The glass shall be horizontally tempered as per DIN: 1249 Part-12 having no tong or suspension mark and shall have machined edges with no burrs or sharp surfaces.





c) Laminated Glass Two panes of Clear or Tinted Float Glass shall be laminated using a layer of PVB.76 mm. Laminated glass shall be provided where specified. The preparation of Laminated Glass shall be as per BS: 952 Part-1.

d) Mirrors Mirrors shall be Copper Silvered Float Glass backed with two coats of paint applied by curtain coat technology.

e) Insulating Glass The Insulating Glass shall conform to BS: 5713 and shall comprise two panes of Float Glass fixed with a gap of 12mm created by a spacer and hermetically sealed around the edges leaving a dehydrated air space.

8.11.3 Powder Coatings Coating for applications to aluminium alloys extrusion, sheets and preformed sections for architectural purposes and their application, finish, performance, etc., shall be 65 microns and to conform to BS: 6496 for powder coatings. The coating (pure polyester) shall be as made by Berger or Nero coat or Jenson and Nicholson or approved equivalent.

8.11.4 Weather Stripping Weather stripping shall be wool pile manufactured by an approved Company. The profile shall be as follows:

Application Base Width Pile Height

Sliding windows and doors 6.7mm 7.0mm

Casement windows 6.0mm 5.0mm

Swing doors 9.0mm 8.0mm

Gaskets shall be of Ethylene Propylene Diene Monomer (EPDM) of approved profile and manufacturer.

8.11.5 Handling and Storing Materials Aluminium Work Fabrication and Components All self-finished work shall be wrapped, taped or protected in an approved manner with non-absorbent coverings. These shall be delivered to a programme to reduce or eliminate site storage. Coverings shall be removed just sufficient to enable jointing and assembling and shall be replaced thereafter.

8.11.6 Glass Glass shall be stored in dry, shaded and ventilated areas, on firm straight supports. Water collection (condensation) between panes shall be prevented. Mirrors shall be delivered wrapped and shall be kept wrapped until the time of fixing. Different types of mirrors/glasses shall be stacked separately with proper identification.

8.12 Workmanship 8.12.1 General

Aluminium work shall be undertaken in accordance with sound engineering practice and as follows:

a) Aluminium work shall be done as much as possible in the properly equipped workshop.

b) Site work shall be restricted to fixing and other operations that cannot be undertaken in the workshop.

c) Burrs, sharp edges and angles, coarse file marks, excess weld metal and similar imperfections shall be removed.

d) Work shall not be permitted to corrode or otherwise deteriorate between fabrication and final treatment/fixing.

e) Aluminium work shall be fixed in the works in a manner that prevents corrosion due to contact with incompatible metals and other materials.

8.12.2 Bending and Joint Faces Aluminium shall be shaped by bending with machine without weakening or otherwise damaging the same. Joint faces shall be formed to fit accurately in full contact. A suitable joint coating shall be used for bolted or screwed connections.

8.12.3 Cutting Glass





All edge and surface treatment shall be done at the glass works after cutting to size. Glass shall be cut to produce clean square edges. Any work to Toughened Glass shall be undertaken by the glass manufacturer prior to the toughening process. The edge of multiple glazed units shall not be nipped.

8.13 Design The glazing for the building, including windows, skylights and doors, shall be designed by the manufacturer as per BS: 6262 British Standard Code of Practice for Glazing for buildings, to withstand wind loadings as given by IS: 875 and provide seismic isolation and restraint for buildings located in Seismic Zone-II as per IS code. The Contractor shall submit complete design calculations for the design of the glazing for the approval of the Engineer. The Contractor shall order materials only after the designs are approved by the Engineer.

8.14 Performance The performance of windows, glazing, doors, skylights shall be as given in BS: 6375 Parts 1 and 2 for weather tightness, operation and strength.

8.15 Tests Tests for performance shall be carried out by the Contractor as per following: BS: 5368 Part 1 – Air Permeability Test BS: 5368 Part 2 – Water Tightness Test under Static Pressure BS: 5368 Part 3 – Wind Resistance Test The Engineer shall decide as to which windows shall be subjected to test.

8.16 Test Report The test reports shall be submitted in quadruplicate as per the format given in BS: 5368 Part-4.

8.17 Sub Frames All aluminium work shall be fixed to mill finished aluminium tubular sub frames. The sub frames shall be fixed to brick work/concrete work using expansion bolts as directed by the Engineer

8.18 Mock-up and Samples Before preparation of shop drawings the Contractor shall submit samples of all preformed and extruded sections proposed to be used. The Contractor shall also submit samples of colours of coating based on the colours requested by the Engineer. Once preliminary approval is given and shop drawings are approved by the Engineer, the Contractor shall submit final samples of typical windows, complete in all respects.

8.19 Sealants Silicone sealants of approved colour and make shall be used as specified.

8.20 Isolation Where aluminium comes into contact with masonry, brickwork, plaster or dissimilar metals, it shall be coated with an insulating coat of lacquer, paint or tape to ensure the elector chemical corrosion is avoided. The Contractor shall submit his proposal for the approval by the Engineer-in-Charge before related materials are ordered.

8.21 Protection The Contractor shall protect the powder coated aluminium sections with clear or coloured tape. The tape shall not disfigure the finish. The Contractor shall protect installed work with suitable measures to the entire satisfaction of the Engineer.

8.22 Protection Against Damage Care shall be taken to avoid damage from any cause at all stages. Packing pieces used for protection shall not disfigure or otherwise permanently mark the works. Surface protection shall be afforded by careful handling and the avoidance of the use of hooks, crowbars or other implements that are likely to damage the stone, marble, granite, limestone, timber, doors, windows, metals, glass, etc. Oils, grease, paint; cement slurry and liquid agents liable to cause staining shall not be used in close proximity to the area in which the materials are stacked. Protection during Construction – Decorative surfaces shall be carefully protected during construction by a temporary cover of adequate strength and durability. Protection of finished work – At all stages of the contract it is essential that all works are properly and effectively protected.





Particular attention shall be given to permanently exposed surfaces, especially arises and decorative features. The protection may be by timber strips, hessian or polyethylene, but shall not be such as will damage, mark, or otherwise disfigure the work. Polyethylene heavy-duty sheeting may be used as protection against rain. It may be necessary in certain cases to avoid contact of water with the materials. Timber battens protecting sills or other rises shall be retained in position as long as possible. Suitable packing shall be used to ensure that scaffolding does not damage erected stone, marble, granite or other finished works. Work on the upper stages of the super structure shall not be allowed to damage or disfigure the work in the lower levels. Unless special precautions are taken for winter working, the use of mortar shall be avoided when the thermometer reads 2 degree and falling and the joints shall be protected. Any disfigurement, discolouration or imperfection whatsoever due to any reason shall not be accepted and the Contractor shall either remedy the same or redo the work at no extra cost. The decision of the Engineer as to whether any work either in whole or in part is acceptable or not shall be final and binding on the Contractor.

8.23 Glazing Adhesive labels for indicating “Glazing completed” shall be easily removable without scraping. Marking with lime shall not be used for this purpose. Glass shall be protected against mechanical damage. Any alkaline splashes shall be removed before they harden.

8.24 Tolerances The size of aluminium work shall not vary by more than ± 1.5mm.

8.25 Cleaning and Completion On completion of the first area of aluminium work and glazing and the quality of work accepted, the same shall be cleaned of all dust and other deposits. This area of aluminium work and glazing shall be retained as a sample of the finished work, wherein the effects of weather, movement and other conditions shall be reviewed over a period not exceeding one month and the effects if found leading to unsatisfactory work, shall be remedied by the Contractor, until a satisfactory sample of finished work is accepted. All other work shall thereafter be completed to the same standard and quality as approved.

8.26 Acceptance Criteria Acceptance of Work at Intermediate Stage The work executed on any day shall be checked at the end of that day or the next day before commencement of further work. Any work found to be of acceptance quality or not in accordance with the specification should be rejected, removed and replaced before proceeding with further work.

8.26.1 Final Acceptance of Work Various stages of approval are required to be met by the Contractor. Regardless of the acceptance of work at intermediate stages, the final acceptance shall only be accorded once the entire work is complete in one area of the building; after all other works as per this Contract have also been duly completed and accepted.

8.27 Ironmongery For fixing ironmongery and friction hinges, if the wall thickness of the extruded aluminium section is not adequate to take the threading of the screws, the Contractor shall provide additional thickness with built-up sections, etc., as required. All ironmongery including sliding gear for sliding glazing’s / windows and the friction hinges for side hung projected windows shall be supplied and installed by the Contractor. The Contractor shall supply Catalogues and samples for approval of the Engineer.

8.28 SPECIFICATIONS FOR STEEL ROLLING SHUTTERS Generally all works shall be in accordance with section 7.10 of MAHAPWD Specifications 2007-08 in addition to section 10.8 of CPWD Specifications 1996. Rolling shutters shall conform to IS 6248. These shall include necessary locking arrangements and handles etc. These shall be suitable for fixing in the position as specified i.e. outside or inside on or below lintel or between jambs of the opening. The door shall be either push or pull type or operated with mechanical device supplied by the firm. Shutters up to 10 sq. metre shall be of push and pull type and shutters with an area





of over 10 sq. metre shall generally be provided with reduction gear operated by mechanical device with chain or handle, if bearings are specified for each of operation, these shall be included in the rates.

8.28.1 Shutter 8.28.1.1 The shutter shall be built up of interlocking lath section formed from cold rolled steel

strips. The thickness of the sheets from which the lath sections have been rolled shall be not less than 1.20 mm. Shutters above 9 meters in width should be divided in 2 parts with provision of one middle fixed or movable guide channel or supported from the backside 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 not less than 12 mm to provide sufficient curtain of stiffness for resisting manual pressures and normal wind pressure. Each lath section shall be continuous single piece without any welded joint. When interlocked, the lath sections shall have a distance of 75 mm rolling centres. Each alternate lath section shall be fitted with malleable cast iron or mild steel clips securely riveted at either ends, 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.

8.28.2 Spring The spring shall be of coiled type. The spring shall be manufactured from high tensile spring steel wire or strips of adequate strength conforming to IS 4454 – Part I.

8.28.3 Roller and brackets The suspension shaft of the roller shall be made of steel pipe conforming to heavy duty as per IS 1161. For shutter up to 6 metre width and height not exceeding 5 metre, steel pipes of 50 mm nominal bore shall be used. The shaft shall be supported on mild steel brackets of size 375 x 375 x 3.15 mm for shutters up to a clear height of 3.5 metre. The size of mild steel brackets shall be 500 x 500 x 10 mm for shutters of clear height above 3.5 m up to 6.5 m. The suspension shaft clamped to the brackets shall be fitted with routable cast iron pulleys to which the shutter is attached. The pulleys and pipe shaft shall be connected by means of pretensioned helical springs to counter balance the weight of the shutter and to keep the shutter in equilibrium in any partly open position. When the width of the opening is greater than 3.5 metre, the cast iron pulleys shall be interconnected with a cage formed out of mild steel flats of at least 32 x 6 mm and mild steel dummy rings made of similar flats to distribute the torque uniformly. Self-aligning two-row ball bearing with special cast iron casings shall be provided at the extreme pulley and caging rings shall have a minimum spacing of 15 mm and at least 4 number flats running throughout length of roller shall be provided. In case of shutters of large opening with mechanical device for opening the shutter the roller shall be fitted with a pinion wheel at one end which in contact with a worm fitted to the bracket plate, caging and pulley with two ball bearing shall be provided.

8.28.4 Guide channel The width of guide channel shall be 25 mm the minimum depth of guide channels shall be as follows

Clear width of shutters Depth of guide channel

Up to 3.5 m 65 mm

3.5 m up to 8 m 75 mm

8 m and above 100 mm

The gap between the two legs of the guide channels shall be sufficient to allow the free movement of the shutter and at the same time close enough to prevent rattling of the shutter due to wind. Each guide channel shall be provided with a minimum of three fixing cleats or supports for attachment to the walls or column by means of bolts or screws. 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 channels shall be attached to the jambs, plumb and true either in the overlapping fashion or embedded in grooves, depending on the method of fixing.





8.28.5 Cover Top cover shall be of mild sheets not less than 1.25 mm thick and stiffened with angle or flat stiffeners at top and bottom edges to retain shape. Lock plates with sliding bolts, handles and anchoring rods shall be as per IS 6248.

8.28.6 Fixing The arrangement for fixing in different situations in the opening shall be as per IS 6248. Brackets shall be fixed on the lintel or under the lintel as specified with raw, plugs, and screws bolts etc. The shaft along with the spring shall then be fixed on the brackets. The lath portion (shutter) shall be laid on ground and the side guide channels shall be bound with ropes etc. The shutter shall then be placed in position and top fixed with pipe shaft with bolts and nuts. The side guide channels and cover frames shall then be fixed to the wall through the plate welded to the guides. These plates and bracket shall be fixed by means of steel screws bolts, and raw plugs concealed in plaster to make their location invisible. Fixing shall be done accurately in a workman like manner that the operation of the shutter is easy and smooth.

8.28.7 Measurements Clear width and clear height of the opening for rolling shutter shall be measured correct to a mm. The clear distance between the two jambs of the opening shall be clear width and the clear distance between the sill and soffit (bottom of lintel) of the opening shall be the clear height. The area shall be calculated in square metres correct to two places of decimal.

8.28.8 Rate The rate shall include the cost of materials and labour involved in all the operations described above including cost of top cover and spring except ball bearing and mechanical device of chain and crank operation, which shall be paid for separately.

8.29 SPECIFICATIONS FOR STEEL ROLLING GRILLS Generally, all works shall be in accordance with section 7.11 of MAHAPWD Specifications 2007-08 in addition to section 10.9 of CPWD Specifications 1996.

8.29.1 Rolling grill is to be provided as shown in the approved drawings and instructed by the Engineer in charge.

8.29.2 Rolling grills are similar in design, construction and operation of rolling shutters and all the provisions shall be applicable to rolling grills except in respect of the shutter portion, and shall conform to IS 6248.

8.29.3 Shutters Rolling grill shutter and the rolling grill portion of the rolling shutter – cum – grill shall be fabricated with 8 mm diameter mild steel round bars. Straight bars and bars bent to the required profile are placed alternatively and held in position with 20 mm wide and 5 mm thick mild steel flat links. Straight bars shall be spaced not exceeding 150 mm centre to centre and the bars bent to required profile shall be placed symmetrically between two consecutive straight bars. Unless otherwise specified or directed by the engineer, bars placed alternatively with straight bars shall be bent to form a corrugated profile such that the pitch of the corrugation is 100 to 120 mm and the depth of corrugation is 80 to 100 mm. All the bent bars shall have uniform profile. Straight bar along with the adjoining bent bars on it both sides shall be held in position by passing the bars through holes in the links. Each link shall have three holes and the length of the links shall be such that the distance from the centre of the hole to the nearest edge of the flat is not less than the diameter of the hole. The corner of the links shall be rounded. All links shall be of uniform size and shape. The spacing of the links measured along the straight bar shall be of uniform size and shape. The spacing of the links measured along the straight bar shall be the same as centre to centre distance between two consecutive crests/troughs of the bars bent to the required profile. Each bar and link shall be a continuous single piece without any joint.

8.29.4 Measurement and rate The measurements and rate shall be as specified in 8.28. In case of Rolling Shutter – cum –Grill, where the area of the grill portion is half or less than half the area of opening, it shall be measured and paid as rolling shutter and where the area of grill portion is more than half the area of opening, it shall be measured and paid as rolling grill.





9 WATER PROOFING

9.1 Waterproofing of Raft and Retaining Walls 9.1.1 Waterproofing of Raft and Retaining walls by external tanking (including grouting of

Concrete) 9.1.1.1 External tanking (including grouting of concrete) of basement, trenches, tunnel etc.

shall be carried out using an approved acrylic chemical waterproofing compound, in stages given below:

9.1.1.2 Stage 1: After the lean concrete has been laid to receive the RCC raft, a 345 mm thick brick toe wall in Cement Mortar 1:6 shall be constructed, on the perimeter of the area to be water proofed. The height of this wall shall be equal to the thickness of the RCC Raft. The brick toe wall shall be paid separately under the item of Brickwork.

9.1.1.3 Stage 2: Base The external tanking treatment shall be carried out for the base raft over the lean concrete in the following sequence.

a) A layer of cement slurry mixed with the acrylic-waterproofing compound shall be spread over the lean concrete.

b) In each layer where acrylic-waterproofing compound is to be used it shall be mixed in the ratio of 400 gms per 50 kg. Of cement unless specified otherwise.

c) Thereafter a 25mm thick (minimum) bedding layer of cement mortar 1:3 (one part cement: three parts course sand) mixed with acrylic waterproofing compound shall be laid.

d) Curing shall be done by spraying water for 7 days. e) A layer of Kota/Cuddapa stone slabs of approximately 600 x 600mm and having

minimum thickness of 30mm shall be laid. The joints between the stones shall be 6mm. After laying the joints shall be raked and sealed with cement mixed with acrylic waterproofing compound (in the ratio 1:1).

f) A layer of cement mortar 1:4 (one part cement: four parts coarse sand) mixed with acrylic waterproofing compound shall be laid and finished smooth.

g) Curing shall be done by spraying water for 7 days. h) The waterproofing shall be turned up along the brick wall on the perimeter of the

basement raft. The work shall be carried out as described under walls. NB: The above specification shall also be followed for the roof of basement.

9.1.1.4 Stage 3: Grouting of Concrete 9.1.1.4.1 Raft

Placing and prefixing of 15mm M.S. nozzles of length 0.5D where D is the depth of the raft shall be done on the construction joints and pour strips. The spacing of the nozzles shall be 1 m apart in both directions in the raft to enable grouting to be done. The pipes shall project 50mm above the top of the raft and shall be plugged using M.S. caps. The RCC shall be cast after placement of the nozzles as required. After the concrete of raft has attained proper maturity the injection of cement mixed with non-shrink polymeric grouting compound through the nozzles under maximum pressure of 2.5 kg/sqcm. By hand/air/electric/pump shall be carried out. The nozzles shall be sealed after injection operation is over with a cementitious rendering with quick setting admixture of CICO make or approved equivalent. The above specification shall also be followed for the roof of basement if required.

9.1.1.4.2 Retaining Wall On removal of the form work if the external surface is found to be honeycombed, irregular surface shall be rendered with cement: sand mortar (1:3) after removing oil and greasy substances, if any. Placing and pre or post fixing of 25mm M.S. nozzles of length reaching half the wall thickness shall be done along construction joints and pour strips. The spacing of the nozzles shall be 1m to 1.5 m apart in both directions. In the case of prefixing this step shall be executed before concreting of retaining walls. Care shall be taken to terminate the concreting at the level of injection nipples. After the concrete of retaining wall has attained proper maturity the injection of cement mixed with non-shrink polymeric grouting compound through the nozzles under maximum pressure of 2.5 kg/sqcm. By hand/electric pump shall be carried out.





The nozzles shall be sealed after injection operation is over with a cementitious rendering with quick setting admixture of CICO make or approved equivalent.

9.1.1.4.3 Stage 4 : External tanking of Walls After the completion of the RCC raft and retaining walls up to the ground floor level, external tanking of the external surface of the retaining walls shall be carried out in the following sequence. The external tanking layer for the walls shall have an overlap over the external tanking layer provided along the brick toe wall in stage 2 and the joint sealed.

a) A layer of red sand stone slabs/ Cuddapa slabs of approximate size 600 x 600mm and having a minimum thickness of 30mm shall be laid with a gap of 15mm between the wall and the stone. This gap shall be filled with cement slurry mixed with acrylic waterproofing compound.

b) The joints of the stone tiles shall be inspected and any improperly filled joints shall be raked and sealed with cement mixed with the acrylic waterproofing compound.

c) Curing shall be done by spraying water for 7 days. d) Thereafter a 15mm thick layer of cement mortar 1:4 (1 part cement: 4 parts

course sand) mixed with acrylic waterproofing compound shall be splashed on the exterior surface of the stone wall, to cover the stone and joints thoroughly and uniformly.

The external tanking work for the wall shall be carried out in approved heights not exceeding 800mm and shall be taken up to heights as shown on the drawings / as directed and duly sealed with an approved silicone sealant at the top (The item of silicone sealant shall not be paid separately). Cement slurry shall use minimum water for consistency to permit workability and floor. The treatment of separation joints shall be undertaken as per the specifications given under clause 9.1.2 which shall be measured and paid for separately.

9.1.2 Treatment of Separation Joints in the Basement Retaining Walls The exterior wall surface separation joints in the basement retaining walls shall be independently treated, and each wall and shall be sealed using approved sealant. The gap shall be provided with expanded polystyrene foam filler, duly fixed to the surface cast first with suitable adhesive and sealed using an approved Polysulphide sealant. The treatment of the separation joints shall be carried out as per the construction drawing. The work of Polysulphide sealant shall be carried out as per the specifications given under Section 19 Caulking and Sealants. Only the quantity of the Polysulphide sealant shall be measured. The bitumen felt, the sandstone used for tapping the joint etc. shall not be measured. The rate quoted for the Polysulphide sealant is deemed to include for the same.

9.2 Waterproofing to Toilets, Kitchens etc. Waterproofing treatment to floor slabs and walls, chhajjas, roof projections, toilets, kitchens etc. in the building shall be done as described below.

a) The surface shall be prepared by chipping all loose materials/ mortar cleaned with a wire brush and coir brush in order to remove all loose and deleterious matter etc.

b) If any bores are there then the same shall be grouted using Non shrink grout SHRINKKOMP 20 or equivalent.

c) The area to be water proofed shall be ponded with the water and leakage / dampness shall be marked in the ceiling below.

d) Nipple shall be fixed at such locations wherever leakage persists and along the construction joints are pressure grouted using neat cement slurry and mixed with expensive grouting additive CERA EXPAN 250 or equivalent.

e) V grooves shall be cut along concrete / Brick work junctions and construction joints, cracks and the same shall be filled with polymer modified CERA LATEX SBR Mortar or equivalent with proper coving at corners.

f) Acrylic polymer based waterproofing system CERA LISTIC or equivalent shall be applied in two coats on cleaned surface.

g) 20mm thick plastering shall be done with 1:4 CM and mixed with CERAPROOF IWP Liquid or equivalent at the dosage of 200mm per bag of cement.

h) The bores shall be packed using polymer modified concrete after the pipes are laid. The treated areas shall be completed by ponding water.

9.3 Waterproofing and Testing





The treated area (flat and horizontal only) shall be tested by allowing water to stand on the treated areas to a depth of 150mm for a minimum period of 72 hours. The treated area (flat and horizontal) shall have a continuous slope towards the rainwater outlets and no water shall pond anywhere on the surface. The roofs shall be water-tight and shall be tested on completion by flooding the roof with water to a minimum depth of 25mm fir 24 hrs. Where it is impracticable, because of roof falls or otherwise, to contain a 25mm depth of water, the roof shall have water applied by a continuous hose of sprinkler system to provide a sheet flow of water over the entire area of the roof for not less than 6 hrs. In either case the roof shall be considered satisfactory if no leaks or damp patches show on the soffit. Should the structure not satisfy either of these tests, then after completion of the remedial work it should be retested in accordance with this clause. The roof insulation and covering should be completed as soon as possible after satisfactory testing.

9.4 Protection The Contractor shall protect the waterproofed areas from damaged by other agencies by providing temporary catwalks at no extra cost to the Engineer.

9.5 Guarantee The Contractor shall provide a guarantee of 15 years for the waterproofing work carried out as per the enclosed format on a non-judicial stamp paper.





10 SEISMIC JOINTS/ EXPANSION JOINTS

10.1 Scope of Work The work shall include providing and installing sealed seismic joints for the building in accordance with the requirements and details given in the Specifications, drawings, Schedule of Quantities, together with the manufacturer’s instructions, all to the complete satisfaction of the Engineer. The work shall involve sealing the Seismic joints using proprietary designed extruded seals, which may be mechanically fastened between extruded metal shapes, depending on the application. The design shall allow for joint movement in all direction and shall guard against moisture ingress. The latter shall be provided for all external joints and where directed by the Engineer. The complete details of the material proposed to be used shall be furnished to the Engineer for his approval and shall be used only after obtaining the written approval of the Engineer. The contractor shall furnish the design calculations, prepared by the manufacturer of the seismic joints, when required by the Engineer to enable the Engineer to satisfy himself regarding the suitability of the materials and adequacy of the design of the seismic joints. The work shall be carried out under the supervision of the manufactured/by an experienced specialist sub-contractor who shall be appointed only after prior approval of the Engineer.

10.2 Materials The seismic joint materials shall be procured from an approved manufacturer such as Watson Bowman Acme Corporation, represented by Sanfield (India) Pvt. Ltd. or an approved equivalent. The material shall conform to the following codes/publications.

a) Aluminium Extrusions shall conform to ASTM B221. The alloy shall be either 6061-T6 or 6063-T5.

b) Aluminium sheet and plates shall conform to properties of ASTM B209. The alloy shall be either 6061-T6 or 6063-T5 or 5052-H32.

c) Steel shapes shall conform to ASTM-A588. d) Stainless steel shall conform to ASTM-A-204 GR304 or ASTM-A-479 GR 304. e) Bronze Extrusions: Material shall be Architectural Bronze 385 Alloy. f) Elastomeric Compression Seal: These shall be neoprene compound with a

Durometer Type ‘A’ Shore hardness of 55+5 and a tensile strength of 2000 psi and shall conform to ASTM D-2628.

g) Moisture Barrier shall be vinyl moisture barrier as recommended by the joint manufacturer or an approved equivalent, all as subject to the approval of the Engineer.

h) Thermal Plastic Rubber shall be as per the manufacturer’s standard, subject to the approval of the Engineer.

i) Fire rated joint system shall have independent laboratory test reports reflecting the endurance result of the materials run to ASTM-E-119 time temperature curve.

j) Elastomeric Joint Systems: The elastomer shall comply with U.S. Federal Specification - TT-S-0027-E (3) with a Shore A hardness of 25 and allow movement of + 35% joint movement. The choice of colour within the range of colours offered by the manufacturer shall be done by the Engineer. The Elastomer shall be applied in the factory to pre-treated Anodized Aluminium retainers with continuous retainer legs. All corners shall be prefabricated. Blockout installation shall be provided at site by the Contractor as per the dimensions given by the manufacturer.

k) Lubricant adhesive used shall be a one-part moisture curing polyurethane and aromatic hydrocarbon solvent mixture and shall conform to ASTM D4070.

l) Visual Seal shall be dense neoprene with a Durometer Shore “A” hardness of 70+5 and in accordance with ASTM C-864 or thermoplastic rubber with a Durometer Shore A hardness of 73 + 5 in accordance with manufacturer’s standard physical properties.

m) Functional seal shall be flame retardant vinyl material. n) Sealant shall be a one-part Polysulphide base synthetic rubber sealant conforming

to Federal Specifications TT-S-00230C Type 11. o) The Contractor shall provide all necessary accessories, related parts, devises,

anchors etc. required for completing the installation. 10.3 Fabrication





Aluminium sections shall have factory-drilled holes spaced as per manufacturer’s recommendation. Extrusions shall be miter cut at the site to suit directional changes. Extrusions shall be supplied to site in their original packing in lengths as fabricated to suit the building dimensions. Steel shapes shall be supplied in lengths as fabricated to suit the building dimensions. Aluminium sections shall have mill finish unless otherwise specified. Steel sections shall be blast cleaned at site prior to the installation of the neoprene seal. The cleaned metal surfaces which come in contact with the seal shall be protected against rusting till the seal and the adhesive are placed against the metal surface. The details of the finished colours offered by the manufacturer for Stainless Steel and Electrometric components shall be furnished to the Engineer to enable him to exercise his choice.

10.4 Execution The seismic joint system shall be installed strictly as per the manufacturer’s instructions and as directed by the Engineer. The seismic joint system shall be adjusted to the proper widths for the ambient temperature at the time of installation. The Contractor shall prepare all surface and/or recesses for mounting Aluminium extrusions. The surfaces must be flat and smooth. The variations in surfaces affecting joint installation shall not be permitted and shall be corrected prior to installation. All the surfaces to receive the joint system shall be free from dirt, water, frost and any other loose foreign debris, which may be detrimental to effective joint system. At each joint location the metal extrusions shall be installed first. The seal element shall be installed subsequently in one continuous piece. If any field cutting/mitring of the seal shall be done to accommodate directional changes, the same shall be replaced using adhesive recommended by the manufacturer. The joint to be sealed shall be prepared by removal of any foreign materials and patching of any spalled areas so as to give a neat clear joint with uniform gap. For the compression seal the lubricant adhesive recommended by the manufacturer shall be applied continuously to the inner phase of the clean joint. Armoured block out shall be provided for fixing compressive seal. The bottom portion of the seal shall be compressed and inserted into the joints and position within it to the proper depth with the aid of an installation tool.

10.5 Cleaning and Protection The work shall be protected with the manufacturers specified standard protective paper. The same shall be removed from the exposed trim piece after finish work in adjacent areas are completed. The exposed surface shall be cleaned with a suitable cleaner which shall not harm the factory applied finishes. Compression seal shall be protected from damage during construction of adjacent areas until completion of the structure. The excessive adhesive from the exposed surfaces of the compression seal shall be cleaned with a solvent cleaner as recommended by the manufacturer.

10.6 Delivery, Storage and Handling The product shall be delivered to the site in each manufacturers original, intact, labelled containers and stored under cover in a dry location until installed. The products shall be stored off the ground and shall be protected from weather and construction activities. The exposed trim pieces of the joint system shall be delivered to the site in a manufacturers standard protective paper or wrapping.

10.7 Shop Drawings The Contractor shall prepare shop drawings to inter alia show the outline of the structure as built and the manner in which the seismic joints are to be provided. The shop drawings (template drawings) shall also show typical expansion joint cross-sections indicating all pertinent dimensions, general construction, component connections, anchorage methods and hardware locations.

10.8 Acceptance of Work 10.8.1 Periodic Acceptance of Work

The work shall be checked periodically at the end of each stage of installation, before commencement of the next stage. Any work found to be not acceptable vis-a-vis tolerance, lines, levels, finish, etc. shall be rejected, removed and replaced before proceeding with further work.





10.9 Final Acceptance of Work The final acceptance shall only be accorded once the entire work is complete in one area of the building; after all other works as per this Contract have also been duly completed and accepted. The Contractor shall ensure that the joints are so installed that they prevent rainwater from reaching to the inside. All units and joints between units shall be designed to prevent ingress of water by capillary. The Contractor shall ensure that the risk of attack or infestation by micro-organisms, fungi, insects and other vermin is minimal and also that there is no risk of ingress of vermin into the building.

10.10 Protection The contractor shall protect all work until handing over. Special protection as directed shall be provided for floor joints to prevent their being damaged due to execution of other works either under this Contract or those of other agencies damaging the joints or marring their appearance and finish.





11 CAULKING AND SEALANTS

11.1 Scope of Work 11.1.1 The work shall include providing caulking and sealants for expansion/ separation/

construction/movement joints, gaps between similar and dissimilar materials etc. and at any other location and situation as directed by the Engineer, in accordance with the design, patterns, shapes, thickness, details, all as shown on the “Construction” drawings or as specified or as per the manufacturer’s instructions all as directed by the Engineer complete in all respects to give the quality of finished work as desired by and to the entire satisfaction of the Engineer.

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

11.2 Materials 11.2.1 Caulking and Sealants 11.2.1.1 Caulking and sealants shall be as follows:

a) Work below ground level and/or in contact with water: One-part gun-grade Polysulphide sealant conforming to BS: 5215. The sealant shall be of an approved color and shall be non-staining to the stone for cladding.

b) Work above ground level: One-part gun grade silicone sealant conforming to BS: 4254: 1983 or ASTM C920- 87, Type M, Grade-NS, Class 25 such as Thioflex- 600 or any other approved equivalent. The sealant shall be of an appr9ved colour and shall be non-staining to the stone for cladding.

11.2.2 Ancillary Materials 11.2.2.1 The Contractor shall provide all ancillary materials such as cleaning solutions, epoxy

mortar, primer, tool cleaner, bond breaker tape, filler boards, back up material, backing rods, polyethylene foam, masking tapes, sealant slot former etc.

11.2.3 Primer 11.2.3.1 Primer for sealants shall only be as recommended by the sealant manufacturer. Primer

shall have been tested for compatibility and durability with the sealant to be used and on samples of the surfaces to be selected.

11.2.4 Backdrop Material 11.2.4.1 Backdrop material shall be an expanded polyethylene of nominal density 35 kg/cum as

recommended by the sealant manufacturer. It shall be of non-absorbent and non-staining material compatible with the sealant used. Tube or rod stock shall be rolled into the joint cavity.

11.2.5 Bond-preventive Materials Bond-preventive materials shall be pressure-sensitive adhesive polyethylene tape or Aluminium foil.

11.3 Equipment The Contractor shall inter alia provide the following plant and equipment for the work. T-paddle, follower plate, solid barrel gun, plastic nozzle, wire brush, heavy duty 500 rpm electric drill, palette knife, masking tape and paint brush for priming etc.

11.4 Handling Precautions 11.4.1 Uncured material shall be prevented from coming into contact with the skin. Protective

clothing, goggles, barrier creams and rubber gloves shall be used as and where required. At the end of each working period the skin shall be thoroughly cleaned with soap and warm water for a resin removing cream. Solvents shall not be used for cleaning the skin. Proprietary skin cleaners may be used. The manufacturer’s recommendations and precautions shall be adhered to.

11.4.2 Health and Safety 11.4.2.1 For specialist advice on material health and safety data reference may be made to the

manufacturer’s data. 11.5 Working Life

Care shall be taken to ensure that material with adequate shell life is provided. Material whose shell life is over shall not be used in the works and shall be removed from the site forthwith. Depending on the storage, temperature and humidity, only one unit shall be drawn from the storage.

11.6 Curing Period





No portion of the work where sealant has been applied shall be allowed to be submerged or be wetted by any liquid for a period of 7 days after application of the sealant. This period may be modified depending on the temperature and humidity prevalent at the time.

11.7 Recommended Movement 11.7.1 The sealant shall be capable of withstanding the movement as per the codes. 11.8 Colour 11.8.1 The colour of the sealant shall be as per the manufacturer’s data sheet or colour chart

and shall be as approved by the Engineer. 11.9 Environmental Requirements 11.9.1 The ambient temperature shall be within the limits as given by the manufacturer, when

the caulking and sealants are applied. The work shall not be carried out in a dusty atmosphere or when it is raining or when the humidity is high.

11.9.2 Caulking and sealants shall not be applied when the ambient temperature is below 4 degree C. When the ambient temperature is below 10 degree C but greater than 4 degree C, the sealant containers shall be stored for some hours at 21 degree C, to ease mixing and application.

11.10 Delivery and Storage 11.10.1 Materials shall be delivered to the job site in the manufacturer’s original

unopened containers. 11.10.2 The containers shall include the following information on the label: a) Name of supplier, b) Name of material, c) Formula, d) Lot number, e) Colour, f) Date of manufacture, g) Mixing instructions, h) Shell life and i) Curing time. 11.10.3 Materials shall be carefully handled and stored to prevent contamination of

foreign materials to exposure to temperatures exceeding 35 degree C. 11.11 Joints 11.11.1 The effective width to depth ratio shall be as per the table given below unless directed

otherwise by the Engineer. Table – 20.1

Surfaces Joint Width Joint Depth

Minimum Maximum

For metal, glass or other nonporous surfaces:

6mm 6 mm 6 mm

Over 6mm ½ of width Equal to width

For concrete masonry or stone:

6 mm 6 mm 6 mm

Over 6mm up to 12mm

6 mm Equal to width

Over 12mm ½ of width ½ of width

11.12 Surface Preparation 11.12.1 General 11.12.1.1 The surface of joints to be sealed shall be clean, dry, sound and free of all release

agents, water repellents, laitance, oil, grease, dirt, chalk, particles of mortar, dust, loose rust, loose mill scale and other foreign substances. Oil and grease shall be removed with solvent and the surfaces shall be wiped with clean clothes.

11.12.2 Concrete and Masonry Surfaces 11.12.2.1 Where surfaces have been treated with curing compounds, oil or other such materials,

the materials shall be removed by sandblasting or wire brushing. Laitance, efflorescence and loose mortar shall be removed from the joint cavity. The surfaces / edges shall be repaired with epoxy mortar to give smooth and even surfaces to correct lines and levels with a uniform gap for the length to be sealed.

11.12.3 Steel Surfaces Steel surfaces to be in contact with sealant shall be sandblasted if sandblasting is not practical or would damage adjacent finish work, the metal shall be scrapped and wire





brushed to remove loose mill scale. Protective coatings on steel surfaces shall be removed by sandblasting or by a solvent that leaves no reside.

11.13 Application 11.13.1 Masking Tape 11.13.1.1 Masking tape shall be placed on the finished surface on one or both sides of a joint

cavity to protect adjacent finished surfaces from primer or compound smears. The masking tape shall be removed within 10 minutes after the joint shall be filled and tooled.

11.13.2 Bond-preventive materials 11.13.2.1 Bond-preventive materials shall be installed on the bottom of the joint cavity and other

surfaces to prevent the sealant from adhering to the surfaces covered by the bond-preventive materials. The materials shall be carefully applied to avoid contamination of adjoining surfaces or breaking bond with surfaces other than those covered by the bond-preventive materials.

11.13.3 Backstops 11.13.3.1 The back or bottom of joints constructed deeper than specified shall be packed tightly

with an approved backstop material to provide a joint of the depth specified. Where it is necessary to provide a backstop of a caulking compound, the joint shall be tightly packed.

11.13.4 Primer The primer shall be used in accordance with the manufacturer’s instructions. The primer shall be applied to the joint surfaces to be sealed only and not spill over or be applied to surfaces adjacent to the joints.

11.14 Application of Sealant 11.14.1 The sealant shall be gun-applied with a nozzle of proper size to fit the width of the

joint indicated and shall be forced into grooves with sufficient pressure to expel air and fill the groove solidly. The sealant shall be uniformly smooth and free of wrinkles.

11.14.2 The plastic nozzles shall be inserted on the gun and cut to appropriate size. The sealant shall be gunned into joints using an even trigger pressure. The nozzle shall be cleaned occasionally.

11.14.3 The sealant shall be pressed into joints with a wet spatula and tooled within five minutes of application. The jointly shall be tooled slightly concave after the sealant is installed. The tooled joint shall present a smooth and professional joint giving the desired finish and shape.

11.14.4 The masking tape shall be removed immediately after tooling. 11.14.5 Application equipment shall be cleaned with a tool cleaner, recommended by the

manufacturer, after wearing PVC or rubber gloves and whist the sealant is still in an uncured state.

