Sabarmati River Front Development Corporation Limited
1st Floor, Inside Health Development Dr. Ramanbhai Patel Bhavan, West Zone Office, AMC, Usmanpura, Ahmedabad
BID DOCUMENT
CONSTRUCTION OF FOOT OVER BRIDGE (FOB) JOINING PROMENADES
OF RIVER SABARMATI BETWEEN ELLIS BRIDGE AND SARDAR BRIDGE, ON THE SABARMATI RIVERFRONT
VOLUME- 02
IV) Technical Specifications
BID DOCUMENT
FOR
CONSTRUCTION OF FOOT OVER BRIDGE (FOB) JOINING PROMENADES OF RIVER SABARMATI BETWEEN ELLIS BRIDGE AND SARDAR BRIDGE, ON THE SABARMATI RIVERFRONT
INDEX
Section Particulars Page No.
Invitation for Bids
I Instructions to Bidders
II General Conditions of Contract
III Contract Data
IV Technical Specifications
V Form of Bid (As per Annexure – II, Section -I)
VI Bill of Quantities
VII Drawings
VII Documents to be furnished by bidder
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SECTION IV TECHNICAL SPECIFICATIONS
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Section IV: Technical Specifications Table of Clauses
A. CIVIL WORKS Preamble to Technical Standards & Specifications
1.0 Grouting of Base Plates & Bolt Holes
2.0 Additional Specifications for Pre-Cast Concrete
3.0 Additional Specifications for Pumped Concrete
4.0 Additional Specifications for Concrete M60 And Above
5.0 Form Work
6.0 Structural Steel Works
7.0 Pile Foundation
8.0 List of Approved Makes/ Likely Suppliers
B. ARCHITECTURAL FINISHING WORKS 1.0 Block Masonry -Solid, Hollow & Light Weight Concrete Blocks
2.0 Plastering and Pointing
3.0 Flooring, Skirting, Dado & Cladding
4.0 Painting
5.0 Railings
6.0 Stainless Steel Sheet Cladding
7.0 Tensile Membrane (Fabric) Roofing System
8.0 Horticulture Works
9.0 List Of Approved Make / Manufacturers
C. ELECTRICAL WORKS
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A. CIVIL WORK
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Preamble to Technical Standards & Specifications for Civil Works The Technical Specifications contained herein shall be read in conjunction with the other Bidding Documents as specified in Volume-I.
The Technical Specifications in accordance with which the entire work described hereinafter shall be constructed and completed by the Contractor shall be (The General Technical Specifications) “SPECIFICATIONS FOR ROAD AND BRIDGE WORKS” (Fifth Revision, April, 2013) issued by the Ministry of Road Transport and Highways (formerly the Ministry of Surface Transport) Government of India, and published by the Indian Roads Congress.
Where reference is made in the Contract to specific standards codes to be met by the materials, plant, and other supplies to be furnished, and work performed or tested, the provisions of the latest current edition or revision of the relevant standards as on date of tender and codes in effect shall apply, unless otherwise expressly stated in the contract. Where such standards and codes are national, or relate to a particular country or region, other internationally recognised standards which ensure a substantially equal or higher performance than the standards and codes specified will be accepted subject to the Engineer’s prior review and written approval. Difference between the standards specified and the proposed alternative standards must be fully described in writing by the Contractor and submitted to the Engineer at least 28 days prior to the date when the Contractor desires the Engineer’s approval. In the event the engineer determines that such proposed deviations do not ensure substantially equal performance, the Contractor shall comply with the standards specified in the documents.
The following Clauses have been added/modified to the ‘Specifications for Road and Bridge Works (Fifth revision, April 2013).
Grouting of Base Plates & Bolt Holes
Additional Specifications for Pre-Cast Concrete
Additional Specifications for Pumped Concrete
Additional Specifications for Concrete M60 And Above
Form Work
Structural Steel Works
Pile Foundation
In the absence of any definite provisions on any particular issue in the aforesaid Specifications, reference may be made to the latest codes and specifications of IRC, BIS, BS, ASTM, AASHTO and CAN/CSA in that order. Where even these are silent, the construction and completion of the works shall conform to sound engineering practice as approved by the Engineer and in case of any dispute arising out the interpretation of the above, the decision of the Engineer shall be final and binding on the Contractor.
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1.0 Grouting of Base Plates & Bolt Holes
1.1 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.
1.2 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.
1.3 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.
1.4 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.
1.5 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.
1.6 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.
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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.
1.7 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.
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2.0 Additional Specifications for Pre-Cast Concrete
The provision in this section shall be considered supplementary to general provisions for reinforced concrete works.
2.1 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.
2.2 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.
2.3 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 + 6 mm per 3 m length with a maximum variation of + 20 mm.
2) Cross-sectional dimensions should not vary by more than the following :
± 3 mm for sections less than 150 mm thick
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± 4 mm for sections over 150 mm & less than 450 mm
± 6 mm for sections over 450 mm to 1000 mm
± 10 mm for sections over 1000 mm
3) Deviation from straight line in long sections should not be more than + 6 mm up to 3 m, + 10 mm for 3 m to 6 m, + 12 mm for 6 m to 12 m.
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3.0 Additional Specifications for Pumped Concrete
3.1 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.
3.2 Fine aggregates
The fine aggregate to be used for the work should be of “River sand” conforming to Zone – II as per IS – 383 / clause 2.1.1. The quality and acceptance criteria should be followed as per IS – 383 / 1970 with latest correction slips. 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 not exceed 5%. The tests acceptance criteria for fine aggregates shall be same as per CPWD specifications.
3.3 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
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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.
3.4 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.
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4.0 Additional Specifications for Concrete M60 And Above
4.1 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
Granulated Slag However, the cement content excluding any mineral admixtures shall not exceed 450kg / cu.m except with the prior approval from Engineer
Also cement contents + binder should not be less than 380kg / cu.m of concrete
The water / (cement + binder) ratio should generally not exceed 0.33, but in no case more than 0.40.
4.2 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.
4.3 The temperature of concrete at the time of placement shall not exceed 300C. 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.
4.4 Use of Micro-silica / silica fume.
a. Mineral admixture in the form of micro-silica 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 micro-silica is used in powder form the contractor shall take all precautions against potential health hazards during handling of the material.
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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.
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5.0 FORM WORK
5.1 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.
5.2 Materials
Formwork shall be of steel 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 prominent 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 (centering, 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.
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.
5.3 Design and Drawings
All temporary works such as formwork, false work, staging, launching girder, cantilever form traveler scheme etc. shall be designed by the Contractor. The permissible stresses in materials of formwork, false work, staging, launching girder & cantilever form traveler 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.
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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 tolerances. 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, stiffness, wailers or any other supporting arrangement) shall not be more than 3mm.
All the formwork, launching truss and cantilever form traveler 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 of the work 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.
5.4 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:
i) Plain slab soffit, and sides of beams, girders, joists and ribs and side of walls, fins, parapets, sun-breakers, etc. shall be suitably stiffened and made with Steel plates not less than 4 mm thick of specified sizes stiffened with a suitable structural framework and fabricated true to plane.
ii) Bottoms of beams, girders and ribs, sides of columns shall be made with steel plates not less than 5 mm thick of specified sizes stiffened with a suitable structural framework, and fabricated true to plane
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iii) For Precast segments, piers, pier heads, portals etc. suitable steel form work is to be used unless otherwise specified by Engineer.
5.5 Formwork for Sloped Surfaces
i) 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.
ii) 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.
5.6 Formwork for Curved Surfaces
i) 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.
ii) 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.
5.7 Erection of Formwork
The following shall apply to all formwork:
i) 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).
ii) 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.
iii) 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
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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. iv) 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. v) 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. vi) 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. vii) 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. viii) 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. ix) 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
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the whole time that is left in place. Nothing extra shall be paid to contractor for oiling the moulds. x) 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 plumb-ness 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. xi) 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
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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-centering period. (IS:8989 Safety code for erection of concrete framed structures).
xii) 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.
xiii) 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.
5.8 Concrete Finishes
This section deals with the surface of concrete on which forms had been fixed while concreting.
i) 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.
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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:
a) Finish F1:
This type of finishes may be acceptable for the surfaces that will otherwise be permanently concealed. Surface treatment shall be the this finish applies to surfaces where roughness is not objectionable, or surface 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.
b) 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.
c) 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.
d) 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.
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ii) 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:
a) 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 leveling and screeding to produce an even uniform surface. Surface irregularities shall not exceed 10mm.
b) 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.
c) 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.
d) 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
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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 centimeter per 30cm of width. Finishes of floor and roof slabs shall be sloped, if required, by the Engineer.
5.9 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.
5.10 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 behavior 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.
5.11 Age of Concrete at Removal of Formwork
In accordance with MoRTH Specifications 2013 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.
5.12 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
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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.
5.13 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 proprietory form work is used, the number. of times they can be used will be determined by the Engineer.
5.14 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 h 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 280C.
The form liners should be shrinkage free, solvent free and should be impervious to abrasion by Concrete, resistant to concrete pressure and heat resistant up to 700 degree Celsius dry heat. Formwork liner fixation should be factory made under close tolerances and stage inspections.
5.15 Information to be Supplied by Manufacturers of Proprietary Systems of Form Work
i) General
a) 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
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of the manufacturer not having been made clear or due to wrong assumptions on the part of the user.
b) The user shall refer unusual problems of erection/assembly not in keeping with intended use of equipment, to the manufacturer of the equipment. ii) Information Required
If proprietary system of formwork is to be used, detailed information as given herein shall be furnished to Engineer for approval before use.
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 suppliers 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 and properties 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.
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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.
5.16 Measurements
Unless stated otherwise, the rate for concrete in plain concrete, reinforced concrete or in Pre-Stressed concrete shall be deemed to include the cost of all formwork/shuttering, staging, launching, their making, fixing, removal, repair for re- use etc.
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6.0 STRUCTURAL STEEL WORKS
6.1 General
Fabrication and Erection of Steelwork shall be done according to Indian Railway Standard – “Specification for Fabrication and erection of Steel girder Bridges and Locomotive Turn-Tables” – Serial No B1-2001 and IRC 24:2010.
The above specifications shall be read in conjunction with the Indian Railways codes / standards, specifications given hereafter, CPWD specifications 1996 and other relevant reference specifications described in the section 1 of these specifications. However, in case of any contradiction, Railway Standard B1 and IRC 24 shall prevail.
Contractor’s responsibilities 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 for erection or maintenance including specifically structural steel plates, shapes, 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, slings, hemp or manila ropes, winches, small tools and tackles, jacks, 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 and 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.
6.2 Drawings
i) The Engineer will supply to the Contractor profile drawings showing sizes of all structural members and typical connection details.
ii) 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.
iii) 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
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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.
iv) 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.
6.3 Material
6.3.1 Structural Steel
All structural steel shall be of tested quality and shall conform to one of the following standards:
a) IS 2062 E 410 class killed and normalized / control-cooled
b) IS 2062 E 550 class killed and normalized / control-cooled and copper bearing for high tensile steel; Grade II for welded work. Note: Plates less than 12 mm thick need not be normalized or control-cooled
c) Steel for bolts shall comply with property class 8.8 as specified in IS 1367
d) Steel for drifts shall be accordance with IS:1875 for forged quality steel or IS:7283 for hot rolled bars
e) Steel for rivet bars shall comply with the requirements of IS:1148 for hot rolled rivet bars and IS:1149 for high tensile rivet bars for general structural purposes. For high strength low alloy structural steel rivet bars with enhanced corrosion resistance for use in bridges, steel shall comply with the requirement of IRS:M-43
f) The dimensions of all rolled sections must agree with the contract drawings or as agreed to between the Purchaser and the Contractor.
g) The rolling and cutting tolerances shall be in accordance with IS: 1852 or as agreed to between the Purchaser and the Contractor if closer tolerances are desired they shall be shown in the drawing.
h) All the steel sections used in the' fabrication must have mill test certificate dearly indicating the specification to which the steel conforms and whether steel is killed and normalized. All tile cast mark numbers/ heat mark numbers,
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shall be recorded along with the number of plates in a register as soon as the plates are received in the workshop. Whenever the steel is received without any test certificate, a sample test piece from plate of each cast mark number is to be cut and sent for testing for quality. For quality only when it is established that the plates are of required specification these shall be processed for cutting. If it is required may be X-Rayed for checking.
i) Use of steel of any quality other than those mentioned above would require the prior approval of the Engineer.
Pins and Expansion Rollers
a) Pins arid Expansion Rollers shall be made from steel conforming to IS: 2004 (Class 3 steel).
b) Expansion rollers may, alternatively be turned from approved carriage and wagon axles Only, axles manufactured after 1931 shall be used for the manufacture of rollers. USFD test shall be conducted to ensure freeness from internal flaw. Test pieces shall be left as an integral part of the roller with the stamp of the supplier on it so that the Accepting Authority can cut-off the test pieces and check if required.
The following codes shall also be applicable IS: 34 Basic carbonate of lead for paints. IS: 51 Zinc chrome for paints. IS: 57 Red lead for paints and other purposes. IS: 75 Linseed oil, raw and refined. IS: 77 Linseed oil, boiled for paints. IS:102 Ready mixed paint, brushing, red lead, non-setting, priming. IS: 104 Ready mixed paint, brushing, zinc chrome priming. IS: 123 Ready mixed paint, brushing, finishing, semi-gloss, for general purposes to Indian Standard colours. IS: 209 Zinc ingot IS: 210 Grey iron casting IS: 549 Split pins IS: 808 Dimensions for hot rolled steel beam. column, channel and angle sections. IS:813 Scheme of symbols for welding IS: 814 Covered electrodes, for, manual metal-arc welding of carbon and carbon manganese steel. IS: 816 Code of practice for use of metal-arc welding for general construction in mild steel. IS: 817 Code of practice for training and testing of metal arc welders Code of Practice for safety and health requirements in electric and gas IS: 818 welding and cutting operations IS: 822 Code of procedure for inspection of welds.
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IS: 823 Code of procedure for manual metal arc welding of mild steel IS: 887 Animal tallow. IS: 958 Temporary corrosion preventive grease, soft, film cold, application. IS: 962 Code of practice for architectural and building drawings. IS: 1030 Carbon steel castings for general, engineering purposes. IS: 1148 Hot rolled steel rivet bars (upto 40mm dia) for structural purposes. IS: 1149 High tensile steel rivet bars for structural purpose. IS: 1363 Hexagon head bolts, screws and nuts of product grade C. IS: 1364 Hexagon head bolts, screws arid nuts of product grade A and B. (all parts) IS: 1367 Technical supply conditions for threaded fasteners. all parts IS: 1387 General requirements for the supply of metallurgical mateials IS: 1458 Railway bronze ingots and castings. IS: 1599 Method for bent test IS: 1673 Mild steel wire cold heading quality. IS: 1730 Steel plates, sheets, strips and flats for structural and general engineering purposes-dimensions. IS: 1745 Petroleum. hydrocarbon solvents. IS: 1852 Rolling. and cutting tolerances for hot rolled steel products. IS: 1875 Carbon steel billets, blooms, slabs and bars for forging. IS: 1929 Hot forged Steel rivets for hot closing (12 to 36 mm diameter). IS: 2002 Steel plates for pressure vessels for intermediate and high temperature service including boilers. IS: 2004 Carbon steel forging for general engineering purposes. IS: 2016 Plain washers IS: 2062 2011 – Hot Rolled Medium and High Tensile Structural Steel specification. IS: 2074 Ready mixed paint, air drying, red oxide-zinc chrome, priming IS: 2339 Aluminium paint for general purposes, in dual container IS: 2590 Primary aluminium ingots for re-melting for general engineering purposes. IS: 2638 Flat split cotters. IS: 3063 Fastners single coil rectangular section spring washers. IS: 3502 Steel chequered plates. Acceptance test for wire flux combination for submerged arc IS: 3613 welding IS: 3640 Hexagon fit bolts IS: 3658 Code of practice for liquid penetrant flaw detection Code of practice for ultrasonic pulse echo testing by contact and IS: 3664 immersion methods IS: 3696 Safety codes for scaffolds and ladders IS: 3757 High strength structural bolts Submerged arc welding of mild steel and low alloy steels – IS: 4353 recommendations IS: 4899 Ferritic and martensitic steel casting for use at low temperatures IS: 5369 General requirements for plain washers and lock washers. IS: 5334 Code of practice for magnetic particle flaw detection of welds IS: 5372 Taper washers for channels. IS: 5374 Taper washers for I beams. IS: 5666 Etch primer.