11.14.6 Cleaning 11.14.6.1 The surfaces adjoining the caulked and sealed joints shall be cleaned of smears and

other soiling resulting from the caulking and sealing application as the work progresses. Sealant adhering to, porous surfaces shall be left until is just cured and then removed by abrasion or other mechanical means.

11.15 Guarantee For guarantee refer clause 1.4.3.





12 MISCELLANEOUS WORKS

12.1 Plastering Mesh The materials shall be of Arpitha make or approved equivalent. Plaster mesh 100mm wide manufactured out of bolt dipped galvanized iron of nominal thickness 0.35mm with zinc coating of 120 Gms per Sqm width along route of walls chipped for services, junctions between RCC and brick wall or any two different materials is to be used.

12.1.1 Applications For Chasing works done for Electrical conduits and water lines discretionary methods are to be used for selection of the widths of the mesh so that extra 50 mm width of plaster mesh runs on either side of the chasings. The nailing has to be 300 mm part. Very importantly the mortar has to be compacted in the spaces in between pipes, conduits and chasings before the plaster mesh is fixed. A high-quality plaster mesh (expanded galvanized iron metal) for primarily as an anti-cracking reinforcements in plastering of wall beam and wall column joints to avoid cracks is to be used.

12.1.2 Measurements Length to the nearest cm. And overall should be calculated in Rmt correct to two decimal places.

12.1.3 Rates Rates are including cutting and providing mesh including all labour charges for fixing.





13 SITE DEVELOPMENT AND HORTICULTURE WORKS 13.1 Scope

The scope of work covered by this section of the specification shall include, required ground preparation after site grading, provision and spreading to top soil, provision and planting of trees, shrubs, ground cover and lawns.

13.2 Materials 13.2.1 Top Soil/Good Earth

Topsoil shall be fertile agricultural soil, free from foreign matter like building rubbish etc. non-saline and non-alkaline a sandy loam with the following particle distribution: Sand 2mm - 0.05 mm 55 - 66% Silt 0.05mm – 0.002 mm 25 - 30% Clay Less than 0.002 mm 10 - 15% Topsoil material shall comply with the following chemical characteristics: PH 6.0 – 7.5 Saturated soil. Conductivity 2mm hos Saturated extract. Free carbonates 0.5% Air-dried soil. Chlorides 200 ppm Saturated extract. Sulphites exchangeable 200 ppm Saturated extract. Sodium q 15% Neutral normal ammonium acetate. Nitrates 75 ppm Saturated extract. Phosphorus 10-25 ppm 1:5 sodium bicarbonate extractant. (30 min. shake). Potassium 100-400 ppm 1:5 ammonium nitrate extractant (30 min. shake). Baron 1.5 ppm Hot water soluble. One test per 50 cum of soil shall be carried out for particle size analysis, pH value and conductivity. Other constituents shall be tested at the rate of one test per 500 cum. of soil.

13.3 Growing medium Growing medium shall consist of top soil as defined above plus soil additives as specified.

13.4 Manure/Sludge/Compost Manure shall be well rotted, unleached animal dung with not more than 15% vegetable matter, farm yard manure. It shall be from an approved source and shall be disease and pest free.

13.5 Peat Peat shall be of the sphagnum moss variety and coarsely shredded from an approved source. It shall have pH value between 3.3 and 6.0 at 25 deg.C. fine peat moss is not acceptable.

13.6 Grass Seed or Sods Grass seed or sads shall be 100% bermuda grass seed or sods shall be fresh when supplied and shall be obtained from an approved source, together with a certificate giving the name of the supplier and quoting the certified percentage of purity and generation. Approval of the sods/seeds and source shall be obtained before the order is placed.

13.7 Grass Mulch Gravel mulch shall consist of clean well-rounded gravel pebbles with maximum nominal diameter of 38 mm.

13.8 Anti-Desiccant Spray If used, this shall be of an approved type mixed and applied in accordance with the manufacturer’s recommendations.

13.9 Polyuronide Compound This shall be of an approved type mixed and applied in accordance with the manufacturer’s recommendations.

13.10 Superphosphate Fertilizers This shall be a single superphosphate with minimum content of 18% P205.

13.11 Water Watering shall be carried out with fresh water with electrical conductivity test that 2 milliohms/cm at 25 deg.C. and sodium chloride content less than 500 mg/litre. Water samples shall be tested at approved laboratories and the test certificates forwarded to the Engineer.

13.12 Plant Containers





Plant containers shall be of tin clay, PVC or other approved material and shall have drainage holes. They shall be capable of easy removal to avoid damage to the plant or root ball, and shall be of sufficient size for the plant material contained therein.

13.13 Stakes and Ties Tree stakes shall be used for all trees and shall be round debarked hardwood 3.0M long, treated with a non-toxic wood preservative like creosote with 3 required for each tree. Stakes shall be driven 200mm below the bottom of tree pits and made from and located to provide good support to all sides of the tree when planted. Trees ties shall be of rubber or fabric webbing and 25mm wide minimum. Ties shall be provided with a buffer piece to ensure that the tree, when planted, at no time touches the stake. All ties shall be of sufficient length to allow for the size of the tree and for adjustments that will need to be made up to such time as the tree no longer requires support. Three ties per tree shall be provided sufficient to ensure that the tree cannot touch the stakes. The ties to be tied to tree or shrubs saplings in a figure of eight.

13.14 Neam/Castor Cake The cake shall be free from grit, and any other foreign matter. It should be undecorticated and pulverized. The cakes should be got from an approved source.

13.15 Trees Trees shall be minimum mature size 2M high as noted on landscape plan with a well formed balanced head, strong leader and a clean straight trunk and located to provide good support to all sides of the tree when planted. The tree saplings to have well developed root and shoot system. Trees shall be provided with tree guard and shall be staked.

13.16 Shrubs & Creepers a) A large shall have all the following characteristics:

- A seeding or rooted cutting that has been transplanted and which has a bushy habit. - Bushiness encouraged by pruning with a minimum of three one year old vigorous shoot

well. - Furnished to produce a diameter two-thirds of the height. - A height as noted on plans or 1 M high.

13.17 Ground Cover Plants A ground cover plant shall have all the following characteristics:

- Well-developed vigorous shoots. - A well-developed vigorous root system. - Length of minimum 0.4 M long or as noted in planting-plan.

13.18 Tree Guards Tree guards shall be of mild steel or made of bricks as/MAHAPWD specifications, 1.6 m above the ground level.

13.19 Interlocking Block Paving Works 13.19.1 Quality

The block for the paving works shall be of approved quality and make. The blocks shall be 60 mm thick having and the specified size and type and grey or red or combination of them.

13.19.2 Sub-base and Base Over the prepared and consolidated sub grade a layer of sub-base using crushed aggregate shall be laid to falls and slopes to a compacted thickness of 100 and compacted with C-10 tonne roller. Over the prepared sub-base, a layer of 3mm and down find sand shall be laid to a thickness of 50 mm and accurately screed and levelled and compacted to 38 mm in thickness and to required falls and slope to the satisfaction of the Engineer.

13.19.3 Layers The blocks shall be laid on top of the prepared base in required pattern as directed by the Engineer. On completion of the laying work, approved fine screened sand shall be spread over the paving and the joints filled with fine sand and compacted as directed by the Engineer. Extra sand on the surface shall be removed by brush. When required, edge blocks shall be cut clear and sharp with approved tools and as per manufacturer’s instructions. The cut edges shall be rubbed smooth before laying. Compaction with a power vibrating plate (wacker model VPH 70) shall be used suitably as recommended by the approved proprietary manufacturer. Any blocks damaged during laying shall be





replaced. The entire work of the installation and materials shall meet the approval of the Engineer.

13.20 Yellow Strip 13.21 General

Plastromark Thermo plastic hot applied road marking paint (yellow or white) of thickness 2mm of STP Limited make or equivalent as per BS 3262 (Part I & Part II with up to date amendments) shall be laid on flame finished granite/bituminous road surface with the help of self-propelled applicator machine providing 100mm/75mm wide uniform marking of paint as required.

13.21.1 Container Each bag containing materials shall have clear marking as follows:

a) Manufacturer’s name and place. b) Batch number. c) Date of manufacture. 13.21.2 Preparation

Solid block of silica sand and crushed calcite aggregate, extender (calcium carbonate), pigments (Titanium dioxide as per BS 1831) and thermoplastic hydrocarbon resin binder plasticised with mineral oil shall be mixed proportionately as per manufacturer’s printed instruction to form uniform slurry/paste and put them into melter for heating. The temperature shall be raised gradually to 170oC with the gas fire and to be kept constant. The material in the container shall be stirred thoroughly by hand stirrer from time to time to keep the material homogeneously mixed and consistent.

13.21.3 Laying Dust, sand, oil, grease, etc., shall be removed from the road surface and the road surface shall be absolutely clean before application of paint. First the lines shall be drawn on the granite or asphalt base by help of string marker (a string coated with white chalk or powder) and the nylon cord shall be nailed on the lines marked by chalk. The marker or applicator machine shall be kept parallel to the nylon cord. The hot material shall be poured to the dragging shoe of the applicator machine and pushed slowly. Simultaneously the soda glass beads of special shape and free from flaws shall be spreader from glass dispenser to the hot applied thermoplastic paint uniformly at the rate of minimum 250 gm per square metre. Then the material shall be left protected, till dried and set properly. The traffic can be opened after one hour minimum of application. In case of granite a coat of special primer shall be applied before laying of thermoplastic paint. Markings shall be free from raggedness at their edges and shall be uniform and free from streaks.

13.22 Cement concrete Designer Tile 13.22.1 Material

The cement concrete designer tiles will be Eurocon tiles or equivalent for flooring of nominal sizes 416mm x 416mm, 361 mm x 361mm or as specified by the Engineer in charge. The sizes of the tiles to be used shall be as shown in the drawings or as required by the Engineer in charge. Step tiles are to be provided as shown in the drawings.

13.22.2 Quality The tiles shall conform IS: 1237: 1980 Specifications. The overall thickness of the tiles

shall not be less than 22mm. The weight of the floor tile shall not be less than 4.5 kg per Sqft.

13.22.3 Laying, finishing and curing The tiles shall be laid on a flat surface or sloped surface as indicted in the drawings using

cement mortar as specified and as per the instructions of the Engineer in charge. The tiles joints shall be grouted with pigment of same colour as that of the tiles. The tile works shall be cured for a minimum period of 7 days.

13.22.4 Handling and Storage The contractor shall ensure that the same colour of the tiles is used. Any damaged tiles or

faded tiles shall be replaced or returned. 13.22.5 Measurements

Tiles flooring shall be measured separately and in square meter correct to two places of decimal. Length and breadth shall be measured correct to a cm before laying skirting, dado or wall plaster. No deduction shall be made nor extra paid for voids not exceeding





0.20 square meter. Deductions for ends of dissimilar materials or other articles embedded shall not be made for areas not exceeding 0.10 square meter. Nothing extra shall be paid for laying the floor at different levels in the same room.

13.22.6 Rates The rate shall include the cost of all the materials and labours involved in all the

operations described as above.





14 LIST OF APPROVED MANUFACTURERS

14.1 All materials and products shall conform to the relevant standards/specifications of IS code, BS Code etc. and shall be of approved make and design. A list of manufacturers / vendors is given in clause 14.2 herein below for guidance. The approval of a manufacturer/vendor shall be given only after review of the sample / specimen by the Engineer. The complete system and installation shall also be in conformity with the Clause – 1.6 – “Applicable Codes, Standards and Publications”.

14.2 List of approved makes for products and materials is given below. Other equivalent manufacturers may be considered with prior approval.

List of Approved makes

S.No. Details of Materials/Products Manufacturer’s Name



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PARTICULAR SPECIFICATION - PUBLIC HEALTH ENGINEERING

(STATION)



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1 GENERAL REQUIREMENTS 1.1 Introduction

All equipment, supply, erection, testing and commissioning shall comply with the requirements of Indian Standards and code of practices given below as amended up to 30th March. 2007. All equipment and material being supplied by the contractor shall meet the requirement of IS.

1.2 Standards, Codes and Regulations The entire system and its basic components shall comply in all respect to the relevant International Standards and regulations of the National Building Code of India (NBC), and Bureau of Indian Standards.

In addition to the International Standards and NBC listed in the Technical Specifications, the Design shall also be governed by all applicable local codes, regulations, standards and requirements issued by all the Local Authorities, agencies and services providers. Given below is the list of standards to be followed at least, note that this list is not exhaustive

1.3 General IS: 27 Pig Lead

IS: 554 Dimensions for pipe threads where pressure tight joints are IS: 779 Specification for water meters (domestic type) IS: 782 Specification for caulking load IS: 800 Code of practice for general construction in steel

IS: 1068 Electroplated coatings of nickel plus chromium and copper plus nickel plus chromium

IS: 1172 Code of Basic requirements for water supply drainage and sanitation IS: 1367(Part 1) Technical supply conditions for threaded steel fasteners:Part 1 Introduction

and general information IS: 1367(Part 2) Technical supply conditions for threaded steel fasteners: Part 2 Product

grades and tolerances IS: 1726 Specification for cast iron manhole covers and frames IS: 1742 Code of practice for building drainage

IS: 2064 Selection, installation and maintenance of sanitary appliance code of practice

IS: 2065 Code of practice for water supply in buildings IS: 2104 Specification for water meter for boxes (domestic type) IS: 2373 Specification for eater meter (bulk type)

IS: 2379 Colour code for identification of pipe lines IS: 2527 Code of practice for fixing rainwater gutters and down pipes for roof

drainage IS: 2629 Recommended practice for hot dip galvanizing on iron and Steel

IS: 3114 Code of practice for laying of cast iron pipes IS: 4111 (Part 1) Code of practice for ancillary structures in sewerage system: Part 1

manholes. IS: 4127 Code of practice for laying glazed stoneware pipes

IS: 4853 Recommended practice for radiographic inspection of fusion welded butt joints in steel pipes

IS: 5329 Code of practice for sanitary pipe work above ground for buildings IS: 5455 Cast iron steps for manholes IS: 6159 Recommended practice for design and fabrication of material, prior to

galvanizing IS: 7558 Code of practice for domestic hot water installations IS: 8321 Glossary of terms applicable to plumbing work IS: 8419(Part 1) Requirements for water filtration equipment: Part 1 Filtration medium sand

and gravel IS: 8419(Part 2) Requirements for water filtration equipment: Part 2 under drainage system IS: 9668 Code of practice for provision and maintenance of water supplies and fire

fighting IS: 9842 Preformed fibrous pipe insulation

IS: 9912 Coal tar based coating materials and suitable primers for protecting iron and steel pipe lines



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IS: 10221 Code of practice for coating and wrapping of underground mild steel pipelines

IS: 10446 Glossary of terms relating to water supply and sanitation IS: 11149 Rubber Gaskets IS: 11790 Code of practice for preparation of butt-welding ends for pipes, valves,

flanges and fittings IS:12183(Part 1) Code of practice for plumbing in multistoried buildings: Part 1 water supply IS: 12251 Code of practice for drainage of building basements IS: 5572 Code of practice for sanitary pipe work BS: 6700 Specification for design, installation, testing and maintenance of services

supplying water for domestic use within buildings and their cartilages BS: 8301 Code of practice for building drainage BSEN: 274 Sanitary tap wares, waste fittings for basins, bidets and baths General

technical specifications 1.4 Pipes and Fittings

IS: 458 Specification for precast concrete pipes (with and without reinforcement) IS: 651 Salt glazed stone ware pipes and fittings IS:1239 (Part 1) Mild steel, tubes, tubular and other wrought steel fittings: Part 1 Mild Steel

tubes IS: 1239(Part 2) Mild Steel tubes, tubular and other wrought steel fittings: Part 2 Mild Steel

tubular and other wrought steel pipe fittings IS: 1536 centrifugally cast (spun) iron pressure pipes for water, gas and sewage IS: 1537 Vertically cast-iron pressure pipes for water gas and sewage IS: 1538 Cast Iron fittings for pressure pipes for water, gas and sewage IS: 1879 Malleable cast iron pipe fittings IS: 1978 Line pipe IS: 1979 High test line pipe IS: 2501 Copper tubes for general engineering purposes IS: 2643(Part 1) Dimensions for pipe threads for fastening purposes: Part 1 Basic profile and

dimensions IS: 2643(Part 2) Dimensions of pipe threads for fastening purposes: Part 2 Tolerances IS: 3468 Dimensions for pipe threads for fastening purposes: Part 3 Limits of sizes IS: 3468 Pipe nuts IS: 3589 Seamless or electrically welded steel pipes for water, gas and sewage (168.3

mm to 2032 mm outside diameter) IS: 3989 Centrifugally cast (spun) iron spigot and socket soil, waste and ventilating

pipes fittings and accessories IS: 4346 Specifications for washers for use with fittings for water services IS: 4711 Methods for sampling steel pipes, tubes and fittings IS: 6392 Steel pipe flanges IS: 6418 Cast iron and malleable cast iron flanges for general engineering purposes IS: 7181 Specification for horizontally cast-iron double flanged pipe for water, gas

and sewage 1.5 Valves

IS: 778 Specification for copper alloy gage, globe and check valves for water works purposes

IS: 780 Specification for sluice valves for water works purposes (50 mm to 300 mm size)

IS: 1703 Specification copper alloy flat valves (horizontal plunger type) for water supply fittings

IS: 2906 Specification for sluice valves for water works purposes (350mm to 1200mm size)

IS: 3950 Specification for surface boxes for sluice valves IS: 5312 (Part 1) Specification for swing check type reflux (non-return) valves: Part 2 Multi

door pattern IS: 5312 (Part 2) Specification for swing check type reflux (non-return) valves: Part 2 Multi

door pattern IS:12992(Part 1) Safety relief valves, spring loaded: Design IS: 13095 butterfly valves for general purposes



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1.6 Sanitary Fittings IS:771 (Part 1 to 3) Specification for glazed fire clay sanitary appliances IS: 774 Specification for flushing cistern for water closets and urinals (other than

plastic cistern) IS: 775 Specification for cast iron brackets and supports for wash basins and sinks IS: 781 Specification for cast copper alloy screw down bib taps and stop valves for

water services IS: 1700 Specification for drinking fountains IS: 2548 (Part 2) Specification for plastic seats and covers for water closets: Part 1 Seats and

covers IS: 2556 (Part 1) Specification for vitreous sanitary appliances (Vitreous china): Part 1

General requirement IS: 2556 (Part 2) Specification for vitreous sanitary appliances (Vitreous china): Part 2

Specific requirements of wash-down water closets IS: 2556 (Part 3) Specification for vitreous sanitary appliances (Vitreous china): Part 3

Specific requirements of squatting pans IS: 2556 (Part 4) Specification for vitreous sanitary appliances (Vitreous china): Part 4

Specific requirements of wash basins. IS: 2556 (Part 6 Sec 2) Specification for vitreous sanitary appliances (Vitreous china): Part

6 Specific requirements of urinals, section 2 half stall urinals. IS: 2556 (Part 6 Sec 4) Specification for vitreous sanitary appliances (Vitreous china): Part

6 Specific requirements of urinals, section 4 partition slabs. IS: 2556 (Part 6 Sec 5) Specification for vitreous sanitary appliances (Vitreous china): Part

6 Specific requirements of urinals, section 6 water spreaders for half stall urinals.

IS: 2556 (Part 7) Specification for vitreous sanitary appliances (Vitreous china): Part 7 Specific requirements of half round channels.

IS: 2556 (Part 8) Specification for vitreous sanitary appliances (Vitreous china): Part 8 Specific requirements of siphoning wash down water closets.

IS: 2556 (Part 11) Specification for vitreous sanitary appliances (Vitreous china): Part 11 Specific requirements for shower rose.

IS: 2556 (Part 12) Specification for vitreous sanitary appliances (Vitreous china): Part 12 Specific requirements for floor traps.

IS: 2556 (Part 15) Specification for vitreous sanitary appliances (Vitreous china): Part 15 Specific requirements of universal water closets.

IS: 2692 Specification for ferrule for water services IS: 2717 Glossary of terms relating to vitreous enamelware and ceramic metal

systems IS: 2963 Specification for waste plug and its accessories for sinks and wash basins IS: 3311 Specification for waste plug and its accessories for sinks and wash basins IS: 5961 Specification for cast iron gratings for drainage purposes IS: 6249 Specification for gel-coated glass fibre reinforced polyester resin bath tubs IS: 9758 Specification for flush valves and fitting for water closets and urinals Water

Quality Tolerance IS: 3025 (Parts 1- 44) Method of sampling and test (physical & chemical) for water and waste water

IS: 4764 Tolerance limits for sewage effluents discharged into inland surface waters IS: 10500 Drinking Water

1.7 Pumps & Vessels IS: 1520 Specification for horizontal centrifugal pumps for clear cold fresh water IS: 2002 Steel plates for pressure vessels for intermediate and high temperature

service including boilers IS: 2825 Code for unfired pressure vessels IS: 4648 (Part 1) Code of practice for lining of vessels and equipment for chemical processes

Part 1: Rubber lining IS: 5600 Specification for sewage and drainage pumps IS: 8034 Specification for submersible pump sets for clear, cold, fresh water IS: 8418 Specification for horizontal centrifugal self priming pumps



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1.8 Abbreviations

ACRONYM DESCRIPTION

PLUMBING & FIRE FIGHTING

ASD Aspirating Smoke Detector

BRE Building research Establishment

BSI British Standards Institute

BSP British Standard Pipe threads

CCITT International Telegraph and Telephone Consultative Committee (Comité Consultatif Internationale de Télégraphique et Téléphonique)

Bottom of Form

CCL Communication Certification Laboratory

CENELEC European Committee for Electrotechnical Standardization (Comité Européen de Normalisation Electrotechnique) CGP Clean Gas Panel

CISPR The International Special Committee on Radio Interference (Comite International Special des Perturbations Radioelectriques ) CRT Cathode Ray Tube

CSD Combined Services Drawing

E&M Electrical & Mechanical

EMC Electro Magnetic Compatibility

EN European Norms

EPROM Erasable Programmable Read Only Memory

FAHU Fresh Air handling Units

FM Factory Manuals

FR Fire Resistance

FRP Fibre Reinforced Plastic

FSSD Fire Safety and Shelter Department

HDHC Hard Drawn High Conductivity

HDLC High-level Data Link Control

HMI Human Machine Interface

HRC High Rupture Capacity

HVAC Heating, Ventilation and Air Conditioning

IDC Insulation Displacement Connection

IE Indian Electricity Rules

IEE Institution of Electrical Engineers

IFAT Integrated Factory Acceptance test

IP Ingress Protection

ISM Industrial, Scientific and medical band

ITU-T International Telecommunication Union - Telecommunication Standardization Sector ACRONYM DESCRIPTION

LCD Liquid Crystal Display

LCX Leaky Coaxial Cable

LED Light Emitting Diode

LPC Loss Prevention Council

LSC Local Sequential Control

MAP Main Alarm Panel

MMI Man Machine Interface

PCB Pollution Control Board

ROM Read Only Memory

RP Repeater Panel

RTV Response Threshold Value



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SAP Sub Alarm panel

SCADA Supervisory Control and Data Acauisition

SEM Structural, Electrical and mechanical

SFSRTS Standard for Fire Safety in Rapid Transit Systems

SPDT Single Pole Double Throw

SWC Station Wide Contractor

TCF Technical Construction File

UL Underwriters Laboratories

UPS Uninterruptible Power Supply

V DC Volt Direct Current

VDE Verband der Elektrotechnik (German Association for Electrical,Electronic and Information Technologies)

VESDA Very Early Smoke Detection and Alarm

WLAN Wireless Local Area Network

2 SANITARY FIXTURES AND FITTINGS 2.1 Scope

Scope of work covers supply, installation, testing and commissioning of: i) Sanitary ware ii) Chromium plated (CP) fittings iii) Any other work to complete the systems The contractor shall get the installation along with associated water supply distribution system and drainage system approved by the Nagpur Water Supply and Sewerage Board or other licensing authorities/owner.

2.2 Standards All sanitary ware shall generally conform to IS: 2556 part I to VIII unless stated otherwise.

2.3 Materials 2.3.1 General

All sanitary ware and CP fittings shall be new, best of quality and of approved make, type and colour. All samples of materials with specifications/catalogues, performance data, shall be submitted and got approved before use on the work by the authorized representative. Approved samples along with other approved equipment/materials shall be neatly displayed on a board and such a display board of samples shall always be in exhibition in the construction office of the engineer-in-charge. Such display shall be used for the day-to-day checking of the materials on site.

Wherever multiple choices of fixtures are offered, the client shall have the final choice.

All fixtures shall be complete with all accessories as required for the working of the said fixture as specified.

2.3.2 European WC European WC shall be wash down, floor mounted in white glazed vitreous chinaware with integral P or S trap as required. Wash down WC shall be supported on floor. The WC shall be provided with 32mm dia C.P. brass flush valve as specified in the schedule of work or shown on drawing.

Each WC shall be provided with a solid plastic seat. The seat shall be fixed to the WC with CP brass pillar bar hinges. Rubber buffers shall be provided for the cover.

2.3.3 Urinals Urinals shall be 430X260X350mm flat back wall hung urinal in white glazed vitreous chinaware of size mentioned in the schedule of work. Urinals shall be provided with: 1) 15 dia spreader 2) 32 dia CP dome waste 3) 32 dia CP P-trap with unions 4) CP wall flange and pipe All exposed pipes and fittings shall be of CP. The urinals shall be fixed with CP brass screws.



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Urinal flushing shall be through an auto flush valve with electrically operated solenoid valve activated by infra-red sensor.

Auto flush shall be concealed in wall and flush pipe shall be of copper or GI except the exposed part as specified.

Waste pipe for urinals shall be of: GI pipes, heavy quality as per IS 1239 as specified in the schedule of work or shown on drawings.

Urinal partitions shall be white Rajgarh Marble or as approved by Architects 25mm thick, 1050 x 600mm size fixed in wall by cutting chase and making good in cement mortar (1:2) finished to match the surroundings.

2.3.4 Wash Basin Wash basins shall be white glazed vitreous chinaware of size, shape and type specified in the schedule of work. Each basin shall be complete with: 1) CI or galvanized steel supporting brackets & clips as required. 2) 32 dia CP waste and overflow 3) Waste with rubber plug and CP chain as specified 4) One no. pillar tap of 15 mm size 5) One no. 15 mm CP brass angle cock 15 mm size with CP brass flexible connection from

angle cock to taps. The tap shall be automatic in operation. Necessary solenoid valve (electrically operated) activated by infrared sensor shall be included.

2.3.5 Toilet Paper Holder Toilet paper holder shall be white glazed vitreous china or chrome plated of size, shape and type specified in the Bill of quantities.

Porcelain toilet paper shall be fixed in walls and set in cement mortar 1:2 (1 cement: 2 coarse sand) and fixed in relation to the tiling work.

The latter (chrome) shall be fixed by means of screws / capping having finish similar to the toilet paper holder in wall/temper partitions with raw I plugs or nylon sleeves. When fixed on timber partition, it shall be fixed on a solid wooden base member provided by the Owner’s Site Representative.

2.3.6 Drinking Water Fountain Drinking water fountain shall be well mounting type made of vitreous china, stainless steel or any other material as given in the Bill of quantities. The drinking water fountain shall be with anti-squirt bubble less, self-closing valve type with automatic volume regulator. The drinking water fountain shall be provided with an anti-splash back and integral strainer with 32mm or 40mm cast brass trap.

2.3.7 Liquid Soap Dispenser Liquid Soap Dispenser shall be wall/counter mounted suitable for dispensing liquid soaps, lotions, detergents. The cover shall lock to the body with concealed locking arrangement, opened only be key provided.

Liquid soap dispenser body and shank shall be of high impact resistance material. The piston and spout shall be stainless steel with 1 litre capacity polyethylene container.

2.3.8 Toilets for the disabled Where specified in washroom facilities designed to accommodate physically disabled, accessories shall be provided as directed by the Owner’s Site Representative.

Stainless steel grab brass of required size suitable for concealed or exposed mounting and preened non-slip gripping surface shall be provided in all washroom. The flushing cistern/valve shall be provided with chromium plated long handles.



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2.4 Installation All sanitary ware and CP fittings shall be installed in accordance with the interior requirements. Neat workmanship and maintaining exact position and level of each fixture shall be the sole objective of the installation. Care shall be taken to fix inlet and outlet pipes at correct positions. Faulty positioning shall be made well without any damage to the finished floor or wall titling and any damage to the finished surfaces shall be made good at the tenderer / contractor's cost.

In order to ensure quality of workmanship and compliance with interior requirements, one or two mock-up installations shall be done and got approved. Fixtures used in the mock-up may be reused with the approval of the Engineer-in-charge.

All fixing accessories like bolts, nuts, brackets etc. as required shall form part of the installation. All such accessories shall be CP brass or galvanized or stainless steel as approved by the Engineer-in-charge. All exposed pipes and bends shall be of CP brass.

Wall-hung European WC shall be mounted on CI chairs, which are fixed to the wall and floor using Anchor fasteners. The bolts and nuts used for fixing the chairs shall be stainless steel and the fixing bolts for the WC and chairs could be CP brass or stainless steel. Floor-mounted WC shall be fixed with Anchor fasteners using stainless steel bolts and nuts. The gap between the WC and floor or wall shall be neatly sealed with waterproof non-hardening sealant of approved colour. The sealant should not extrude beyond the footprint or WC outline.

All WC's shall be aligned and levelled with the floor and wall tiles so as to present an integrated look. Utmost care and skill shall be exercised to achieve a good installation in keeping with the interior designs.

Urinals shall be fixed to the wall using anchor fasteners and stainless-steel bolts and nuts. The urinals shall be held in line and level according to the interior designs and tile modules. Partitions, wherever required to be provided, shall also maintain line and level as shown on drawings and as required. Supply spreader and drain piping and P-trap shall be of CP brass and installed in a neat and workman like manner. No unseemly bends or wooden support pieces shall be permitted.

Wall-mounted wash basins shall maintain line and level as specified by the interior drawings and also with the tile modules. The supply connections shall be of CP brass from the angle stop valves to the pillar taps and shall display good workmanship. Drain connections shall have a CP trap with unions and exposed CP drainpipe and a wall flange. In the case of counter mounted basins extreme care shall be taken to independently and adequately supporting the basin and aligning with the opening in the counter slab. Supply and drain connections shall be same as for wall mounted basins. The gaps between basin and wall or counter shall be neatly sealed with a non-hardening sealant of approved colour.

All accessories like the mirror, soap dish etc shall be neatly fixed as per interior designs. Good workmanship is the essence of all sanitary installation for achieving the interior design objectives.

During the construction period, the contractor shall protect all the sanitary fixtures from damage due to accidental or even intentional mechanical impact with hard objects and also misuse and vandalism.

2.5 Testing and Acceptance The sanitary fixtures form the final terminal units of the water supply and drainage system and should meet the performance needs as a terminal unit. Each fixture shall be inspected for scratches or chippings and alignment before acceptance.



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The following design flows shall be verified and validated for acceptance.

WC Flush Valve 15 ltrs to 20 liters per flush

Provide test 32 dia valve connection at the lowest floor and highest floor

Pillar taps 15 lpm max. 6lpm min

Wash Basin Full basin drain time 3 min

To be measured and validated

Urinal Flush Valve 2 lpm max. lpm minimum

All tests shall be conducted at each and every fixture except for flush valves which shall be at the lowest and highest test connections to be made on each riser / down take. The contractor shall make the temporary valve connections which shall be plugged with a brass after validation.

2.6 Mode of measurement European water closet with flush valve or flushing cistern, flush bend, plastic seat and lid shall be measured and paid as a unit or as shown in the schedule of work. Wash basin with supporting brackets CP waste, P-trap, inlet connections, stop cocks, flexible pipes and mixer fitting shall be measured and paid as a unit or as shown in the schedule of work.

Urinals as mentioned in schedule, CP brass flush pipe, CP brass spreaders, CP brass waste with CP brass P-trap solenoid valve and sensor shall be measured as a unit and paid.

2.7 Mock Up The contractor shall install all pipes, fixtures, clamps and accessories and fixing devices in mock-up shaft and room so constructed as directed by Engineer without any cost. The materials used in the mock-up may be reused in the works if found undamaged.

Any tiles or finished surfaces or floors damaged by the contractor while doing his work shall be made good with new tiles or other finishing material. No payment shall be admissible for such repairs. The engineer may, at his discretion get the damaged work repaired by other agencies and debit the cost of such repairs to the contractor.



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3 WATER SUPPLY WORKS 3.1 Basis of Design

The Plumbing, Sanitary and Drainage for the project are designed keeping in view the following.

Requirement of adequate and equal pressure availability of cold water lines in Staff Room Toilets, Public Toilets and other identified areas.

Adequate storage of water in underground raw + overhead treated domestic water tanks provision of firefighting appurtenance such as fire hydrants, hose reel, and portable extinguishers

Levels of roads / pavements and other services in the area

Landscape layout The execution of works and materials used shall be as per the latest relevant. I.S. specifications.

Wherever reference has been made to Indian Standard or any other specifications, the same shall mean to refer to the latest specification irrespective of any particular edition of such specification being mentioned in the specifications below or Bill of quantities.

3.2 Concept of the System The following services are envisaged for the station: Domestic water supply through overhead gravity feed system. Sewage and Sullage collection system based on IS: 1742 and applicable standards for domestic drainage. Storm / Rain water drainage system from various levels of the building and disposal to available storm water drain. Firefighting system for the complex comprising of Hydrant, Hose Reels, Sprinklers and portable fire extinguishers

3.3 Water Storage & Distribution System 3.3.1 Water Requirement

The water requirement for the project is proposed to be based on the provisions of IS: 1172 and prevalent practice.

3.3.2 Source of water It is expected that part of the daily domestic water requirement for the complex shall be through municipal mains supply / bore wells

3.3.3 Water Distribution The water distribution for hot and cold water supply for the complex shall be designed on principle of gravity flow. Raw water from underground water storage tank is transferred and stored in the overhead water storage tank. Water from overhead tank is supplied by gravity to the station.

3.4 Piping Material The pipes shall be galvanized mild steel welded pipes and screwed and socketed tubes confirming to the requirement of I.S 1239-1982 required for medium grade. They shall be of the diameter (Nominal bore) as specified. The pipes and sockets shall be clearly finished, well galvanized in and out and free from cracks, surface flaws, laminations and other defects. All screw flaws, laminations and other defects. All screw threads shall be clean and well cut. The ends shall be cut clean and square with the axis of the tube. Unless otherwise specified all concealed pipe shall be G.I ‘B’ class and exposed pipe shall be G.I. ‘B’ class. All screwed tubes and sockets shall have pipe threads confirming to the requirements of IS: 554–1961 (or revised) screwed tubes shall have threads while the sockets shall have parallel the threads.

3.5 Pipe Fittings The fittings shall be of malleable cast iron or galvanized mild steel tubes as called for complying with all the appropriate requirements given above designated by the respective nominal bores of the pipes for which they are intended.



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The fitting shall be of malleable cast iron or galvanized mild steel tubes as called for complying with all the appropriate requirements given above designated by the respective nominal bores of the pipes for which they are intended. The fitting shall have screw threads at the ends and conforming to the requirement of IS: 554–1964 (or revised). Female threads or fittings shall be parallel and male threads (except on running nipples and collars of union) shall be maintenance/Repair/Replacement of pipes.

3.6 Valves 3.6.1 Ball Float Valve:

The ball valve shall be of high pressure type shall be of sizes as specified. The normal size of a ball valve shall be that corresponding to the size of the pipe to which it is fixed. The ball valve shall be of brass or gun metal as specified, and the float of copper sheet. The minimum thickness of copper sheet used for making the float shall be of 0.45 mm for float exceeding 115 mm dia. Plastic floats may also be used if specified. The body of the high pressure ball valves when assembled in working conditions with the float immersed to not more than half of its volume shall remain closed against a test pressure of 3.5 kg/sq.cm. The ball valve shall generally conform to I.S. specification No.1703:1862. The weight of ball cock and the size of the ball cock shall be as per I.S. Specification.

3.6.2 Brass full way Valve: Full way valve is a valve with suitable means of connection for insertion in a pipe line for controlling or stopping the flow. The valve shall be of brass fitted with a cast iron wheel and shall be of gun metal gate valve type opening full way of the size as specified. The valve shall be of best quality or approved by the Engineer-in-charge.

3.6.3 Gun-metal full way valve with wheel: These shall be of the gun metal fitting with wheel and shall be of gate valve type opening full way & of the size as per specification. These shall generally conform to I.S 7780-1957.

3.6.4 Butterfly Valves: All valves shown in the drawings for water piping for sizes 50 mm and above shall be wafer type butterfly valves. The valves should be suitable for mounting between flanges drilled to IS 6392 Table 10 to 20. The valve body shall be cast iron. Body liner shall be integrally moulded and bonded to the body. The material shall be Buna-N Rubber. This body liner shall provide seating to the valve disk and “Gasket Joint” with mating pipe flanges. The valve disk material shall be Stainless steel or Ductile (SG) Iron with Nickel Coating. The valve stem shall be high tensile stainless steel (AISI 410). The Valve Stem shall be sealed properly using ‘O” rings. All valves up to 200 mm NB shall be provided with flow control levers. Valves of 250 mm NB and above shall be provided with gear operated levers. The valve should have a pressure rating of ANSI 150.

3.6.5 Ball Valves All valves for shut-off purposes for sizes of 50 mm and below shall be ball valves. The valve body and body connector shall be carbon steel as per ASTM A216-WCB, the ball and stem shall be stainless steel SS 304/316. The seats and stem packing shall be PTFE. All Valves shall have socket weldable ends, in 2/3 piece construction and the central portion could be bolted out for maintenance. All valves should be supplied in full bore construction. The valves should have a pressure rating of ANSI 150.

3.6.6 Foot Valves Provide cast iron body with brass disc and strainer of approved quality, wherever shown.

3.6.7 Sluice Valve The sluice valves are used in a pipe line for controlling or stopping flow of water. They shall be of specified size and class and shall be of inside non-raising screw type spindle with either double flange or double sockets ends and cap or hand-wheel.

These shall in all respects comply with the Indian Standard Specification I.S 780 - f 1963 for valves upto and including 300 mm, size and No. BDC (429) p2 for valves above 300 mm size Class - I sluice valves are used for maximum working pressure of 10 kg/cm2 (100 meter head) and Class - II sluice valves for 15 kg/cm2 (150 meter head). The body, domes, covers, wedge gate and stuffing box shall be of good quality cast iron, the spindle of bronze the nut and valves seats of leaded tin bronze. The bodies, spindles and other parts shall be truly machined with surfaces smoothly finished. The area of the water way of the fitting shall be not less than the area equal to the nominal bore of the pipe. The valve wheel shall be marked with an arrow to show the direction to turn for closing the valves. The valve shall be fully examined and cleared of all foreign matter before being



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fixed. The fixing of the valve shall be done by means of bolts, nuts and 3 mm rubber insertions or chemically treated compressed fibre board of 1.5 mm thick minimum thickness and of weight not less than 0.183 gm per sq.cm. with the flanges of spigot and the socketed tail pieces drilled, to the same specification in the case of S & S pipe and with flanges in case of flanged pipes. The tail pieces shall conform to I.S 1938 - 1960. These shall be jointed to the pipe line by means of lead caulked joints.