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IS: 5905 Sprayed aluminium and zinc coatings on iron and steel. IS: 6586 Recommended practice for metal spraying for protection of iron steel. IS: 6610 Heavy washers for steel structures. IS: 7215 Tolerances for fabrication of steel structures IS: 7283 Hot rolled bars for production of bright bars and machined parts for engineering applications. IS: 8629 Code of Practice for Protection of Iron and Steel structures from atmospheric corrosion IS: 9954 Pictorial surface preparation standards for painting of steel surfaces IS: 9595 Metal-arc welding of carbon and carbon manganese steels recommendations. IS: Tolerances for erection of steel structures 12843
IRS Specifications
R 19 Wheels and axles for carriages and waqons. M-3 Class I, II ,III & IV steel forgings, blooms for forgings and Billets for rerolling. M-28 Classification, testing and approval of metal-arc welding electrodes for use on Indian Railways. M-39 Classification, testing approval of sub-merged arc welding wire flux combination. M-41 Corrosion resistance steel. M-42 High strength low alloy structural steel with enhanced corrosion resistance. M-43 High strength low alloy structural steel rivet bars with enhanced corrosion resistance. T-12 Flat bottom railway rails. P-31 Zinc chromate read-oxide primer.
ROSO's Specifications
M&C/PCN/102196 Epoxy zinc phosphate primer. M&C/PCN/103l86 Epoxy micaceous iron oxide M&C/PCN/109/88 Polyurethane red oxide. M&CIPCN/110/88 Polyurethane aluminium. M&C/PCN/111188 High build Epoxy paint. 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.
6.3.2 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
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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.
6.3.3 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 / 1363 / 1364.
6.3.4 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.
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.
6.4 Workmanship and Fabrication :
6.4.1 The whole work shall be representative of the highest class of workmanship. The greatest accuracy shall be observed in the design, manufacture and erection of every part of the work to ensure that all parts will fit accurately together on erection. For manufacture of the components of all spans to be made strictly interchangeable as specified in clause 6.4.21, approved set of same jigs and assembly fixtures shall be used. The- tolerances in manufacture shall be in accordance with as shown in Cl 6.16. The Contractor shall state which of the following alternative methods of manufacture he/ she intends to adopt
i) The whole of work to be erected complete and pieces marked to .place.
ii) All spans to be made strictly interchangeable as specified hereafter
The Contractor shall maintain a master steel tape of approved make for which he/ she has obtained a certificate of accuracy from any National Test House or Government recognized institutions competent to do so. All cutting of plates including profile cutting of closed sections shall have to be carried out based on full scale shop
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layout duly approved by Engineer in charge. The shop layout has to be made based on approved fabrication drawing.
6.4.2 Templates
The templates throughout the work shall be of steel. The template shall be used for marking of cutting material and as well as profile machining for girders of railway loading. Templates shall be used for marking of drilling holes in steel structures other than girder of railway loadings. In case where actual materials from a bridge have been used as templates for drilling similar pieces the Engineer / his representative will decide whether they are fit to be used as part of the finished structure.
6.4.3 Flattening and Straightening
All steel materials, plates, bars and structural shall have straight edges flat surfaces and be free from twist. If necessary, they shall be cold straightened or flattened by pressure before being worked or assembled unless they are required to be of curvilinear form. Pressure applied for straightening or flattening shall be such as it would not injure the material and adjacent surfaces or edges shall be in close contact or at uniform distance throughout.
Flattening and straightening under hot condition shall not be carried out unless authorized and approved by the Engineer / his representative.
6.4.4 Planning and Shearing
Except where otherwise indicated, cutting of all plates and sections shall be affected by shearing or sawing, All edges shall be clean, square and true. Wherever possible the edges shall be cut in a shearing machine, which will take the whole length of the plate in one cut.
Should the inspection find it necessary, the cut edges shall be ground afterwards. Planning or machining of the edges or surface shall be carried out when so specified in the contract drawings or where specifically ordered by the Engineer. Where machining is specified, the plates or all sections shall be cut in the first instance to such a size so as to permit not less than 3mm of metal being removed from each sheared edge or end, in the case of plates or sections of 12mm or less in thickness and not less than 6mm or metal being removed in the case of plates and sections exceeding 12mm in thickness.
The butting ends of all booms and struts where spliced shall be faced in an end milling machine after members have been left completely fabricated. In the case of
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compression members the face shall be machined so that the faces are at right angle to the axis of the members and the joint when made, will be in close contact throughout. At the discretion of the Engineer / his representative, a tolerance of O.4mm may be permitted at isolated places on the butting line.
6.4.5 Flame Cutting
Flame cutting by mechanically controlled torch/torches shall be accepted both in the case of mild steel and high tensile steelwork. Provided the edge as given by the torch is reasonably clean and straight, plates may be cut to shape and beams and other sections cut to length with a gas culling torch, preferably oxyacetylene gas should be used.
All flame cut edges shall be ground to obtain reasonably clean square and true edges. Draglines produced by flame cut should be removed.
Unless machining has been specifically provided for, special care is to be taken to ensure that ends of all plates and members are reasonably in close contact and the faces are at right angles to the axis of the members and joints, when made, are also reasonably in close contact.
Use of multi-head flame cutting machine having multiple oxy acetylene torches is desirable for higher productivity and reducing the distortion due to cutting operation. Plasma arc cutting method can also be employed. This process offers less heat input causing less distortion:
6.4.6 Drilling
All, holes shall be drilled. Holes for countersunk heads of rivets, bolts or screws shall be drilled to the correct profile, so as to keep the heads flush with the surface Holes for countersunk heads of rivets, bolts or screws shall be drilled to the correct profile so as to keep the heads flush with the surface.
Holes for turned bolts, should be 1mm under drilled in shop and should be reamed at site to suit the diameter of turned bolt.
Where the number of thicknesses to be riveted exceeds three or the total thickness is 90mm or more, the rivet holes, unless they have been drilled through steel bushed jigs, shall be drilled out in place 3mm all round, after assembling. In such cases the work shall be thoroughly bolted together.
The steel bushes shall be case hardened by an approved process and checked for diameter after the heat treatment. The bores of bushes shall initially have a tolerance
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of –0.1mm, 0.1 mm. The tolerance shall be checked from time to time and when the bores exceed a tolerance of –0mm, +0.4mm, the bushes shall be rejected. For this purpose, go and no-go gauges are to be used. Tolerances for checking jigs from master plates shall be +Omm-0.13mm.
The work shall be taken apart after drilling and all burrs left by the drill and the 'harp edges of all the rivet holes completely removed.
6.4.7 Parts in Contact
All steel work intended to be rivetted or bolted together shall be in contact over the whole surface.
Drifts as shown in Fig. 2 may be used for drawing light members into position but their use on heavy members should be restricted to securing them in their correct I
positions. In no case, shall drifting be allowed to such an extent that holes are I distorted. I Drifting to enlarge unfaired holes is prohibited. The holes that will have to be I enlarged to admit rivets should be reamed provided the Engineer permits such reaming after satisfying himself about the extent of inaccuracy' and the effect of I
reaming on the soundness of the structure. The Employer / Engineer retains the right I to reject all steel work if the holes are not properly matched.
6.4.8 Making of Joints
Cleaning of permanent contact surfaces:– Surfaces which will nave permanent contact, shall be removed of paints and mill scale down to bare metal, clean and dried and immediately a coating of red lead to IS:102 shall be applied. Care shall be taken to see that all burrs are removed and no surface defects exist before the Parts are assembled.