3.6.8 Valve Schedules

Service Type Size Rating Ends Materials

Cold Water

Butterfly 50 mm NB & above

150 Wafer type slip on

Cast iron body

Cold Water

Ball with through bore 3 piece construction

40 mm NB & below

150 Screwed Cast steel body and SS Ball.

Cold Water

Dual Plate Check Valve

100 mm NB 150 Wafer type slip-on

Cast Steel & SS flap

Service Type Size Pressure Ends Materials

Water Gate 65 300psi/ Screwed Bronze

Water Gate 75 & Over 20 kg/ Flanged C.I body bronze trim

Water Globe 65 & under 20 kg/ cm2 Screwed Bronze

Water Globe & Angle 65 & under 20 kg/ cm2 Screwed Bronze

Water Globe & Angle 65 & over 20 kg/ cm2 Flanged Iron body bronze trim

Water Horizontal Vertical check

65 & under 20 kg. cm2 Screwed Bronze


65 & under 20 kg. cm2 Screwed Bronze


65 & under 20 kg. cm2 Flanged Iron body bronze

S.No Type of Valve Size Construction Ends

a. Isolating Valve 15mm to 50mm 65mm & above

Gun Metal Gun Metal

Screwed Flanged

b. Sluice Valve & Butterfly Valve 65mm & above Cast Iron Flanged

c. G.M. non return valve 15mm to 50mm 65mm & above

Gun Metal Gun Metal

Screwed Flanged

d. Flap Type – non return valve 65mm & above Cast Iron Flanged

3.7 Other Pipe Fittings 3.7.1 Water Meters

Water meters of approved make and design shall be supplied for installation at locations as shown. The water meters shall meet with the approval of local supply authorities. Suitable valves and chambers or wall meter box to house the meters shall also the be provided along with the meters. The meters shall conform to Indian Standard IS: 779 and IS : 2373 Provision shall also be made to lock the water meter. The provision shall be such that the lock is conveniently operated from the top. Where the provision is designed for use in conjunction with padlocks the hold provided for padlocks shall be a diameter not less than 4mm.

3.7.2 Installation of water meter and stop cock The G.I lines shall be cut to the required lengths at the position where the meter and stop cock is required to be fixed. Suitable fittings shall be attached to the pipes. The meter and stop cock shall be fixed in a position by means of connecting pipes, jam nut and socket etc. The stop cock shall be fixed near the inlet of the water meter. The paper disc inserted in the ripples of the meter shall be removed. And the meter installed exactly horizontal or vertical in the flow line in the direction shown by the arrow cast on the body of the meter. Care shall be taken that the factory seal of the meter is not disturbed. Wherever the meter shall be fixed to a newly fitted pipe line, the pipe line shall have to be completely washed before fitting the meter.



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3.7.3 Air valve Automatic air valves shall be provided at all high points in the piping system for venting. All valves shall be of 15mm pipe size and shall be associated with an equal size isolation ball valve. Automatic air valves shall also be provided on hot water risers. Discharge from the air valves shall be piped through a galvanized steel pipe to the nearest drain or sump. All pipes shall be pitched towards drain points.

3.7.4 Pressure Gauges Pressure gauges shall be provided as shown on the approved drawings and include in bill of quantities. Care shall be taken to protect pressure gauges during pressure testing. The pressure gauge shall be constructed of die cast aluminium and stove enamelled. It shall be weather proof with an IP 55 enclosure. It shall be a stainless-steel Bourdon tube type pressure gauge with a scale range from 0 to 16kg / cm square and shall be constructed as per IS:3524. Each pressure gauge shall have a siphon tube connection. The shut off arrangement shall be by ball valve.

3.8 Pipe Laying 3.8.1 Cutting in masonry walls

Cold water distribution pipes to fixtures and equipment exposed to view in the bathrooms, kitchens, and sanitary compartments shall be chased into walls or floors or placed in wall cavities. The contractor shall be responsible for cutting all notches. Chases and recesses in walls and floors and only a diamond cutter shall be used. The maximum size of conduit or pipe permitted to be concealed in floor slabs shall be 32 mm diameter unless otherwise approved by the Engineer In-charge The chases up to 7.5 x 7.5 cm shall be made in the walls for housing GI pipes etc. These shall be provided in correct positions as shown in the drawings or directed by the Engineer In charge. Chases shall be made by chiselling out the masonry to proper line and depth. After the pipes etc are fixed in chases, the chases shall be filled with cement mortar 1:2:4 or as may be specified, and made flush with the masonry surface. The concrete surface shall be roughened with wire brush to provide a key for plastering.

Where pipes pass through beams or structural walls, subject to the approval of the Structural Consulting Engineer, the Contractor shall ensure that sizes and locations of openings required are formed in when the relevant beams or walls are cast

3.8.2 Pipe Support Tender drawings indicate schematically the size and location of pipes. The contractor on the award of the work shall prepare detailed working drawings, showing the cross-sections longitudinal sections, details of fittings locations of isolating and control valves drain and air valves and all pie supports. He must keep in view the specific openings in buildings and other structure through which pipes are designed to pass.

Piping shall be properly supported on suspended from on stands clamps hangers as specified and as required. The contractor shall adequately design all the brackets, saddles anchor clamps and hangers and be responsible for their structural stability.

Pipe work and fittings shall be supported by hangers or brackets so as to permit free expansion and contraction. To permit free movement of common piping support shall be from a common hanger bar. Pipe hangers shall be provided at the following maximum spacing:

Pipe Dia (mm) Hanger Rod Dia (mm) Spacing between supports

Up to 25 6 2

33 to 50 10 2.7

80 to 100 12 2.7

125 to 150 16 3.6

200 to 300 19 5.3

Insulated piping shall be supported in such a manner as not to put undue pressure on the insulation. 14 gauge metal sheet shall be provided between the insulation and the clamp, saddle or roller, extending at least 15c.m on both sides of the clamps saddles or roller.



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All pipe work shall be carried out in a proper workman like manner causing minimum disturbance to the existing services buildings roads and structure. The entire piping work shall be organized in consultation with other agencies work so that area can be carried out in one stretch. Cut-outs in the floor slab for installing the various pipes area are indicated in the drawings. Contractor shall carefully examine the cut-outs provided and clearly point out wherever the cut-outs shown in the drawings, do not meet with the requirements. The contractor shall make sure that the clamps brackets saddles and hangers provided for pipe supports are adequate or as specified / approved by Consultants. Piping layout shall take due care for expansion and contraction in pipes and include expansion joints where required. All pipes shall be accurately cut to the required sizes in accordance with relevant BIS codes and burrs removed before laying. Open ends of the piping shall be closed as the pipe is installed to avoid entrance of foreign matter.

3.8.3 External Works The galvanized iron pipes and fittings shall be laid in trenches. The widths and depths of the trenches for different diameters of the pipes shall be given as in the table below, and shall be enough to have a clear cover of at least 400 mm above the top of pipes.

Dia of Pipe Width of trench Depth of Trench

15 mm to 50 mm 300 mm 600 mm

65 mm to 100 mm 450 mm 750 mm

At joints and multi pipe routes the trench width shall be widened where necessary. To work of excavation and refilling shall be done true to line and gradient The pipes shall be painted with two coats of anti-corrosive bitumastic paint of approved quality and wrapped with Hessian cloth impregnated with bitumen. The pipes shall be laid on a sand cushion layer of 75 mm. river sand and filled with excavated earth. The surplus earth shall be disposed off as directed. The filling shall be done after testing & rectifying leakages and after final passing of work by Engineer In charge / Owners Representative at site. When the excavation is done in rocks the bottom shall be cut deep enough to permit the pipes to be laid on a sand cushion of minimum 75 mm. In case of bigger diameter pipes where the pressure is very high thrust blocks of cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregates of 20 nominal size) shall be constructed on all bends to transmit the hydraulic thrust without impairing the ground and spreading it over a sufficient area, as directed by the Engineer-in-charge / Owners Representative at Site. In case of bigger pipes (80mm dia and above), thrust blocks of cement concrete 1:2:4 (1 cement :2 coarse sand : 4 graded stone aggregated of 20mm nominal size) shall be constructed on all bends as directed by the Owner’s site representative. \

3.9 Connections to various Mechanical equipment supplied by other agencies All inlets outlets, valves, piping and other incidental work connected with installation of mechanical equipment supplied by other agencies all be carried out by the contractor in accordance with the drawings, requirements for proper performance of equipment manufacturers instructions and the directions of the Owner’s site representative / Engineer In-charge. The equipment’s to be supplied by the other agencies consist mainly for air-conditioning and any other service. The work of connections to the various equipments shall be done through proper union and isolating valves. The work of effecting connections shall be executed in consolation with and according to the requirement of equipment suppliers, under the directions of the Owner’s site representative / Engineer In-charge. The various aspects of connection work shall be executed in a similar way to the work of respective trade mentioned elsewhere in these specifications.

3.10 Testing of Joints The contractor shall notify the Engineer In-charge three days in advance of any test so that the Architect can witness the tests if he so wishes. All water supply system shall be tested to hydrostatic pressure test of at least one and a half (1.5) times the maximum pressure but not less than 10Kg/Sq.cm for a period of not less than 8 hours. All leaks and defects in joints revealed during the testing shall be rectified and got approved at site by retest. Piping required subsequent to the above pressure test shall be retested in the same manner.



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System may be tested in sections and such sections shall be entirely rested on completion. The contractor shall make sure that proper noiseless circulation of fluid is achieved through the entire piping network of the system concerned. In case of improper circulation, the contractor shall rectify the defective connections. He shall bear all expenses for carrying out the above rectification’s including the tearing up and refinishing of floors and walls as required. In addition to the sectional testing carried out during the construction, contractor shall test the entire installation after connections to the overhead tanks or pumping system or mains. He shall rectify all leakages and shall replace all defective materials in the system. Any damage done due to carelessness, open or burst pipes or failure of fittings, to the building furniture and fixtures shall be made good by the contractor during the defects liability period without any cost. After commissioning of the water supply system, contractor shall test each valve by closing and opening it a number of times to observe if it is working efficiently. Valves which do not effectively operate shall be replaced by new ones at no extra cost and the same shall be tested as above. A test register shall be maintained and all entries shall be signed and dated by contractor(s) and Owner’s site representative.

3.11 Measurements The length above ground shall be measured in running meter correct to cm for the finished work which shall include pipe and fittings such as coupling, bends, tees, elbows, reducers, crosses, plugs, sockets, nipples and nuts, unions. Deductions for length of valves shall be made. Rate quoted shall be inclusive of all fittings, clamps, cutting holes chased and making good the same and all items mentioned in the specifications and bill of quantities. All pipes below ground shall be measured per linear meters (to the nearest cm) and shall be inclusive of all fittings e.g. coupling tees, bends, elbows, unions, deduction for valves shall be made rate quoted shall be inclusive of all fittings, excavation, back filling and disposal of surplus earth, cutting holes and chase and making good all item mentioned in bill of quantities.

3.12 Masonry Chambers 3.12.1 General

All masonry chambers for stop cocks, sluice valves, etc., shall be built as per supplied drawings.

3.12.2 Excavation The excavation for chambers shall be done true to dimension and levels as indicated on plans or as directed by the Engineer-in-charge.

3.12.3 Bed Concrete This shall be cement concrete 1:3:6 (1 cement : 3 fine sand : 6 graded stone aggregate 40 mm nominal size).

3.12.4 Brick Work This shall be in Class B bricks (Table Moulded) with crushing strength not less than 35 kg / sq.cm in cement mortar 1:5 (1 cement : 5 fine sand).

3.12.5 Plastering Plastering not less than 12 mm thick shall be done in cement mortar 1:3 (1 cement: 3 coarse sand) finished with a floating coat of neat cement.

3.12.6 Surface Box: This shall be of cast iron, well made and free from casting and other defects. All sharp edges shall be removed and finished smooth. The shape and dimensions for surface boxes for stop cocks, sluice valves, etc., shall be as per approved samples.

3.12.7 Measurements Masonry chambers shall be measured as No. of units and the item may or may not include, excavation and back-filling as detailed in the BOQ.

3.12.8 Rating The rate shall include the cost of materials and labour involvement in all the operations described above, except the excavation in soft or decomposed and hard rock. The difference in cost, between ordinary soil and soft or decomposed or hard rock as the case may be, shall be paid for separately if the rock is met with.

3.13 Connection of RCC Water Tanks The contractor shall provide all inlets, outlet, washouts, vents, ball cocks, overflows control valves and all such other piping connections including level indicator to water storage tanks



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as called for. All pipes crossing through RCC work shall have puddle flanges fabricated from MS/GI pipes of required size and length and welded to 6/8 mm thick MS plate. All puddle flanges must be fixed in true alignment and level to ensure further connection in proper order. Full way gate valves of an approved make shall be provided as near the tank as practicable on every outlet pipe from the storage tank except the overflow pipe. Overflow and vent pipes shall terminate with mosquito proof grating. The overflow pipe shall be so placed to allow the discharge of water being readily seen. The overflow pipe shall be size as indicated. A stop valve shall also be provided in the inlet water connection to the tank. The outlet pipes shall be fixed approximately 75mm above the bottom of the tank towards which the floor of the tank is sloping to enable the tank to be emptied for cleaning.

3.14 Disinfection of Piping system and Storage Tanks Before commissioning the water supply system the contractor shall arrange to disinfect the entire system as described in the succeeding paragraph. The water storage tanks and pipes shall first be filled with water and thoroughly flushed out. The storage tanks shall then be filled with water again and disinfecting chemical containing chlorine added gradually while tanks are being filled to ensure thorough mixing. Sufficient chemical shall be used to give water a dose of 50 parts of chlorine to one million parts of water. If ordinary bleaching powder is used, the proportions will be 150 gm of power to 1000 liters of water. The power shall be mixed with water in the storage tank. If a proprietary brand of chemical is used the proportions shall be specified by the manufacturer. When the storage tanks is full the supply shall be stopped and all the taps on the distributing pipes are opened successively working progressively away from the storage tank. Each tap shall be closed when the water discharged begins to smell of chlorine. The storage tank shall then be filled up with water from supply pipe and added with more disinfecting chemical in the recommended proportions. The storage tank and pipe shall then remain charged at least for three hours. Finally, the tank and pipes shall be thoroughly flushed out before any water is used for domestic purpose.

The pipe work shall be thoroughly flushed before supply is restored. 3.14.1 Sterilization of Mains

After the pipe work has been tested and approved, but before it is coupled, it shall be sterilized with a solution of chloride of lime.

3.15 System Testing Plumbing equipment fixtures, piping etc., shall be free of stampings, marking (Except those required by codes) iron cutting and other foreign materials. Cold and drinking water systems shall be cleaned thoroughly filled and flushed with water. The entire mechanical apparatus shall operate at full capacity without objectionable noise or vibrations. On completion of the works, the following tests shall be performed to the satisfaction of the consultants/clients representative before issue of virtual completion certificate, if so required. 1. Smoke Test 2. Hydraulic Test 3. Performance test for fixtures 4. Tests for anti-siphonage system 5. Pump rating and output 6. Inspection of all units and fixtures. The contractor shall arranged for similar tests during the progress of works to ensure that there are no defects in material/work ship in portions of work to be concealed or embedded under the floor or walls in ceiling and get this approved by the consultants. The under-floor pipe works shall not be closed without the approval of consultants. Test entire system of soil, waste and vent piping by smoke test after scaling all traps. Water tests: Tests entire system or sections of system by closing all openings except the highest opening and filling system with water to the point of overflow. If the system is tested in sections, plug each opening except the highest opening of the section filled with water. Keeps the water in system or in portion under test for at least 45 minutes before inspection starts with test pressure/head lasting for two hrs. The system must be tight at all joints.



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Test all down spouts or rain headers and their branches within the building by water as described for the above soil waste and vent system. All tests on below ground lines shall be continued until backfill on such lines is Completed to disclose any damages caused by back filling.

3.16 Reverse Osmosis Plant 3.16.1 Technical Specifications

Plant of 50 m3/day treatment capacity (@ 2.78 m3/hr. capacity operating for 18 hrs. per day) Reverse Osmosis Water Treatment Plant of 2.78 m3/hr treatment capacity as per following parameters,

3.16.2 Key Raw Water Parameter: 1. Total Dissolved Solids = Maximum 3000 ppm 2. Source of Raw Water = Bore-well Key RO Treated Water Parameters: 1. Total Dissolved Solids < 100 ppm (without pH correction). Reverse Osmosis Plant shall consist of the following: Supplying, Fixing, Testing and Commissioning of skid mounted automatic Reverse Osmosis Water conditioning system of 2.78 m3/hr. capacity with minimum recovery of 65%, consisting of 2 nos. raw water pumps (1 working + 1 standby), solenoid valve at inlet, micron filter, 1 nos. high pressure pump (in S.S. construction), reverse osmosis membrane block, anti-scalant dosing & post treatment pH correction & chlorine dosing systems with 100 litres chemical dosing tanks, MIMIC & power cum control panel with PPLC based SIRO-Logic controller with necessary flow & pressure indicators. RO plant electrical panel shall also have starters for RO plant feed pumps, level controllers for chemical dosing tanks & treated water tank level controlling. The RO plant shall also comprise of Pre-treatment Chlorination & De-chlorination equipment complete with ORP controller & automatic dump valve. Interconnecting Piping Work, Power & control cabling within the RO plant. RO plant shall be complete with C.I.P. (Cleaning in Place) equipment for periodic membrane cleaning.

3.17 Borewell 3.17.1 Scope

The scope of this section comprises the supply, installation, testing and commissioning of bore. The contractor shall make all necessary application and arrangements for his work to be inspected by the Local Authorities, Consultants and Site personnel. The contractor shall be solely responsible for obtaining the Authorities approval of his works prior to the handing over of the complete borewell to the owner. The general character and the scope of work to be carried out under this contract is illustrated in the following specification. It gives only general guidance as regards design, drilling and construction of tube-wells. The construction and testing of tube-well shall be as per IS 2800-1979, (part I & II). The contract is an item rate contract. All payments shall be made for the actual work executed. The required minimum yield shall be ensured by the contractor.

3.17.2 Selection of site The proposed site for the tube-well decided based on hydro geological tests carried out, shall be examined by tenderer. The tenderer shall satisfy himself about the suitability of site selected for the drilling of tube-well. If any changes are required, these shall be got approved from the Engineer prior to starting the work. Any previous data available with the contractor regarding nearby tube-wells should be made use of to evolve suitable procedure for drilling, developing, testing etc.

3.17.3 Geological data During the drilling time, contractor shall collect the samples of different strata @3 mtrs. It shall be carefully examined and analyzed and data shall be preserved carefully and handed over to the Engineer’s Representative. The contractor shall make one drilling time log during the execution of work for the bore well.

3.17.4 Design and lowering of pipe assembly The length and diameter of the housing pipe (blind and slotted) and the capacity and head of the pump have been tentatively selected based on information available presently. However, the selection would depend on the actual conditions encountered during drilling. Housing and casing pipes shall be freshly painted before lowering into the bore. Cantering guides are to be used to ensure verticality. The depth of the casing and its size shall be



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selected so as to seal the entire clay which moves up to the point of an encountering hard rock.

3.17.5 Gravel packing All gravels shall consist of hard, well rounded particles reasonably uniform in diameter and shall be of a size, determined after analyzing the character of the water bearing formation tapped. The gravel around the screen shall be uniform.

3.17.6 Development of tube-well The well shall be developed either by surging and agitating or by over pumping and back washing with an air lift and high velocity jetting etc. Any other acceptable method may also be adopted. This development process shall be continued until the stabilization of sand and gravel pack has taken place. Over pumping shall be done at 25% higher discharge than the expected yield of the well. The development shall be continued till sand free discharge is obtained. Maximum permitted sand shall be 20PPM by volume after 20 min of starting the pump. Subsequently, 12-16 hrs. continuous pumping must be carried out to measure draw down and recovery to draw up pump specifications and yield of the tube well.

3.17.7 Disinfection The well shall be disinfected after completion of test for yield. All the exterior parts of the pump coming in contact with the water shall be thoroughly cleaned and dusted with powdered chlorine compound. In fact, it shall be disinfected every time when a new pump is installed or the one replaced after repairs.

3.17.8 Grouting and sealing Grouting and sealing of tubewell shall be done as instructed by the engineer. To ensure a satisfactory seal, it shall be applied in one continuous operation. Sealing of the tubewell shall be done by grouting the annular space between bore and the housing pipe, thickness of grouting depending upon the quality of water.

3.17.9 Handing over of the tubewell The tubewell shall be handed over to the engineer’s representative in complete shape. The housing pipe shall be closed by a well cap for the period between the completion of the tubewell and the installation of the pump set. The following information shall be furnished by the drilling agency on completion of the tubewell: Strata chart of the tubewell indicating the different types of soils met with at different depths. Samples of strata collected, neatly packed and correctly marked in sample bags. Chart of actual pipe assembly lowered indicating the size of pipes, depth ranges, where slotted/strainer pipes have been used, depth and diameter of housing pipe, reduced level of the top of the housing pipe and the diameter and depth of the bore hole.

Position of every joint in the well assembly.

Hours of development done by compressed air pump sets or by other means.

Pumping water level and draw down at the developed discharge. Result of yield test.

Routine chemical and bacteriological tests on the water for.

Suitability for drinking.

Suitability for construction.

Two attested copies of all test certificates by the testing agency approved by the engineer.

3.17.10 Tubewell pumps Tubewell pumps shall be a compact unit made up of a submersible motor with shaft connected by a sleeve. The pump shall be single/multi stage centrifugal pump with stainless steel jacket and non-return valve fitted to the pump discharge. The pump shall be provided with sleeve bearings and the motor with sleeve and thrust bearings. All these bearing shall be water lubricated and protected against the ingress of sand by suitable structural elements. Different parts of tubewell pumps shall be made from following materials:

1. Suction casing Cast iron

2. Diffuser Cast iron

3. Impeller Bronze

4. Pump shaft Chrome steel



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5. Thrust bearing housing Cast iron

6. Upper/Lower bearing Carbon steel

7. Thrust bearing plate Stainless steel

8. Rotor complete Chrome steel

9. Bearing bush for motor Gunmetal

10. Stator casing

Seamless steel

3.17.11 Electrical works 3.17.11.1 Cables

Contractor shall provide all power and control cables from motor control centre to motor. Cables shall conform to IS: 1554 and carry ISI mark. Wiring shall conform to IS:694. All power cables shall be 3.5/4 core aluminium conductor PVC insulated/ PVC sheathed FRLS armoured cables of 1100 volts grade with fire proof coating of approved make. All control cables and wiring cables shall be copper conductor PVC insulated armoured and PVC sheathed 1100 grade. All cables shall have stranded conductors. The cables shall be in drums as far as possible and bear manufacturer’s name.

3.17.12 Motor control centres Cubicles switch board of wall mounted as approved shall be fabricated from preferably 14 gauges with 16 swg doors, M.S. sheet with dust and vermin proof construction. It shall be powder coated with stove enamelled paint of approved make and shade. It shall be fitted with suitable etched plastic identifications plates for each motor. The cubicles shall be in general comprise of the following (switchgear as given in the schedule of quantities).

Income main fuse switch unit with HRC fuses of required capacity.

Isolation switch fuse unit one for each motor.

Fully automatic DOL Starter appropriate for motor rating with ON/OFF push buttons and on/off indicating neon lamps for individual motor.

Single phase prevents or & overload protection of appropriate rating for each motor.

Selector switch for pump operation.

Panel type ampere meters of appropriate rating one for each motor.

Panel type voltmeter on incoming main with rotary selector switch to read voltage between phase to neutral and phase to phase.

Rotary switch for manual or auto operation for each pump.

Space for liquid level controllers specified separately in this contract. The panel shall be prewired with colour coded wiring (all interconnecting wiring from

incoming main to switch gear, meters and accessories within the switch board panel). 3.17.13 Shop drawings

The contractor has to submit the model of submersible pump that he proposes to install. The shop drawings for electrical panel shall also be submitted for approval before the installation.

3.17.14 Installation The pumps and accessories shall be installed in a true workman like manner true to level and grade in accordance with the best current practice. Vendor shall employ sufficient and proper equipments for lifting and placing of pumping equipment, in a manner which shall not strain or cause damage to the existing structures. If any damage is done, the sample shall be made good to the satisfaction for the engineer’s representative without any additional cost. The vendor shall submit detailed shop drawing showing sizes of all piping, valves, etc. for approval. The work shall be started only after approval of shop drawings.

3.17.15 Commissioning On completion of the work in all aspects, the vendor shall start up the pumps in a manner normally done for the continuous operation for a period of not less than 48 hours and shall rectify and adjust the pumps and equipments for leakages and balancing the system. After satisfactory commissioning of the pumps, the vendor shall conduct performance tests to satisfy the engineer’s representative that all pumps and equipments are performing to the rated outputs of any or all pumps and equipment shall be rectified or replaced if the same is not performing in accordance with the specifications.



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3.17.16 Guarantees On award of the work the vendor shall submit a guarantee covering the quality and performance of all materials and installations under the contract. This guarantee shall cover each and every material whether manufactured by the contractor or not. Vendor shall specify a suitable procedure to test the rated performance of the equipment and the system and shall provide all necessary equipments, gauges, etc. for conducting such tests.

3.18 Pumps, Accessories and Associated Electrical Works 3.18.1 Pumping Sets

Water supply pumps shall be suitable for clean filtered water. Pumps shall be single or multistage, vertical pumps with S.S. body, S.S. impeller, stainless steel shaft and coupled to a TEFC electric motor by means of a flexible coupling and C.I. base plate. Each pump shall be provided with a totally enclosed fan cooled induction motor of suitable H.P. The motors shall be suitable for 400/440 Volts, 3 phase, 50 cycles A.C. Power supply. Each pumping set shall be provided with a 150 mm dia gunmetal “BOURDEN” type pressure gauge with gunmetal isolation cock and connecting piping. Provide vibration eliminating pads appropriate for each pump.

3.18.2 Submersible Sump Pumps Pumps shall operate with high water level in sump and stop at low water level by means of an electronic level controller/ float ball valve.

Pumps for drainage shall be single stage, single entry pump.

Each pump shall be provided with air cooled squirrel cage induction motor suitable for 415 volts, single/three phase ±10%, 50 cycle A.C. power supply.

Each pump shall be provided with inbuilt liquid level controller for operating the pump between predetermined levels.

The pumping set shall be for stationary application and shall be provided with pump connector unit. The delivery pipe shall be joined to the pump through a rubber diaphragm, and bend and guide pipe for easy installation.

Pump shall be provided with all accessories and devices necessary and required for the pump to make a complete working system.

3.18.3 Level Controller Provide and install low voltage transistorized level controllers as specified below. Each level controller shall be provided with required number of PVC sheathed stainless steel probes. All sumps shall be provided with two pumps, one running and one standby, the pump panel shall be provided with an auto/off/manual and a pump selector switch. At high-water level conditions the pump selected by the selector switch will first start automatically. If for some reason the level continues to rise, the second pumps would start automatically at extra high level. If for some reason the level of water in the sump continues to rise then a third sensor would provide an audio-visual alarm at specified point. Each controller shall be provided with an audible alarm for low water level and High-water level in underground tank.

3.18.3.1 Raw water pumping system To start/cut pump at high water level and stop at low water level in the sump.

3.18.3.2 Sump pump To start pump at high water level and stop at low water level in the sump.

3.18.4 Vibration Eliminators Provide on all suction and delivery lines double flanged reinforced neoprene flexible pipe connectors. Connectors should be suitable for a working pressure of each pump. Length of the connector shall be as per manufacturers’ details. Flexible connector shall be of approved make only.



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4 DRAINAGE WORK 4.1 Salt Glazed Stone ware pipe

All pipes with spigot and socket ends shall inform to be 651 – 1980 and shall be of grade ‘I’ as specified. These shall be sound, free from visible defects such as fire cracks or hair cracks. The pipes shall give a sharp clear note when struck with a light hammer. These shall be no broken blisters or chipping on the spigot or socket. The appropriate thickness of 60 cm pipes shall be given in the table below:

Internal Diameter of the Pipe

Thickness of the weight of each barrel and of as kept pipe per m

Mm mm Kg.

100 12 14

150 16 22

200 17 33

230 19 44

250 20 52

300 25 79

The length of pipes shall be 60 cm exclusive of the internal depth of the socket. 4.2 Trenches for Stone ware pipes

Unless otherwise mentioned the widths of trenches for various dia of stoneware pipes shall be as given in the table given below for depth up to 3 m

Size of pipes Width of trench 100 mm dia 450 mm 150 mm dia 600 mm 200 mm dia 700 mm 250 mm dia 750mm 300 mm dia 900 mm

Wherever depth exceeds 3 m, the width will be increased by 1.1 m

4.3 Laying of Stone ware pipes All pipes shall be laid on a bed of 15cm cement concrete of 1:1:8 using 10 to 12cm graded granite aggregates projecting on each side of the pipe to the width of the trench specified. The pipes with their crown level at 1.20m. Depth and less from ground shall be covered with 15cm thick concrete above the crown of the pipe ends sloped off to meet the outer edges of the concrete to give a minimum thickness of 15cm all round the pipe. Pipes laid at a depth greater than 1.20m at crown shall be concreted at the sides up to the level of the centre of the pipe and sloped off from the edge to meet the pipe tangentially. The pipes shall be carefully laid to the alignments, levels and granites shown on the plans and sections, great care shall be taken to prevent sand etc., from entering the pipes. The pipes between two manholes shall be laid truly in a straight line without vertical or horizontal undulation. The pipes shall be laid with socket up the gradient. If the excavation has been carried to low, the desired levels shall be made up with concrete 1:5:10 (1 cement; 5 fine sand: 10 graded stone aggregate 40 mm nominal size) for which no extra payment shall be made. If the floor of the trench consists of rock or very hard ground that cannot easily be excavated to a smooth surface the pipe shall be laid on a levelling course of concrete the pipe shall be laid on a levelling course of concrete as desired.

4.4 Jointing of Stone ware pipes Tarred gasket of hemp yarn soaked in thick cement slurry shall first be placed round the spigot of each pipe and the spigot shall then be slipped home well into the socket of the pipe previously laid. The pipe shall then be adjusted and fixed in the correct position and the gasket caulked tightly home so as to fill not more than 1/4th of the total depth of the socket. The remainder of the socket shall then be filled with stiff mixture of cement mortar in the proportion of 1:1 (1 cement: 1 fine sand). When the socket is filled a filler shall be formed round the joint with a trowel forming an angle of 45 degree with the barrel of the pipe. The joints shall be tested hydraulically as per given below and no concerting for encashment shall be done unless pipes are jointed and tested after a day’s work any extraneous material shall be removed from the inside of the pipe. The newly made joints shall be cured.



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4.5 Testing of Joints Hydraulic test: Stoneware pipe used for sewers shall be subjected to a test pressure of 1.5m or required head of water at the highest point of the section under test. The test shall be carried out by suitable plugging the low end of the drain and the ends of the connection, if any and filling the system with top and a sufficient length of vertical pipe jointed to it so as to join with a connection to a hose ending in a funnel which could be raised or lowered till the required head is obtained and fixed suitably for observation. During the test required head is maintained for 30 minutes by adding water from a measuring vessel at 10 minutes interval and the average quantity added shall not exceed 1 liter per hour 100m length per 100mm dia of pipe. Where leakage will be visible the defective part of the work shall be removed and made good, at no extra cost.

4.6 Refilling of Trenches In case where pipes are bedded on concrete, special care shall be taken in refilling trenches to cement the displacement and subsequent settlement at the surface resulting in uneven surface and dangers to foundations etc., the backfilling materials shall be packed by hand under the around the pipe and rammed with a shovel and light tamper. The refilling shall raise evenly on both side of the pipe continued up to 50 mm above the top of pipe so as not to disturb the pipe. The remainder of the backfill shall not be done until 7 days have elapsed for brick sewers and 14 days for concrete sewer unless local conditions of materials are suitable for the earlier placing of a load on the pipes. The tapping shall become progressively heavier as the depth of the backfill increases.

4.7 Cast Iron Pipes Cast iron pipes and fittings shall be of good and tough quality and dark grey on fracture. The pipes and fittings shall be true to shape smooth and cylindrical their inner and outer surface being as nearly as practicable concentric. They shall be sound and nicely cast, shall be free from cracks taps pinholes and other manufacturing defects. The pipes and fittings shall conform to IS: 3989 / IS: 1729 as called for. Fittings shall be of required degree with or without access door. All access doors shall be made up with 3mm thick insertion rubber gasket of white lead and tightly bolted to make the fittings air and water tight. The fittings shall be of the same manufacture as the pipes used for soil and waste. All CI pipes and fittings shall bear the manufacturer’s name and ISI specification to which it conforms. All pipes and fittings shall be coated internally and externally with the same material at the factory, the fittings being preheated prior to total immersion in a bath containing a uniformly heated composition having a tar/other suitable base. The coating material shall have good adherence and shall not scale off. The coating shall be smooth and tenacious and hard enough not to flow when exposed to a temperature of 77 degree C but not so brittle at a temperature of ‘0’ degree C as to chip off when scratched lightly with a pen knife. All pipes and fittings before installation at site shall be tested hydrostatically to a pressure of 0.45 Kg/sq. cm without showing any sign of leakage sweating or other defects of any kind. The pressure shall be applied internally and shall be maintained for not less than 15 minutes. All these tests shall be carried out in the presence of the representative of the Project Manager. Alternatively, a test certificate from manufacturers is obtained before dispatch of material to site.

4.7.1 Cast Iron Specialties If required, cast iron specialty items such as deep seal floor traps, urinal traps, trap integral pieces with integral inlet/outlet connections manhole cover with frame, chamber cover etc shall be fabricated to suit individual location requirements. The contractor shall arrange the fabrication of these items from an approved source.

4.7.2 Lead Caulked joints with Pig Lead: The approximate depth and weights of Pig Lead for various diameters of CI pipes and specials shall be as follows:

Nominal size of pipe (mm) Leader per joint (kg) Depth of Lead Joint (mm) 50 0.77 25 80 0.88 25 100 0.99 25 150 1.5 38



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4.7.3 Cast Iron Class (LA) pipes All drainage passing under building floor and passing through retaining wall shall be cast iron class (L) pipes (IS : 1536) Cast iron class (LA) pipe shall be such that they could be cut, drilled or machined. Pipe centrifugally cast is unlined water cooled moulds shall be heat treated in order to achieve the necessary mechanical properties and to relieve casing stress; provided that the specified mechanical properties are satisfied.

4.7.4 Material Cast iron pipe shall be centrifugally spun cast iron and conforming to IS: 1536-1976

4.7.5 Fittings Fittings shall be used for cast iron class (LA pipes shall conform to IS: 1538-1976). Whenever possible junction from branch pipe shall be made by wyes. All cast iron water main pipes and fittings shall be manufactured to IS: 1536 of tested quality. The pipes and fittings shall either be spigot or socket type or as called for. The pipes and fittings shall be of uniform material throughout and shall be free from all manufacturing defects.

4.7.6 Joints Cast iron class (LA) pipe used for soil and waste pipes shall be jointed with refined pig lead conforming to IS: 27-1977, sufficient skein of jute rope shall be caulked to leave minimum space of 25mm for the pig lead to be poured in. After surface lead shall be caulked in to the joint with caulking tools and hammer of proper width. All surface lead shall be out and joint left flush with the rim of the socket. One continuous lead pour shall be thoroughly caulked at least 3 times around.

4.7.7 Laying Fittings used for CI drainage pipe shall conform to IS: 1538-1976. Wherever possible junction from branch pipes shall be made by a Y/tee. Lead Caulked joints with Pig Lead: The approximate depth and weights of Pig Lead for various diameters of CI pipes and specials shall be as follows:

Nominal size of pipe (mm) Leader per joint (kg) Depth of Lead Joint (mm)

80 1.8 45

100 2.2 45

125 2.6 45

150 3.4 50

200 5.0 50

250 6.1 50

The spigot of pipe of fittings shall be centered in the adjoining socket by caulking. Sufficient turns of tarred gasket shall be given to leave a depth of 45mm when the gasket has been caulked tightly home. Joining ring shall be placed round the barrel and against the face of the socket. Molten pig lead shall then be poured to fill the remainder of the socket. This shall then be done in one pouring. The lead shall then be solidly caulked with suitable tools and hammers weighting not less than 2 kgs. For lead wool joints the socket shall be caulked with tarred gasket, as explained above. The lead wool shall be inserted into the sockets and tightly caulked home skin by skin with suitable tools and hammers of not less than 2 Kg weight until joints is filled.

4.8 Pipes Hangers, Supports, and Clamps All vertical pipes shall be fixed by clamps and angle brackets truly vertical. Branch pipes shall be connected to the stack at the same angle as that of the fittings. No collars shall be used on vertical stacks. Each stack shall be terminated at top with a cowl (terminal guard). Horizontal pipes running along ceiling shall be fixed on structural adjustable clamps of special design shown on the drawings or as directed. Horizontal pipes shall be laid to uniform slope and the clamps adjusted to the proper levels so that the pipes fully reset on them. Contractor shall provide all sleeves, openings, hangers, inserts during the construction. He shall provide all necessary information to the building contractor for making such provisions in the structure as necessary. All damages shall be made good to restore the surfaces.



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Clamps shall be of approved design and fabricated from MS flats (which shall be enamel painted after fabrication) of thickness and sizes as per drawings or contractor’s shop drawings. Clamps shall be fixed in accordance to manufacturer’s details / shop drawings to be submitted by the contractors. When required to be fixed on RCC columns walls or beam they shall be fixed with approved type of expansion anchor fasteners (Dash fasteners) of approved design and size according to load. Structural clamps e.g. trapeze or cluster hangers shall be fabricated by electro-welding from MS structural members e.g. rods angles channels flats as per contractors shop drawings shall be enamel painted after fabrication.

4.9 Cement Concrete Pipe The pipes shall be with reinforcement as required and of the class as specified. Those shall conform to 15: 458: 1971. The reinforced cement concrete pipes shall be manufactured by centrifugal process. M/s. Indian Hume pipe company. All pipes shall be true to shape, straight, perfectly sound and freed from cracks and flows. The external and internal surface of the pipes shall be smooth and hard. The pipes shall be free from defect resulting from imperfect grading of the aggregate, mixing or molding. The pipes shall be R.C.C light duty, NP type. Concrete used for the manufacture of reinforced concrete pipes and collars shall not be leaned than 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregated). The maximum size of aggregate should not exceed one third of the thickness of the pipe or 20 mm whichever is smaller. The reinforcement in the reinforced concrete pipe shall extend throughout the length of the pipe. The circumferential and longitudinal the specified hydrostatic pressure and further bending stresses due to the weight of water.