Bolting and Drifting- Only barrel drifts as per Fig. 2 (please refer sketch at the end of this section) shall be used in erection. They may be used for drawing light members into position; but their use on heavy members shall be restricted to securing them in their correct position. Any apparent error in shop work, which prevents the assembling and fitting up of the parts by the proper use of these drifts, shall be investigated immediately, As all work, is rigidly inspected in the manufacturers wok before despatch, these difficulties should not arise and the cause should be first be sought In the use of incorrect components or the transposition of a correct part. It is usually important that parts should be correctly handled. Should error still persist, the
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matter shall be immediately reported to the Engineer who will decide what action is to be taken. No reaming shall be undertaken wlthout the written authority of the Engineer, except for the under drilled holes meant for turned bolts. If approved, the Contractor shall supply, at his/her own expense, any special rivets that maybe required. Copies of all correspondence relative to the recourse to reaming and the- use of over-size rivets shall invariably be sent by the Engineer for information to the inspectorate concerned.
Joints shall normally be made by filling not less than 50% of the holes with service bolts and barrel drifts in the ratio of four to one. The service bolts are to be fully tightened up as soon as the joint is assembled.
Special methods of erection other than described in Appendix III In cases where the joints have to withstand stresses arising from special method of erection, provision is to, be made to take the whole stress that will or may occur. Cylindrical drifts and turned bolts shall be used to withstand such stresses and no reliance is to be placed on the service bolts for this purpose. Up to maximum of 40% of the holes of each member of the joint are to be filled with drifts and balance of strength required, is to be attained with turn bolts. The position and number of the (trifts and bolts will be intimated by the Engineer. The 'condition mentioned above must be observed and the bolt fully tightened up as soon as the joint is made.
Where the manufacturing of girders has been done in accordance with clause 33 relating-to steel girder bridges, the erection shall be done in accordance with Appendix III. However, if the Contractor desires to adopt any other method of erection, tie/she shall submit the scheme and obtain the approval of the Engineer. It shall be ensured that when in position; the girder has the camber as per drawing.
Emergency Jointing:- In the event of an emergency arising such as the staging is in danger of being carried away by floods before the rivetting can be completed, the joints shall be made secure by filling 40% of the holes with cylindrical drifts and equal number with service bolts fully tightened.
6.4.9 Erection and Equipment
The Contractor shall provide at his/ her own cost all tools, machinery, equipment, temporary supports and erection materials etc. as necessary for the expeditious execution of the work and shall erect the structural steel and iron work, in every respect as covered by the contract and in accordance with the drawings and specifications,
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If any labour, material, plant staging haulage and storage facilities are to be provided by the Employer / Engineer details of such items and the conditions under which these are to be supplied shall be clearly specified, in the contract agreements. In the absence of any such provisions in the agreement, the Contractor shall make his/ her own, arrangement for such items.
Before starting the work, the Contractor shall advise the Engineer fully as to the method he/ she, proposes to follow and the amount and character of equipment he/she proposes to use, which shall be subjected to the approval of the Engineer. The approval of the Engineer shall not be considered as relieving the Contractor of the responsibility for the safety of his/her method or equipment or from carrying the work in full accordance with the drawings and specifications.
All temporary work shall be properly designed and substantially constructed for the loads, which it will be called upon to support. Adequate allowance and provision of a lateral forces and wind 'loads shall be made according to local conditions and ensure that support shall not settle during erection.
Careful and periodical inspection of plants shall be made by the Contractor to ensure that all, tackle, ropes chains and other important lifting gear and machinery are in good order and fit for service and well up to the capacity for which they are required.
When chains are used for lashing, care must be taken to protect the edges of members to avoid the marking and distortion otherwise caused.
Span erected upon staging shall be supported upon suitable blocks, which shall ensure that the girders shall be at the correct elevation and alignment when completed. If other methods of erection be adopted where staging in situ is not employed special means shall be used to ensure this.
The method used for lifting and slinging flexible members shall be brought to the notice of the Engineer and shall be Subject to his/her approval.
Temporary bracing shall be provided to take care of stresses from erection equipment or other loads carried during erection.
6.4.10 Bearings and Anchorages
Bed plates shall be set to required level and fixed accurately in position by giving full and even bearing by setting them on a layer of cement sand and cast iron chips as approved and directed by the Engineer.
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The Contractor shall drill the holes where necessary and set the anchor bolts. The bolts shall be set accurately and fixed with cement grout or any other grouting material as approved by the Engineer completely filling the holes.
6.4.11 Rivets and Rivetting
Deleted.
6.4.12 Field Rivets, Bolts, Nuts· and Service Accessories
The work is to include supply of all units, bolts, nuts, washers etc. required to complete erection at site with an allowance for wastage etc. of 12.5% of the net number of field rivets, bolts and washers required subject to a minimum number of five in each item.
The Contractor shall be responsible for supplying site rivets of approved length. The length of such rivets shall be verified by snapping a few rivets of each length in the presence of the Engineer / his representative. In the case of rivets with long grips (with grip exceeding 6 times the diameter) specimen rivets on the test piece shall be cut to see if the holes are totally filled even though the rivets are tight under the usual hammer tests.
Black hexagonal bolts (Service bolts) with nuts and ordinary platter's washers .and drifts for use in the erection of the work shall also be supplied at 60% (45% bolts and 15% drifts) of the number of field rivets per span in each size (this includes wastage). The Employer / Engineer may however, specify a reduction in the quantities of service bolts etc. if more than one span of each type is ordered.
6.4.13 Smithed Work
All joggles shall be performed by pressure, Craned sections or knees can be formed by forging or by gas cutting and, Wilding by any approved electric arc process, Any bending, forging, cutting or welding shall be carried out in such a manner as not to impair the strength in the metal. Forging shall be annealed as Indicated in the drawing.
If drop forging through dies is resorted to, excessive forging in one Operation shall be avoided. Where necessary, a series of intermediate stage dies shall be manufactured and used.
6.4.14 Welding
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Welded construction work shall be carried out generally in accordance with the provisions of Indian Railway Standard Welded Bridge Code and subject to further specifications given in the following paragraphs.
All welds should be done by submerged arc welding process either fully automatic or semi-automatic. Carbon dioxide welding or manual metal arc welding only be done only for welds of very short runs or of minor importance or where access of the locations of weld do not permit automatic or semi-automatic welding.
Except for special types of edge preparation, such as single and double ‘U’ single and double 'J' the fusion edges of all the plates which are to be joined by welding may be prepared by using mechanically controlled automatic flame cutting equipment and then ground to a smooth finish. Special edge preparation should be made by machining or gouging.
Welding procedures:- The welding procedure shall be such as to avoid distortion and minimize residual shrinkage stresses. Properly designed jigs should be used for assembly. The welding techniques and sequence, quality, size of electrodes. voltage and current required shall be as prescribed by manufacturers of the material and welding equipment. The Contractor should submit full details of welding procedure in proforma given in Cl 6.19 and 6.20.
Site welding should not be undertaken except in special circumstances with the approval of the Engineer. Site welding should be confined to connections having low stresses, secondary members, Bracings etc.
Manual metal arc welding may be done taking adequate precautions as per IS:9595 and under strict supervision.
6.4.15 Sequence of' Welding Pass
For fabrication of welded composite girders channel shear connectors shall be weld on top flange plate prior to assembly of I-section. This facilitates correction of any distortion of flange plate developed during the welding of channel shear connectors.
In making a typical I-section four fillet welds are to be made. The welding sequence to be followed is indicated by number 1 to 4 as shown in the Fig. 3.
Whenever a square butt weld in a 10 or 12mm thick plate is required to be made. the. sequence to be adopted is shown in Fig. 3.
6.4.16 Bolts, Nuts and Washers
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Bolts, Nuts and Washers shall be in accordance with the following specifications:-
Black hexagonal bolts to IS: 6639 and IS 1367, Nuts to IS: 1363. HSFG Bolts as per IS : 4000.
Precision and turned bolts with nuts and hexagonal screws to IS: 1364.
Plain washers to IS: 2016 and IS: 5369.
Spring washers - IS: 3063.
Taper washers - IS: 5372 and IS: 5374.
Manufacture, workmanship, Marking, Packing etc. for Bolts and Nuts shall comply with the requirements of IS: 1367.
Where the head and nuts bear on timber. square washers having the length of each side not less than three diameters of the bolt and the thickness not less than one quarter of the diameter, shall be provided. Steel wrought iron or malleable cast iron taper washers shall also be provided for al heads and nuts bearing on bevelled surfaces.
For black (service) bolts a clearance (difference in diameter) of 1.5mm for all sizes of bolts shall be allowed.
Where turned bolts are required they shall be carefully turned and shall be parallel, throughout the barrel. Holes for turned bolts should be 1 mm under-drilled in shop and should be reamed at site to suit the diameter of the turned bolts.
The following limits of tolerances shall be permitted upon the diameter of the shank of turned bolts arid, of the holes which they are to fit:
Limit of tolerance Shank of bolt (mm) Hole (mm)
High 0.000 +0.125
Low –0.125 0.000
The shank of each turned bolt shall be of such a length that it is in full contact with the work, throughout, the screwed portion being made at least 1.5mm less in diameter than the shank or to suit the next smaller size of screw thread. The shank portion shall be joined to the threaded portion by a 45° chamfer within the thickness of the washer. Washers with perfectly flat faces should be provided with all turned bolts.
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The washers under the nut shall have a hole of 1.5mm larger in diameter than the shank of the bolt and shall have a thickness of not less than 6mm so that the nut. When screwed up, shall not bear on the shoulder of the bolt.
6.4.17 Connecting Pins
All connecting pins shall be finished accurately to gauge and parallel throughout straight and with smooth surface entirely free from flaws and of sufficient length to ensure that, all parts connected thereby shall have a full bearing on the pin. They shall be turned to a smaller diameter at the end for the thread and driven to place with a pilot nut where necessary to preserve the thread.
6.4.18 Pin Holes
Pinholes shall be bored smooth straight and true to gauge and at right angles to the axis of the member. Boring shall only be done after the member has been rivetted up and the diameter of the pin shall not be less than that of the hole by more than 0.5mm.
6.4.19 Bearing and Expansion Gear
Deleted.
6.4.20 Erection in Contractor's Works
The work shall be temporarily erected complete at the Contractor’s work for inspection by the Engineer / his representative, with the exception of such riveting as has to be done at site, so that accuracy of fit and perfection of workmanship may be assured. The work shall be put together with sufficient numbers of parallel drifts or turned bolts or both to bring the pieces into place. When so erected all holes left to be filled at site shall be so fair that a parallel gauge turned to a diameter 0.8 mm less than that of the hole, of a length equal to the depth of the hole, can be passed through them without difficulty. No drift shall be used anywhere in the work larger in any part than the hole in which it is to be driven. Holes for turned bolts, which have been 1mm under-drilled in shop, should be reamed at site by the erecting agency.
6.4.21 Interchangeability
Every span is to be temporarily erected complete in Contractor's works adopting the method of giving camber as explained in clause 34 and all parts as marked to their place, unless the whole of the work is made completely interchangeable by the use of steel jigs and hard steel bushes controlled by master gauges, in which case the first span must be completely erected to test the accuracy of the templates. Further
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spans or part span assemblies built from parts selected at random by the Engineer / his representative shall be erected from time to time to check the accuracy of the work as the Engineer / his representative may require.
If the work is considered interchangeable by the Engineer / his representative a simplified scheme of marking will be permitted, i.e. all pieces which are identical shall bear one distinguishing mark irrespective of the span to which they belong. Should the interchangeability not to the satisfaction of the Engineer / his representative, the whole of the spans must be erected complete and an parts marked to their place without additional charge. The tenderers must state in their tenders whether they intend to adopt complete interchangeability or not.
Under special arrangement with the Employer / Engineer, it shall be permissible for approved portions of the work to be dispatched before complete erection of the first span, provided the Contractor satisfies the Engineer / his representative that Such portions of the work are strictly interchangeable and will assemble correctly and accurately in the complete structure.
6.4.22 Camber
In order to ensure that the fabrication and erection of main girders shall be such as to eliminate secondary stresses in the loaded span, the nominal length (i.e. the lengths which will give no camber) of member shall be increased or decreased by the amount shown on the camber diagram supplied by the Employer / Engineer.
For setting of the angles of intersection of the chords and web members and also for templating the gusset, full size of panels with nominal lengths of the members, shall be used. Similarly, the machining of all chords butts shall be to suit the nominal outline as defined as above.
The procedure for erecting, the span at Contractor's work shall be as specified. The site rivettinq holes shall be rivetted or bolted and drilled as specified in Appendix III.
When supported, on blocks or stagings, the girders shall be erected to the camber specified in the fabrication drawings according to which the girders have been manufactured. A camber diagram indicating the relevant height of each panel point when erected on blocks at the manufacturing works shall be supplied by the Engineer.
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The cambering of the main girders along with pre-stressing, when all panel points are supported on the blocks or staging shall be carried out in accordance with Appendix 'A' of Steel Bridge Code.
Special methods of erection, such as cantilever erection or erection by floatation, will require special erection drawings approved by the Engineer, which must not be deviated from.
In the case where the girders are erected on. yielding supports such as a 16 service span, due allowance shall be made for the anticipated yield when the camber blocks are set out.
Frequent checks shall be made of the camber of girders during erection and care taken to see that the camber as per drawing is obtained when the girder is completely assembled. When span is supported on ends and intermediate supports are removed the dead load camber shall be recorded and entered in bridge register. This will, provide the reference to compare the camber checked during technical inspection to ascertain the loss of camber.
6.4.23 Testing
The Engineer / his representative shall be empowered, at his/ her discretion to make or have made under the supervision, any of the tests specified in the specifications mentioned herein in addition to such other tests as he/she may consider necessary at any time upto the completion of the contract and to such an extent as he/ she may think necessary to determine the quality of all materials used therein. In doing so, he/ she shall be at liberty any reasonable procedure he/ she may think fit to select, identify, have cut-off and take possession of test pieces from the material either before during or after its being worked up into the finished product.
He shall also be empowered to call for a duly authenticated series of mechanical tests to be obtained from the maker for these materials used in the work and to accept the same in lieu of other tests to the extent he/she deems fit. The Contractor shall supply the material required for the test pieces and shall also prepare the test pieces necessary.
The test shall be carried out by the Contractor, for which Contractor shall provide all facilities including supply of labour and plant. Engineer / his representative may at his/ her discretion direct the Contractor to despatch such tests pieces as he/ she may require to the National test House or elsewhere as he/ she may think fit for such testing purposes.
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6.4.24 Check on Tests Made at Contractor’s Work
The Engineer / his representative may at his/ her discretion, check test results obtained at Contractor’s work by independent tests at National test House.
The Engineer / his representative shall at all times be empowered to examine and check the working of the Contractor’s plant before and after using it. Should the Contractor’s plant be found in the Engineer / his representative’s opinion, unreliable he/ she is empowered to cancel any tests already carried out in this contract and have Test House or elsewhere, as he/ she may think fit.
6.4.25 Analysis
The Contractor shall supply authenticated copies of analysis of any materials used in the contract when required to do so by the Engineer / his representative who shall be empowered to accept them to the extent he/ she thinks fit. In addition to the above samples may at the Engineer / his representative’s discretion be subjected to complete analysis at the National test House or elsewhere as the Engineer / his representative may determine the cost of the same to be borne by the Employer.
6.4.26 Inspection – General
The Engineer / his representative shall have free access to the works of the Contractor at all reasonable times and shall be at liberty to inspect the process of manufacture at any such time and to reject in whole or part, any work or material that does not conform to the provisions of this Specification and may order the same to be removed, replaced or altered at the expense of the Contractor. All gauges and templates necessary to satisfy the Engineer / his representative of the complete interchange ability of parts must be supplied by the Contractor free of cost.