4.9.1 Laying of pipe Loading, transporting and unloading of concrete pipes shall be done with care. Handing shall be such as to avoid impact. Gradual unloading by inclined plane or by chain block is recommended. All pipe sections and connections shall be inspected carefully. Mechanical appliances may not be used. Pipes shall be laid true to line and grade as specified. Laying of pipe shall proceed upgrade of a slope. If the pipes have spigot and socket joints, the socket end shall face upstream. In the case of pipe with joints to be made with loose collars, the collars shall be slipped on before the next pipe is laid. Adequate and proper expansion joints shall be provided where directed. IN case where the foundation conditions are unusual such as in the proximity of trees or holes, under existing or proposed manholes etc., the pipe shall be encased all round in 15 cm thick cement concrete 16:5:10m (1 cement: 5 fine sand: 10 graded stone aggregate 10mm nominal size) or compacted sand or gravel. In case where the natural foundation is inadequate the pipes shall be laid either in concrete cradle supported on proper foundation or on any other suitably designed structure as specified. Of concrete cradle bedding is used the depth of concrete below the bottom of the pipe shall be at least 1/4th of the internal dia and shall extend up to the sides of the pipe at least to a distance of 1/4th of the outside diameter. For pipes 300mm and over in dia. the pipe shall be laid in this concrete bedding before the concrete has set. Pipes laid in trenches in earth shall be bedded evenly and firmly and as far up the haunches of the pipe to the bed. This shall be fit the curve of the pipe or by compacting the earth under around the curve of the pipe to form an even bed. Necessary provision shall be made for joints wherever required. When the pipe is laid in a trench in rock, hard clay or other hard material the space below the pipe shall be excavated and replaced with an equalizing bed of conc., etc sand or compact earth. In on place shall pipe be laid directly on such hard material When the pipes are laid completely above the ground the foundations shall be made even and sufficiently compacted to support the pipeline without any material settlement. Alternatively, the pipeline shall be supported on P.C.C saddle blocks. Similar arrangement shall be made to retain the pipeline in the proper alignment such as by shaping the top of the supports to fit the lower part of the pipe. The distance between the supports shall be supported as far as possible close to the joints. In no case shall the joint come in centre of the span. Care shall be taken to see that superimposed loads greater than the total load equivalent to the weight of the pipe when running full shall not be permitted.

4.9.2 Jointing of pipes Joints are generally of rigid type. When specified flexible type joints may also be provided.



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4.9.3 Spigot and socket joint (rigid) The spigot of each pipe shall be slipped home well into the socket of the pipe previously laid and adjusted in the correct position. The opening of joint shall be filled with stiff mixture of cement mortar in the proportion of 1:2 (1 cement: 2 sand), which shall be rammed with caulking tool. After a day’s work any extraneous material shall be removed from the inside of the pipe and the newly made joint shall be cured.

4.9.4 Collar joint (rigid) The two adjoining pipes shall be butted against each other and adjusted in correct position. The collar shall then be slipped over the joint, covering equally both the pipes. The annular space shall them be slipped over the joint, covering equally both the pipes. The annular space shall be filled with stiff mixture of cement mortar 1:2 (1 cement: 2 fine sand), which shall be reamed with caulking tool. After a day’s work any extraneous materials shall be cured.

4.9.5 Testing of joints, Refilling of Trenches The testing of joints, refilling of trenches for concrete pipes shall be similar to specification for stone ware pipe.

4.10 Soil, Waste & Vent Pipes Soil waste and vent pipes in shafts under the floors / suspended below slab shall consist of cast iron pipes as described earlier. Waste pipes from bottle trap to floor / urinal traps for wash basin urinal and sink shall be GI pipes and fittings. All Horizontal pies running below the slab and along the ceiling shall be fixed on structural adjustable clamps sturdy hangers of the design as called for in the drawings. The pipes shall be laid in uniform slope and proper levels. All vertical pipes shall be truly vertical fixed by means of stout clamps in tow sections bolted together built into the walls wedged and neatly jointed. The branch pipes shall be connected to the stack at the same angle as that of fittings. All connections between soil waste and ventilating pipes and branch pipes shall be made by using pipe fittings with inspection doors for cleaning. Pipes shall be fixed in a manner as to provide easy accessibility for repair and maintenance and shall not cause obstruction in shafts. Where the horizontal run off the pipe is long or where the pipes cross over building expansion joints etc. suitable allowance shall be provided for any movements in the pipes by means of expansion joint etc. such that any such movement does not damage the installation in any way. All cast iron pipes and fittings shall be jointed with best quality soft pig lead free from all impurities conforming to IS 27. Before jointing the interior of the socket and exterior of the spigots shall be thoroughly cleaned and dried. The spigot end shall be inserted into the socket right up to the back of the socket and carefully centered by two or three laps of threaded spun yarn, twisted into ropes of uniform thickness, well caulked into the back of the socket. No piece of yarn shall be shorter than the circumference of the pipe. The jointed pipe line shall be at required levels and alignment. The reminder of the socket is left for the lead caulking. Where the gasket has been tightly held a jointing ring shall be placed round the barrel against the face of the socket. Molten pig lead shall be poured to fill her remainder of the socket in one pouring. The lead then shall be solidly caulked with suitable tools by hammering right round the joints to make up for the shrinkage of the molten metal on cooling and preferably finish 3mm behind the socket face. The depth of the lead joints for the cast iron pipes shall be 45mm for the pipes up to 100mm dia and 50mm for the beyond 100mm dia respectively. The joint shall not be covered till the pipe line has been tested under pressure. Rest of pipe line shall be covered so as to prevent the expansion and contraction due to variation in temperature.

4.11 Pipe Protection Cast iron soil and waste pipes under floor in sunken slabs and in wall chases (when cut specially for the pipe) shall be encased in cement concrete 1:2:4 mix (1 cement : 2 coarse and : 4 stone aggregate of 12 mm size) 10cm bed and all-round. When pipes are running well above the structural slabs, the encased pipes shall be supported with suitable cement concrete pillars of required height and size at intervals directed by the Project Manager.

4.12 Cutting and Making good Pipes shall be fixed and tested as building proceeds. The contractor shall provide all necessary holes cutouts and chases in structural members as building work proceeds.



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Wherever holes are cut or let originally they shall be made good with cement concrete 1:2:4 (1 cement: 2 coarse and: 4stone aggregate 20mm nominal size) or cement mortar 1:2 (1 cement: 2 coarse sand). Cured and the surface restored to original condition.

4.13 Painting Soil waste vent and rain water pipes in exposed location in shafts and pipe space shall be painted with two or more coats of ready mix oil paint to give an even shade. Before painting all dust and extraneous matter shall be removed. Paint shall be of approved quality and shade. Where directed by the Owner’s site representative pipes shall be painted in accordance with approved pipe colour code. Pipe in chase shall be painted with two coats of bitumen paint covered with polythene tape and a final coat of bitumen paint. Exposed pipes shall be painted with synthetic enamel paint after removing dust and extraneous matter. C.I Soil and waste pipes below ground and covered in cement concrete shall not be pained.

4.14 Testing Testing shall be done in accordance with IS: 1172 and IS: 5329 except as may be modified herein under. Entire drainage system shall be tested for water tightness and smoke tightness during and after completion of the installation. No portion of the system shall remain untested. Contractor must have adequate number of expandable rubber below plugs, manometers smoke testing machines pipe and fitting work tests. All materials obtained and used on site must have manufacturer’s hydraulic test certificate for each batch of materials used on the site. Before use at site all CI pipes shall be tested by filling up with water for at least 30 minutes. After filling, pipes shall be struck with a hammer and inspected for blow holes and cracks. All defective pipes shall be rejected and removed from the site within 48 hours. Pipes with minor sweating may be accepted at the discretion of the Project Manager. Soil and waste pipes shall be tested in sections after installation by filling up the stack with water. All openings and connections shall be suitably plugged as approved by the Project Manager. The total head in the stack shall be 4.5 m at the highest point of the section under test. The period of test shall be minimum for 30 minutes or as directed by the Project Manager. If any leakage is visible the defective part of the work shall be cut and made good. On completion of the work the entire installation shall be tested by smoke testing machine. The test shall be conducted after the plumbing fixtures are installed and all traps have water seal or by plugging the outlets with bellows plugs. Apply dense smoke keeping the top of stack open and observe for leakages. Rectify or replace defective sections. After the installation is fully complete, it should be tested by flushing the toilets, running at least 20% of all taps simultaneously and ensuring that the entire system is self draining has no leakages blockages etc rectify and replace where required. A test register shall be maintained and all entries shall be signed and dated by the Contractor and the Project Manager or his representative. All pipes in wall chase or meant to be encased or buried shall be hydro tested before the chase in plastered or the pipe encased or buried.

4.15 Traps 4.15.1 Floor Traps

Floor traps where specified shall be siphon type full before P or S type cast iron having a minimum 50mm deep seal. The trap and waste pipes when buried below ground shall be set and encased in cement concrete blocks firmly supported on firm ground or when installed on a sunken RCC structural slab. The blocks shall be in 1:2:4 mix (1 cement: 2 coarse and: 4 stone aggregate 20mm nominal size). Contractor shall provide all necessary shuttering and centering for the blocks. Size of the block shall be 30 x 30 cms of the required depth.

4.15.2 Floor Trap Inlet / Hopper Bath room traps and connection shall ensure free and silent flow of discharging water. Where specified contractor shall provide a special type of floor inlet fitting fabricated from GI pipe, with one two or three inlet sockets welded on side to connect the waste pipe. All joint between waste hopper and CI inlet socket shall be lead caulked. Inlet shall be connected to a CI “P” trap. Floor trap inlet and the traps shall be set in cement concrete blocks where buried in floors without extra charge. Floor trap for the shower cubicle shall



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suit and as per the approval of Owner’s site representative. All fabricated hopper shall be hot dip galvanized.

4.15.3 Floor Trap Grating Floor and urinal traps shall be provided with 100-150mm square or round stainless steel gratings, with frame and rim of approved design and shape or as specified in the Bill of quantities approved by the Owner’s site representative.

4.16 Cleanout Plugs 4.16.1 Floor Clean Out Plug

Clean out plug for soil. Waste or rain water pipes laid under floors shall be provided near pipe junctions bends, tees, “Ys” and on straight runs at such intervals as required as per site conditions. Clean out plugs shall terminate flush with the floor level. They shall be threaded and provided with key holes for opening. Clean out plugs shall be cast brass suitable for the pipe dia. With screwed to a GI socket. The socket shall be lead caulked to the drain pipes.

4.16.2 Cleanout on Drainage Pipes Cleanout plugs shall be provided on head of each drain and in between at locations indicated on plans or directed by Owner’s site representative. Cleanout plugs shall be of size matching the full bore of the pipe but no exceeding 150mm dia CO plugs on drains of greater diameters shall be 150mm dia. Fixed with a suitable reducing adapter.

4.16.3 Floor cleanout plugs shall be cast brass. Cleanouts provided at ceiling level pipe shall be fixed to a CI flanged tail piece. The cleanout doors shall be specially fabricated from light weight galvanized sheets and angles with hinged type doors with fly nuts gasket etc as per drawing.

4.17 Gully Traps Gully traps shall conform to 15: 651 – 1980. These shall be sound, free from visible defects such as fire cracks or hair cracks. The glaze of the traps shall be free from crazing. They shall give a sharp clear note when struck with a light hammer. There shall be no broken blisters. The size of the gully trap shall be as specified and all dimensions will be as per drawing. Each gully trap shall have one C.I. grating of square size corresponding to the dimensions of inlet of gully trap. It will also have water tight C.I. cover with frame inside dimensions 300 x 200 mm, the cover weighing not less than 2.72 kg., the grating cover and frame shall be of sound and good casting and shall have truly square machined seating faces.

4.17.1 Excavation The excavation for gully traps shall be done true to dimensions and levels as indicated on plans or as directed by the engineer – in – charge.

4.17.2 Fixing The gully trap shall be fixed on cement concrete foundation 600-x 600cm square and not less than 10 cm thick. The mix for the concrete will be 1:5:10 (1 cement 5 fine sand: 10 graded stone aggregate 10mm nominal size) the jointing of gully outlet to the branch drain shall be done similar to jointing of S.W. pipe.

4.18 Brick Masonry Chamber After fixing and testing gully and branch drain, a brick masonry chamber 300 x 300 (inside) in Class b bricks in cement mortar 1:5 (1 cement 3 find sand) shall be built with a 9” thick brick work round the gully trap from the top of the bed concrete 1:5:10 (1 cement: 5 fine sand: 10 graded stoned aggregate 10mm nominal size). The upper portion of the chamber i.e., above the top level of the trap shall be plastered inside with waterproof cement mortar 1:3 (1 cement: 3 coarse sand) finishing with a floating coat of neat cement. The corners and bottom of the chamber shall be rounded off as to slope towards the grating and form a hopper C.I cover with framed 300 x 200 mm (inside0 shall then be fixed on the top of the brick masonry with cement concrete 1:2:4 (1 cement: 2 coarse sand: 1 graded stone aggregate 20mm nominal size) and rendered smooth. The finishing top of cover shall be left about the adjoining ground level so as to exclude the surface water from entering the gully trap.

4.19 Manholes, Inspection Chambers, Gullies 4.19.1 Inspection Chambers

Where depth of sewer is less than 1.2m., below outside rectangular made up/finished level of paving, Chambers shall be used having size as specified. Usual sizes are 600 x 600 or 600 x 900. These shall be constructed in the sewer line at such places and levels and dimensions



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as indicated on the drawing. Sizes specified shall be clear internal dimensions of the chamber.

4.19.2 Manholes Where depth of sewer exceeds 1.5m., with respect to outside made up ground/finished level of paying circular conical manholes shall be provided. Various types and sizes of manholes are specified for manholes shall be supplied to the contractor. In the absences of such drawings the manhole details as per IS 4111-1974 Part 1 to be followed. Manholes and inspection chambers, which are provided on roads or where heavy vehicular traffic is expected, are provided with heavy duty C.I airtight frame & cover. With double seal as per IS 1726-1974 for those built on footpaths, carriage drives and cycle tracks, medium duty covers shall be provided. For locations within domestic premises or areas not subjected to wheel traffic loads they shall be provided with light duty covers.

4.19.3 Construction of manholes, Inspection chambers and gullies, 4.19.4 Excavation

This shall be done to dimensions and levels on the drawings. 4.19.5 Bed Concrete

Base of the manholes shall be constructed in P.C.C. 1:2:4 using 10mm to 12mm graded stones Thickness shall be 200mm up to 4.25mm and 300mm for depths more than 4.25mm or as specified by the Engineer-in charge.

4.19.6 Brickwork Brickwork shall be in C.M. 1:3 constructed with Class B wire cut bricks. Bricks masonry in arches and arching over the pipe shall be in C.M. 1:3 Walls shall be generally built in 225mm thickness for inspection chambers and manholes up to a depth of 2.1m and 350mm for depth over 2.2

4.19.7 Plastering Walls of manholes shall be plastered inside with arrange 15mm thick cement plaster 1:3 using W.P. Compound and finished smooth. Where ground water table is high, external surfaces of manholes shall also be plastered in C.M. 1:3.

4.19.8 Filleting 75mm fillet shall be made with C.M. 1:3 all round the external joint between the bed concrete and brick masonry wall of manhole.

4.19.9 Benching Channels and benching inside the manhole or inspection chamber shall be done in C.C. 1:2:4 and rendered smooth with cement.

4.19.10 R.C.C. Cap RCC M 150 cap of 1:2:4 150mm thickness shall be provided on top of manholes for fixing the manhole frame.

4.19.11 Footrest Footrests shall be C.I runs weighing 5.41 Kg. And conforming to IS2064-1973 made up of 20mm square or round bars. There shall be embedded 20cm deep in 20 x 20 x 10 cm blocks of PCC 1:2:4 the blocks with C.I foot rest placed on its centre shall be cast in-situ along with masonry. Footrests shall be placed 300mm apart vertically and 375 mm horizontally in staggered fashion. First footrest shall be 450mm below top. Footrest shall be painted with coal tar or bituminous paint and the portion embedded shall be painted with thick cement slurry before fixing.

4.19.12 Manhole frames and covers Approximate weights for various dimensions of frames and covers various duties shall be as follows: (All M.H. cover of Heavy duty & medium duty shall be of double seal type and duty single seal type).

Size Heavy Duty Kg. Medium Duty Kg. Light Duty Kg.

Rect. 510 x 455 - 80+54=144 23+15=19

500mm dia Cir. - 58+58=116 -

560mm dia Cir. 108+100=203 64+64=128 -

Square 455x55 - - 13+7=20

Square 510x610 - - 25+13=38

Square 560x560 100+100=200 - -



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The cover and frames shall be clearly cast and shall be free from air and sand holes and form cold shits. They shall be neatly dressed and carefully trimmed. All castings shall be free from voids either due to shrinkage gas inclusion or other causes. Covers shall have raised chequered design on the top surface to provide adequate non-slip grip. The cover shall be capable of easy opening and closing and it shall be fitted in the frame in a workman-like manner. Covers shall be gas and water girth. Size of the cover shall be the clear internal dimension of frame. 2-1/2% variation in weights shall be permissible. Covers and frames shall be coated with a black anti corrosive paint of bituminous composition. The coating shall be smooth and tenacious. It shall not flow at 53 degree C. and shall not drip off at O degree C. The covers shall be so fixed as to be flushed with ground surface. After completion the manhole covers shall be sealed by means grease.

4.19.13 Testing Manhole, after it is raised above highest expected sub-soil water level in monsoon, shall be suitably plugged with brick masonry or wooden or any other type of plug. Manhole under test shall then be filed with water up to general subsoil water level does not drop to more than 50mm in one hour, it shall be deemed as water tight. During testing the pit around shall be kept free of water and contractor shall observe the places where leakage takes place and takes steps to correct the same. Filling earth around manholes shall be done after testing.

4.19.14 Drop Connection In cases where branch pipe sewer enters the manhole of main pipe sewer at level Higher than the main sewer by more than 600mm a drop connection should be provided as per typical drawing for drop connection. For 150 and 250mm main line, the difference in level between the water line and the invert level of branch line is less than 60cm. a drop connection may be provided within the manhole by giving ram. If the difference in level is more than 60cm. the drop should be provided externally.

4.19.15 Excavation The excavation shall be done for the drop connections at the place where the branch line meets the manholes. The excavation shall be carried up to the bed concrete of the manhole and to the full width of the branch line.

4.19.16 Laying At the end of branch sewer line stoneware shall be fixed to the line, which shall be extended through the wall of the manhole by a horizontal piece of S.W. pipe to form an inspection or cleaning eye. The stoneware drop shall be connected to the tee at the top and the S.W. bend at the bottom. The end shall be extended through the wall of the manhole by a piece of C.I pipe which shall be made with cement concrete 1:2, (1 cement: 2 coarse sand: 4 graded stone aggregate 20mm, nominal size) and finished smooth to connect the main channel. The joint between S.W. pipe and tee and S.W. branch line shall be made with cement mortar 1:1 (1 cement: 1 fine sand) as per Para 2.1.3 for S.W. pipes. The exposed portion of the drop connection shall be encased all round with a single brickwork in C.M. 1:4 and pointed. The holes made in the walls of the manholes shall be good with brickwork in cement mortar 1:4 (1 cement: 3 coarse sand) on the inside of the manholes wall. The excavated earth shall be backfilled in the trench in level with the original ground level.

4.20 Rain Water Drainage 4.20.1 Rigid P.V.C Pipes for Rain Water: 4.20.1.1 General

P.V.C. pipes shall conform to the relevant specification of I.S 4985 of SWR quality. They shall be made of Polyvinyl Chloride (PVC) and shall be sound with good surface finish, mechanical strength and capacity. During manufacture only those additives may be added to produce the above characteristics. No additives shall be added separately or together in quantities sufficient to constitute toxic hazard, or impair the fabrication or welding properties of the pipe or impair its physical or chemical properties. All pipes shall be spigot and socket type (bell end type).

4.20.1.2 Pipe Sizes and Wall Thickness - 6 kg class Pipe Dia (mm) Wall Thickness (mm)

110 mm 3.7 to 4.3 mm 160 mm 5.4 to 6.2 mm 200 mm 6.8 to 7.9 mm



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4.20.1.3 Tolerances Tolerances on diameters and Wall thickness shall be as per I.S. 4985.

4.20.1.4 Fittings All fitting shall be injection moulded socket fittings with or without inspection doors as specified and shall be in accordance with the requirements of the relevant I.S. 7834. Pressure ratings and Tolerances shall be as per I.S. 4985.

4.20.1.5 Laying and Jointing Pipes shall be cut to length required including the portion to be inserted in the socket with a hacksaw. The pipe shall be cut square. Pipes and Sockets shall be clean and dry and burrs removed both inside and outside with a file. The surface to surfaces to be in contacted shall be roughened with emery paper, and dry fit checked. After cutting and chamfering the pipe as described above, insert the pipe into the socket without seal ring and mark along the pipe, when it is fully inserted. Fix the rubber ring into the groove without twisting it. Apply superior quality jointing lubricant to the chamfer end of the pipe right upto the mark made on the spigot or to the socket end of fitting. Push the pipe firmly into the socket till the tap between the mark on the spigot and socket is about 10 mm to allow for thermal expansion.

4.20.1.6 Rain Water and basement Collection Gratings The rain water collection grating at the Terrace level shall be of C.I. Grating with C.I frame embedded on to the water proof surface. Water proofing shall be done around the pipe, frame and grating to ensure the water tightness around the collection point. Adequate slope on the terrace level shall be provided for collecting all rain water at the collection gratings. The rain water collection at the balconies shall be done using PVC Nahani trap of 75 mm dia installed concealed in the concrete slab and connected to the vertical main PVC rain water stack, at the collection point heavy brass C.P frame with C.P grating shall be provided. The C.P frame shall be laid in the slab above the pipe with water seal joint alround the frame to sewers after traps and not in the storm water drainage systems.

4.20.1.7 Balcony / Planter drainage Wherever required, all balconies terraces planters and other frontal landscape areas will be drained by vertical down takes or other type of drainage system show on the drawings and directed by the project manager.

4.21 Septic Tank In unsewered area, arrangements for sewage being treated in a septic tank, effluent from which should be given secondary treatment either in a biological filter or on the land on in a sub-surface disposal system. Surface and sub-soil water should be excluded from finding way into the septic tank. Wastewater may be passed into the septic tank provided the tank and the means for extra liquid. Depending on the location of the water table and the nature of the strata, the type of disposal for the effluent from the septic tank shall be decided. Dimensions: Septic tanks shall have minimum width of 75cm, minimum width of one meter below water level and a minimum liquid capacity of the one cubic meter. Length of tanks shall be 2 to 1 times the width. Cover and Frames: Every septic tank shall be provided with C.I cover of adequate strength. The cover and frames shall be 500mm dia. (MD) minimum or 610mm x 455mm (LD). Ventilating Pipe: Every septic tank shall be provided with C.I. Ventilating pipe of at least 50mm diameter. The top of the pipe shall be provided with a suitable cage of mosquito proof wire mesh. The ventilating pipe shall extent to a height, which would cause no small nuisance to any building in the area. Generally, the ventilating pipe may extend to a height of about 2m. When ten septic tank is at least 15m away from the nearest building and to a height of 2m. above the top of the building when it is located closer than 15 meters. The ventilating pipe may also be connected to the normal soil ventilating system of the building where so desired. Disposal of Sludge: The sludge from septic may be delivered into covered pit of or into a suitable vehicle for from the site. Spreading of sludge on the ground in the vicinity shall not be allowed. Testing: Before the tank is commissioned for use, it shall be tested for water tightness by filling it with water and allowing it to stand for 24 hours. It shall then be topped up, if



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necessary, and allowed to stand for a further period of 24 hours, during which time the fall in the level of the water shall not be more than 1.5.cm Commissioning of Septic Tank: The tank shall be fixed with water to its outlet level before the sewage is let into the tank. It shall, preferably, be seeded with small quantities of well digested sludge obtained from septic tanks or sludge a small quantity of decaying organic matter, such as digested cow dung, may be introduced. Dislodging of Septic Tank: Septic tanks shall be desludged periodically, the intervals of desludging, depending upon the design of the septic tanks and the capacity in relating to its users. Desludging may be done when the sludge level reaches a predetermined level. A portion of the sludge may be left in the tank to seed the free deposits. Desludging shall, preferably, be carried out by hydrostatic head or by using a portable pump. Manual handling of sludge shall be discouraged. Sub surface Absorption system: The effluent from septic tank shall be disposed of by soak pit or dispersion trench depending on the position of the sub-soil water level, soil and sub-soil conditions and the size of the installation. Rate: The rate shall include the cost of materials and labour involved in all the operation, except sub-surface absorption system.

4.22 Soak Pits Construction: The earth excavation shall be carried out to the extract dimensions as shown in the Figure. In the soak pit shall be constructed a honeycomb dry brick shaft 45 x 455 and 292.5cm high. Round the shaft and within the radius of 60cm shall be placed well-burnt brickbats. Brick ballast of size from 50 to 80mm nominal size shall be packed round the brickbats up to the radius of 90cm. The remaining portion shall be filled with ballast of 10mm nominal size. The construction of shaft and filling of the bats and the ballast shall progress simultaneously. Cover and Drain: Over the filling shall be placed single matting, which shall be covered with minimum layer of 7.5cm earth. The shaft shall be covered with 7.5cm thick stone or R.C.C. slab. 10cm wide and 10cm deep brick egging with bricks of class designation 755 shall be provided round the pit. The connection of the open surface drain to the soak pit shall be made by means of 100cm diameter S.W. pipe with open joints. Measurements: Soak pit shall be enumerated. Rate: Rate shall include the cost of labour and material involved in all the operations described above.



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5 DRAWINGS

Plumbing drawings are diagrammatic but shall be followed as closely as actual construction permits. Any deviations made shall be conformity with the architectural and other services drawings.

Architectural drawings shall take precedence over plumbing or other services drawings as to all dimensions.

Contractor shall verify all dimensions at site and bring to the notice of the Engineer all discrepancies or deviations noticed. Engineer-in-charge decision shall be final.

All equipment/materials dimensions to be incorporated and shall take precedence over small scale drawings.

Any drawings supplied with the tender shall be returned in good conditions along with the tender.

Any drawings issued by the Engineer-in-charge for the works are the property of the engineer/consultant and shall not be lent, reproduced or used on any works other than intended without the written permission of the engineer.

MAHA-METRO Tender No. P1C-06/2018 Part 2: Work Requirement


Green Building Specification (Station)


PARTICULAR SPECIFICATION – IGBC NORMS

(STATION)





ANNEXURE-A SCOPE OF WORK

Metro Stations are quite different from typical buildings so considering this factor and upcoming demand, Indian Green Building council has launched a dedicated rating system for Metro stations which is known as Mass Rapid Transit System (MRTS) rating. This rating system is based on key requirements inside and outside of any Metro stations that are required to make world class and sustainable metro stations. The services will include complete Facilitation for achieving green rating for Metro stations via following:

Sustainable sites

Water Efficiency

Energy Efficiency

Material Conservation

Indoor Environment and Comfort 1. SCOPE OF WORK AND METHODOLOGY The Consultant is required to provide services for IGBC Mass Rapid Transit System (MRTS) rating for 9 stations which are a part of this contract. The scope of work for the mentioned services has been prepared as per IGBC Mass Rapid Transit System (MRTS) rating guidelines. The Consultant has to provide following services for the project as per the IGBC Mass Rapid Transit system (MRTS) rating: IGBC MRTS Facilitation for 5 categories which includes

Site Selection & Planning Water conservation, Energy Conservation, Material Conservation, Indoor Environment & Comfort Energy Analysis and Day lighting simulation Commissioning of Equipments Energy Monitoring

The scope of work in respect of the above items is discussed in more detail in following sections. 2. IGBC MRTS CERTIFICATION FACILITATION The Green Building consultant will work with the design team, owners, and other consultants to coordinate and facilitate IGBC Mass Rapid Transit System for Pune Metro. This will include:

1. Pune Metro Project registration

2. Coordinate and facilitate IGBC MRTS submittal

3. Communication with IGBC for queries related to the project

4. Coordinate final IGBC MRTS submittal

5. Respond to IGBC queries The detailed scope for work under IGBC MRTS facilitation is as follows:

2.1 PREPARE A PRELIMINARY IGBC MRTS FEASIBILITYREPORT Preliminary IGBC MRTS Report will include credit analysis and target rating level. The Consultant will create and update a project matrix that describes the specific tasks to be implemented by various members of the design team and compile documentation pertinent to IGBC MRTS. 2.2 IGBC MRTS DESIGN FACILITATION AND DOCUMENTATION SCOPE Assist the design team in obtaining the highest possible rating as per the Owner's requirements and Architect's design. Review calculations and provide technical support for selected IGBC MRTS points under credits for:

Sustainable Selection and Planning (SSP) Water Efficiency (WE) Energy Efficiency (EE)





Materials Conservation (MC) Indoor environment and Comfort (EC) Innovation in Design & Construction (IDC)

1. Provide guidelines for specifications related to critical environmental criteria for the product types selected (e.g. VOC Limits, prohibited compounds, minimum levels of recycled content etc.) and on submittal requirements. Vet the tender document to ensure the tender technical specification meets the IGBC MRTS requirement.

2. Prepare and provide all necessary templates for the design team, so as to meet IGBC MRTS requirements.

3. Facilitate project team in preparing the documentation as stipulated by IGBC MRTS. The documentation process will require collaboration and cooperation from the design and construction teams. Drawings or drawing files, cut sheets, and other information will be provided to the Consultant by the design team. It will be the Consultant's responsibility to communicate with the design team the documentation required, the form required and within the proper timeframe.

4. The Consultancy team will filter, cross validate, verify consistency, add value and consolidate to make the document suitable for submission to IGBC.

5. Scrutinize the documents before submission to IGBC. Provide inputs on previous credit interpretation requests.

6. The Consultant would hand-hold the team right from registration of the project to achievement of the IGBC MRTS rating on all aspects related to rating.

3 ENERGY ANALYSIS The proposed building will be analyzed with respect to traction and non-traction load keeping IGBC MRTS rating as a baseline and suggest the suitable energy conservation measures for improving the energy performance of stations. 3.1 BUILDING LEVEL: FACADE ANALYSIS Due to variant solar insulation on the façade, the same façade can be designed for different specifications from bottom to top. The following may vary: Fenestration area and percentage, shading strategies Organization of regularly occupies spaces e.g. occasionally used spaces like conference rooms can be placed near the top receiving more solar radiation. Selection of glass type, (heat resistance glass near top and high visibility glass near the base) 3.2 COMBINING ECMs (ENERGY CONSERVATION MEASURES) FOR MAXIMIZING ENERGY Prioritizing and evaluation of combined ECMs. Cases prioritized based on the resultant savings from each ECM. Eventually, all ECMs that yield satisfactory results will be combined into a single case. Several configurations of Base Case + ECMs need to be defined and stimulated before arriving at the best or optimum combination of ECMs. 3.3 DEVELOPING THERMAL SPECIFICATIONS As a result of the simulation exercise thermal specifications will be provided for building envelope materials to enhance the energy performance of the building. Examples of thermal specifications include:

1 Fenestration U-value 2 Fenestration Shading Coefficient (SC) 3 Fenestration coatings 4 U-values for wall(s) construction 5 R-value for wall insulation 6 U-value for roof construction 7 R-value roof insulation 8 Emissivity of roof finish

3.4 LIGHTING LEVELS AND DAYLIGHTING ANALYSIS





The existing design will be analyzed to incorporate daylighting. Lighting levels will be analyzed both qualitatively and quantitatively to arrive at a daylit building. Electrical lighting design will be optimized through recommendations on illumination levels and light source. A daylighting analysis for all perimeter zones will be performed using the daylighting module of Visual DOE 3.0. Recommendations regarding fenestration VLT (Visual Light Transmittance), U-factory, and shading Coefficient will be based on trade-offs within lighting energy and heating & cooling energy components as demonstrated by the simulating software. 3.5 OUTPOUT REPORTS FROM SIMULATION SOFTWARE Summarize the results through spreadsheet-based post-simulation processing and tabulate electrical and fuel-end-use total and energy savings by source energy. 3.6 FINAL ANALYSIS AND SUMMARY REPORT The entire process of simulation and energy analysis as well as water efficiency calculations will be included in a summary report. This will include a description of the project, a record of all modeling. 3.7 SOFTWARE USED

1 Ecotect (Preliminary design, site analysis, solar radiation, shading, and sun path analysis). 2 DOE 2.1 E (Visual DOE 4.1 Interface and manual editing for advanced options) 3 DOE 2.2 (Equest interface with manual editing for advanced options) 4 Energy Plus (Design Builder interface with manual editing as needed) 5 Radiance (For detailed daylighting design) 6 Ansys Fluent (CFD software for advanced HVAC and natural ventilation analysis) 7 Dialux and Calculux (for landscape and exterior lighting analysis) 8 Any other software that may be required to carry out day lighting simulation that is

acceptable to the rating body.

4. COMMISSIONING OF EQUIPMENT AND SYSTEM 4.1 RESPONSIBILITY OF THE CONSULTANT The Consultant is responsible for implementation of all fundamental commissioning procedures. The Consultant would carry out the following: Overall supervision of commissioning process of equipment/systems Report to the owner regarding the performance of the building system/equipment Introduce standard procedures and strategies to ensure implementation of Owner's Post Occupancy Evaluation. After the commissioning of project, when the data for energy performance is available for the building, the energy simulation model wil be modified and calibrated. This can be used for troubleshooting building performance issues and for future upgrades and retrofits. 5 ENERGY MONITORING Demonstrate sub metering for the following energy use:

HVAC equipment and system – Lighting Elevators and Escalators Onsite Renewable energy systems Power back up systems Develop Measurements and Verification (M&V) plan in place for the below applications HVAC equipment and systems Lighting Elevators and Escalators Onsite Renewable energy systems Power back up system

5 The certification work shall be completed along with the commissioning of the section.

MAHARASHTRA METRO RAIL COPORATION LIMITED

(A Joint-Venture of Govt. of India & Govt. of Maharashtra)


DESIGN BASIS REPORT

VERSION – D (March 2017)

MAHARASHTRA METRO RAIL CORPORATION LIMITED



Telephone: 020-26051072

DESIGN AND CONSTRUCTION OF

ELEVATED STATIONS



TABLE OF CONTENTS

Section Page No.

1. INTRODUCTION…………………………………………........... 1

1.1 Brief Description of the Project………………………………...... 1

1.2 Scope……………………………………………………………... 2

1.3 Units……………………………………………………………… 3

2. DESIGN SPECIFICATION FOR STATION BUILDING……… 3

2.1 Materials………………………………………………………….. 3

2.1.1 Cement…………………………………………………………… 3

2.1.2 Concrete………………………………………………………….. 3

2.1.3 Pre-stressing Steel for Tendons………………………………… 3

2.1.4 Structural Steel…………………………………………………… 3

2.1.5 Reinforcement……………………………………………………. 4

2.2 Durability………………………………………………………… 4

2.2.1 Concrete Grades………………………………………………….. 4

2.2.2 Cover to Reinforcement………………………………………….. 4

2.2.3 Fire Resistance period……………………………………………. 5

2.2.4 Crack Width check……………………………………………….. 5

2.3 Clearances………………………………………………………... 5

2.4 Design Loads……………………………………………………... 5

2.4.1 Dead Loads……………………………………………………….. 5

2.4.2 Superimposed Dead Loads (SIDL)………………………………. 5

2.4.3 Imposed (Crowd Live) Load……………………………………... 6

2.4.4 Earthquake Loads………………………………………………… 6

2.4.5 Wind Loads………………………………………………………. 7

2.4.6 Collision / Impact Loads/Derailment Loads…………………….. 7

2.4.7 Construction and Erection Loads………………………………… 7

2.4.8 Temperature……………………………………………………. 7

2.4.9 Shrinkage…………………………………………………........... 7

2.4.10 Creep………………….…………………………………………. 7

2.4.11 Earth & Water Pressure...………………………………………... 7

2.4.12 Surcharge Load….………...……………………………………... 8

2.4.13 Pre-stressing Force…….…………………………………………. 8

2.4.14 Long Welded Rail Force ………………………………………… 8

2.4.15 Settlement……………….………………………………………. 8

2.4.16 Other Forces and Effects…………………………………………. 8

2.5 Design Load Combinations………………………………………. 8

2.5.1 Ultimate Load Combinations…………………………………….. 8

2.5.2 Serviceability Load Combinations……………………………….. 9

2.6 Deflection Criteria………………………………………………... 9

2.6.1 Lateral Sway……………………………………………………… 9

2.7 Fatigue Check…………………………………………………….. 9

2.8 Foundations………………………………………………………. 9

2.8.1. Types of Foundation……………………………………………... 9

2.8.2. Design of Pile…………………………………………………….. 10

2.8.3. Foundations………………………………………………………. 10

2.9 Design of Water Retaining Structure…………………………….. 10

3 List of Design Codes and Standards……………………………... 10

Maharashtra Metro Rail Corporation Limited

___________________________________________________________________________________ Design Basis Report – Elevated Stations P a g e 1

1. INTRODUCTION 1.1. Brief Description of the Project

Two corridors have been identified for implementation in Phase-I of Pune Metro Rail Project as per details given below:

Corridor I: North-South Corridor: Pimpri Chinchwad (PCMC) to Swargate Alignment from (-) 450 m to 16589 m From dead end (Ch. – 450 m) of PCMC station to dead end of Swargate station (Ch. 16139m), the length of corridor 1 is 16.589 km, out of which 5. km is underground and remaining 11.570 km is elevated Including length of Switch Over Ramp(SWR). Total 14 numbers of stations have been planned along this corridor out of which 9 are elevated and 5 are underground stations. Corridor II: East-West Corridor: Vanaz (Kothrud) to Ramvadi Alignment from (-) 684.8 m to 14665 m From dead end (Ch – 684.8 m) of Vanaz station to dead end of Ramvadi station (Ch. 13790m), the length of corridor 2 is 14.665 km. Total 16 number of elevated stations have been planned along this corridor. This design basis report pertains to elevated stations of North-South and East-West corridors of Pune Metro Rail Project.