6.4.27 Erection Mark
Every portion of the work shall be distinctly stencilled with paint with letter size not less than 10 mm for guidance in the erection in the field, and stamped with the letters specified in the drawings. In the case of non-interchangeable work, the system of marking shall be in accordance with the drawings prepared by the tenderer and approved by the Employer
6.4.28 Weight of Steelwork for Payment
Payment shall be made on the tendered weight to be calculated in accordance with the nominal weight of the sections as specified on the drawings & approved material list. Detail fabrication drawing showing edge preparation, welding detail & sequence
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and material list shall be prepared by the successful bidder and will be submitted for approval from employer/ Engineer prior to commencing the fabrication work.
No additional quantity shall be considered in arriving at fabricated/ erected tonnage for wastages, rolling margin error, weld deposit and bolts except for the holding down bolt for foundation
Gusset areas shall be calculated on the basis of minimum enveloping rectangle and skew cuts will be considered as containing rectangle for purposes of calculating weights.
Should the actual weight fall short of the calculated weight by more than 2.5%, the material if accepted, will be paid for the actual weight only. Should the actual weight exceed the actual calculated weight, payment will be made for calculated weight only.
In the event of a dispute arising as to the weight of a portion of steelwork, a weighment shall be made in the presence of the Inspecting Officer.
6.4.29 Rivet and Bolt Lists
The Contractor shall also supply, without charge, three complete lists of the rivets, bolts, service bolts, washers and drifts required for erecting the work at site, showing the parts of the work to which the various rivets and bolts belong and having each item marked so as to indicate the particular case in which it will be found.
6.5 Supplementary specifications for steelworks
6.5.1 For all the works, workmanship shall be of first class quality, throughout, in conformity with this specification, IRS B1-2001 and IRC 24:2010, and true to line, level and dimension as shown in the drawings or instructed by the Engineer.
6.5.2 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 neither twisted nor 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.
6.5.3 Cutting shall be done automatically. Hand flame cutting will not be permitted.
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6.5.4 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.
6.5.5 Holes for bolts shall be drilled to conform 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.
6.5.6 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 tests shall be carried out by the Contractor at his cost.
6.5.7 Safety requirements should conform to SP:70, IS : 7205, IS : 7273 and IS : 7269 as applicable and should conform to safety, economy and rapidity.
6.5.8 As much work 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.
6.5.9 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.
6.5.10 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.
6.5.11 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.
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6.5.12 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.
6.5.13 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.
6.5.14 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.
(a) Strength-quality with parent metal.
(b) Absence of defects
(c) Corrosion resistance of the weld shall not be less than that of parent material in an aggressive environment.
6.5.15 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.
6.6 Testing of Welds
6.6.1 Butt welds - Radiographic testing of 50% of welds as per IS 1182. + 20% weld through ultrasonic testing
6.6.2 Fillet welds - Ultrasonic testing of 10% of welds.
6.6.3 All welded connections shall be inspected as per IS:822
6.6.4 All welds shall be tested by "Dye penetration test".
6.6.5 Agency for testing of weld shall be approved by the Engineer prior to testing.
6.6.6 Defective 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.
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6.6.7 No extra payment shall be made for the tests indicated above.
6.7 Welders Qualification Criteria
6.7.1 All welders shall be tested generally as per IS 7310 (Part I) for all positions.
6.7.2 The positions for which welders shall be tested as follow,
6.7.2.1 Flat position
6.7.2.2 Horizontal Position
6.7.2.3 Vertical upward position
6.7.2.4 Vertical downward position
6.7.2.5 Overhead position
6.7.2.6 For Pipes
6.7.2.6.1 Welding longitudinal vertical with pipe position having axis horizontal,
6.7.2.6.2 Vertical upwards with pipe axis horizontal.
6.7.2.6.3 Horizontal upwards with pipe axis vertical.
6.7.2.6.4 Butt Welding of pipes
6.7.2.6.5 Branch connection of pipes
6.7.3 The destructive and non destructive testing shall be carried out as per table 1 and clause 8.2.1 of IS 7310(Part 1). However all test specimen shall be tested with 100% radiography in case of butt weld. The acceptance criteria shall be as per table 2 of IS 7310(Part 1).
6.7.4 The approval of welder shall be recorded as per Appendix A of IS 7310 (Part 1).
6.8 Protection of Steel Works (IS : 8629):
6.8.1 Removal of oil & grease from the metal surface by using petroleum hydrocarbon solvent to IS: 1745
6.8.2 Prepare the surface by Sand or grit blasting to SA 2.5 where specified shall be carried out in accordance with IS: 9954.
6.8.3 All exposed surfaces of members shall be painted with two coats of epoxy zinc phosphate primer of DFT 60 at shop and one intermediate coat of epoxy Micaceous Iron Oxide paint of DFT 100 and two finish coat of polyurethane aluminium of DFT 40 each.
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6.8.4 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.
6.8.5 The steel work, prior to delivery, shall be cleaned form scale, rust, dirt and oil / 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.
6.8.6 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.
6.8.7 The spraying equipment shall be compatible with the paint material, fitted with necessary gauges and controls and approved by the Engineer.
6.8.8 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.
6.8.9 The workmen 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.
6.8.10 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.
6.8.11 In addition, the following specification shall apply to the shop painting of contact and inaccessible surfaces:
6.8.11.1 Surfaces to be painted shall be thoroughly cleaned from scale, rust, dirt, grease etc. by the methods mentioned above.
6.8.11.2 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
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other defects which would prevent the solid seating of the parts and would interfere with the development of friction between them.
6.8.11.3 All inaccessible enclosed surfaces of members shall be completely sealed by applying two coats of epoxy zinc phosphate primer of DFT 60 and one coat of epoxy Micaceous Iron Oxide paint of DFT 100 and all such members and tubes shall have their ends closed by suitable plates welded in position.
6.8.12 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.
6.8.13 Surfaces to be in contact with concrete shall not be painted.
6.9 Erection & Site Work
6.9.1 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.
6.9.2 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.
6.9.3 Immediately prior to erection any rust in the paint area shall be removed by power wire brushing to a standard equivalent to SA3.
6.9.4 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.
6.9.5 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.
6.9.6 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
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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.
6.9.7 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.
6.9.8 The Contractor is entirely responsible for the safety and 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, riveting or welding is completed. The Contractor shall supply and fix, without extra charge, any temporary bracing which may be necessary.
6.9.9 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.
6.9.10 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.
6.9.11 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 50 mm 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.
6.9.12 Only workmen experienced and skilled in steel erection shall be employed for the work. The safety of the workmen as well as that of the structure is Contractor’s prime responsibility.
6.10 Rectification of damaged materials
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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.
6.11 Inspection
6.11.1 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 such tests shall be borne by the contractor.
6.11.2 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.
6.11.3 During Inspection, the component/member shall not have any load or external restraint.
6.12 Grouting of steel bases
6.12.1 Before grouting of stanchion bases, the contractor shall take the following action:
i) Inform the Engineer.
ii) Clean all holes, openings, recesses and the top of foundations of all dirt, mud, water, oil or other extraneous matter.
iii) A frame shall be placed in position around the base plate with a provision for placing or injecting grout.
iv) The contractor shall provide screed bars or mild steel flats and fix them in mortar.
v) Holes shall be provided on the stanchion bases for escape of air.
6.12.2 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 levelled and approval of the Engineer obtained.
6.12.3 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
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holes. "Non-shrink" cements, additives of approved makes shall be used for all grouting operations.
6.12.4 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:
i) Mixed as a stiff mortar well rammed into place from all sides.
ii) Mixed as thickly as possible consistent with fluidity and poured under a suitable head and tamped until the space has been properly filled.
6.13 Holding down and Anchor bolts
6.13.1 The holding down and anchor bolts should conform to the requirements laid down in IS: 5624 or as directed by the Engineer.
6.13.2 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.
6.13.3 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.
6.13.4 Grouting of bolt tubes shall be carried out after the steelwork or equipment have been aligned, plumbed and levelled.
6.14 Tolerances
6.14.1 All tolerances shall be in accordance with IS: 7215 unless otherwise specified.
6.14.2 The maximum deviation for line and level shall be + 3.0mm for any part of the structure including for location of column centres.
6.14.3 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.
6.14.4 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.