1.2. Scope The object of this Design Basis Document is to establish a common procedure for the design of “Elevated Stations for Pune Metro Rail Project”. This is meant to serve as guide to the designer but compliance with the rules there in does not relieve them in any way of their responsibility for the stability and soundness of the structure designed. The design of Elevated Stations requires an extensive and thorough knowledge and entrusted to only to specially qualified engineers with adequate practical experience in structural designs. The DBR is only for structural design of Elevated Stations. Extended platform portion which is generally on single column or portal type structure shall be designed as part of viaduct. The structural elements connected to the member on which metro live loads are supported may also be designed with taking loads applicable as specified in “Approved/ Tendered Design Basis Report (DBR) for Viaduct of Pune Metro Rail Project”. LWR forces shall be specified by the Metro, if RSI analysis is not practicable. Load combination as per “Approved/ Tendered Design Basis Report (DBR) for Viaduct of Pune Metro Rail Project” shall also be considered. Other structural elements such as secondary beams, stub columns etc., may be designed as per IS 456. Structures, where Metro Live loads are not applicable, the design of Plain and Reinforced Concrete structures will generally be governed by IS:456, pre-stressed concrete structures will generally be governed by IS:1343. Steel structures design shall generally be governed by IS: 800. Seismic design shall be governed by IS: 1893.

1.3. Units

The main units used for design will be: [t], [m], [mm], [kN], [KN/m2], [MPa], [0C], [rad]. 2. DESIGN SPECIFICATION FOR STATION BUILDING 2.1. Materials 2.1.1. Cement

For plain and reinforced concrete structures cement shall be used as per clause 5.1 of IS: 456 and in case of pre-stressed concrete structures as per clause 5.1 of IS: 1343.

2.1.2. Concrete

As per clause 6, 7, 8, 9 and 10 of IS:456 in case of Plain and Reinforced Concrete structures and Clause 6, 7, 8, 9 and 10 of IS:1343 for Pre-stressed concrete structures.

Short term modulus of elasticity (Ec) shall be taken as per cl. 6.2.3.1 of IS: 456 for Plain and Reinforced Concrete structures and IS: 1343 for Pre-stressed concrete structures. The modular ratio for concrete grades shall be taken as per Annex B of IS: 456. The Density of concrete shall be as per IS: 456.


_____________________________________________________________________________________P a g e 2 Design Basis Report – Elevated Stations

2.1.3. Pre-stressing Steel for Tendons As per clause 5.6.1 of IS: 1343. 2.1.3.1. Young’s Modulus As per pre-stressing steel used in accordance with Para 2.1.3 above. 2.1.3.2. Pre-stressing Units

As per clause 13 of IS: 1343. 2.1.3.3. Maximum Initial Pre-stress

As per clause 19.5.1 of IS: 1343. 2.1.3.4. Density

Weight of strands shall be as per relevant clauses of IS codes as per material being used as indicated in para 2.1.3 above.

2.1.3.5. Sheathing

As per clause 12.2 of IS: 1343. 2.1.4 Structural Steel Structural steel used shall confirm to

a) Hollow steel sections as per IS: 4923-1997 b) Steel for General Purposes as per IS: 2062. c) Steel tubes for structural purpose shall be as per IS: 1161. Note: (i) Grade of steel to be used shall be indicated, shall not be less than minimum grade as

applicable, based on whether structure is taking moving loads or not and relevant code as indicated in note (ii) and (iii) below.

(ii) Design of steel structure will be governed by IRS Steel Bridge Code in case structure is taking moving loads of Metro, otherwise will be governed by IS: 800. In case of composite (steel-concrete) structures it will be governed by IS: 11384 & IS: 3935.

(iii) Fabrication shall be done in accordance with IRS BI (Fabrication Code) in case structure is taking moving loads of Metro, otherwise shall be done as per IS: 800.

2.1.5. Reinforcement

As per clause 5.6 of IS: 456 for Plain and Reinforced concrete structures and as per clause 5.6.2 of IS: 1343 for Pre-stressed concrete structures.

Note: For Seismic zone III,IV & V HYSD steel bars having minimum elongation of 14.5 percent and conforming to requirements of IS:1786 shall be used.

2.1.5.1. Reinforcement Detailing

All reinforcement shall be detailed in accordance with clause 12 and 26 of IS: 456 for Plan and reinforced concrete structures, as per clause 12.3 and 19.6.3 of IS: 1343 for pre-stressed concrete structures. Ductile detailing of seismic resisting RC elements, shall comply with ductile requirements of IS: 13920.

2.2. Durability

Durability of Concrete shall be as per clause 8.0 of IS: 456 for Plain and Reinforced Concrete structures, as per clause 8.0 of IS: 1343 for Pre-stressed Concrete structures and Section 15 of IS: 800 for Steel Structures.

2.2.1. Concrete Grades

The minimum grade of concrete for all structural elements including piles, blinding layers and levelling courses shall be as under:



Sr. No. Structural component Minimum Grade of

concrete

A Pre-tensioned girders M50

B

Superstructure- deck slab, beams Pier and Pier arm Portal beams Pedestal Shear key and Seismic stoppers

M40

C Crash barrier, Pier protection M40

D Slabs, Beams, Walls, Columns M35

E Pile, Pile cap, Open foundation, Basement slab, Ancillary building foundation slab, Retaining wall

M35

F Solid slab M40

G Blinding concrete or levelling course M15

2.2.2. Cover to Reinforcement

As per clause 26.4 of IS: 456 for Plain and Reinforced Concrete Structures and clause 12.3.2 of IS: 1343 for pre-stressed concrete structures. Cover to pre-stressing steel shall be in accordance with clause 12.1.6 of IS: 1343.

2.2.3. Fire Resistance period

All the structural elements in the station building shall be designed for a minimum fire resistance period of 2 hours. The minimum element thicknesses for this fire resistance shall be as per clause 21 of IS: 456 for Concrete structures and as per Section 16 of IS: 800 for Steel structures.

2.2.4. Crack Width Check

All structural concrete elements shall be designed to prevent excessive cracking due to flexure, early age thermal and shrinkage. Flexural crack width shall be checked in accordance with clause 35.3.2 and 43 of IS: 456 for Plain and Reinforced Concrete Structures and clause 20.3.2 and 24.2 of IS: 1343 for Pre-stressed Concrete structures.

2.3 Clearances

(i) Clearance for Road Traffic: As per relevant IRC specifications and Road Authority requirements.

(ii) Clearance for Railway Traffic: Indian Railways Schedule of Dimensions (SOD) shall be applicable.

(iii) Clearances for Metro Traffic: As per Approved/ Tendered SOD of Pune Metro Rail Project.

(iv) For utility services- The clearances to utilities, drainage etc. shall be as mandated by the utility owner/ department.

2.4 Design Loads Elementary loads to be considered for design are: - Dead Loads DL Super Imposed Loads SDL Imposed (Crowd Live) Loads LL Earthquake Loads EQ Wind Loads WL Collusion/Impact Loads/Derailment Loads CL*

Construction & Erection Loads EL



Temperature Loads OT Shrinkage S Creep EP Surcharge Loads (Traffic, building etc.) SR Pre-stress Force PR Long Welded Rail Force LWR Differential Settlement DS *Load as applicable shall be taken.

2.4.1. Dead Loads

Dead load shall be based on the actual cross section area and unit weights of materials and shall include weight of the materials that are structural components of Elevated Station and permanent in nature.

2.4.2. Superimposed Dead Loads (SIDL)

Superimposed dead loads include all the weights of materials on the structure that are not structural elements but are permanent. Note: The SIDL can be of two types: Fixed or non-variable, and variable. In case Metro certifies that a portion of SIDL is of fixed or non-variable type and is not likely to vary significantly during the lift of the structure and a special clause for ensuring the same is incorporated in the Metro’s maintenance manual, the load factors applicable for dead load may be considered for this component of SIDL. The minimum distributed and concentrated loads shall be in accordance to IS: 875. Wherever SIDL values are not available in relevant codes, the following values shall be adopted: Stations For platform slab, the following assumptions will be taken:

Suspension load -2.0 kN/m2 uniform loads. (Suspension load will be considered as load of false ceiling, plumbing & electrical equipments, Escalator Pits etc. This load is applicable wherever necessary.)

PSD - As per contractor’s specifications. For the concourse area, the following assumption will be taken:

Suspension load -2.0 kN/m2 uniform loads. (Suspension load will be considered as load of false ceiling, plumbing & electrical equipments)

Lift and Escalator support shall be designed as per manufacturer’s details. NOTE: - The wall loads will be taken based on actual location shown in architectural drawings. External wall load/glazing load will be taken as per details provided in architectural drawings.

SIDL for two tracks Details of SIDL for two tracks:

Cables 0.7 kN/m

Cable troughs with cover 7.4 kN/m

Cable trays 0.1 kN/m

Concrete plinths for rails + Rail + Pad 31.0 kN/m

Miscellaneous (OCS, signaling,) 4.0 kN/m

Hand Rail 0.8 kN/m

Total: 44 kN/m for two tracks

22 kN/m for one track Say 50 kN/m for two tracks 25 kN/m for one track

2.4.3. Imposed (Crowd Live) Load Imposed loads on station buildings are those arising from occupancy and the values includes, normal use by persons, furniture and moveable objects, vehicles, rare events such as concentrations of people and furniture, or the moving or stacking of objects during times of re-organisation of refurbishment, this shall be as per clause 19.3 of IS:456.



2.4.4. Earthquake Loads

Earthquake design shall follow the seismic requirements of IS: 1893 (Part-I). The provision as per “Approved/ Tendered Design Basis Report for Viaduct of Pune Metro Rail Project” shall be followed structures are taking moving loads of metro.

2.4.4.1. Drift Limitation

The storey drift in the building shall satisfy the drift limitation specified in cl. 7.11.1 in IS: 1893.

2.4.4.2. Seismic Detailing (i) For reinforced concrete structures as per IS: 13920. (ii) For other structures as per IS: 4326.

2.4.5. Wind Loads

The wind load shall be calculated as per IS: 875 part 3. 2.4.6. Collision/Impact Loads/Derailment Loads

(i) For road traffic as per IRC 6. (ii) For metro as per IRS Bridge Rule. (iii) Clause 6.1.2 of IS 875 (Part-5).

2.4.7. Construction and Erection loads

The weight of all temporary and permanent materials together with all other forces and effects which can operate from any part of structure during erection shall be taken into account. Allowances shall be made in the permanent design for any locked in stresses caused in any member during erection.

2.4.8. Temperature

As per clause 19.5 of IS: 456. Temperature gradient shall be considered as per Clause 215 of IRC-6, if applicable.

2.4.9. Shrinkage

The shrinkage strains shall be evaluated as per clause 6.2.4 of IS: 456 for Plain and Reinforced Concrete Structures and clause 6.2.4 of IS: 1343 for pre-stressed concrete structures. For structure supporting Metro loading the effects of shrinkage as per Cl. 5.2.3 of IRS-CBC shall be considered.

2.4.10. Creep

The creep strains shall be evaluated as per clause 6.2.5 of IS: 456 for Plain and Reinforced Concrete Structures and clause 6.2.5 of IS: 1343 for pre-stressed concrete structures. For structure supporting Metro loading the effects of creep as per Cl. 5.2.4 of IRS-CBC shall be considered.

2.4.11. Earth & Water Pressure

In the design of structures or parts of structures below ground level, such as retaining walls and underground pump room/water tank etc. the pressure exerted by soil or water or both shall be duly accounted for. When a portion or whole of the soil is below the free water surface, the lateral earth pressure shall be evaluated for weight of soil diminished by buoyance and the full hydrostatic pressure. (As per IS: 875 Part 5).

All foundation slabs/footings subjected to water pressure shall be designed to resist a uniformly distributed uplift equal to the full hydrostatic pressure. Checking of overturning of foundation under submerged condition shall be done considering buoyant weight of foundation. If any of the structure supporting Metro Loading is subjected to earth pressure, the loads and effects shall be calculated in accordance with Cl. 5.7 of IRS Substructure Code.



2.4.12. Surcharge Load

In the design of structures or parts of structures below ground level, such as retaining wall and underground pump room/water tank etc. the pressure exerted by surcharge from stationary or moving load, shall be duly accounted for.

2.4.13. Pre-stressing Force (PR) The pre-stressing Force should be as per IS-1343. 2.4.14. Long welded Rail Force

A rail structure interaction [RSI] analysis is required because the continuously welded running rails are continuous over the deck expansion joints. The interaction occurs because the rails are directly connected to the decks by fastening system.

1. Rail structure interaction studies shall be done as per provisions of UIC 774-3 R with the following parameters specified in consultation with track design engineers:

i) Track resistance in loaded and unloaded conditions. ii) Maximum additional stresses in rail in tension as well as compression

on account of rail-structure interaction. iii) Maximum vertical deflection of the girder at ends.

2. Software and general methodology to be used for carrying out Rail-Structure interaction analysis must be validated before adopting the same.

3. Representative stretches must be chosen for carrying out Rail-Structure interaction.

4. Checks must be performed for break in rail continuity due to unusual conditions fractures or for maintenance purposes.

5. RDSO Guidelines for carrying out RSI studies shall be preferred. 6. LWR forces shall be considered in appropriate load combination as per IRS-CBC.

2.4.15 Settlement Maximum and differential settlement shall not exceed, as provided in Table 1 of IS: 1904. 2.4.16. Other Forces and Effects

As per clause 19.6 of IS: 456. 2.5. Design Load Combination 2.5.1 Ultimate Load Combinations

Each component of the structure shall be designed and checked for all possible combinations of applied loads and forces. They shall resist effect of the worst combination. Following shall be considered: - (i) Load combinations and factors as per Table 18 of IS: 456 Plain and Reinforced

Concrete Structures. (ii) Load combination and factors as per Table 7 of IS: 1343 for pre-stressed concrete

structures. (iii) Load combination as per Section 3 and factors as per Section 5 of IS: 800 for Steel

structures. (iv) Load combination as per clause 6.3 of IS: 1893 (Part-I). (v) Load combinations as per IRS CBC and RDSO guidelines for Seismic design of Railway

Bridges where Metro live loads are applicable. Note:

i) Load combination for construction load case shall be decided by Metro as per methodology of construction.

(ii) Reference of IRC: 6 or IS: 875 (Part5) be taken for collision case if collision of road vehicles are involved as applicable.

2.5.2. Serviceability Load Combinations



The following load combinations and load factors shall be used for design for serviceability limit state:

(i) Load combinations and factors as per Table 18 of IS: 456 for Plain and Reinforced Concrete Structures.

(ii) Load combination and factors as per Table 7 of IS: 1343 for pre-stressed concrete structures.

(iii) Load combination as per Section 3 and factors as per Section 5 of IS: 800 for Steel structures.

(iv) Load combinations as per IRS CBC where Metro live loads are applicable. 2.6. Deflection Criteria

The deflection limitations as per clause 23.2 of IS: 456 for Plain and Reinforced Concrete Structures and clause 20.3.1 of IS: 1343 for Pre-stressed concrete structures shall be followed.

2.6.1. Lateral Sway

The lateral sway at the top of the building due to Wind loads should not exceed H/500, where H is the height of the building.

2.7. Fatigue Check

Fatigue phenomenon needs to be analysed only for those structural elements that are subjected to repetition of significant stress variation (under traffic load). Fatigue check for (i) RCC and PSC structures – As per clause 13.4 of IRS CBC. (ii) Steel Structures –

(a) In case of Metro live loads, as per clause 3.6 of IRS Steel Bridge Code shall govern. If λ* values are required to be used, the train closest to the actual train formation proposed to be run on the metro system shall be used. Otherwise, detailed counting of cycles shall be done.

(b) For other cases as per Section 13 of IS: 800. *Damage equivalence factors (As per IRS Steel Bridge Code).

2.8 Foundations 2.8.1. Types of Foundation

Considering the nature of ground; type of proposed structures, expected loads on foundations, the following type of foundations are considered practical: (a) Spread or pad footing (b) Raft foundation (c) Pile foundation No matter the type of foundation to be adopted, the following performance criteria shall be satisfied: 1) Foundation must not fail in shear 2) Foundation must not settle by more than the settlements permitted as per Table-1 of IS:

1904. 3)

2.8.2. Design of Pile IS: 2911 shall be followed for design of pile, load capacity etc. Pile Settlement

Methods of estimating the settlement of deep foundations depend upon the type of deep foundation and the manner of transfer of loads from the structure to the soil. Theoretical estimation of settlement shall be done in accordance with IS: 8009 (Part II) by integrating the vertical strain for the entire depth of soil and rock formation. The settlement of each pile and/or pile group should be determined and it should be demonstrated that such total and/or differential settlement can be tolerated by the structure.

2.8.3. Foundations



IS: 1904 shall be followed for design of foundations in soil. The safe bearing capacity for shallow foundations shall be calculated in accordance with IS: 6403.

Computation of Settlements of Foundations The calculation for settlement of foundations shall be done as per:

IS:8009 Part-1 for shallow foundations

IS:8009 Part:2 for deep foundations

2.9 Design of Water Retaining Structure It should be designed as per IS: 3370.

3. List of Design Codes and Standards The designs of station buildings shall be carried out as per provisions of this Design Specifications. Reference shall be made to following codes for any additional information. Order of preferences of codes shall be as follows: -

i. IS ii. IRS iii. IRC iv. BS or Euro Code v. AASHTO

MAHARASHTRA METRO RAIL CORPORATION LIMITED (A JOINT VENTURE OF GOVT. OF INDIA & GOVT. OF MAHARASHTRA)

Pune Metro Rail Project

SCHEDULE

OF

DIMENSIONS

FOR

STANDARD GAUGE (1435 mm)

(25 kV AC OHE TRACTION) (Elevated and At-Grade Section)

Version- F May 2017

MAHARASHTRA METRO RAIL CORPORATION LIMITED 101, The Orion, Opposite Don Bosco Youth Centre,

Koregaon Park, Pune- 411001 E-mail: mahametrorail.etenders.in Website: www.punemetrorail.org

Telephone: 020-26051072




_____________________________________________________________________ i May 2017

INDEX

Approval Letter

Preamble……………………………………………………………………………1

Introduction…………………………………………………………………………2 CHAPTER – I GENERAL

1.1 Spacing of Tracks……………………………………………………………………….. 3

1.2 Curves……………………………………………………………………………………. 3

1.3 Gradients………………………………………………………………………………… 3 1.4 Buildings and Structures………………………………………………………………. 4

1.5 Kinematic Envelope……………………………………………………………………. 5 1.6 Structure Gauge……………………………………………………………………….. 5

1.7 Extra Clearance on Curves…………………………………………………………… 6 1.8 Minimum Track Spacing on Curves…………………………………………………. 7

1.9 Derailment Guard……………………………………………………………………… 9 CHAPTER - II STATIONS 2.1 Spacing of Track at Stations…………………………………………………………. 10 2.2 Platforms……………………………………………………………………………….. 10 2.3 Track Gradient in Platform……………………………………………………………. 11

2.4 Interlocking and Signal Gear…………………………………………………………. 11

2.5 Points and Crossings…………………………………………………………………. 11

2.6 Super elevation and Speed at Stations on Curve with Turnouts of……………… 13

Contrary and Similar Flexure

2.7 Additional Clearance for Platforms on Curves…………………………………….. 13

CHAPTER - III ROLLING STOCK 3.1 Passenger Electric Multiple Units……………………………………………………. 14

3.2 Locomotives and Engineering Service Vehicles……………………………………. 15

CHAPTER - IV OVERHEAD ELECTRIC TRACTION-25 kV AC 50 Hz

4.1 Electrical Clearances for At-Grade and Elevated Section…………………………. 16

CHAPTER – V PLATFORM GATE

5.1 Platform Gate Setting Out Dimensions……………………………………………….. 18


_____________________________________________________________________ ii May 2017

LIST OF APPENDICES

APPENDIX NO. DESCRIPTION PAGE NO.

Appendix –1 Permissible Speed, Cant and Minimum 19

Track Spacing on Curves

Appendix – 2 Extra Horizontal Clearance on Curves 20 (Curvature effect)

Appendix – 3 Cant Effect on Kinematic Envelope– Horizontal 22 (Vehicle Speed 90 kmph)

At-Grade and Elevated sections

Appendix – 3i Cant Effect on Kinematic Envelope– Horizontal 23 (Vehicle Speed 40 kmph) At-Grade and Elevated sections

Appendix – 3A Cant Effect on Structure Gauge (Corresponding to 24 90 kmph KE) – Horizontal

At-Grade and Elevated Sections

Appendix – 3A Cant Effect on Structure Gauge (Corresponding to 25 40 kmph KE) – Horizontal

At-Grade and Elevated Sections

Appendix – 4 Additional Clearance for platforms on curves 26


_____________________________________________________________________ iii May 2017

LIST OF FIGURES

FIGURE DESCRIPTION PAGE NO

Figure No. NMSG-1 Kinematic Envelope for 90 kmph (At-Grade and Elevated Sections)

27

Figure No. NMSG – 1A Kinematic Envelope for 40 kmph (At-Grade and Elevated Sections) at platform

28

Figure No. NMSG – 2 Structure Gauge – At-Grade and Elevated Sections on level or Constant Grade Tangent Track

29

Figure No. NMSG – 3 Effect of cant on Kinematic Envelope

30

Figure No. NMSG – 3A Effect of cant on Structure Gauge

31

Figure No. NMSG- 4 Effect of vertical curve on Structure Gauge

32

Figure No. NMSG-5 Structure Gauge at Elevated/ At-Grade station with side platforms on level or Constant Grade Tangent Track

33

Figure No.NMSG-6 Structure gauge at Elevated / At-Grade station with island platform on level or constant grade tangent track

34

Figure No.NMSG-7 Platform Gate Elevated/ At-Grade (Platform) on level or constant grade tangent track

35


___________________________________________________________________ Page 1 of 35 May 2017

SCHEDULE OF DIMENSIONS

STANDARD GAUGE (1435 mm)

PREAMBLE

Pune Metro rail has adopted Standard Gauge with 25 kV AC OHE Traction System. The Schedule of

Dimensions has been prepared based on following factors: -

1. The Kinematic Envelope and other infringements have been calculated for 2900 mm wide and

4200 mm high (pantograph in locked down position) rolling stock, based on the Kinematic

Envelope calculations. The track and vehicle maintenance shall conform to the clearances

indicated therein, during the period these Rolling Stocks are in operation.

2. Track shall be maintained to the tolerances taken for calculation of Kinematic Envelope.

3. The clearances are based on assumption that windows are sealed and all doors are closed

during movement / operation.

4. The Structure Gauge indicated in the SoD shall not be violated under any circumstances except

for platform coping, platform gate and track access gate.

5. The Kinematic Envelope(s) indicated in the SoD shall not be violated under any circumstances.

6. The Vehicle Kinematic Envelope for 40 kmph shall be applied only within the confines of

stations. At all other locations, the Kinematic Envelope corresponding to 90 kmph vehicle speed

with 100 kmph side wind speed shall be used for determining the Structure Gauge and Electrical

clearances. The maximum speed for passenger operation shall be 80 kmph.

7. Maximum operating speed at platform shall be 40 kmph and Kinematic Envelope will not be

infringed under any circumstances.

8. This SoD is applicable for ballasted/ballastless track on mainline and ballasted/ballastless

track in Depots.

9. For evacuation of passengers, in case of emergency, including in cases of derailment of the

end coaches, emergency doors provided at both ends (front & rear) of the train shall be used

for evacuation. The emergency doors will open and rest between or onto the track plinth and

the space available between the track-plinths shall be used as walkway. The evacuation will

be done under the supervision of train operator and/or station staff.

10. No workman/equipment/structure is allowed between vehicle and structure gauge during

operation/movement of train.


___________________________________________________________________ Page 2 of 35 May 2017

INTRODUCTION

The dimensions given in this Schedule of Dimensions are to be observed in all works on 1435 mm

gauge (STANDARD GAUGE), unless prior sanction has been obtained from the Railway Board through

the Commissioner of Metro Railway Safety/Chief Commissioner of Railway Safety (as per applicability)

to execute works which infringe this Schedule of Dimensions.

This Schedule of Dimensions is applicable to Elevated and At-Grade sections of Pune Metro Rail, which

shall be with 25 kV AC Traction system and Over Head current collection. The Rolling Stock shall be

2900 mm wide and 4200 mm high (maximum with pantograph in locked down condition or without

pantograph) with sealed windows and doors closed while in motion.

Elevated Systems shall be with suitable over ground structure such as Viaduct. Elevated section shall

have suitably designed Ballastless (DFF) Track. At-Grade system and the Depot area may have either

Ballasted Track or Ballastless Track.

The Schedule of Dimensions (SoD) has been divided into five chapters as under

Chapter-I ------------------- General

Chapter-II ------------------- Stations

Chapter-III ------------------- Rolling Stock

Chapter-IV ------------------- Electric Traction

Chapter-V ------------------- Platform Gate


___________________________________________________________________ Page 3 of 35 May 2017

CHAPTER-I

GENERAL 1.1 SPACING OF TRACKS

Minimum centre to centre distance of tracks without any structure in between tracks for tangent

(straight) track for Elevated sections and At-grade sections: 3650 mm

Note: See Appendix-1 for minimum track centers distance on curves.

1.2 CURVES

1.2.1 Minimum radius of curves (horizontal)

i) On main running lines

Elevated and At-Grade Sections 120 m

ii) Depot and other non-passenger Lines 100 m

iii) At passenger platforms 1000 m

1.2.2 Check Rail / Restraining Rail

Check Rail / Restraining Rail shall be provided on curves on main line where radius is 190 m or

less. Check rail/Restraining rail shall not be mandatory for curves in depots, yards and non-

passenger lines, where speed is less than 25 kmph. The clearance between check

rail/restraining rail and running rail shall be suitably decided by metro.

1.2.3 Minimum radius of vertical curve 1500 m

Note: No vertical curve shall be provided in platform area.

1.2.4 Cant and Cant Deficiency

a) Maximum Cant on curves 110 mm

b) Maximum Cant Deficiency 85 mm

1.3 GRADIENTS

1.3.1 The maximum grade (compensated) shall be 4%.

Note:

(i) There will be no change of gradient in transition portion of curves.

(ii) The gradient will be compensated for curvature at the rate of 0.04% per degree of curve.

1.3.2 Maximum permissible gradient on turnouts

(i) On Ballasted Track 0.25 %

(ii) On Blallastless Track 3.0 %

Note:

(i) There shall be no change of gradient (i.e. vertical curve) on and within 15.0m

(desirable)/3.0 m (minimum) of any turnout on Ballastless track. In case of Ballasted

track, there shall be no change of gradient on and within 30 meters of any turnout.


___________________________________________________________________ Page 4 of 35 May 2017

(ii) There shall be no horizontal curve within 15.0 m (desirable)/3.0 m (Minimum) of any

turnout on Ballastless Track and 30 meters of any Turnout on Ballasted Track.

(iii) Turnout shall normally be installed on straight track. In exceptional situations, turnout

may take off from curve provided that the radius of lead curve (main line as well as well

as diverging line) is not less than 190m. The negotiability of rolling stocks on such turnout

must be certified by rolling stock supplier and confirmed through oscillation trial and a

suitable speed restriction should be imposed on main and/or diverging the based on track

geometry and other considerations, if required. In case of turnout installed on curved

track, the minimum distance for commencement of vertical curve or another horizontal

curve shall be 15m for Ballastless track. Turnout shall not be laid on transition curve.

(iv) The limit of turnout for above purposes shall be taken from Stock Bail Joint (SRJ) to end

(i.e. heel) of crossing for Ballastless track. For Ballasted track, it shall be from SRJ to last

common sleeper behind end of crossing.

(v) The maximum permissible gradient on turnout and the location of turnout with respect to

vertical/horizontal curves in vicinity shall be confirmed from rolling stock supplier for the

negotiability of rolling stock.

(vi) The above stipulations shall also be applicable for turnout to be laid outside station limit,

if any.

1.4 BUILDINGS AND STRUCTURES

1.4.1 Minimum horizontal distance from centre of track to any structure (except at passenger

platform) for heights above rail level on level/constant grade tangent track shall be as under:

-

Elevated and At-Grade Sections

Height from rail level Horizontal distance from C.L. of track

i. Up to 65 mm 1465 mm

ii. 65 mm to 200 mm 1465 mm increasing to 1640 mm

iii. 200 mm to 305 mm 1640 mm

iv. 305 mm to 930 mm 1640 mm increasing to 1735 mm

v. 930 mm to 1095 mm 1735 mm increasing to1740 mm

vi. 1095 mm to 3310 mm 1740 mm increasing to 1825 mm

vii. 3310 mm to 3775 mm 1825 mm decreasing to 1546 mm

viii. 3775 mm to 6200 mm 1546 mm

Also refer to Figure No. NMSG-2

Note:

i) Extra clearances shall be provided for curves as laid down at Para-1.7.

ii) The term ‘structure’ covers any item including light ones like ladders, isolated

posts, cables etc. erected alongside the track except for passenger platform.

iii) Minimum lateral clearance for OHE masts for tangent track for at-grade and elevated

sections shall be 2150 mm from centre line of nearest track.

iv) Minimum lateral clearance for OHE masts for tangent track at depot shall be 1950

mm from centre line of nearest track.


___________________________________________________________________ Page 5 of 35 May 2017

v) For passenger platform, refer to Para-2.2.1 to 2.2.3 of Chapter-II.

1.5 KINEMATIC ENVELOPE

For the Kinematic Envelope for level or constant grade tangent track, refer to:

a) Figure No. NMSG-1 for At-Grade and Elevated Sections.

b) Figure No. NMSG-1A for At-Grade and Elevated sections at passenger platform.

Note:

Extra clearances shall be provided for curves as laid down at Para-1.7

1.6 STRUCTURE GAUGE


The Structure Gauge (Fixed Structure Line) has been arrived at by allowing minimum

clearance of 150 mm to Kinematic Envelope and minimum electrical clearance of normally

340 mm from 25 kV live parts conforming to the stipulations in Chapter-IV of this SoD.

Refer to Figure No. NMSG-2 for Structure Gauge for outside stations on level or constant grade

tangent track.

Note:

Extra clearances shall be provided for curves as laid down at Para-1.7

1.7 EXTRA CLEARANCES ON CURVES

Following are the extra clearances considered for curves.

Abbreviations used in Para-1.7:

C is the distance between centres of bogies in metres,

C1 is the coach (vehicle) length in metres,

R is the radius of curve in metres,

Ca is the Cant applied in mm,

h is the height from rail level in mm and

g is the distance between centres of rails in mm

1.7.1 INSIDE OF CURVE

A. Curvature effect

i) Mid throw at the center of the vehicle = V (in mm) =125xC2/R

ii) Clearance due to gauge widening on curves

For values of items (i) and (ii) above, refer to Appendix-2

Note:

Lateral shift of 26 mm due to nosing is included in Kinematic Envelope for tangent track (and

as a result, included in Structure Gauge also) shall be subtracted from the total extra

clearance worked out as at Para-1.7.1(A)-i &ii above for inside of a curve in case the value

of mid throw (V) is equal to or greater than 26 mm. In case the value of mid throw (V) is less

than 26 mm, the curvature effect shall be due to widening of the gauge only. (The Mid throw

minus 26 mm shall be taken as zero).

B. Clearance for Cant


The lean ‘L’ due to Cant at any point at height ‘h’ above rail level is given by:

L = Ca x h/g (all in mm)


___________________________________________________________________ Page 6 of 35 May 2017

For values of Structure Gauge (E1) for inside of a curve with cant effect only, (as

shown in Figure No. NMSG-3A), refer to Appendix-3A for At-Grade and Elevated

Sections.

C. Clearance for vertical curve (vertical throw)

Vertical Throw V1 and V2 (in mm) for vertical curve shall be calculated as under:

V1 (with vehicle centre in sag or vehicle end on summit)

= 125xC2/R

V2 (with vehicle centre on summit or vehicle end in sag)

= (125xC12/R)-(125xC2/R)

For values of vertical throw V1 & V2 due to vertical curves of different radii, refer to NMSG-4.

1.7.2 OUTSIDE OF CURVE

A. Curvature effect

i) End throw at the end of vehicle = Vo (in mm)

= [125xC12/R]-[125xC2/R]

ii) Clearance due to gauge widening on curves iii) Additional nosing due to gauge widening on curves

The values of items (i) to (iii) are shown in Appendix-2

B. Clearance for Cant

Elevated, and At-Grade sections

The lean ‘L’ due to Cant at any point at height ‘h’ above rail level is given by:

L = (-) Ca x h/g (all in mm)

-ve sign indicates relief due to cant or reduction in clearance required.

Note: Full relief for lean due to cant (Ca) is to be taken into account only for calculation of track

spacing without any structure between tracks. In case there is a structure adjacent to track,

relief for lean is to be taken into account only if the cant provided is greater than 50 mm and

shall be limited to a value = (Ca - 50) x h/g.

For values of Structure Gauge (F1) on outside of curve with Cant effect only (as shown in

Figure No. NMSG-3A), refer to Appendix-3A for Elevated and At-Grade Sections.

C. Clearance for vertical curve (Vertical throw)

The provisions at Para-1.7.1 (C) above shall be applicable in this case also.

For values of vertical throws V1 & V2 due to vertical curves of different radii, refer to NMSG-4.

1.8 MINIMUM TRACK SPACING ON CURVES


The worst case will be when the end of a bogie carriage on the inner track is opposite the centre of a similar carriage on the outer track.

1.8.1 Without any structure between tracks


___________________________________________________________________ Page 7 of 35 May 2017

The minimum track spacing on curves without any structure between tracks shall be the sum of the following:

i) (E + F),

ii) T1 (Extra lateral clearance due to curvature on inside of curve

iii) T2 (Extra lateral clearance due to curvature on outside of curve

iv) Minimum clearance between adjacent Kinematic Envelopes stipulated is as

under:-

300 mm for Elevated and At-Grade Sections.

Where, ‘E’ is the distance from vertical axis of centre line of canted track to canted

Kinematic Envelope on inside of curve at a height ‘h’ (from rail level) for a given cant

(Figure No. NMSG-3) and

‘F’ is the distance from vertical axis of centre line of canted track to canted

Kinematic Envelope on outside of curve at a height ‘h’ (from rail level) for a given

cant (Figure No. NMSG-3).

Notes:

i) The value of ‘F’, calculated from the formula at Figure No. NMSG-3 includes full relief due to Cant.

ii) The sum of 'E' and 'F' for same height (which are with Cant effect only) shall be the maximum of values calculated for various heights from rail level.

For values of E, F, T1 and T2, refer to the Appendices as shown below:

SECTIONS For E & F For T1 &T2

Elevated and At-Grade 1. 3 for 90 kmph KE

2. 3i for 40 kmph KE

2

1.8.2 With a structure between adjacent tracks

The minimum track spacing on curves with a structure between tracks shall be the sum of the following:

i) (E1 +T1) Minimum clearance to the structure from centre line of track on inside

of curve (for outer track)

ii) (F1 +T2) Minimum clearance to the structure from centre line of track on outside of curve (for inner track)

iii) Width of structure between adjacent tracks (measured across the tracks).

Where,

E1 is the horizontal distance from vertical axis of centre line of track to canted

Structure Gauge on inside of curve for a given cant, (Ref Fig no: NMSG-3A)

F1 is the horizontal distance from vertical axis of centre line of track to canted

Structure Gauge on outside of curve for a given cant, (Ref Fig no: NMSG-3A)

T1 is extra lateral clearance due to curvature on inside of curve and

T2 is extra lateral clearance due to curvature on outside of curve.


___________________________________________________________________ Page 8 of 35 May 2017

Notes:

(i) The values of ‘E1’ and ‘F1’ for a given cant Ca, shall each be the maximum of values

at different heights of structure from rail level. In case the cant provided is greater

than 50 mm on inner track, the value of F1 shall be for the cant of (Ca-50) mm. In

case the cant provided is 50 mm or less on inner track, the value of F1 shall be for

ZERO cant.

(ii) Minimum track spacing, so worked out with a structure between the adjacent tracks

shall not be less than that calculated as per Para 1.8.1 for tracks without any

structure between adjacent tracks.

For values of E1, F1, T1 and T2, refer to the Appendices as shown below:

SECTIONS For E1 & F1 For T1 &T2

Elevated and At-Grade 1. 3A for Structure Gauge

corresponding to 90 kmph

KE.

2. 3Ai for Structure Gauge

corresponding to 40 kmph

KE.

2

1.9 DERAILMENT GUARD

(a) Derailment Guard shall be provided on inside/outside of running rail on viaduct.

(b) Lateral Clearance between the running rail and the derailment guard shall be 210 ± 30

mm. It shall not be lower than 25 mm below the top of running rail and shall be clear of

the rail fastenings to permit installation, replacement and maintenance.

Note:

In case of Double Resilient Base Plate Assembly Fastening System as approved by MoR, the

lateral clearance between running rail and the derailment guard shall be 250±20 mm.


___________________________________________________________________ Page 9 of 35 May 2017

CHAPTER - II

STATIONS

2.1 SPACING OF TRACKS AT STATIONS

Minimum spacing of tracks at station on straight and on curve of radius of 1000 m and flatter, without any structure between tracks

Elevated & At-Grade stations 3700 mm

Note: ‘Station Limits’ means platform portion only from SoD point of view.

2.2 PLATFORMS

2.2.1 Maximum horizontal distance from centre of track to face of passenger platform coping

(i) For Elevated/At-Grade section 1525 mm

2.2.2 Minimum horizontal distance from centre of track to face of passenger platform coping

(i) For Elevated/At-Grade section 1520 mm

Notes:

a) Platform faces shall be flared away smoothly from the centre line of the track at either

end for a distance of 1500 mm beyond passenger area so as to give from centre of track a

dimension:

1590 + 5 for At grade and Elevated Stations

b) For additional clearance for platforms on curves, refer to Para-2.7

c) The track access gates at the end of platform up to a height of one meter from top of

platform shall not infringe the Kinematic Envelope.

2.2.3 Height above rail level for passenger platform: Maximum Minimum (a) Ballasted Track 1085 mm 1075 mm

(b) Ballastless Track (DFF) 1095 mm 1085 mm

2.2.4 (i) Minimum horizontal distance of any isolated structure on 2500 mm

a passenger platform from the edge of coping except platform

gate and track access gate which is provided in the flared portion

of the platform end.

ii) Minimum horizontal distance of any continuous structure on 3000 mm

a passenger platform from the edge of coping except platform

gate and track access gate which is provided in the flared portion

of the platform end.

Notes: a) The structure on the platform is treated as isolated if the length along the platform

length is 2000 mm or less. Any structure having a length exceeding 2000 mm is treated

as continuous structure. The clocks/mirrors/CCTV screens etc shall not be considered

structures and shall be located at a minimum horizontal distance of 1000 mm from

platform edge/coping with minimum height of 2000 mm from top of platform.


___________________________________________________________________ Page 10 of 35 May 2017

2.2.5 For Structure Gauge at stations at Elevated Stations and At-Grade, refer to figure no NMSG-

5 & NMSG-6.

2.3 TRACK GRADIENT IN PLATFORM

Gradient of track in station platform length shall be as under:

(a) Maximum gradient 1 in 400

(b) Desirable Level

Note: There shall be no change in gradient in platform line.

2.4 INTERLOCKING AND SIGNAL GEAR

Maximum height above rail level of any part of interlocking or signal gear on either side of centre of track subject to the restrictions embodied in Note below shall be as under:

At-Grade and Elevated Stations

From C.L. of track to 1330 mm 25 mm

From 1330 mm to 1465 mm 25 mm increasing to 65 mm

From 1465 mm to 1640 mm 65 mm increasing to 200 mm

Note: Except for check rails on curves, ordinary and diamond crossings or wing rails and point rails

of crossings leading to snag dead ends, or such parts of signalling gear as are required to be

actuated by the wheels, no gear or track fittings shall project above rail level for a distance

of 229 mm outside and 140 mm inside the gauge face of the rails.

2.5 POINTS & CROSSINGS

2.5.1 Maximum clearance of check rail opposite nose of crossing 42 mm

2.5.2 Minimum clearance of check rail opposite nose of crossing 40 mm

2.5.3 Minimum clearance between switch rail and stock rail at heel 60 mm

of switch

2.5.4 Maximum clearance of wing rail at nose of crossing 43 mm

2.5.5 Minimum clearance of wing rail at nose of crossing. 41 mm

2.5.6 Minimum clearance between toe of open switch and stock rail. 160 mm

2.5.7 Minimum radius of curvature for slip points, turnouts and 140 m

crossovers.

2.5.8 On main lines, the turnouts and diamond Crossings shall be of the following types

a) 1 in 9 type turnout 190 m radius

b) 1 in 7 type turnout 190 m radius (Desirable)

140 m radius (Exceptional circumstances)


___________________________________________________________________ Page 11 of 35 May 2017

c) Scissors cross-over of 1 in 9 type consisting of 4 acute turnouts of 1 in 9 and 1 diamond

crossing.

d) Scissors cross-over of 1 in 7 type consisting of 4 acute turnouts of 1 in 7 and 1 diamond

crossing.

2.5.9 On depot lines, non-passenger lines like pocket track, depot entry lines etc, the turnouts

and diamond Crossings shall be of the following types:

a) 1 in 7 type turnout 140 m radius

b) Scissors cross-over of 1 in 7 type consisting of 4 acute turnouts of 1 in 7

and 1 diamond crossing.

c) 1 in 7 derailing switches/ 1 in 7 type symmetrical split turnout.

2.5.10 Diamond crossings not to be flatter than 1 in 4.444.

Note:

a) The above restrictions shall not apply to moveable diamond crossings.

b) Switches and crossings shall not be located on transition curves & vertical curves.

b) There must be no change of super elevation (of outer over inner rail) between points 18

m outside toe of switch rail and nose of crossings respectively, except in the case of

special crossing leading to snag dead-ends or under circumstances as provided for in item

2.6 below.

2.5.11 Minimum length of tongue rail 9000 mm

2.6 SUPER-ELEVATIONS AND SPEED AT STATIONS ON CURVES WITH TURNOUTS OF CONTRARY

AND SIMILAR FLEXURE.

2.6.1 Main Line:

Subject to the permissible run through speed based on the standard of interlocking, the

equilibrium super-elevation, calculated for the speed of the fastest train may be reduced by

a maximum amount of 85 mm without reducing speed on the main line.

2.6.2 Turnouts:

i) Curves of contrary flexure

The equilibrium super-elevation (s) in mm should be = (1510/127)*(V2 / R)

Where,

R = Radius of turnout in meters and V is speed on turnout in Kmph.

The permissible negative super-elevation on the turnout (which is also the actual super-

elevation of the main line) may then be = (85 – s) mm.

ii) Curves of similar flexure

The question of reduction or otherwise of super-elevation on the main line must necessarily

be determined by the administration concerned. In the case of a reverse curve close behind


___________________________________________________________________ Page 12 of 35 May 2017

the crossing of a turnout, the super-elevation may be run out at the maximum of 1 mm in

400 mm.

2.7 ADDITIONAL CLEARANCE FOR PLATFORMS ON CURVES

The additional clearance for platforms on curves shall be provided as shown at Appendix-4

Note:

As the minimum radius of curve for stations is 1000 m, there will be no super elevation and

gauge widening on passenger platform lines.


___________________________________________________________________ Page 13 of 35 May 2017

CHAPTER-III

ROLLING STOCK

3.1 PASSENGER ELECTRIC MULTIPLE UNITS

3.1.1 (a) Maximum Length of the coach body (including end fairings)

(a) (b) Maximum width of the vehicle (b)

(c) Height of the coach body

(maximum with pantograph in

locked down condition)

21940 mm

2900 mm 4200 mm

3.1.2 Distance between bogie centres

14850+ 250 mm

3.1.3 Kinematic Envelope for level tangent track

a. For At-Grade and Elevated Sections except for

passenger platform.

b. For At-Grade and Elevated Sections at passenger

platform.

Figure No. NMSG-1 Figure No. NMSG-1A

3.1.4 Minimum clearance above rail level under dynamic condition of

fully loaded vehicle under worst condition** for bogie and axle

mounted equipment.

75 mm

3.1.5 Minimum clearance above rail level under dynamic condition of

fully loaded vehicle under worst condition*** for body mounted

equipment.

102 mm

**The “worst condition” means it is with deflection of primary suspension and maximum tread wear.

***The “worst condition” means it is with deflection of primary suspension and, deflated air spring and maximum tread wear.

3.1.6 Wheel

a) Maximum wheel gauge back to back distance

b) Minimum wheel gauge back to back distance

1360 mm 1358 mm

3.1.7 a) Maximum diameter on the tread (measured at 70 mm from wheel gauge face)

b) Minimum diameter on the tread (measured at 70 mm

from wheel gauge face)

860 mm 780 mm

3.1.8 a) Minimum projection for flange of new wheel (measured at 70 mm from wheel gauge face)

28 mm 36 mm


___________________________________________________________________ Page 14 of 35 May 2017

b) Maximum projection for flange of worn wheel (measured at 70 mm from wheel gauge face)

3.1.9 a) Maximum thickness of flange of wheel measured from wheel gauge face at 18 mm from outer edge of flange.

b) Minimum thickness of flange of wheel measured from wheel gauge face at 18 mm from outer edge of flange.

32.5 mm 22 mm

3.1.10 Minimum width of wheel 135±1 mm

3.1.11 Incline of tread 1 in 20

3.1.12 Floor Height

a) Maximum height above rail level for floor of any unloaded

vehicle

b) Minimum height above rail level for floor of fully loaded

normal vehicle

1130 mm

1100 mm

3.1.13 a) Maximum height of centre coupler above rail level for unloaded vehicle

b) Minimum height of centre coupler above rail level for fully loaded vehicle

815 mm 740 mm

3.1.14 Maximum length over couplers 22600 mm

3.1.15 Length of rigid wheel base for single bogie 2200 to 2600 mm

3.1.16

Maximum distance between any two adjacent axles

12900 mm

3.2 LOCOMOTIVES AND ENGINEERING SERVICE VEHICLES

Other items of rolling stock, viz shunting locomotives, OHE maintenance and inspection cars,

emergency re-railing vans, track machines, etc., used on Pune Metro System (where these

cars would be plying) will conform with the Kinematic Envelope of the Passenger Electric

Multiple Units as shown in Figure No NMSG - 1 for Elevated & At-Grade sections and Figure

No NMSG-1A for Elevated & At-Grade sections at platforms.

CHAPTER-IV

ELECTRIC TRACTION

(OVERHEAD ELECTRIC TRACTION 25 kV/AC 50 CYCLES PER SECOND)

Note: Special precautions must be taken to maintain following clearances:

4.1 ELECTRICAL CLEARANCES FOR AT-GRADE AND ELEVATED SECTIONS

4.1.1 The clearances between 25 kV live parts and earthed parts of fixed structures or moving loads

shall be as large as possible. The minimum electrical clearances (vertical and horizontal) to

be maintained under the worst condition of temperature, wind, etc. between any live part


___________________________________________________________________ Page 15 of 35 May 2017

of the overhead equipment or pantograph and parts of any fixed structures (earthed or

otherwise) or moving loads shall be below:

Vertical Clearance: (i) Long Duration 250 mm

(ii) Short Duration 200 mm

Horizontal/Lateral Clearance:

(i) Long Duration 250 mm

(ii) Short Duration 200 mm

Note:

(a) Long Duration means when the conductor is at rest and Short Duration means when

the conductor is not at rest.

(b) Normally, a minimum vertical distance of 340 mm shall be provided between rolling

stock and contact wire to allow for a 20 mm temporary raising of the track during

maintenance. Wherever the allowance required for track maintenance exceeds 20

mm, the vertical distance between rolling stock and contact wire shall

correspondingly be increased.

(c) Where adoption of above clearance is either not feasible or involves abnormally high

cost, a minimum vertical distance of 250 mm shall be provided between rolling stock

and contact wire. At such locations, the following factors shall be maintained.

i) Track to be frozen by providing permanent bench mark to indicate the level of track

to be maintained.

ii) Erection tolerance shall be taken as zero.

iii) OHE span length shall be kept 36m or below to restrict the oscillation of contact

wire.

4.1.2 Height of contact wire:

Minimum height from rail level to the underside of live Conductor wire

i) In the open…………………………………………..…….. 5000 mm

ii) Special locations (under bridges, in tunnels) for locked

down height of pantograph …...…………………….….. 4800 mm

iii) In depot open area……………………………….…….... 5200 mm iv) In carriage sheds and depot where the staff will likely to be working on the roof of Rolling Stock during the maintenance………………………………………………. 5500 mm

Note:

a) The normal height from rail level to the underside of contact wire is 5000 mm

b) On curves, all vertical distances specified in items 4.1.3 above, shall be measured

above level of the inner rail, increased by half the super-elevation.


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4.1.3 Maximum variation of the live conductor wire on either side of the centre line of the track

under static conditions:

i) On straight …………………………………….. +200mm

ii) On Curves …………………………………….. +300mm

Note: These limits would not apply to special locations like insulated overlaps and out of run wires.

4.1.4 Maximum width of pantograph collector:

The Kinematic Envelope with the size of Pantograph adopted shall be within the Kinematic

Envelope shown at Figure No. NMSG-1.


___________________________________________________________________ Page 17 of 35 May 2017

CHAPTER-V

PLATFORM GATE

5.1 PLATFORM GATE SETTING OUT DIMENSIONS

Minimum Platform Gate width 2000 mm

Minimum Platform Gate height 1500 mm

Maximum Platform Gate threshold offset from track centerline –

straight track 1530 mm

Minimum Platform Gate panel offset from track centerline –

straight track 1535 mm

Minimum Platform Gate header offset from track centerline 1530 mm

Note:

(a) Assumed plus/minus 300 mm stopping accuracy.

(b) Platform gate at stations on curves shall be considered separately taking into account

the additional clearance as per Appendix-4.

(c) Platform gates are designated as railway operational structures. Therefore, platform

gates may infringe the Structure Gauge, but does not infringe the kinematic envelope

and having minimum clearance of 10 mm from kinematic envelope to platform gate (refer

NMSG-7)

(d) The deflector attached to the bottom of the sliding door shall be designed in order not

to protrude beyond the gate threshold.


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Appendix-1

PERMISSIBLE SPEED, CANT AND

MINIMUM TRACK SPACING ON CURVES.

ELEVATED AND AT-GRADE SECTIONS

RADIUS OF CURVE

CANT MAXIMUM

PERMISSIBLE SPEED

MINIMUM DISTANCE BETWEEN ADJACENT TRACKS

See note (a)

(m) mm kmph mm

3000 or more 15 80 3650

2800 15 80 3650

2400 20 80 3650

2000 20 80 3650

1600 25 80 3650

1500 30 80 3650

1200 35 80 3650

1000 40 80 3700

800 55 80 3700

600 70 80 3750

500 90 80 3750

450 95 75 3750

400 105 75 3800

350 110 70 3800

300 110 65 3850

200 110 50 3900

175 110 50 3900

150 110 45 3900

150* 0 30 4000

120 110 40 4000

120* 0 30 4000

Notes: (a) The track spacing shown in the table above is without any column/structure between two

tracks and is with equal cant for both outer and inner tracks. b) Track spacing shown in Table above is not applicable to stations which should be calculated

depending on specific requirement but should not be less than spacing specified in para 2.1. c) Track spacing is calculated as per Para 1.8 (i.e E+F+T1+T2+300 m) d) Figures for any intermediate radius of curvature may be obtained by adopting the value for

sharper curve. e) Cant provided is limited to desirable value of 110 mm. f) Maximum cant deficiency is 85 mm.

* Curves to be provided in depots.


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Appendix-2

EXTRA HORIZONTAL CLEARANCE ON CURVES

(CURVATURE EFFECT)

INSIDE OF CURVE

REFERENCE: PARA 1.7.1

RADIUS OF

CURVE

MID-THROW

(28500/R)

NOSING INCLUDED IN K.E/ STRUCTURE

GAUGE FOR TANGENT TRACK

EXTRA GAUGE WIDENING ON

CURVES

EXTRA HORIZONTAL

CLEARANCE ON CURVE

REMARKS

(m) (mm) (mm) (mm) (mm)

(R) (V) ( N ) (G) (T1)

100 285.0 26.0 9.0 268

(G) EXTRA GAUGE WIDENING ON

CURVES SHARPER THAN 1000 m RADIUS: 9 mm FOR CURVES WITH RADII

SHARPER THAN 500 m AND 5 mm

FOR CURVES WITH RADII OF 500 m TO LESS THAN 1000 m.

120 237.5 26.0 9.0 221

150 190.0 26.0 9.0 173

175 162.9 26.0 9.0 146

200 142.5 26.0 9.0 126

250 114.0 26.0 9.0 97

300 95.0 26.0 9.0 78

350 81.4 26.0 9.0 64

400 71.3 26.0 9.0 54

450 63.3 26.0 9.0 46

500 57.0 26.0 5.0 36

600 47.5 26.0 5.0 27

700 40.7 26.0 5.0 20

800 35.6 26.0 5.0 15

900 31.7 26.0 5.0 11

1000 28.5 26.0 0.0 3

T1=V-N+G for V EQUAL TO OR GREATER THAN (N) AND T1= G

for V < (N)

1200 23.8 26.0 0.0 0

1500 19.0 26.0 0.0 0

1600 17.8 26.0 0.0 0

2000 14.3 26.0 0.0 0

2400 11.9 26.0 0.0 0

2800 10.2 26.0 0.0 0

3000 or more

9.5 26.0 0.0 0

Note: Mid throw ( in mm ) V = (125 x C2) /R= 28500/R

Where 'C' is the distance between bogie centers=14.850+0.250=15.100m OR 14.85 - 0.250=14.600 m

The worst case will be with C=15.100 m

R is the radius of curve in metres.

Mid throw (in mm) V = (125 x C2) /R= 28500/R


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OUTSIDE OF CURVE REFERENCE: PARA 1.7.2

RADIUS OF

CURVE

END-THROW

(33525/R)

EXTRA GAUGE WIDENING ON

CURVES

EXTRA NOSING DUE TO EXTRA

GAUGE WIDENING

EXTRA HORIZONTAL

CLEARANCE ON CURVE

REMARKS

(m) (mm) (mm) (mm) (mm)

(R) (Vo) (G) (EN) (T2)

100 335.3 9.0 2.3 347

120 279.4 9.0 2.3 291 (G) EXTRA GAUGE

WIDENING ON CURVES SHARPER

THAN 1000 m RADIUS: 9 mm FOR CURVES WITH RADII

SHARPER THAN 500 m AND 5 mm

FOR CURVES WITH RADII OF 500 m TO LESS THAN 1000 m.

150 223.5 9.0 2.3 235

175 191.6 9.0 2.3 203

200 167.6 9.0 2.3 179

250 134.1 9.0 2.3 145

300 111.8 9.0 2.3 123

350 95.8 9.0 2.3 107

400 83.8 9.0 2.3 95

450 74.5 9.0 2.3 86

500 67.1 5.0 1.3 73

600 55.9 5.0 1.3 62

700 47.9 5.0 1.3 54

800 41.9 5.0 1.3 48

900 37.3 5.0 1.3 44

1000 33.5 0.0 0.0 34

T2=Vo+G+EN EN=Gx0.25198630

1

1200 27.9 0.0 0.0 28

1500 22.4 0.0 0.0 22

1600 21.0 0.0 0.0 21

2000 16.8 0.0 0.0 17

2400 14.0 0.0 0.0 14

2800 12.0 0.0 0.0 12

3000 or more

11.2 0.0 0.0 11

Note: End Throw ( in mm ) Vo= (125 x C1

2) /R - (125xC2)/R = 33525/R

Where 'C' is the distance between bogie centres = 14.850+0.250=15.100m OR 14.850-.250=14.600 m

Worst case will be with C=14.600 m

'C1' is length of coach in meters = 21.940 m and 'R' is radius of curve in meters.


____________________________________________________________________________________________________________________________________________________________ Page 22 of 35 May 2017

PUNE METRO


____________________________________________________________________________________________________________________________________________________________ Page 23 of 35 May 2017

PUNE METRO


____________________________________________________________________________________________________________________________________________________________ Page 24 of 35 May 2017

PUNE METRO


____________________________________________________________________________________________________________________________________________________________ Page 25 of 35 May 2017

PUNE METRO


________________________________________________________________________________________________________ Page 26 of 35 May 2017

Appendix-4 Additional Clearance for Platforms on Curve

Elevated and At-Grade stations

Radius (metre)

Cant (mm)

Extra Clearance (mm)

Remarks

Inside of curve

Outside of curve

1. Extra Clearance for curves: a) Inside of curve = Midthrow = 125C2/R = 28500/R and C, Distance between bogie centres = 15.10m for the worst case and R is radius of curvature in metre. b) Outside of curve = Endthrow = (125C1

2/R) - (125C2/R) = 33525/R where C1, Length of the vehicle = 21.94m (including end fairings) and C, Distance between bogie centres = 14.60m for the worst case and R is radius of curvature in metre. 2. Additional Sway has not been taken to reduce the extra clearance on curved platforms.

3000 0 10 11

2800 0 10 12

2400 0 12 14

2000 0 14 17

1800 0 16 19

1600 0 18 21

1500 0 19 22

1200 0 24 28

1000 0 29 34

STATION BUILDING CONTRACTORS’ INTERFACES

1.0 GENERAL INTERFACE REQUIREMENTS

1.1 General

1.1.1 In these Specifications, unless otherwise stated, the term “Contracts” refers to all the relevant Contracts and the term “Contractors” refers to all the relevant Contractors.

1.1.2 This document shall be read in conjunction with the relevant paragraphs of the relevant General Specification and Parti cular / Technical Specifications. The Contractors shall ensure all requirements of the General Specification and PS/TS pertaining to the contracts are fully resolved and implemented.

1.1.3 The Contractors shall ensure that all requirements of the Specification pertaining to interfaces are properly satisfied.

1.1.4 The requirements specified herein are by no means exhaustive and it remains the responsibility of the respective Contractors to develop and execute an interface plan during execution of the work to ensure that:

(i) All interface issues between the contracts are satisfactorily resolved (ii) Supply, installation and testing of equipment and software are fully coordinated

(iii) All equipment supplied in the contracts are fully compatible with each other

1.2 Interface Management

1.2.1 Each Contractor shall establish a structured process to integrate with other systems to ensure safe, reliable and efficient operations under both normal and degraded conditions to the satisfaction of the Employer / Engineer.

1.2.2 Each Contractor shall ensure that the equipment supplied under the respective Contract are properly interfaced and integrated with other systems.

1.2.3 Each Contractor shall appoint competent and experienced person with no fewer than 5 years of railway project experience who shall be the single point of contact for all interface design and testing works with the interfacing contractors and the Employer / Engineer.

1.2.4 Each Contractor shall be responsible for interface identification, establishment, construction and testing works either in the capacity as the Lead Contractor or Participating Contractor.

1.2.5 The Lead Contractor will be responsible to initiate, plan, coordinate and produce jointly with the Participating Contractors all the required interfaces and interface design documents and interface progress reports for submission to the Engineer for acceptance. The Lead Contractor will also prepare and submit all interface meeting minutes and interface progress reports to the Engineer for information.

1.2.6 The Participating Contractor shall collaborate fully with the Lead Contractor in the development and finalization of the interface design, joint production of the interface documents and interface progress reports.

1.2.7 The costs for all interface design and testing works shall be deemed to be included in the Contract sum regardless of the actual extent of effort required or expended by the Contractors.

1.2.8 The Contractors shall be fully responsible for the management and control of its subcontractors in relation to all interfacing activities carried out under the Contract.

2.0 INTERFACES WITH POWER SUPPLY CONTRACTORS

2.1 Definition and Scope

2.1.1 This specification describes the interface requirements between Station Building Contractors / DDCs and Power Supply Contractors. 2.1.2 Station

Building Contractors / DDCs shall be the Lead Contractor and Power Supply Contractor shall be the Participating Contractor.

2.2 Contractors’ Responsibilities

2.2.1 This specification outlines the Contractors’ interface requirements, which are based on the Technical Studies carried out during the early stages of the Project.

2.3 Scope of Interface & Division of Responsibilities

1.1.1 The Station Contractor(s) and Power Supply Contractor shall co-ordinate interactively in order to achieve the functional and operational requirements of the system. The roles and activities of the two Contractors shall include minimum following but not limited to:

Item No.

Item Description PS Contractor Station Building Contractors

Station Civil

1 ASS Room / Building

Shall provide the layout drawings to Station Building Contractor

Shall design and construct ASS room / building to be requirement of the PS Contractor.

2 Installation of 33 kV, cables and control

cable

Shall provide weight & dimensions of the

cables. Shall supply & install 33 kV and other

cables

Shall design & provide and install cable path (duct,

Shall provide suitable opening, cable tray, cable trough, containment and HDPE pipe for carrying cables inside ASS and at track crossings as per

requirement.

Shall take into consideration the bending radius of cable

Item No.


metallic brackets, cable trays etc.) as per requirement.

Shall co-ordinate and give requirements to the Station Contractor for the cable path, gallery size, route alignment and mounting requirements for cables in the Station area

Shall co-ordinate with Station Contractors for provision of opening, cable tray, cable trough, containment and HDPE pipes of adequate size to carry the cables inside ASS and at track crossings.

and covering of cables in public places.

3 Temporary Power For Installation, testing & commissioning

Shall co-ordinate with Station Contractor for provision of suitable sockets inside ASS rooms for temporary power

Shall pay to the Station Contractor for the power consumption

Note: If temporary power is not available from Station Contractor, then PS Contractor shall make his own arrangement.

Shall provide sockets for temporary power, if available, inside ASS rooms as per requirement

Shall provide suitable meters for calculating the consumption

4 Installation of Equipment in ASS

Shall supply, transport and install ASS Equipment including Transformers, 33kV Switchgear, Distribution Boards etc. as per Specifications.

Shall provide equipment layout drawing. Shall provide necessary foundations for transformers, panels other equipment etc. Alternatively, the Contractor can provide suitably designed anchor-fasteners to fix transformers, 33kV panels, Battery chargers etc. to the basic floor/pedestal

Shall coordinate with Station Contractors for suitable design of ASS rooms to ensure smooth passage for carrying the equipments inside ASS.

Shall coordinate with Station Contractors for suitable openings for cable and earthing connections and cable entry from viaduct cable duct to ASS room.

Shall construct ASS rooms keeping in view the specific requirements of PS Contractor regarding passages, ingress / egress routes, door size, knock out panels, floor openings etc. for access of heavy equipments forming permanent works

Shall provide ASS room complete in all respects, including flooring, lighting, ventilation, power sockets, access doors, rolling shutters, windows, ventilators and interior finish, but excluding foundations for transformer and panels.

Shall provide cut-outs in floor for cable entry to the requirements of PS Contractor.

Shall make provision for passage/crossing of various cables in the station along the walls, under the platform copings etc. for cable entry from viaduct cable duct to ASS room.

Item No.


Shall confirm the fire safety provisions

Shall provide dimensions and weights of various equipment

Shall arrange material handling equipment at his own cost or hire the same from Station Building Contractor and pay necessary hiring charges to Station Building Contractor

Shall provide hatch, gantry beams and loading deck for carrying heavy equipments and materials to substations. Shall provide lifting hooks in ASS rooms as per requirements of PS Contractor.

Shall provide suitable fire safety provisions in equipment rooms.

5 Earthing and bonding arrangements at stations

Shall provide schematic arrangement of earthing and bonding schemes in the stations

Shall connect station earth mats to Earth Cable by appropriate size copper cable or equivalent MS connections

Shall connect structure earth terminals to Earth Cable through 70 mm2 copper cable

Shall connect various structures at station to Earth Cable as per schematic

Shall Coordinate for requirements of earthing and bonding schemes

Shall associate with PS Contractor to verify the earthing-bonding of structure as per approved scheme.

Shall provide necessary earth terminals, earth mesh etc. and risers and respect the schematic earthing drawing

Shall ensure provision of minimum of 50mm dia pipe (5 Nos.) on each platform under the floor for continuity of earthing platform shelter / canopy.

6 Earthing in ASS Shall provide the earthing design calculations and requirements to Station Contractors.

Shall associate during the installation of earth mat. Shall jointly check the resistance of the earth mat after installation.

Shall provide and connect various equipments to Earth Bus/METs inside ASS with GI / Copper strips.

Shall provide the earth resistivity details for design of earth mat.

Shall install the earth mat according to approved design.

Shall install Earth Bus / METs (main earth terminals connected to the earth mats) inside ASS to facilitate the connection of equipments.

Station E&M

1 Lighting and ventilation in ASS

Shall provide heat load for electrical equipment inside ASS.

Shall interface with Station Contractors for any special requirements or preferred locations of lights, fans, exhaust

Shall design adequate ventilation and lighting system for ASS

Shall provide for special requirements or preferred locations of lights, fans, exhaust fans and other services.

Item No.


fans and other services.

2 Supply to ACDB at ASS

Cable laying from designated LV panel to ACDB at ASS Providing emergency supply (DG, UPS) feeder in emergency panel or other suitable point

Installing cable support from LV panel to ACDB in ASS

Shall connect the cable at the LV panel end

3 SCADA integration of main incomers and coupling breaker of 415V distribution board (for station)

Shall provide RTU and designated terminal board for connection of C&M cables from 415V CBs to RTU

Shall provide E&M cable connection from MDB to RTU in the designated terminal board.

4 Connection from transformer to MDB (cables)

Shall provide LT terminals for connection of multiple runs of 3.5 core LT cables and openings in enclosure for cable entry so that no modification on or inside the transformer enclosure is required to be done by E&M contractor.

Shall provide cable paths and shall connect the transformer to the LV Distribution Board by means of suitable cables as per specifications for each connection.

5 Connection from transformer to MDB (bus duct)

Facilitate connections from transformers to LT CBs, provide necessary opening in enclosure suitable reinforced to strengthen and prevent sagging of enclosure.

Shall supply and install MDB and bus duct from transformer to MDB.

6 33kV/415V auxiliary transformer protection

Shall coordinate relay settings on transformer primary side with those of secondary side provided by E&M

Shall do the same on secondary side

7 Transformer door interlock

Shall provide wiring and interlock for transformer enclosure door

Shall install interlock supplied by PS Contractor on MDB

8 Inter-tripping between main LV circuit breakers and the 33kV MV circuit breakers of the auxiliary transformers

Shall provide inter-tripping circuits as per requirements shown in specifications for stations

Shall coordinate

10 Viaduct lighting and socket outlets

Shall design and provide the viaduct lighting and socket arrangement as per specifications. Shall provide the LV power / feeder requirements to E&M Contractor to enable

Shall coordinate with PS Contractor and make necessary provision of feeders for the viaduct lighting and sockets in appropriate LV panels

Item No.


him to make provisions of necessary feeders of adequate capacity in the LV distribution scheme.

3.0 INTERFACE WITH OCS/OHE CONTRACTOR


3.1.1 This specification describes the interface requirements between Station Building Contractors / DDCs and OCS (or OHE) Contractor. 3.1.2

Station Building Contractors / DDCs shall be the Lead Contractor and OCS Contractor shall be the Participating Contractor.




3.3.1 The Station Contractor(s) and OCS Contractor shall co-ordinate interactively in order to achieve the functional and operational requirements of the system. The roles and activities of the two Contractors shall include minimum following but not limited to:

Item No.

Item Description OCS Contractor Station Building Contractors

A Station Civil

1 SSP/SP/SS Room / Building

Shall provide the layout drawings to Station Building Contractor

Shall design and construct SP/SSP/SS room / building to be requirement of the OCS Contractor.

2 Installation of 25 kV, cables and control cable

Shall provide weight & dimensions of the

cables. Shall supply & install 25 kV and other

cables

Shall design & provide and install cable path (duct, metallic brackets, cable trays etc.) as per requirement.

Shall co-ordinate and give requirements to the Station Contractor for the cable path, gallery size, route alignment and mounting requirements for cables in the Station area

Shall provide suitable opening, cable tray, cable trough, containment and HDPE pipe for carrying cables inside equipment room and at track crossings as per requirement.

Shall take into consideration the bending radius of cable and covering of cables in public places.

Item No.


Shall co-ordinate with Station Contractors for provision of opening, cable tray, cable trough, containment and HDPE pipes of adequate size to carry the cables inside SP/SSP/SS and at track crossings.

3 Temporary Power For Installation, testing & commissioning

Shall co-ordinate with station contractor for provision of suitable sockets inside SSP/SS rooms for temporary power

Shall pay to the Station Contractor for the power consumption

Note: If temporary power is not available from Station Contractor, then OCS Contractor shall make his own arrangement.

Shall provide sockets for temporary power, if available, inside SSP/SS rooms as per requirement

Shall provide suitable meters for calculating the consumption

4 Installation of Equipment in SSP/SS/SP

Shall supply, transport and install SSP/SS Equipment including 25kV Switchgear, Distribution Boards etc. as per Specifications.

Shall provide equipment layout drawing. Shall provide necessary foundations for transformers, panels other equipment etc. Alternatively, the Contractor can provide suitably designed anchor-fasteners to fix panels, Battery chargers etc. to the basic floor/pedestal

Shall coordinate with Station Contractors for suitable design of SSP/SS rooms to ensure smooth passage for carrying the equipments inside SSP/SS.

Shall coordinate with Station Contractors for suitable openings for cable and earthing connections and cable entry from viaduct cable duct to SSP/SS room.

Shall confirm the fire safety provisions

Shall provide dimensions and weights of various equipment

Shall construct SSP/SS rooms keeping in view the specific requirements of OCS contractor regarding passages, ingress / egress routes, door size, knock out panels, floor openings etc. for access of heavy equipments forming permanent works

Shall provide SSP/SS room complete in all respects, including flooring, lighting, ventilation, power sockets, access doors, rolling shutters, windows, ventilators and interior finish, but excluding foundations for transformer and panels.

Shall provide cut-outs in floor for cable entry to the requirements of OCS Contractor.

Shall make provision for passage/crossing of various cables in the station along the walls, under the platform copings etc. for cable entry from viaduct cable duct to SSP/SS room.

Shall provide hatch, gantry beams and loading deck for carrying heavy equipments and materials to switching

Item No.


Shall arrange material handling equipment at his own cost or hire the same from Station Building Contractor and pay necessary hiring charges to Station Building Contractor

stations. Shall provide lifting hooks in SSP/SS rooms as per requirements of OCS Contractor.

Shall provide suitable fire safety provisions in equipment rooms.

5 Earthing and bonding arrangements at stations

Shall provide schematic arrangement of earthing and bonding schemes in the stations

Shall Coordinate for requirements of earthing and bonding schemes

Shall associate with PS and OCS Contractors to verify the earthing-bonding of structure as per approved scheme.

Shall provide necessary earth terminals, earth mesh etc. and risers and respect the schematic earthing drawing

Shall ensure provision of minimum of 50mm dia pipe (5 Nos.) on each platform under the floor for continuity of earthing platform shelter / canopy. 6 Earthing

in SSP/SS Shall provide the earthing design calculations and requirements to Station Contractors.

Shall associate during the installation of earth mat. Shall jointly check the resistance of the earth mat after installation.

Shall provide and connect various equipments to Earth Bus/METs inside SSP/SS with GI / Copper strips.

Shall provide the earth resistivity details for design of earth mat.

Shall install the earth mat according to approved design.

Shall install Earth Bus / METs (main earth terminals connected to the earth mats) inside SSP/SS to facilitate the connection of equipments.

7 Support for OHE from platform shed roof trusses

OCS Contractor will provide general arrangement showing suspension members from station ceiling, from which OCS can be supported. OCS Contractor will also indicate typical bending moment and direct load arising from OCS at suspension points.

OCS Contractor will prepare detailed drawings for support of OCS from suspension members.

Station Contractor will provide the necessary steelwork and bolt-holes etc. to enable the suspension members to be supported from the platform shed roof trusses.

8 Providing OCS masts / anchors

OCS Contractor will indicate the locations where masts / anchors are required to be provided (in the pegging plans)

Station Contractor will provide holding down bolts as per approved drawings (used on viaduct to take the

Item No.


on external parapets at stations

OCS Contractor will provide bolted base OCS masts / anchors etc.

baseplate)

9 Providing electrical and mechanical clearances for OCS

OCS Contractor will provide the necessary clearance diagrams showing minimum clearances required from OCS

Station Contractor will ensure that the clearance diagrams are respected and there are no infringements

10 Warning and indicator boards

Shall coordinate and inform locations of OCS warning and indicator boards

Shall furnish the relevant drawings

Shall review the fixing arrangement

Shall supply and install all warning and indicator boards

Shall provide suitable cuts in fixings for indicator boards in station areas

B Station E&M

1 Lighting and ventilation in SSP/SS

Shall provide heat load for electrical equipment inside SSP/SS.

Shall interface with Station Contractors for any special requirements or preferred locations of lights, fans, exhaust fans and other services.

Shall design adequate ventilation and lighting system for SSP/SS

Shall provide for special requirements or preferred locations of lights, fans, exhaust fans and other services.

2 Supply to ACDB at SSP/SS

Cable laying from designated LV panel to ACDB at SSP/SS

Providing emergency supply (DG, UPS) feeder in emergency panel or other suitable point

Installing cable support from LV panel to ACDB in SSP/SS

Shall connect the cable at the LV panel end

4.0 INTERFACE WITH SIGNALING & TRAIN CONTROL (S&TC) CONTRACTOR


4.1.1 This specification describes the interface requirements between Station Building Contractors / DDCs and S&TC Contractor. 4.1.2 Station Building

Contractors / DDCs shall be the Lead Contractor and S&TC Contractor shall be the Participating Contractor.




4.3.1 The Station Contractor(s) and S&TC Contractor shall co-ordinate interactively in order to achieve the functional and operational requirements of the system. The roles and activities of the two Contractors shall include minimum following but not limited to:

Item No.

Subject Station DDCs / Contractor S&TC Contractor

Station Civil

1 Layout of rooms at the station: Signalling Equipment room (SER), UPS, Signalling maintenance room, and Station control rooms (SCR).

Design Prepare and furnish station drawings; Incorporate room requirements and routing of Cable ducts/ cable trays. Provision of space for Emergency stop plunger.

Construction

Rooms complete with structures, false ceiling if necessary, finishes, fire protection, doors etc.

Construct false flooring in signal equipment room on the mainline.

Design: Mark cable t rays on the stat ion drawings in c lose coordination with the DDCs. Review design with the DDCs. Co -ordinate closely with Stat ion Construct ion Contractors to ensure the requirements at s i te are met.

Construction:

Provide equipment foundations / pedestals. Install all S&TC equipment, cables etc. Seal the gaps after cable installation work with fire resistant material. 2 Station Control Room:

Space for workstations / ESP and other Signalling equipments.

Design Incorporate design requirement of S&TC Contractor in the SCR room

Construction Construct the SCR room as per approved design

Design: Furnish layout of Signalling equipment within Station Control Room for S&TC equipment in close coordination with the DDCs and/ or Station construction contractor.

Construction: Install Signalling equipment within Station Control Room. 3 Provision of Earthing at

stations in equipment rooms.

Design of earth and earth bus bar of < 1Ω

Installation of Earth bus bar < 1Ω in equipment rooms and its connectivity from earthmat.

Set up the earth bus inside S&T equipment rooms (SER, SMR and SCR) from the earth bus bar provided in UPS (S&T) room.

Item No.


4 DCS Mast Design and construct to accommodate DCS mast base plate

Provide design data of DCS mast to DDCs / Civil Contractor

Install the DCS mast

Station E&M

1 Lighting, air-conditioning etc. for signaling equipment rooms at the station

Rooms complete with fire protection, lighting fixtures, Air-conditioning & ventilation and power sockets.

Provide Cable ducts /Hangers / cable trays up to the rooms.

General lighting and power or testing of signaling system

Design:

Mark cable trays on the station drawings in close coordination with the civil design / construction contractor.

Review the designs and coordinate closely with construction contractor to ensure the requirements at site are met.

Construction: Construct all cable trays within the rooms required for the Telecom System. Install all telecom equipment, cables etc. Seal the gaps after cable installation work with fire resistant material.

2 Cabling infrastructure for Signalling at stations

Design

Incorporate routing of Cable ducts/ hangers / trays for Signalling main cables throughout the station.

Design details to be worked out in interface with S&TC and other system design requirements.

Construction Station E&M Contractor shall provide Cable ducts/ cable trays / Hangers/ raceways/ duct/ trough/ conduits/ concealed conduit /embedded conduit/ pipes(GI, HDPE, Hume)/ containments for routing S&TC cables from viaduct to station area, laying throughout the station area including concourse, platform, entry / exit, road track, roof, staircase etc.

Design:

Mark cable tray requirement on the GAD/ CSD in close coordination with the DDCs and/ or Station (Civil and E&M) construction contractors.

Furnish and review requirements of EMC for cabling.

Review and confirm design with the DDCs and closely co-ordinate with construction contractor to ensure that the requirements at site are met.

Construction: Install cables for all S&TC systems.

Install cable trays / hangers for routing signalling cables inside signal equipment room and signal maintenance

Item No.


General lighting will be provided by Station Contractor. For testing, power will be provided by Station E&M Contractor.

room.

Seal the gaps after cable installation work with fire resistant material.

3 Power for signalling UPS

Provision of twin feeders for signalling system UPS in the emergency power panel

Laying of LV cables from emergency power panel upto the signalling UPS room

Cable connection at emergency panel end

Providing design requirements to E&M Contractor

Coordinating for cable sizing and routing

Cable connection at UPS end

5.0 INTERFACE WITH TELECOMMUNICATION (TEL) CONTRACTOR


5.1.1 This specification describes the interface requirements between Station Building Contractors / DDCs and Telecom Contractor.