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6.15 Records to be Maintained
6.15.1 Jigs register
This register shall be maintained for keeping record of details of jigs, their approval and modification/rectification to the jigs. One page should be allotted for each jig and details mentioned in the following proforma:-
1. Description of jig:
2. Jig No.:
3. Shipping mark of the component for which jig is made:
4. Drawing No. for the component:
Date of Observation/inspection Compliance action Initial of Supervisor inspection notes Incharge 1 2 3 4
In the beginning of Register, a statement of jigs shall also be placed in the following proforma:
Jig No. Description of Shipping mark Drg.No. as per Inspecting Jig. of the which jig is official‟s component made/modified approval details 1 2 3 4 5
6.15.2 Rivet checking register
This register shall be maintained for keeping record of rivet quality checking and replacement of defective rivets. Register shall be maintained in the following proforma.
Component Date of Rivetting Number and Number of Number of description rivetting party nature of defective defective defective rivets rivets rivets replaced replaced
1 2 3 4 5 6
After rivetting, component has been inspected and defective rivets have been replaced, the Supervisor Incharge of rivetting should put a stencil mark on the component to this effect.
6.15.3 Material offering and inspection register
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This register shall be maintained separately for each work order for keeping record of material offered for inspection, inspection remarks and passing details. One page should be allotted for individual members or fittings. Proforma shall be as under:-
1. Description of component/fitting:
2. Shipping mark:
3. Quantity required per span:
Span No. Initial of Inspecting Compliance Seal & initial Despatch & Supervisor officials action of Inspecting consignee offering Remarks official details material for inspection.
1 2 3 4 5 6
6.15.4 RDSO inspection notes and compliance register
This register shall be maintained for record of compliance action taken on RDSO Inspection notes. In this register one copy of the inspection note received from RDSO shall be pasted and compliance action recorded against each item.
6.15.5 Welding procedure data register
In this register complete details of welding of welded girders shall be maintained in the proforma as under:
Name of work:______
Contract/Work Order No. ______
Span No.______
Date of welding Girder Weld joint Name of WPSS No. component and description welder/Ticket No followed its Sl.No.
1 2 3 4 5
Welding Welding parameters Weld Run Radiogra Initial of consumable used repair on/Run ph no. if Supervi- details off any sor tabs. Incharge No. if any
Electrode Flux Current Arc Travel 11 12 13 14
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/ wire (amp.) Voltag Speed e (volt) (m/min )
6 7 8 9 10
The welding data record to be submitted to RDSO while offering the welded girders for inspection, shall be prepared based on the details recorded in this register.
6.15.6 Radiographic inspection register
Record of radiographic inspection of welded girders shall be maintained in the register in the proforma given below:
Name Span Girder Weld joint Date of Radio- Obser- Result Initial of of No. Part description radiographic graph vation Supervisor work inspection No. Incharge 1 2 3 4 5 6 7 8 9 6.15.7 Statement of material test certificates
Name of Work______Contract/Order No..______Span No..______
Girder Type and Material Cast No. Steel Steel Initial of Component Size of Test quantity as Manufacturer/ Super- description rolled Certificate per the Supplier visor and section No. test Incharge. identification certificate No.
1 2 3 4 5 6 7 One page should be allotted for each span.
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6.16 Manufacturing Tolerances
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6.17 Erection of Open Web Girder Span
6.17.1 The joints of the chords shall be drifted, bolted and preferably rivetted to their geometric outline.
6.17.2 All other members are to be elastically strained into position by external forces, so that as many holes as possible are fair when filled with rivets.
6.17.3 Drifting of joints shall be avoided as far as possible, and when necessary should be done with greater care and under close expert supervision. Hammers not exceeding 1 kg.(2 lb) in weight should be used with turned barrel drifts and a number of holes drifted simultaneously, the effect of the drifting being checked by observation of adjacent unfilled holes.
6.17.4 The first procedure during erection consists of placing camber jacks in position on which to support the structure. The camber jacks should be set with their top level and with sufficient run-out to allow for lowering of panel points except the centre by the necessary amount to produce the required camber in the main girders. It is essential that the camber is accurately maintained throughout the process of erection and it should be constantly checked. The jacks shall be spaced so that they will support the ends of the main girders and the panel points. The bottom chord members shall then be placed on the camber jacks carefully levelled and checked for straightness and the joints made and rivetted up.
6.17.5 The vertical and diagonal web members, except the end posts, shall then be erected in their proper position on the bottom chords. Temporary top gussets, the positions of the holes in which they are corrected, for the camber change of length in the members, should be used to connect the top ends of the members. This will ensure that the angles between the members at the bottom joints are as given by the nominal outline of the girders. The verticals and diagonals shall then be rivetted to the lower chords.
6.17.6 All panel points, except the centre, shall now be lowered by the amount to produce the correct camber in the main girders as shown on the camber diagram.
6.17.7 The top chord shall be erected piece by piece working symmetrically starting from the centre outwards, each piece being cambered in turn
6.17.8 The temporary top gussets, if used, shall be replaced by the permanent gussets in the same sequence as the erection of the top boom members.
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6.17.9 The end posts shall be erected last. The upper end connection should preferably be made first and if there is no splice in the end raker, the final closure made at the bottom end connection. If there is a splice, the final closure should be made at the splice.
6.17.10 When cantilever method of erection is used, the above procedure does not apply.
6.18 Permissible deviations for driven rivets
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6.19 Proforma for Welding Procedure Specification Sheet
Name and address of Fabricator: Welding procedure specification No
1. Weld joint description: 2. Base Metal : 3. Welding Process : 4. Welding position : 5. Welding consumables : 5.1 Electrode/wire Class : Dia : Drying method:
5.2 Flux Class : Type: Drying method: 5.3 Shielding gas: 6.0 Base Metal preparation: 6.1 Joint design details: (Give sketch showing arrangement of parts, welding groove details, weld passes & their sequence etc.) 6.2 Joint preparation: 7. Welding current: Type: Polarity: 8. Welder qualification: 9 Welding parameters and technique: 9.1 Welding Parameters: Weld Electrodes/ Current Arc Wire Travel Electrical Gas flow Pass wire (amp) Voltage feed speed stickout rate No. dia.(mm) (volt) speed (m/min) (mm) (litre/min.) (m/min)) 1 2 3 4 5 6 7 8
9.2 Welding sequence and technique: (Give sketch showing sequence and direction of welding). 10. Provision of run in and run-off tabs: 11. Cleaning of weld bead before laying next weld bead: 12. Root preparation before welding other side of groove weld: 13 Preheating and inter pass temperature: 14 Peening 15 Post weld treatment: 16 Rectification of weld defects: 17 Inspection of weld. 18. Any other relevant details
Prepared by Signature______Designation ______Date ______(for & on behalf of Fabricator).
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6.20 Proforma for Welding Procedure Qualification Record
NAME AND ADDRESS OF FABRICATOR
1. Description of weld joint: 2. Welding procedure specification no.: 3. Name of welder: 4. Date of preparation of test piece: 5. Dimensions of test piece: 6. Base Metal: 7. Welding Process: 8. Welding position: 9. Welding Current: Type: Polarity:
10 Weld joint design details: 11 Welding consumables: 11.1 Electrode/wire Class: Dia: Brand:
11.2 Flux Class: Type: Brand:
11.3 Shielding gas: 12. Welding parameters:
Weld Electrode Current Arc Wire feed Travel Electrical Shielding pass wire dia (amp) voltage speed speed stick out gas flow No. (mm) (volt) (m/min.) (m/min.) (mm) rate (lit/min.) 1 2 3 4 5 6 7 8
13. Preheating and interpass temperature: 14. Results of Qualification Tests:
Test Specimen No. Result 1 2 3 Non-destructive tests: i) Visual examination: ii) Dye penetrant test: iii) Magnetic particle test: iv) Radiographic/Ultrasonic test:
Destructive tests: i) Macro-examination: ii) Hardness survey: iii)Fillet weld fracture test: iv) Transverse tensile test:
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Tensile strength Yield Stress Location of fracture v) All-weld tensile test: Tensile strength Yield Stress Elongation % vi) Guided bend test: Root bend test Face bend test Side bend test vii) Any other tests Any other tests:
Signature ______
Designation ______
Date ______
(for & on behalf of Fabricator).