5.1.2 Station Building Contractors / DDCs shall be the Lead Contractor and Telecom Contractor shall be the Participating Contractor.




5.3.1 The Station Contractor(s) and Telecom Contractor shall co-ordinate interactively in order to achieve the functional and operational requirements of the system. The roles and activities of the two Contractors shall include minimum following but not limited to:

SN Subject Station DDCs / Contractors Telecom Contractor

Station Civil

1 Layout of relevant equipment rooms at the station

Prepare and furnish station drawings; Incorporate room requirements and routing of Cable ducts / cable trays.

Design: Mark requite requirements in close coordination with the civil design / construction contractor.


Rooms complete with structures, false ceiling if necessary, finishes, fire protection, doors, etc.

Construct false flooring in Telecom equipment room on the mainline.

Review design with the civil design contractor. Coordinate closely with construction contractor to ensure the requirements at site are met.

Construction:

Provide equipment foundations/ pedestals. Install all telecom equipment, cables etc. Seal the gaps after cable installation work with fire resistant material.

2 Station Control Room Design Incorporate design requirement of Telecom Contractor in the SCR room viz. Space for workstations / and other telecom equipments etc.

Construction Construct the SCR room as per approved design

Design: Furnish layout of telecom equipment within Station Control Room for telecom equipment in close coordination with the civil design and/ or construction contractor.

Construction: Install telecom equipment within Station Control Room.

3 TETRA Radio Tower Shall incorporate the requirement of radio tower at select stations and construct the structure to enable installation of radio tower

Shall provide design requirements for radio tower and shall coordinate appropriately

Shall install the radio towers

4 Provision of Earthing at stations in telecom equipment rooms

Design of earth and earth bus bar < 10

Installation of Earth bus bar < 10 in equipment rooms & its connectivity from earthman.

Set up the earth bus inside equipment room for equipment.

Station E&M

1 Lighting, air-conditioning etc. for telecom equipment rooms at the station

Rooms complete with fire protection, lighting fixtures, Air-conditioning & ventilation and power sockets.

Provide Cable ducts /Hangers / cable trays up to the rooms.

General lighting and power or testing of telecom system

Design: Mark cable trays on the station drawings in close coordination with the civil design / construction contractor.

Review the designs and coordinate closely with construction contractor to ensure the requirements at site are met.

Construction:



Construct all cable trays within the rooms required for the Telecom System. Install all telecom equipment, cables etc. Seal the gaps after cable installation work with fire resistant material.

2 Cabling infrastructure for Telecom systems at stations

Design Incorporate routing of Cable ducts/ hangers / trays for Signalling main cables throughout the station.

Design details to be worked out in interface with Telecom and other system design requirements.

Construction Station E&M Contractor shall provide Cable ducts/ cable trays / Hangers/ raceways/ duct/ trough/ conduits/ concealed conduit /embedded conduit/ pipes(GI, HDPE, Hume)/ containments for routing Telecom cables from viaduct to station area, laying throughout the station area including concourse, platform, entry / exit, road track, roof, staircase etc.


Design: Mark cable tray requirement on the GAD/ CSD in close coordination with the DDCs and/ or Station (Civil and E&M) construction contractors.


Review and confirm design with the DDCs and closely co-ordinate with construction contractor to ensure that the requirements at site are met.

Construction:

Install cables for all Telecom systems.

Install cable trays / hangers for routing telecom cables inside signal equipment rooms


3 Access Control Provide doors & door frames for various rooms duly considering the requirements of Telecom Contractor

Advise the details of ACS equipment to be installed on doors and door frames

4 Power for telecom UPS Provision of twin feeders for telecom system UPS in the emergency power panel

Laying of LV cables from emergency power panel upto the telecom UPS room


Providing design requirements to E&M Contractor


Cable connection at UPS end

6.0 INTERFACE WITH ROLLING STOCK CONTRACTOR

6.1.1 This specification describes the interface requirements between Station Building Contractors / DDCs and Rolling Stock Contractor.

6.1.2 Rolling Stock Contractor shall be the Lead Contractor and Station Building Contractors / DDCs shall be the Participating Contractor.




6.3.1 The Station Contractor(s) and Rolling Stock Contractor shall co-ordinate interactively in order to achieve the functional and operational requirements of the system. The roles and activities of the two Contractors shall include minimum following but not limited to:

SN Subject Rolling Stock Contractor Station Contractor

1 Car Details Shall provide required details of Rolling stock including Length of train cars, height and location of doors for station design

Requires details of Rolling stock including length of train cars, height and location of doors for station design.

2 Kinematic and structural gauges

Shall provide the details of kinematic and structural gauges. Requires details of kinematic and structural gauges

3 Clearances checking

Shall co-ordinate and confirm with station contractor Shall jointly check and confirm the curves, dimensional clearances, gradients, chainages, levels and emergency escape provision

4 Testing and commissioning

Shall co-ordinate and confirm with Station contractor Shall jointly check and confirm the maximum noise / echo level with respect to various operating speeds of rolling stock

5 Integrated testing Require to conduct integrated test with all systems Shall coordinate with RS Contractor to complete testing and commissioning work

7.0 INTERFACE WITH PSD/PSG CONTRACTOR


7.1.1 This specification describes the interface requirements between Station Building Contractors / DDCs and Platform Screen Door / Gate (PSD/PSG) Contractor.

7.1.2 Station Building Contractors / DDCs shall be the Lead Contractor and PSG/PSD Contractor shall be the Participating Contractor.




7.3.1 The Station Contractor(s) and PSD/PSG Contractor shall co-ordinate interactively in order to achieve the functional and operational requirements of the system. The roles and activities of the two Contractors shall include minimum following but not limited to:

SN Subject PSG Contractor Station DDCs / Contractors

Station Civil

1 PSD/PSG Installation

The Contractor shall coordinate with the Civil Works Contractors of each station to confirm the physical arrangements and any modifications thereto prior to the finalization of PSG / PSD System design.

Provide all the required civil works details/inputs including foundations, inserts, openings and other structural works required for the erection of equipment, system and subsystems, in time for casting, to the Station Civil Contractor.

It is the Contractor's responsibility to coordinate with Civil Works Contractor of each station to have joint inspection / survey on Site to ensure that all parts of the Works are provided to the acceptable construction tolerances.

Shall construct the platform including any groove in the platform edge for installation of the PSG / PSD system

Coordinate and cooperate for joint survey / inspection with PSG / PSD Contractor

2 Layout of PSD / PSG rooms at the station

Design: Confirm floor load bearing capacity and room finishes; Furnish weight, dimensions and mounting details of PSG equipment, control panels, UPS unit and other PSG equipments. Furnish layout of PSG equipment Room. Confirm fire safety provisions. Review design with the design contractor. Co-ordinate closely with construction contractor to ensure the requirements at site are met.

Construction:

Design: Furnish location, room layout with dimensions of PSG Equipment Room in relation to the entire station and facilities layout; Furnish details of architectural finishes of the rooms; Incorporate routing of Cable Ducts Cable Trays (within false ceiling).

Incorporate routing of Cable Trays

Construction: Rooms Complete with structures, false ceiling, finishes etc.


Provide equipment foundations/ pedestals. Install all PSG / PSD equipment

Construct all false flooring

3 Provision of earthing at stations in equipment rooms

Design: Confirm and coordinate the design with Civil / E&M Contractor

Construction:

Provision of earth bus inside PSG / PSD Equipment Room from the earth bus bar

Design: Incorporate design of Main Earth including earth pits of Clean and Main Earth. Design of Main Earth (<1 ohm) including earth pits.

Construction:

Main Earth bus bar inside PSG / PSD room and its connectivity from earthmat.

4 PSL Location Shall coordinate for PSL location at platform end walls Shall provide any cut-out, if required, for PSL

Station E&M

1 Lighting, air- conditioning etc. for PSD / PSG rooms at the station

Design: Mark cable duct / cable tray on the civil / architectural/E&M drawings of the station given by the DDCs / construction contractor.

Furnish air-conditioning, ventilation, lighting and power socket requirements. Confirm fire safety provisions. Review design with the design contractor. Co-ordinate closely with construction contractor to ensure the requirements at site are met.

Construction: Install cable trays within the rooms Install all cables etc. Seal the gaps after cable installation work

Design: Furnish details of architectural finishes of the rooms; Incorporate routing of Cable Ducts / Cable Trays.

Incorporate routing of Cable

Trays Construction:

Provide lighting fixtures, Air-conditioning & ventilation and power sockets.

2 Cabling infrastructure for PSG at stations

Design: Mark cable duct/conduits/ tray requirement on the GAD/ architectural/CSD in close coordination with the civil design/E&M and/ or construction contractor.


Design Incorporate routing of Cable ducts/ hangers / trays for PSD/PSG main cables throughout the station.

Design details to be worked out in interface with PSD/PSG and other system design requirements.


Review and confirm design with the DDCs and closely coordinate with construction contractor to ensure that the requirements at site are met.

Construction:

Install cables for all PSD/PSG systems.

Install cable trays / hangers for routing PSD/PSG cables inside signal equipment rooms


Construction Provide Cable ducts / Hangers / cable trays/ raceways/ duct/ trough/ conduits/ concealed conduit /embedded conduit/ pipes(GI, HDPE, Hume)/ containments for routing PSG cables from viaduct to station area, laying throughout the station area including concourse, platform, track etc. within the station area for PSD/PSG systems upto the equipment rooms.


3 LV Power Supply in PSG / PSD room

To provide all power supply arrangement / distribution from isolator onwards including UPS, panels etc.

All central ac/dc rectification, transformation and power conditioning where required, along with any associated control panels and the like shall be provided.


Cable connection at PSD/PSG room end

Provision of twin feeders for PSD/PSG system in the emergency power panel

Laying of LV cables from emergency power panel upto the PSD/PSG room


8.0 INTERFACE WITH AUTOMATIC FARE COLLECTION (AFC) SYSTEM CONTRACTOR


8.1.1 This specification describes the interface requirements between Station Building Contractors / DDCs and AFC Contractor.

8.1.2 Station Building Contractors / DDCs shall be the Lead Contractor and AFC Contractor shall be the Participating Contractor.




8.3.1 The Station Contractor(s) and AFC Contractor shall co-ordinate interactively in order to achieve the functional and operational requirements of

the system. The roles and activities of the two Contractors shall include minimum following but not limited to:

SN Subject Station DDCs / Contractors AFC Contractor Station Civil

1 Ticket Booth (TOM) related works

Design:

Design of booth – number of windows and its location; Design details to be worked out in interface with design requirements.

Construction:

Construction of ticket booth with false ceiling and windows with glass panes,

Construction of trenches/ trough/ raceway/ tray for laying of Power and data cable,

Fare and Route display Counter as per AFC equipment design

Design:

Confirm basic booth sizes and layout;

Furnish equipment sizes and weights;

Furnish equipment mounting details;

Confirm room finishes;

Furnish requirements of cable trenches, cable routing and cable support provisions on walls and floor; holes in counter;

Confirm fire safety provisions;

Review the design from designated contractor.

Construction:

Installation of Ticketing Machines Power & Data cable for ticketing machines

2 Passenger Operated Machines / Ticket Vending Machine (TVM)

Design: Design details to be worked out in interface with design requirements of AFC Contractor

Construction:

Construction of trench / trough/ raceway/ tray for laying of power and communication cables for TVM’s to be installed presently and in future

Design: Furnish requirement of cable trenches, cable routing and cable support provisions

Installation of: TVM Power & Data cable for TVM Ensure security compliance for cards usages on the machine.

3 Passenger Operated Machines / Recharge Card Terminal

Construction of trench / trough/ raceway/ tray for laying of power and communication cables for ticket reader/ Recharge Card Terminal Machines/ Smart Card Vending Machine to be installed presently and in future

Design: Furnish requirement of cable trenches, / trough/ raceway/ tray cable routing and cable support provisions to Civil Contractor All Earthing works for recharge machines

SN Subject Station DDCs / Contractors AFC Contractor

Machines Stone cutting work shall be done by the civil / furnishing contractor.

4 Automatic Gates related works

Design: Design details to be worked out in interface with design requirements of AFC Contractor Location and number of gates to be decided in consultation with AFC contractor.

Construction

Construction of trenches / trough/ raceway/ tray for laying of Power and data / communication cables

Design: Confirm basic gate sizes and booth layout Furnish equipment sizes and weights Furnish equipment mounting details Confirm finishes Furnish requirement of cable trenches, cable routing and cable support provisions Review the design from designated contractor

Construction: Contractor shall be responsible for fencing area uncovered by Gates and shall also provide all furniture. Installation of gates and ticketing machine. Power & Data cables for Gate

Station E&M

1 TOM and AFC Gates

Incorporate design requirements of the AFC Contractor in the E&M designs

Provide: Indoor and outdoor lighting, Air-conditioning, Power points at counters on wall for light & other related works of TOM Earthing requirement for ticketing machines,

Power and Lighting arrangement for AFC Gates

Design:

Furnish requirements of cable trenches, cable routing and cable support provisions on walls and floor; holes in counter;

Furnish lighting requirements;

Confirm fire safety provisions;

Review the design from designated contractor.

Power & data point below counter for AFC

Construction:

Installation of Ticketing Machines and AFC Gates Power & Data cable for ticketing machines

5 Station Control Room related works

Design:

Design details to be worked out in interface with AFC design requirements.

Construction: Indoor and outdoor lighting, Air-conditioning, Power points for Station computer,

Design:

Confirm area / location required for installation of computer / equipments Furnish requirement of cable trenches, cable routing and cable support provisions Furnish lighting requirements Confirm fire safety provisions Review the design from designated contractor

SN Subject Station DDCs / Contractors AFC Contractor

Supply through UPS, Communication line for Station Computer, Construction:

Installation of Station Computer Power & data cables for station computer & printer.

9.0 INTERFACE WITH TRACKWORK CONTRACTOR


9.1.1 This specification describes the interface requirements between Station Building Contractors / DDCs and Trackwork Contractor.

9.1.2 Station Building Contractors / DDCs shall be the Lead Contractor and Trackwork Contractor shall be the Participating Contractor.




9.3.1 The Station Contractor(s) and Trackwork Contractor shall co-ordinate interactively in order to achieve the functional and operational requirements of the system. The roles and activities of the two Contractors shall include minimum following but not limited to:

SN Subject Station Contractor Trackwork Contractor

1 Clearance of track construction envelope

Clear and hand over the track construction envelope as per the track construction program

Ensure availability of track construction envelope

2 Storage facilities and utilization of access period for transportation of material to site.

Provide storage space and advise access period for transport of the track material at site.

Transportation of track material to site in specified space and period so that the construction activities systems / infrastructure are not hampered after access period.

3 Temporary water supplies for construction of track.

Shall coordinate Shall make his own arrangements without affecting the other contractors’ works

4 Details of Cant and horizontal and vertical clearances

Shall ensure that the Platform coping edge has the required horizontal and vertical clearances

Shall take into account these values for track installation

SN Subject Station Contractor Trackwork Contractor

(Platform levels) of platform coping with respect to track center line

with respect to the as constructed track centerline rail level.

5 Construction of track slab Provisions of vertical stirrups / shear connectors / dowels on viaduct deck in station area

Construction of slab utilizing the provisions of vertical stirrups/ shear connector / dowels

6 Details of track drainage. Design and construction of drainage system except the drains required within track.

Furnish details of levels of drainage systems.

Design and construction of drains required within track based on details of levels of drainage system provided by Station Contractor



-Appendices (Stations)

MAHA-METRO SEPTEMBER-16

APPENDIX 1 PROGRAMME REQUIREMENTS

1. GENERAL

(1) Purpose of Programme There are two primary purposes for the requirement of Programme (Scheduling)

information described in this document: a. Evaluation of Tender b. Status Reports during Construction

To provide the Engineer with status reports for managing, monitoring and coordinating the awarded contracts during their execution within the overall multi-contract project schedule.

The requirements are organized in two stages. The first stage is a requirement for all Tenderers and shall be submitted as part of Tender. The second stage is a requirement of the Employer and describes a series of reports to be submitted by the Contractor to the Engineer during the execution of the contract, following the award of Contract.

(2) The Tenderer/ Contractor shall programme his work at all times to meet the Key Dates stated in Appendix 2B to the Employer's Requirements and the specified interface periods for the design and installation of the Works with those of the Designated Contractors and shall during the progress of the Works constantly monitor his progress against the programmes described below.

(3) The Tenderer/ Contractor shall include in all programmes his work obligations towards shared access, shared Site areas and other coincident or adjacent Works Areas.

(4) The Works Programme, and all more detailed or revised versions, shall be submitted to the Engineer in hard copy as well as soft copy for his consent in accordance with the provisions of the GCC.

2. METHODOLOGY (1) The computerized Critical Path Method (CPM) network using the Precedence

Diagramming Method (PDM), has been selected by the Employer as the technique for contract management system and in co-coordinating the multi-contract project. This technique shall also be employed by the Tenderer in preparing their Tender submissions and by the Contractor in their Construction Stage submissions.

(2) Unless otherwise agreed by the Engineer, all programme submitted by the Contractor shall be produced using computerized Critical Path Method (CPM) Networks developed implementing the Precedence Diagramming Method (PDM) with Cost Loaded Charts and Tables.

(3) The Contractor shall implement and use throughout the duration of the Contract, a computerized system to plan, execute, maintain and manage the planning, design, pre-construction, construction, and sub-contracts in executing the CPM scheduling by PDM. The reports, documents & data provided shall be an accurate representation of the current status of the Works and of the work remaining to be accomplished; shall provide a sound basis for identifying problems, deviations from the planned works, and for making decisions; and shall enable timely preparation of the same for presentation to the Engineer.

3. PROGRAMME MANAGEMENT SOFTWARE (1) CPM programming software used shall be Primavera Project Planning (P3) Program -

Ver 2.0b or later. Any other compatible system capable of direct file interchange capability with software program used by the Employer - Primavera (P3), Ver 2.0b can be used with Engineer’s consent. Scheduling software and relevant instruction manuals, licensed for use in connection with the contract, shall be provided by the Contractor according to the Employer’s specifications

(2) The Tenderer may use a system other than Primavera but will be required to demonstrate that full electronic data transfer to Primavera is available and that the various levels of reporting and coding capabilities are at least equivalent to Primavera. Compatibility and comparable performance between Primavera and the Tenderer's proposed system shall be demonstrated in his Tender submission. Should compatibility not be demonstrated to the Employer's satisfaction the Contractor shall utilise Primavera for development, statusing, updating and revision of all the





Programmes during the duration of the Contract. Upon the Engineer's consent of a system other than Primavera, the Contractor shall supply the Engineer with an original licensed copy, including manuals and approved training of the software and any subsequent versions thereof at no extra cost.

4. (Not Used) 5. POST CONTRACT AWARD 5.1 The Contractor shall develop his Tender Programme into the Initial Works Programme

including an outline Narrative Statement and submit within 15 days of the date of the Notice to Proceed and its more detailed version within sixty (60) days of receiving the Engineer’s consent to the proposed Initial Works Programme.

5.2 The first Three Month Rolling Programme shall be submitted within thirty (30) days of the date of Notice to Proceed and all subsequent editions shall accompany the Monthly Progress Report. The Monthly Progress Reports shall also include a Programme Update as described below. These programmes shall subsequently be updated as described below.

5.3 Following the Contractor's Initial Works Programme submission but in any case, no later than six (6) months from the date of award of contract, the contractor shall make submissions of the detailed Works Programme suitably amended to take into account the programmes of Designated Contracts. It is the Contractor's responsibility to ensure timely co-ordination with the Designated Contractors to review, revise and finalise his Initial Work Programme so as not to affect the progress of Works/ and or the works of the Designated Contractors. The resubmitted programme when approved by the Engineer shall form the Baseline Programme against which actual progress of the Contract shall be reckoned. As the work progresses, it may be necessary to update/ revise the Baseline programme but such updating shall only be carried out with the prior consent of the Engineer or when directed by them.

5.4 For Initial & Detail Work Programme submission, one (1) original and six (6) copies each of the following Programmes and Reports shall be submitted to the Engineer: a) Programme: Baseline CPM Network b) Programme: Baseline Milestone based Cost Activity Schedule c) Baseline Schedule Report d) Narrative e) Baseline Physical Progress 'S' curve f) Baseline Resource Charts

5.4.1 The Engineer shall review and comment on the Contractor’s programmes and information submitted under this Clause. The Engineer will confirm his consent or otherwise of the submissions within thirty (30) calendar days.

5.5 The Engineer shall require the Contractor to re-submit within thirty (30) calendar days if he is of the opinion that the programmes and information submitted by the Contractor is unlikely to meet the Contract key dates.

5.6 If in the opinion of the Engineer, any of the Contractor's revised programmes or Baseline Schedule Report is not acceptable, it shall be construed as a failure of the Contractor to meet a Milestone.

5.7 Notwithstanding the above, the Engineer may at any time during the course of the Contract require the Contractor to reproduce the computer-generated Baseline Schedule Report described above to reflect actual activity dates and generate schedules based upon "what if" statements. The initial computer-generated report after receiving the Engineer’s consent will serve as the base against which the contract progress will be measured. Any changes to the Report reflected in subsequent Baseline Schedule Reports shall also require the Engineer’s consent.

5.8 Failure to include any element of work required for performance of the Contract shall not relieve the Contractor from completing all works required under the Contract to achieve the original or any extended key completion date.

6. WORKS PROGRAMME (1) The Works Programme shall show the Contractor's plan for organising and carrying out

whole of the Works. (2) The Works Programme shall be a computerised Critical Path Method (CPM) network

developed using the Precedence Diagramming Method (PDM) and shall be present in bar chart and time-scaled network diagram format to a weekly or monthly time scale.

(3) Tasks in the Works Programme shall be sufficiently detailed to describe activities and events that include, but are not limited to, the following: (a) Key Dates,





(b) All physical work to be undertaken in the performance of the Contract obligations, including Temporary Works,

(c) The requested date for issue of any drawings or information by the Engineer, (d) Incorporation of principal aspects of the Design Submission Programme, (e) Procurement of major materials and the delivery and/or partial delivery date

on-Site of principal items of Contractor's Equipment, (f) Any off-site work such as production or pre-fabrication of components, (g) Installation of temporary construction facilities, (h) Interface periods with Designated Contractors or utility undertakings, (i) Design, supply and/or construction activities of sub-contractors, (j) Any outside influence which will or may affect the Works.

(4) The Works Programme shall show achievement of all Key Dates. (5) Activity descriptions shall be unique, describing discrete elements of work. Any activity

creating an imposed time or other constraint shall be fully defined by the Contractor. (6) The Works Programme shall be organised in a logical work-breakdown-structure including

work stages and phases, and shall clearly indicate the critical path(s). Each activity in the Works Programme shall be coded to indicate: (a) Activity ID and Activity Code. (b) The Engineer may request additional activity coding to the extent available without restraint

to the Contractor’s utilisation of the programme software. When requested, the Contractor shall add the required additional coding to the Programme. The Contractor shall use additional code fields as requested to comply with the requirements and for the use of the Contractor.

(7) Activity duration shall not exceed two (2) weeks, unless otherwise consented to by the Engineer, except non-construction activities such as submittals, submittal reviews, procurement and delivery of materials or equipment and concrete curing. The Contractor shall submit a Programme/Project Calendar cross reference clearly indicating the allowance for holidays.

(8) The Works Programme, in each submission, shall be accompanied by an Activity Report and a Narrative Statement as described below in both electronic (3½" diskettes or CD-R) and hard copy format (time scale logic diagrams in A1 size, reports in A4 size).

(9) Activity Report shall list all activities, and events in the Works Programme, sorted by activity identification number.

The Activity Report shall include the following for each activity and event: (a) Activity identification number and description, (b) Duration expressed in Days, (c) early and late start, & early and late finish dates. Planned start and finish dates, (d) Calculated total float and free float, (e) Predecessor and successor(s), accompanying relationships and lead/lag duration, (f) Imposed time or date constraints, (g) Calendar.

(10) Narrative Statement The Narrative shall be a comprehensive statement of the Contractor’s plan and approach for

the execution of the Works and the achievement of key dates, handover dates, submission dates and any intermediate dates. It shall incorporate outline method statements in respect of major items of work including construction sequences and primary item of plant, Construction Equipment, Temporary Works and the like. It shall fully explain the reasons for the main logic links in the Programme and include particulars of how activity duration are established. This shall include estimated quantities, production rates, hours per shift, work days per week and a listing of the major items of Construction Equipment planned for use on the project. Activities, which may be expedited by use of overtime or additional shifts, shall be identified and explained. A listing of holidays, and other special non-work days being used for the computer reports shall be included.

(11) Baseline Physical Progress 'S' Curve The Contractor shall also submit a forecast Cumulative Physical Progress 'S' curve based on the time-phased distribution of cost in the CPM Network Logic Diagram, expressed in percentage terms. This ‘S’ curve shall be generated from the computerised CPM Network Logic Diagram.

(12) Baseline Resource Charts The Contractor shall also submit a Resource Charts, generated from the Contractor's CPM

Network Diagram, showing the anticipated manpower and main Construction Equipment usage during the execution of the Project.





As an additional monitoring facility, indicator resources shall be assigned to relevant activities for the major items of work. Indicator resources shall be directly allocated for excavation (cum.), piling (no.), pile cap(no, pier & pier cap(no), viaduct(RM), parapet wall(RM) concrete (cum) for station etc. Resource indicators may be input as a daily rate, expected required rate, or as an activity total in the relevant units. These are purely indicative quantities and do not form part of contract.

(13) All submissions of proposed Works Programmes subsequently, after approval of the Initial Works Programme, shall include the actual physical progress of work and forecast of the remaining work. Actual progress shall be stated in percent complete, remaining duration, and actual start and finish dates for each activity in the Works Programme.

7. INITIAL WORKS PROGRAMME

(1) The Initial Works Programme submitted as under Clause 5.1 need not include the full details given under Clause 6 above. It should be a condensed version with combined activities of longer. The outline Narrative Statement shall be in sufficient detail to clearly show the Contractor's intention.

(2) Within sixty (30) days of the Engineer’s consent to the Initial Works Programme, the Contractor shall submit to the Engineer an expanded and more detailed version of the Initial Works Programme containing all of the information and detail required under Clause 5 above.

(3) Such submission shall make use of the Tender Programme submitted earlier but refined to include the best estimates of dates for the work of Designated Contracts which has impact on the Contractor's programme. Such programmes shall be amended subsequently to incorporate the actual dates/ schedule of the affecting contracts. It is the Contractor's responsibility to ensure timely co-ordination with the Designated Contractors to finalise the Initial Programme, without affecting progress of the work.

8. WORKS PROGRAMME REVISIONS (1) The Contractor shall immediately notify the Engineer in writing of the need for any

changes in the Works Programme, whether due to a change of intention or of circumstances or for any other reason. Where such proposed change affects timely completion of the Works or any other Key Date the Contractor shall within fourteen (14) days of the date of notifying the Engineer submit for the Engineer's consent its proposed revised Works Programme and accompanying Narrative Statement. The proposed revised Works Programme shall show the sequence of operations of any and all works related to the change and the impact of changed work or changed conditions.

(2) If at any time the Engineer considers the actual or anticipated progress of the work reflects a significant deviation from the Works Programme, he may request the Contractor to submit a proposed revised Programme which together with an accompanying Activity Report and Narrative Statement, shall be submitted by the Contractor within fourteen (14) days after the Engineer's instruction. The proposed revised Works Programme shall show the sequence of operations of any and all work related to the change and the impact of changed work or changed conditions.

(3) All activities that have negative float must be analysed by the Contractor to identify the impact on the timely completion of the Works or on the achievement of Key Dates.

9. THREE MONTH ROLLING PROGRAMME. (1) The Three Month Rolling Programme shall be an expansion of the current Works

Programme, covering sequential periods of three months. The Three Month Rolling Programme shall provide more detail of the Contractor's plan, organisation and execution of the work within these periods. In particular, the Contractor shall expand each activity planned to occur during the next three(3) month period, if necessary to a daily level of detail.

(2) The Three Month Rolling Programme shall be developed as a Critical Path Method (CPM) network, and shall be presented in bar chart and time-scaled network diagram format. Bar charts shall be presented on an A4 and time-scaled networks diagrams on an A1 size reproducible media. Tasks in the programme shall be derivatives of and directly related to tasks in the approved Works Programme.

(3) The Contractor shall describe the discrete work elements and work element inter-





relationships necessary to complete all works and any separable parts thereof including work assigned to sub-contractors.

(4) Activity duration shall not exceed two (2) weeks unless otherwise consented to by the Engineer.

(5) Each activity in the Three Month Rolling Programme shall be coded, or described so as clearly to indicate the corresponding activity in the Works Programme

10. THREE MONTH ROLLING PROGRAMME REVISIONS AND UPDATE (1) The Three Month Rolling Programme shall be extended forward each month as

described under Clause 5(1) above. Each submission of the Three Month Rolling Programme shall be accompanied by a Programme Analysis Report, describing actual progress to date, and the forecast for activities occurring over the next three-month period.

(2) If the Three Month Rolling Programme is at variance with the Works Programme, the Programme Analysis Report shall be accompanied by a supporting Narrative Statement describing the Contractor's plan for the execution of the activities to be undertaken over the three month period, including programme assumptions and methods to be employed in achieving timely completion.

(3) The Contractor shall revise the Three Month Rolling Programme or propose revisions of the Works Programme, or both, from time to time as may be appropriate to ensure consistency between them.

11. THREE WEEK ROLLING BAR CHART SCHEDULE Once a week, on a day mutually agreed to by the Engineer and the Contractor, a meeting will be held to assess progress by the Contractor during the previous work week. The Contractor shall submit a construction schedule listing activities completed and in-progress from the previous week and the activities scheduled for the succeeding two weeks based on the detailed Works Programme. Copies of the schedule shall be submitted on A3 sized paper.

12. PROJECT CALENDAR For the Project, the Contractor shall adopt 7 days a week calendar, identical calendar for the purpose of programming and Execution of Works. Official documents shall be transacted during 5 days week - Monday through Friday, except for National (Govt. of India) Holidays. For Project purposes, a week begins at 0001 hours on a Monday and ends at 2359 hours on a Sunday. The completion of an activity or the achievement of an event when given a week number shall be taken to mean midnight on the Sunday at the end of the numbered week. An access date or activity start date when given as a week number shall be taken to mean 0001 hours on a Monday of the Numbered week.

13. PROGRAMMING PERSONNEL The Contractor shall submit, as part of its Staff Organisation Plan, the names and required information for the staff to be employed on Works Programming. The principal Works Programmer shall hold reputable professional qualifications acceptable to the Engineer including at least five (5) years relevant experience in programming civil engineering works. Others in the group shall have at least three (3) years experience in such work. The programmers shall be employed by the Contractor full time on the Contract until the completion or such earlier time the Engineer may give his consent.

14. PROGRAMME AND REPORT SUBMISSION FORMAT The Contractor shall submit one (1) original and six (6) copies and one (1) reproducible (for Programmes) of all submissions to the Engineer. All submissions shall be in AO, A1, A3 or A4 size, as appropriate except as may otherwise be agreed by the Engineer. In addition, the computerised programme and report shall be submitted in 3-1/2 inches diskettes (similarly for submissions required under Clause 5.4). The format for all Programme and Report submissions shall be strictly in accordance with the format as stated herein or as requested by the Engineer.

15. FAILURE TO SUBMIT PROGRAMME Failure of the Contractor to submit any programme, or any required revisions thereto within the time limits stated for acceptance by the Engineer, shall be sufficient reason for not making the relevant stage on account payment by the Engineer





APPENDIX- 2 MONTHLY PROGRESS REPORTS

1. GENERAL

(1) The Contractor shall submit to the Engineer, a Monthly Progress Report. This Report shall be submitted by the end of each calendar month and shall account for all work actually performed from 26th day of the last month and up to and including the twenty-fifth (25th) day of the month of the submission. It shall be submitted in a format to which the Engineer shall have given his consent and shall contain sections/sub-sections.

2. FINANCIAL STATUS (1) A narrative review of all significant financial matters, and actions proposed or taken

in respect to any outstanding matters. (2) A spread sheet summarising each activity, the budget, costs incurred during the

period, costs to date, costs to go, cost forecast (total of costs to date and costs to go) and cost variance (difference between cost forecast and budget).

(3) A spread sheet indicating the status of all payments due and made. (4) A report on of the status of any outstanding claims. The report shall in particular

provide interim updated accounts of continuing claims. 3. PHYSICAL PROGRESS

(1) It shall describe the status of work performed, significant accomplishments, including critical items and problem areas, corrective actions taken or planned and other pertinent activities, and shall, in particular, address interface issues, problems and resolutions.

(2) It shall include a simplified representation of progress measured in percentage terms compared with percentage planned as derived from the Works Programme.

4. PROGRAMME UPDATE (For Entire Project) Programme updating shall include :

(a) the monthly Programme Update which shall be prepared by recording actual activity completion dates and percentage of activities completed up to the twenty-fifth (25th ) of the month together with estimates of remaining duration and expected activity completion based on current progress. The Programme Update shall be accompanied by an Activity Report and a Narrative Statement. The Narrative Statement shall explain the basis of the Contractor’s submittal: (i) Early Work and Baseline Submittals – explains determination of

activity duration and describes the Contractor’s approach for meeting required Key Dates as specified in the Contract.

(ii) Updated Detail Programme Submittals – state in narrative the Works actually completed and reflected along Critical Path in terms of days ahead or behind allowable dates. Specific requirements of narrative are:

If the Updated Detailed Work Programme indicates an actual or potential delay to Contract Completion date or Key Dates, identify causes of delays and provide explanation of Work affected and proposed corrective action to meet Key Dates or mitigate potential delays. Identify deviation from previous month’s critical path.

Identify by activity number and description, activities in progress and activities scheduled to be completed.

Discuss Variation Order Work Items, if any. (b) the Programme Status which shall :

(i) show Works Programme status up to and including the current report period, display Cumulative progress to date and a forecast of remaining work.

(ii) be presented as a bar-chart size A3 or A4 and as a time-related logic network diagram on an A1 media, including activity listings;

(c) the Activity Variance Analysis which shall analyse activities planned to start prior to or during the report period but not started at the end of the report





period as well as activities started and/or completed in advance of the Works Programme.

5. KEY DATES STATUS A report on the status of all Key dates due to have been achieved during the month and forecasts of achievement of any missed Key dates, and those due in the next month.

6. THREE MONTH ROLLING PROGRAMME The monthly issue of the Three Month Rolling Programme. 7. PLANNING AND CO-ORDINATION

(1) A summary of all planning/co-ordination activities during the month and details of outstanding actions.

(2) A schedule of all submissions and consents/approvals obtained/outstanding. 8. PROCUREMENT REPORT

(1) A summary of all significant procurement activities during the month, including action taken to overcome problems.

(2) A report listing major items of plant and materials which will be incorporated into the Works. The items shall be segregated by type as listed in the Specifications and the report should show as a minimum the following activities: (a) purchase Order Date - Scheduled/Actual, (b) manufacturer/Supplier and Origin, (c) letter of Credit Issued date, (d) manufacturer/Supplier Ship Date - Scheduled/Actual, (e) method of Shipment, (f) arrival Date in India- Scheduled/Actual.

9. PRODUCTION AND TESTING Deleted 10. SAFETY

(1) A review of all safety aspects during the month including reports on all accidents and actions proposed to prevent further occurrence.

11 ENVIRONMENTAL (1) A review of all the environmental issues during the past month to include all

monitoring reports, mitigation measures undertaken, and activities to control environmental impacts.





APPENDIX 3 QUALITY ASSURANCE

1. General The Contractor shall implement a Project Quality Management Plan in accordance with ISO-

9001 "Quality System - Model for Quality Assurance in Design/Development, Production, Installation and Servicing" to ensure that all materials, workmanship, plant and equipment supplied and work done under the contract meets the requirements of the contract. This plan shall apply to all activities related to the quality of items, including designing, purchasing, inspecting, handling, assembling, testing, storing, and shipping of materials and equipment and different elements of construction work and installations of system components.

The Quality Plan to be prepared by the Contractor and submitted to the Engineer shall follow the requirements of ISO 9000 and address each element therein.

Registration of the Contractor's organisation, or subcontractors or sub-consultants is not required for this Project but the Project Quality Management Plan as submitted shall meet the intent of the ISO 9000 requirement in that there is a comprehensive and documented approach to achieving the project quality requirements.

2. Quality Assurance Management Plan The Project Quality Management Plan (PQMP) shall as a minimum address the quality

system elements as required by ISO 9001, generally noting the applicability to the Contractor's Works Programme for the Project. Procedures or Quality Plans to be prepared by others (Suppliers, Subcontractors, and Sub-consultants) and their incorporation in the overall PQMP shall be identified.

The Contractor shall provide and maintain a Quality Assurance Plan (QA) to regulate methods, procedures, and processes to ensure compliance with the Contract requirements. The QA Plan, including QA written procedures, shall be submitted to the Engineer for his review.

Adequate records shall be maintained in a readily retrievable manner to provide documented evidence of quality monitoring and accountability. These records shall be available to Employer at all times during the term of the Contract and during the Defects Liability Period and for a five year period thereafter.

The Plan shall identify:

Design Process: that control, check and verify the accuracy, completeness and integration of the design shall be performed by certified personnel and in accordance with documented procedure that have the written consent of the Engineer.

Special Processes: that control or verify quality shall be performed by certified personnel and in accordance with documented procedures that have the written consent of the Engineer;

Inspection and Test: Inspection and testing instructions shall provide for reporting non-conformances or questionable conditions to the Engineer; Inspection shall occur at appropriate points in the installation sequence to ensure compliance with drawings, test specifications, process specifications, and quality standards. The Engineer shall designate, if necessary, inspection hold points into installation or inspection planning procedures;

Receiving Inspection: These procedures shall be used to preclude the use of nonconforming materials and to ensure that only correct and accepted items are used and installed;

Identification and Inspection Status: a system for identifying the progressive inspection status of equipment, materials, components, subassemblies, and assemblies as to their acceptance, rejection, or non-inspection shall be maintained;

Identification and Control of Items: an item identification and traceability control shall be provided;

Handling, Storage, and Delivery: provide for adequate work, surveillance and inspection instructions.

The Plan shall ensure that conditions adverse to quality such as failures, malfunctions, deficiencies, deviations, and defects in materials and equipment shall be promptly identified and corrected. The Plan shall provide for establishing, and maintaining an effective and positive system for controlling non-conforming material including procedures for the identification, segregation,





and disposal of all non-conforming material. Dispositions for the use or repair of non-conforming materials shall require the Engineers consent.

3. Plan Implementation and Verification The Plan shall clearly define the QA Organisation. Management responsibility for the QA shall be set forth on the Contractor's policy and organisation chart. The Plan shall define the requirements for QA personnel, their skills and training. Records of personnel certifications shall be maintained and monitored by the QA personnel. These records shall be made available to the Engineer for review, upon request. The QA operations shall be subject to the Engineers, Employer or Employer's authorised representative's verification at any time, including: surveillance of the operations to determine that practices, methods and procedures of the plan are being properly applied; inspection to measure quality of items to be offered for acceptance; and audits to ensure compliance with the Contract documents. The contractor's Quality Audit Schedule shall be submitted to the Engineer for consent every three months or more frequently as required.

The results of Quality Audits shall be summarised in the Contractor's monthly reports. The Contractor shall provide all necessary access, assistance and facilities to enable the Engineer to carry out on-site and off-site surveillance of Quality Assurance Audits to verify that the quality system which has the consent of the Engineer is being implemented fully and properly.





APPENDIX 4 DRAUGHTING AND CAD STANDARDS

1. INTRODUCTION

(1) The purpose of this document is to define the minimum Draughting and CAD standard to be achieved by the Contractor for all drawings produced by the Contractor for the purpose of the Works.

(2) By defining a common format for the presentations of drawings and CAD files, the exchange of drawn information is improved and will maximise the use of CAD in the co-ordination process.

(3) All submissions shall be made to the Employer's Requirement in a format reviewed without objection by the Employer's Requirement and in accordance with the requirements in:

(a) the Contract; (b) the Document Submittal Instructions to Consultants and Contractors.

(4) Paper and drawing sizes shall be “A” series sheets as specified in BS 3429. (5) The following software latest and update version compatible for use with Intel-

Windows based computers shall be used, unless otherwise stated, for the various electronic submissions required:

Document Type Electronic Document Format Text Documents MS Word, Spread Sheets MS Excel, Data Base Files MS Access, Presentation Files MS PowerPoint, Programmes Ver2.0a Primavera for Windows, Suretrack AutoCAD Graphics CorelDraw / AutoCAD Photographic Adobe Photoshop, Desktop Publishing Page Maker CADD Drawings AutoCAD

(6) Media for Electronic File Submission One copy shall be submitted unless otherwise stated in CD-ROM.

(7) Internet File Formats/Standards (a) The following guidelines shall be followed when the Contractor uses the

Internet browser as the communication media to share information with the Employer.

(b) All the data formats or standards must be supported by Microsoft Internet Explorer version 3 or above running on Windows NT and Windows 98.

(c) The following lists the file types and the corresponding data formats to be used on Internet. The Contractor shall comply with them unless prior consent is obtained from the Employer's Requirement for a different Data format:

File Type Data Format

Photo Image Joint Photographic Experts Group (JPEG)

Image other than Photo GIF or JPEG

Computer Aid Design files (CAD) Computer Graphics Metafile (CGM)

Video Window video (.avi)

Sound Wave file (.wav)





(8) The following states the standards to be used on Internet when connecting to database(s). The Contractor shall comply with them unless prior consent is obtained from the Employer's Requirement for a different standard:

Function to be Implemented Standard to be Complied With

Database connectivity Open Database Connectivity (ODBC)

Publishing hypertext language on the World Wide Web

Hypertext Markup Language (HTML)

The hard copy of all documents shall be the contractual copy. 2. GENERAL REQUIREMENTS 2.1 General (1) The Contractor shall adopt a title block similar to that used in the Drawings for all drawings

prepared under the Contract. (2) Each drawing shall be uniquely referenced by a drawing number and shall define both the

current status and revision of the drawing. (3) The current status of each drawing shall be clearly defined by the use of a single letter

code as follows: P - Preliminary Design Drawing D - Definitive Design Drawing C - Construction Reference Drawing W - Working Drawing B - As-Built Drawing M - As Manufactured Drawing E - Employer's Drawing

2.2 Types of drawings

1) ‘Design drawings’ mean all drawings except shop drawings and as-built drawings. 2) ‘Working drawings’ are design drawings of sufficient detail to fully describe the

Works and adequate to use for construction or installation. 3) Site drawings and sketches’ are drawings, often in sketch form, prepared on site to

describe modifications of the Working drawings where site conditions warrant changes that do not invalidate the design.

4) 'Shop drawings' are special drawings prepared by the manufacturer or fabricator of various items within the Works to facilitate manufacture or fabrication.

5) ‘As-built drawings’ show the Works exactly as constructed or installed. They are usually prepared by amending the working drawings to take into account changes necessitated by site conditions and described in Site drawings. These drawings shall be completed on a regular basis as the works progress, and shall not be left until completion of the entire works.

3 COMPUTER AIDED DESIGN & DRAUGHTING (CAD) STANDARDS 3.1 Introduction Scope of Use

Data input procedures between the Engineer and contractors must be co--ordinated, and the key parameters used to form CAD data files must be standardised. The production of all CAD data files shall comply with the following requirements.

3.2 Objectives The main objectives of the CAD standards are as follows:

(a) To ensure that the CAD data files produced for Project are co-ordinated and referenced in a consistent manner.

(b) To provide the information and procedures necessary for a CAD user from one discipline or external organisation to access (and use as background reference), information from a CAD data file prepared by another discipline or external organisation.

(c) To standardise the information contained within CAD data files which may be common to more than one discipline such as drawing borders, title boxes, grid lines etc.

(d) To establish procedures necessary for the management of CAD data files. (e) To ensure all contractors use ‘Model space’ and ‘Paper space’ in the production of

their CAD files’. 3.3 General





(1) To facilitate co-ordination between contractors, it is a requirement that all drawings issued by contractors for co-ordination or record purposes shall be produced using CAD methods. Drawings shall be issued in digital format in addition to the paper copies.

(2) The intent of the issue of digital information is to aid the related design by others. The definitive version of all drawings shall always be the paper or polyester film copies which have been issued by the contractor or organisation originating the drawing.

(3) Drawings and drawing packages issued for co-ordination, record purposes or for acceptance shall be accompanied by a complete set of the corresponding CAD data files.

(4) Any contractor or organisation making use of the CAD data from others shall be responsible for satisfying himself that such data is producing an accurate representation of the information on the corresponding paper drawing which is satisfactory for the purpose for which he is using it. Provided the general principles of this section have been achieved by the originator of the CAD data, contractors making use of the CAD data from others shall not be entitled to require alterations in the manner in which such CAD data is being presented to them.

(5) In particular, automatic determination of physical dimensions from the data file shall always be verified against the figured dimensions on the paper or polyester drawings. Figured dimensions shall always be taken as correct where discrepancies occur.

3.4 Terminology & Associated Standards / Guidelines Any terminology used within this section that is ambiguous to the user shall be clarified

with the Employer's Requirement. British Standard BS1192 is used in principle as a guide for drawing practice, convention, CAD data structure and translation.

3.5 Paper Drawings (1) For the Project “Paper” drawings are considered to be the main vehicle for the

receipt and transmittal of design and production information, typically plans, elevations and sections.

(2) The Project wide accepted media for the receipt and transmittal of “Paper” drawings will be paper and polyester film of various standard ISO ‘A’ sizes. The composition of this information shall be derived from a CAD “Model”.

(3) The CAD derived “Paper” drawing composition will reflect a window of information contained within a CAD “Model Space” file together with a selection of information contained within the associated CAD “Paper Space” file.

3.6 CAD Data Creation, Content & Presentation A consistent method of CAD data creation, together with content and presentation is essential. The method of CAD “Model Space and Paper Space” creation is as follows: (1) Model Space Files

(a) Typically CAD “Model Space” files are required for general arrangement and location plans and will consist of a series of other “Model Space” referenced CAD files covering the total design extents at a defined building level (the number of referenced files should be kept to an absolute minimum). Data contained within a CAD “Model Space” files is drawn at full size (1:1) and located at the correct global position and orientation on the Project Grid / or defined reference points.

(b) Each CAD “Model Space” file will relate to an individual discipline. Drawing border / text, match / section lines or detailed notation shall NOT be included within a CAD “Model Space” file. Dimensions shall be included within a CAD “Model Space” but located on a dedicated layer. Elevations, Long Sections and Cross Sections shall also be presented in CAD “Model Space” as defined above, but do not need to be positioned and orientated on the Project Grid.

(2) Paper Space CAD Files (a) Paper Space” CAD files are utilised to aid the process of plotting “Paper”

drawings and are primarily a window of the CAD “Model Space” file. A “Paper Space” CAD file will typically contain drawing borders, text, match or section lines & detailed notation. Once these files are initially set up and positioned the majority of “Paper Drawing” plots at various approved scales are efficiently and consistently generated by displaying different combinations of element





layers and symbology contained within the “Paper Space” file and the referenced “Model Space” files.

(b) The purpose is to ensure that total co-ordination is achieved between the CAD “Model Space” file and the “Paper Drawing” output during the revision cycle of the design and production process. Duplicated data in “Model and Paper Space” files will not be acceptable unless an automatic update link exists between the two data sets. “Paper Space” files are not typically required as part of the CAD Media Receipt from contractors, unless specifically requested.

3.7 CAD Quality Control Checks (1) Random CAD Quality Control Audits will be carried out by Engineer on all CAD media

received and transmitted. (2) These checks DO NOT verify the technical content of the CAD data received or

transmitted (as this is the responsibility of the originating organisation), however compliance with Project CAD and Draughting Standards shall be checked.

(3) In addition, all contractors who transmit and receive CAD data from the Project shall have CAD quality control procedures in place. A typical quality control procedure shall contain CAD data quality checking routines coupled with standards for CAD data transmittal and archiving.

3.8 CAD Data Transfer Media and Format When CAD data is received & transmittal between Engineer and the Contractor, the media shall be as follows: (a) Data Exchange Format - Autocad Release 14 (.DWG) (b) Operating System - / Window NT 3.51 /Windows 95/98 (c) Data Transfer Media :

3.5” high density diskettes in DOS format (Maximum 10 diskettes) 12cm Compact Disc (650 MB) is highly preferred Portable SCSI harddisk (return to the Contractor upon data transfer) with software

(d) All floppy diskettes or tapes must be labelled on the data shield with: (i) Name of Company (ii) Project Title (iii) Drawing Filenames (for diskettes only) (vi) Diskette No. / Total No. of diskettes or Tape No. / Total No. of Tapes

(e) All media shall be submitted with a completed Form (CAD Disk/Tape Sheet) (f) The Contractor must ensure the supplied media is free from virus. SUB-directories

on tapes or disks are not permitted. If CAD Data is created using UNIX, archive commands must be unrooted.

3.9 CAD Media Receipt & Transmittal (1) CAD Media Transmittal (from the Contractor to Engineer) - this will consist of the

following: (a) CAD Digital Media (disk(s), CD’s or tape (s)) shall typically contain CAD “Model

Space” and “Paper Space” files. (b) CAD data sheet (c) CAD issue / revision sheet (d) CAD Quality Checklist confirming compliance. (e) Plot of each “Model Space” file issued on an A1 drawing sheet (to best fit).

(2) The above CAD media will be collectively known as “CAD Media Transmittal Set”. The CAD data file transmittal format required by Employer' Representative from all contractors shall be in AutoCAD (version 14)

(3) All CAD media received from contractors will be retained by Engineer except for SCSI disk (if used) as an audit trail / archive of a specific contractor’s design evolution.

(4) CAD Media Receipt (from Engineer to the Contractor) (a) CAD media should normally be obtained from the respective interfacing

contractor(s), but should Engineer issue CAD media it will consist of the following:

(i) CAD Digital Media (disk (s) or tape (s)) typically contain only CAD “Model Space” files.

(ii) CAD data sheet. (iii) CAD issue / revision sheet





(b) The above CAD media will be collectively known as the “CAD Media Receipt Set”. The CAD data file transmittal format used by Engineer to all contractors will be in AutoCAD (version 14)

(c) Each CAD transmittal disk / tape will be labelled with proper disk label as approved by the Engineer. Any CAD data transmitted without this label is assumed to be provisional information not to have been quality checked and therefore not formally issued.

3.10 Revisions (1) All ‘Revisions’, ‘In Abeyance’ and ‘Deletions’ shall be located on a common layer.

This layer can be turned on or off for plotting purposes. (2) The following example text indicates the current CAD file revision, i.e. ‘Revision

[A]’. This shall be allocated to a defined layer on all CAD “Model Space” files, in text of a size that will be readable when the CAD “Model Space” file is fitted to the screen, with all levels on.

3.11 Block Libraries, Blocks, & Block Names (1) All Construction Industry symbols produced as CAD Cells shall typically conform to

British Standard BS1192 - part 3. (2) All Blocks created shall be Primitive (i.e. NOT Complex) and shall be placed

Absolute (i.e. NOT Relative). (3) The Contractor's specific block libraries shall be transmitted to Engineer together

with an associated block library list containing the filename (max. 6 characters) and block description. The Contractor shall ensure that the library is regularly updated and circulated to all other users, together with the associated library listing.

(4) All Blocks of a common type, symbols or details should initially be created within a CAD “Model Space File” specifically utilised for that purpose. These files will be made available on request by Employer's Representative.

(5) All Blocks created will typically be 2D unless 3D is specifically requested. In both instances they shall have an origin at a logical point located within the extents of each Block’s masked area or volume.

3.12 CAD Dimensioning Automatic CAD Dimensioning will be used at all times. Any dimensional change must

involve the necessary revision to the model space file. If the CAD Quality Control Checks find that the revisions have not been correctly carried out, the rejection of the entire CAD submission will result.

3.13 CAD Layering All CAD elements shall be placed on the layers allocated for each different discipline. The

layer naming convention to be adopted by the Contractor shall be submitted for acceptance and inclusion within these standards.

3.14 Global origin, Location & Orientation on the Alignment Drawing. (1) Location or Plan information in “Model Space” files shall coincide with the correct

location and orientation on the Project grid for each specific contract. (2) Location plans shall have at least three setting out points shown on each CAD “Model

Space” file. Each setting out point shall be indicated by a simple cross-hair together with related Eastings and Northings co-ordintes. The Civil Contractor(s) will establish the three setting out co-ordinates for their respective works, which will then be used by all other contractors including the Contractor.

3.15 Line Thickness and Colour To assist plotting by other users, the following colour codes will be assigned to the following line thickness / pen sizes.

Colour Code No Line Thickness

Red 10 0.18

White 7 0.25

Yellow 2 0.35

Brown 34 0.5

Blue 130 0.7

Orange 30 1.0

Green 3 1.4

Grey 253 2.0

3.16 CAD Utilisation of 2D & 3D Files





Although the project standard is 2D CAD files, certain disciplines and contractors may use 3D CAD files for specific applications or where the isolated use of 3D aids the design and visualisation process (i.e. Architecture, Survey and Utilities). In these specific instances 3D CAD data will only be transmitted if all other users can use this data. If this is not the case, 3D to 2D translation shall be processed by the creator prior to issue.

3.17 CAD File Numbering (1) Contractors CAD File Numbering shall be described in 2.2 above. (2) Employer CAD File numbering unlike most of the contractors, Employer will not be

required to produce numerous CAD files. This will follow the numbering system Except that the status of the drawing in 2.1(3) shall be "E".

3.18 CAD File Naming Convention – General CAD “Model Space” files shall be named in accordance with general drawing conventions.





APPENDIX -5 WORKS AREAS & TEMPORARY POWER SUPPLY

1. INTRODUCTION (1) The Contractor shall provide within the designated principal Works Areas, at locations

agreed with the Engineer, the compounds and facilities for the Engineer and other contractors of the Employer defined under Clause 2 of this Appendix.

(2) The standard conditions applying to the use of any Works Area by the Contractor for its site facilities are given under Clause 2 of this Appendix.

(3) The Conditions for supply of electricity by the Contractor to Designated Contractors are given under Clause 3 of this Appendix.

2. STANDARD ENGINEERING CONDITIONS The following standard engineering conditions apply to all Works Areas:

(1) Formation (a) The Works Areas shall be formed to the levels that the Engineer has given his

consent. No such levels shall be amended without prior consent of the Engineer. (b) The Works Areas shall be surfaced in a manner agreed with the Engineer,

compatible with their intended use, and, in particular, footpaths and roadways connecting facilities shall be clearly defined. Measures shall be taken to the satisfaction of the Engineer to ensure all areas are properly drained and kept free of static water.

(c) The removal, diversion or reinstatement elsewhere as may be required of any existing works or installation whatsoever within the Works Areas shall be carried out to the satisfaction of the Engineer.

(2) Roads & Parking (a) Space shall be provided within the Works Areas for parking, loading/unloading and

manoeuvring of motor vehicles. (b) Any damage done to the adjoining public roads and fixtures and properties (public

or private ) shall be made good to the satisfaction of the Engineer. (3) Drainage & Sewerage

(a) All storm or rainwater from the Work Areas including any access roads thereto shall be conveyed to the nearest stream course, catch-pit, channel or storm water drain as required by the Engineer. All temporary and permanent works shall be carried out in such a manner that no damage or nuisance are caused by storm water or rain water to the adjacent property.

(b) No drain or watercourse shall be used without consent of the Engineer. (c) Damages or obstructions caused to any watercourse , drain , water- main or other

installations within or adjoining the Works Areas shall be made good to the satisfaction of the Engineer.

(d) Treatment and disposal of sewage and wastewater from the Works Area shall be provided to the satisfaction of the Engineer.

(4) Buildings (a) No permanent structures other than those required for the Permanent Works shall

be Temporary permitted on the Works Areas. (b) Electricity, water, telephone and sewerage shall be provided by the Contractor, as

required, for all temporary buildings. (c) No potable water from the Cochin Corporation shall be used for heating, cooling

and humidification purposes, or vehicle washing without the written consent of the Engineer.

(5) Pedestrian Access Every existing pedestrian access through out the Works Areas shall be maintained in a usable condition at all times to the satisfaction of the Engineer including lighting, signing and guarding.

(6) Fencing The Works Areas shall be secured against unauthorised access at all times. In particular fencing or the like shall be maintained, removed and re-erected in the new location wherever and whenever a Works Area is relinquished in stages.

3. Temporary Water & Power Supply to Designated Contractors Designated Contractors, during construction phase, shall use power & water supply provided by the Contractor. Facilities provided shall be:





(a) at the ends of each station, at concourse level, a mains water supply of 25 mm diameter complete with stopcock; and

(b) at the ends and at the mid point of each station, at both the concourse and platform levels and at agreed locations along the Viaduct (at a maximum distance of 150 m), 415V three phase / 230 V single phase power supply, suitably earthed and each with sockets capable of receiving three (3) electric plugs of the size and type used for hand-held construction equipment.

Such provisions shall be available to the Designated Contractors from the commencement of the first Installation Interfacing and Co-ordination Period until the Permanent water and power supplies are connected and commissioned within the respective stations. The Designated Contractors shall be responsible for reimbursement to the contractor of the utility charges for consumption of mains water and electricity by the Designated Contractors, supplies shall be individually metred for each Designated contractor. The Contractor shall charge the Designated Contractors for consumption of mainswater and electricity at the unit rates as billed to the Contractor by the water and electricity authorities for such utilities.

4 Applicability (1) Where the Contractor is required to provide temporary electrical supplies, or to use,

extend or expand on temporary supplies installed by others, all such activity shall be executed in accordance with Paragraphs of this Appendix.

(2) When the Contractor makes use of temporary electrical supplies provided by others he will observe and comply with the requirements of this Appendix.

5 Work on Site (1) The Contractor shall nominate a representative whose name and qualifications shall be

submitted in writing to the Engineer for review not later than 4 weeks before the appointment and who shall be solely responsible for ensuring the safety of all temporary electrical equipment on Site. The Contractor shall not install or operate any temporary Site electrical systems until this representative is appointed and has commenced duties.

(2) The name and contact telephone number of the representative having been reviewed without objection by the Engineer shall be displayed at the main distribution board for the temporary electrical supply so that he can be contacted in case of an emergency.

(3) Schematic diagrams and the details of the equipment for all temporary electrical installations shall be submitted by the Contractor, and these diagrams together with the temporary electrical equipment shall be submitted to the Engineer for his consent.

(4) All electrical installation work on Site shall be carried out in accordance with the requirements laid down in BS 7375 and the Specification. All work shall be supervised or executed by qualified and suitably categorised electricians, who are registered as such under the Electricity Ordinance 1990/Electricity (Registration) Regulations 1990.

6. Electrical General Temporary electrical Site installations and distribution systems shall be in accordance with:- (1) Indian Electricity Rules (2) The Power Companies’ Supply Rules; (3) Electricity and its subsidiary Regulations; (4) IEE Wiring Regulations (16th Edition); (5) BS 7375 Distribution of Electricity on Construction and Building Sites; (6) BS 4363 Distribution Assemblies for Electricity Supplies for Construction and

Building Sites; and (7) BS 6164 Safety in Tunnelling in the Construction Industry. (8) Any other applicable national standards

7. Materials, Appliances and Components All materials, appliances and components used within the distribution system shall comply with BS 4363 and BS 7375 Appendix A.

8. Design Considerations (1) Distribution equipment utilised within the temporary electrical distribution system shall

incorporate the following features:- (a) flexibility in application for repeated use; (b) suitability for transport and storage; (c) robust construction to resist moisture and damage; and (d) safety in use.





(2) All cabling shall be run at high level whenever possible and firmly secured to ensure they do not present a hazard or obstruction to people and equipment.

(3) The installation on Site shall allow convenient access to authorised and competent operators to work on the apparatus contained within.

9. Mains Voltage (1) The Site mains voltage shall be as per the Electricity Authority, 415V/ 3 phase 4 wire

system. (a) Single phase voltage shall be as per the Electricity Authority, 230V supply. (b) Reduced voltages shall conform to BS 7375.

(2) Types of Distribution Supply The following voltages shall be adhered to for typical applications throughout the distribution systems: (a) fixed plant - 415V/ 3 phase; (b) movable plant fed by trailing cable - 415V /3 phase; (c) installations in Site buildings - 230V /1 phase; (d) fixed flood lighting - 230V/ 1 phase; (e) portable and hand held tools - 115V /1 phase; (f) Site lighting (other than flood lighting) - 115V /1 phase; and (g) Portable hand-lamps (general use) - 115V /1 phase.

(3) When the low voltage supply is energised via the Employer's transformer, any power utilised from that source shall be either 415V 3 phase or / 230V. 1 phase as appropriate. The Contractor shall carry out any conversion that may be necessary to enable him to use power from that source.

(4) Protection of Circuits (a) Protection shall be provided for all main and sub-circuits against excess current,

under and over voltage, residual current and earth faults. The protective devices shall be capable of interrupting (without damage to any equipment or the mains or sub-circuits) any short circuit current that may occur.

(b) Discrimination between circuit breakers, circuit breakers and fuses shall be in accordance with:- (i) BS 88; (ii) BS EN 60898; and (iii) BS 7375; (iv) Any other appropriate Indian Standards.

10. Earthing (1) Earthing and bonding shall be provided for all electrical installations and equipment to

prevent the possibility of dangerous voltage rises and to ensure that faults are rapidly cleared by installed circuit protection.

(2) Earthing systems shall conform to the following standards:- (a) IEE Wiring Regulations (16th Edition); (b) BS 7430; (c) BS 7375; and (d) IEEE Standard 80 Guide for Safety in AC Substation Grounding.

11. Plugs, Socket Outlets and Couplers Low voltage plugs, sockets and couplers shall be colour coded in accordance with BS 7375,

and constructed to conform to BS EN 60309. High voltage couplers and 'T' connections shall be in accordance with BS 3905.

12. Cables (1) Cables shall be selected after full consideration of the conditions to which they will be

exposed and the duties for which they are required. Supply cables up to 3.3KV shall be in accordance with BS 6346.

(2) For supplies to mobile or transportable equipment where operation of the equipment subjects the cable to flexing, the cable shall conform to one of the following specifications appropriate to the duties imposed on it: (a) BS 6708 flexible cables for use at mines and quarries; (b) BS 6007 rubber insulated cables for electric power and lighting; and (c) BS 6500 insulated flexible cords and cables.

(3) Where low voltage cables are to be used, reference shall be made to BS 7375. The following specifications shall also be referred to particularly for underground cables:- (a) BS 6346 for armoured PVC insulated cables; and





(b) BS 6708 Flexible cables for use at mines and quarries. (4) All cables which have a voltage to earth exceeding 65 V (except for supplies from welding

transformers to welding electrodes) shall be of a type having a metal sheath and/or armour which shall be continuous and effectively earthed. In the case of flexible or trailing cables, such earthed metal sheath and/or armour shall be in addition to the earth core in the cable and shall not be used as the sole earth conductor.

(5) Armoured cables having an oversheath of polyvinyl chloride (PVC) or an oil resisting and flame retardant compound shall be used whenever there is a risk of mechanical damage occurring.

(6) For resistance to the effects of sunlight, overall non-metallic covering of cables shall be black in colour.

(7) Cables which have applied to them a voltage to earth exceeding 12 V but not normally exceeding 65 V shall be of a type insulated and sheathed with a general purpose or heat resisting elastomer.

(8) All cables which are likely to be frequently moved in normal use shall be flexible cables. Flexible cables shall be in accordance with BS 6500 and BS 7375.

13. Lighting Installation (1) Where Site inspection of the Works is required during the nights, the Lighting circuits shall

be run separate from other sub-circuits and shall be in accordance with BS 7375 and BS 4363.

(2) Voltage shall not exceed 55 V to earth except when the supply is to a fixed point and where the lighting fixture is fixed in position.

(3) Luminaries shall have a degree of protection not less than IP 54. In particularly bad environments where the luminaries are exposed to excesses of dust and water, a degree of protection to IP 65 shall be employed.

(4) The Contractor shall upgrade the lighting level to a minimum of 200 lux by localised lighting in all areas where required by the Engineer.

(5) Mechanical protection of luminaries against damage by impact shall be provided by use of wire guards or other such devices whenever risk of damage occurs.

14. Electrical Motors (1) Totally enclosed fan cooled motors to BS 4999: Part 105 shall be used. (2) Motor control and protection circuits shall be as stipulated in BS 6164. Emergency stops for

machinery shall be provided. 15. Inspection and Testing

Electrical installations on Site shall be inspected and tested in accordance with the requirements of the IEE Wiring Regulations (16th Edition).

16. Identification Identification labels of a type reviewed without objection by the Engineer shall be affixed to all electrical switches, circuit breakers and motors to specify their purpose.

17. Maintenance: (1) Strict maintenance and regular checks of control apparatus and wiring distribution systems

shall be carried out by an electrician (duly qualified to carry out the said checks) to ensure safe and efficient operation of the systems. The Contractor shall submit for review by the Engineer details of his maintenance schedule and maintenance works record.

(2) All portable electrical appliances shall be permanently numbered (scarf tag labels or similar) and a record kept of the date of issue, date of the last inspection carried out and the recommended inspection period.

18. Metering The Contractor shall install a separately metered and invoiced supply or supplies of electricity for:- (a) Site fabrication facilities; (b) Site workshops and work yards; and (c) Site offices and stores.





APPENDIX 6

METRO CORRIDOR Horizontal and Vertical Alignment

All details with regard to the Horizontal and Vertical Alignment are shown on the plan & profile sheets of the drawings provided in Tender Drawings of the tender document.





APPENDIX 7 CONTRACTOR'S SITE LABORATORY

1. SITE LABORATORY

(1) The Site Laboratory shall be approximately 250m2 in area. It shall consist of the following accommodation : 1 concrete laboratory 60m2 floor area 1 Soil laboratory 30m2 floor area 2 office each15m2 floor area 1 store room 10m2 floor area 1 kitchen 10m2 floor area male toilets, changing room & shower sufficient for 6 persons

(2) The remainder of the 250m2 shall consist of storage area for concrete cube curing tanks. The laboratory, office etc. shall be in one building; the curing tank storage building may be in a separate building, but if so it shall be adjacent to the laboratory building & connected to it by a level, weatherproof passageway. In addition, an area of covered hard standing of 50m2 for motor vehicles shall be provided adjacent to the laboratory.

2. STANDARD OF CONSTRUCTION (1) The laboratory shall be constructed to the best Engineering practice and as

approved by the Engineer. Two independent telephone lines with two extensions each shall be provided for the laboratory. Telephones shall be located in areas as agreed with the Engineer.

(2) A water tank with minimum capacity of 2000 litres shall be installed, as a source of constant water pressure (15 KPa minimum) for each laboratory.

(3) In the case of sinks used for washing samples, adequate trapping and/or separating devices shall be provided to ensure the proper functioning of the facility.

3. FURNISHINGS AND FIXTURES The contractor’s site laboratory shall be provided with required furnishings and fixtures.

4. LABORATORY EQUIPMENT (1) The laboratory equipment, as listed below, shall be approved by the Engineer. The

Contractor shall submit for the Engineer's approval within 2 weeks of the order to commence work the name of the supplier it intends to use for each piece of apparatus together with the relevant catalogue number.

(2) The layout of the equipment in the testing laboratory shall be instructed by the Engineer. The equipment shall be maintained to an accuracy appropriate to the required testing methods with routine calibration by an accredited organisation as recommended by the appropriate Authority. Equipment shall also be calibrated after maintenance or relocation.

(3) The Contractor's site laboratory shall be equipped with the following material testing equipment as a minimum. The nature and quantity of equipment required for testing may be varied by the Engineer depending on the detail of the Contractor's Design and Construction methods or for any other reason which he deems to be valid and necessary for the proper control of quality: Determining Liquid Limit (1 complete set) Liquid limit device (Casagrande type) 1 set Grooving tools 1 No. Evaporating dish 1 No. Spatula 100mm blade 1 No. Laboratory balance, capacity 500 gm, 1 No. (sensitivity 0.01 gms.) Wash bottle, capacity 500 ml. 1 No. Moisture cans, capacity 50 ml. 24 No. Determining Plastic Limit (1 complete set) Evaporating dish 1 No. Spatula 100mm blade 1 No. Glass plate 250mmx250mmx12mm 2 No. Moisture cans, capacity 50 ml. 12 No. Stainless steel rods, 3 mm dia. 2 No. Determining Moisture Content (1 complete set)





Micro Oven, capacity 35 litres, control temperature up to 200 °c 1 No. Balance, capacity 200 gm., sensitivity 0.01 gm. 1 set Lab. Tongs 1 No. Moisture cans 75ml. with lid 36 No. Compaction Characteristics (1 complete set) Standard compaction mould 100mm dia. 1 No. Modified compaction mould 150mm dia. 1 No. Standard compaction Rammer, 2.5 kg. 1 No. Modified compaction Rammer, 4.5kg. 1 No. Straight edge 300mm long 1 No. Sample ejector for 100mm and 150mm mould 1 No. Sample tray 60 x 60 x 8 cm 3 No. Wash bottle, 500 ml. 2 No. Moisture cans 250 ml. 24 No. Density of soil in-place by sand cone method (2 complete set) Sand density cone apparatus, 150mm 2 No. Plate, 300mmx300mm with centre hold 150mm 2 No. Glass jug for sand cone 2 No. Chisel 25mmx 150mm 2 No. Hammer 2 No. One-gallon field cans 24 No. Sampling spoon 2 No. Soft hair brush 2 No. Moisture cans 250 ml. 48 No. Sieve Analysis Sieve shaker (portable) 1 unit Coarse sieves In Sizes from 100mm to 10mm (1 set Fine Sieves #4,#8,#16,#30,#40,#50,#100,#200 each) Pans & Covers Specific Gravity and Absorption of Coarse Aggregate Wire basket, 200mm dia. Heavy duty suspension balance, 20 kg x 1 gm. with accessory for weight in water 1 set Suitable water container 1 No Unit Weight of Aggregate Balance, 100 kg. capacity with 10 gm precision 1 No. Tamping rod 16mm diameter x 600mm long 1 No. Measuring containers (3,10,15,30 litres) 1 each Flakiness and Elongation Flakiness gauge, elongation index 1 set Soundness Test Sodium sulphate 25 kg Soaking tank 1 No. Balance, Capacity 3 kg., Sensitivity 0.1 gm. 1 set Sieves :Coarse 1 set Fine 1 set Concrete Buckets for concrete sampling 12 No. Slump cone 12 No. Tamping rod 12 No Base plate 12 No. Mixing pan for concrete 2 No. Scoop for general purpose 2 No. Concrete thermometer 1 No. Concrete cylinder mould, 150 mm * 300 mm; 100 mm * 300 mm 10 each Concrete cube mould, 100 mm cube & 150 mm cube 10 each Adjustable spanners for dismantling cube moulds 6 No. Capping set 2 No.





Capping compound Concrete curing tank with capacity for 270 cubes, temperature controlled, with circulation system drain and lockable cover 5 No. Schmidt test hammer 1 No. Compression testing machine (simple hand operated) 1 No. Mould oil Temperature chart recorder 1No. Miscellaneous Vernier callipers to measure up to 200mm, with elongated jaws 5 No. Steel rule, 300 mm long graduated 2 No. Rubber gloves 10 pr. Cotton working gloves 20 pr. First aid kit 1 set Wire brush 6 No. Steel tape, 3m, 5m, 30m 3 each Ball peen hammer, 1 kg 2 No. Paint scraper. Approx. 100mm wide 8 No. Float, steel Approx.280 x 120 mm 8 No. Sack barrow 1 No. Shovel: Square Mouthed 2 No. Round Mouthed 2 No. 24-wheel trolley, heavy duty, approx. 0.7m x 1.0m long pneumatic tyred type 1 No. Wheelbarrow, rubber tyred 1 No. Comprehensive tool kit. To include screwdrivers, pliers, Claw hammer, multi-grips, spanners (adjustable) 1 No. Type NR Schmidt Hammer and tester with recording device 1 No. Testing Anvil for Schmidt Hammer test (SHT) 1 No. Chart recording paper for SHT 10 pkts Cover meter for detecting metal objects to depth of 100mm Below the surface of non-magnetic objects 3 No. Noise meter 1 No. RCPT Testing Machine 1No. Permeability Testing Machine 1No.





APPENDIX-8 CONTRACTOR’S LABOUR CAMP

1. EMPLOYER NOT TO PROVIDE QUARTERS FOR CONTRACTOR’S LABOUR The Employer will not provide living accommodation for the use of the Contractor or any of his staff or labour employed on the Works. Living accommodation shall not be established on any land provided to the contractor by the Employer.

2. PROVISION OF LABOUR CAMP The Contractor, shall, at his own expense, make adequate arrangements for the housing, supply of drinking water and provision of bathrooms, latrines and urinals, with adequate water supply, for his staff and workmen directly or through sub-contractors employed on the Works at the location authorised by Engineer. No labour camp shall be allowed at work site or any unauthorised place. The Contractor at his own cost shall maintain all campsites in a clean and sanitary condition. The Contractor shall obey all health and sanitary rules and regulations, and carry out at his cost all health and sanitary measures that may from time to time be prescribed by the Local/Medical Authorities and permit inspection of all health and sanitary arrangements at all times by the Employer, Engineer and the staff of the local municipality or other authorities concerned. Should the Contractor fail to provide adequate health and sanitary arrangements these shall be provided by the Employer and the cost recovered from the Contractor. The Contractor shall at his own cost, provide First Aid and Medical facilities at the Labour Camp and at work sites on the advice of the Medical Authority in relation to the strength of the Contractor’s staff and workmen, employed directly or through sub-contractors. The Contractor shall at his own cost, provide the following minimum requirements for fire precautions:

Portable Fire Extinguishers.

Manual Fire Alarms.

Water Supply for use by the Fire Service. The Contractor at his own cost shall provide necessary arrangements for keeping the camp area sufficiently lighted to avoid accidents to the workers. He should also ensure that electrical installations are done by Trained Electricians. These installations shall be maintained and daily maintenance records must be made available for inspection of the Engineer.

3. CAMP DISCIPLINE The Contractor shall take requisite precautions, and use his best endeavours to prevent any riotous or unlawful behaviour by or amongst his workmen, and others, employed directly or through sub-contractors. These precautions shall be for the preservation of the peace and protection of the inhabitants and security property in the neighbourhood of the Works. In the event of the Employer requiring the maintenance of a Special Police Force at or in the vicinity of the site, during the tenure of the work, the expenses thereof shall be borne by the Contractor and if paid by the Employer, shall be recoverable from the Contractor. The sale of alcoholic drinks or other intoxicating drugs or beverages upon the work, in any labour camp, or in any of the buildings, encampments or tenements owned or occupied by, or within the control of, the Contractor or any of his employees directly or through sub-contractors employed on the work, shall be forbidden, and the Contractor shall exercise his influence and authority to secure strict compliance with this condition. The Contractor shall also ensure that no labour or employees are permitted to work at the site in an intoxicated state or under the influence of drugs. The Contractor shall remove from his camp such labour and their families, as refuse protective inoculation and vaccination when called upon to do so by the Engineer on the advice of the Medical Authority. Should Cholera, Plague or any other infectious disease break out, the Contractor shall at his own cost burn the huts, bedding, clothes and other belongings of or used by the infected parties. The Contractor shall promptly erect new huts on healthy sites as required by the Employer, within the time specified by the Employer, failing which the work may be done by the Employer and the cost recovered from the Contractor.

4. LABOUR ACCOMMODATION The Contractor shall provide living accommodation that is equal to or exceeds the minimum

criteria established in the following sub-sections, needed to house his staff, workers





employed directly or through sub-contractors. The buildings shall be constructed so as to have a minimum life of not less than the length of the Contract.

a. The roofs shall be watertight and laid with suitable non-flammable materials permissible for residential use under local regulations and for which the consent of the Engineer has been obtained.

b. Each hut shall have suitable ventilation. All doors, windows, and ventilators shall be provided with security leaves and fasteners. Back to back units may be avoided.

c. The minimum height of each unit shall be 2.10m and shall have separate cooking place.

d. Suitable no. of common toilet/bath shall be provided. 5. WATER SUPPLY The Contractor shall provide an adequate supply of water for the use of labourers in the

Camp. The provision shall not be less than two gallons of pure and wholesome water per head per day for drinking purposes and three gallons of clean water per head per day for bathing and washing purposes. Where piped water supply is available, supply shall be at stand posts and where the supply is from wells or river, tanks which be of metal or masonry shall be provided. The Contractor shall also at his expense make arrangements for the provision and laying of water pipe lines from the existing mains wherever available and shall pay for all the fees and charges thereof.

6. DRAINAGE The Contractor shall provide efficient arrangements for draining away sullage water so as to

keep the camp neat and tidy. Surface water shall be drained away from paths and roads and shall not be allowed to accumulate into ditches or ponds where mosquitoes can breed.

7. SANITATION The Contractor shall make arrangements for conservancy and sanitation in the labour camps

according to the rules and regulations of the Local Public Health and Medical Authorities. The Contractor shall provide a sewage system that is adequate for the number of residents

in the camp, and which meets the requirements of the Municipality Authorities.





APPENDIX-9

WORK AREA

WORK AREA No land shall be made available by the employer for Casting Yard, Site Offices & Site Laboratories, Labour Camps, and Stores etc. Contractor shall make his own arrangement at his own cost