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7.0 PILE FOUNDATION
7.1 DESCRIPTION
This work shall consist of construction of all cast in situ piles for structures in accordance with the details shown on the drawings and conforming to the requirements of these specifications or as directed by the Engineer.
The work shall be carried out as per IS: 2911 except as modified herein. Piles shall be bored cast in situ piles. The piling shall be done by hydraulically operated rotary drilling machine only.
7.2 SUBSURFACE INVESTIGATION
The complete subsurface investigations of strata in which pile foundations are proposed shall be carried out in advance along with in-situ pile tests. For details of geo technical subsurface explorations, refer Section 2400 of MORTH Specifications and the tender conditions
Boring should be carried up to sufficient depths so as to ascertain the nature of strata around the pile shaft and below the pile tip. Depth of boring shall not be less than 1.5 times estimated length of pile in soil or 15m below the proposed founding level.
7.3 MATERIALS
The basic material shall conform to MORTH and tender Specifications..
7.3.1 Concrete in Piles.
For cast in – situ piles, the grade of concrete, minimum cement content, water cement ration and slump at the time of placement shall be as per Table below:.
Cast in –situ concrete by Tremie Grade of concrete M 35 Minimum cement content 400 kg/m3 Minimum water cement ratio 0.4 Slump (mm) as measured at the time 150-200 Of placement. The terms minimum cement content and minimum water cement ratio mentioned Table 1100-1, are to be based on total cementitious material (inclusive of all mineral admixtures called additives) mentioned in Clause 1007 of MORTH Specifications. Maximum limits for such additives shall be as specified in Clause 1716.2 of these Specifications.
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High alumina cements (i.e. quick setting cement) shall not be used in marine condition. When both chlorides and sulphates are present, in soil or ground water. Sulphate resistant cement shall not be used. For improving resistance against the presentation of chlorides and sulphates from surroundings soil or water , mineral admixtures such as fly ash , silica fumes, GGBS conforming to respective BIS / International standards and as per IRC:112, may be used.
7.4 TEST PILES
Test piles which are shown on the drawings or specified in the contract or installed by the Contractor on his own to determine the lengths of piles to be furnished, shall conform to the requirements for piling as indicated in these Specifications. Test Piles which are used to arrive at the load carrying shall not be incorporated in the structure.
All test shall be installed with the same type of equipment that is proposed to be used for pilling in the actual structure.
Test piles which are not to be incorporated in the competed structure shall be removed to at least 600 mm below the proposed soffit level of pile cap and the remaining hole so formed shall be backfilled with earth or other suitable material.
The piles shall be load tested in accordance with provisions laid down in this Section.
7.5 CAST IN SITU CONCRETE PILES
7.5.1 General
Any liner or borehole which is improperly located or shows partial collapses that would affect the load carrying capacity or the pile, shall be rejected or repaired ad directed by Engineer at the cost of the Contractor.
Boring shall be carried out using rotary equipment. Percussion type of equipment shall be used only if approved by Engineer.
The diameter of the finished piles shall be not less than that specified. A continuous record shall be kept by the Engineer as to the volume of concrete placed in relation to the length of pile that is cast.
Defective piles shall be removed or left in place as judged convenient without affecting the performance or adjacent piles or pile cap. Additional piles shall be provide to replace the defective piles..
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7.5.2 Concreting
Wherever practice, concrete should be placed in a clean dry hole. Prior to the placing of the reinforcement cage, the pile shaft be cleaned of all loose materials. Before concreting of the pile is commenced, it is essential to ensure that no debris remains at the bottom of the shaft, as inadequate cleaning of the base can lead to formation of a soft base or soft toe which may result in reduction cleaning of the base can lead to formation of a soft base of soft tow which may result in reduction of load bearing capacity of the pile.
Reinforcement for the pile as shown on the drawings shall be tied in place to form a cage which is lowered into the pile shaft. Suitable spacers shall be provide to maintain the required cover to reinforcement steel. Reinforcements at the bottom should not be provided with L-bends as these may interfere with cleaning of the pile base.
Where concrete is placed in dry and a casing is present, the top 3 m of the pile shall be compacted using internal vibrators.
Where the casing is withdrawn from cohesive solid for the formation of cast in-situ pile, the concreting should be done with necessary precautions to minimize the softening of the soil by excess water. Where mud flow conditions exist, the casting in- situ piles shall not be allowed to be withdrawn.
Care shall be taken during concreting to prevent the segregation of the ingredients. The displacement or distortion of reinforcement during concreting and while extracting the casting, shall also be avoided.
If the concrete if placed inside precast concrete tubes or consists or precast sections, these shall be form cracks or other damage before being installed.
The concrete shall be properly graded, shall be self- compacting and shall not get mixed with soil excess water, or other extraneous matter. Special care shall be taken in silty clays and other soil which have the tendency to squeeze into the newly deposited concrete and cause necking. Sufficient head of green concrete shall be maintained to prevent inflow of soil or water into the concrete.
The placing of concrete shall be a continuous process from the toe level to the top of the pile. TO ensure compaction by hydraulic static heads , rate of placing concrete in the piles shafts shall not be less than 6 m (length of pile) per hour
7.5.3 Casing
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When concreting is carried out for a pile , a temporary casing should be installed to sufficient depth so as to ensure that fragments of soil from the sided of the hole do not drop into the concrete as it placed. When the bore hole is stabilized using drilling mud, the temporary casing is not required except near the top.
The metal casing shall be of sufficient thickness and strength to hold its original form and show no harmful distortion while driving or when adjacent casing are driven.
Cast in-situ concrete driven piles shall be installed using a properly designed detachable shoe at the bottom of the casing.
Bored cast in- situ piles in soils which are stable, may often be installed with only a small casing length at the top. A minimum of 2 m length of top of bores shall invariable be provided with casing to ensure against loose soil falling into the bore. In cases in which the soil can fall into the hole, it is necessary to stabilize the side of the bore hole with drilling mud, or a suitable steel casing . Permanent steel liner shall be provided at lease upto maximum scour level. The minimum thickness of steel liner shall be 6mm.
Permanent steel liner shall be provided for the full depth of pile in the followings situations where:
The surrounding soil is marine caly3
Soft soil is present
Surrounding soil has sulphate content equal to or more than 1%.
Surrounding water has sulphate content equal to or more than 2500 ppm.
Leakage of sewage is expected
For bored cast in situ piles, casing/liner shall be driven open ended with a pile driving hammer capable of achieving the penetration of the liner to the depth shown in the drawing or as approved by the engineer. materials inside casing shall be removed progressively by airlift, grab, or other approved means.
Where soils liable to flow, the bottom of casing shall be kept sufficiently in advance of the boring tool to prevent the entry of soils in to the casing leading to formation of cavities and settlements in the adjoining ground. The water level inside the casing shall be maintained at the natural Ground Level. The joints of casing shall be made leak proof as possible to minimize the inflow of water or leakage of slurry during concreting.
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The diameter of the boreholes shall not be more than the inside diameter of the liner when the liners are installed before boring. When the liners are installed after boring, the diameter of bore shall not be more that the outer diameter of liner + 2mm unless otherwise approved by the Engineer.
7.5.4 Use of tremie
The concrete should invariable be poured through a tremie with funnel, so that concrete can be properly deposited in the hole without segregation . For concreting done by tremie, the following requirements which are particularly applicable shall be ensured.
The hopper and tremie should be leak proof system.
Diameter to tremie shall be not less than 200 mm for used with 20 mm diameter down aggregate, 3
The first charge of concrete should be placed with a sliding plug pushed down the tube ahead of it or with a steel plate with adequate charge to prevent mixing of concrete and water. However, the plug should not be left in concrete as a lump.
The tremie pipe should always penetrate well into the concrete with an adequate margin of safety against accidental withdrawl of the pipe. The tremie should be always full of concrete.
The pile should be concrete wholly be tremie and the method of deposition should not be changed part way up the pile, to prevent laitance from being entrapped within the pile.
All tremie tubes shall be thoroughly cleaned after use.
For concrete placed through tremie, there is no need to add 10 percent extra cement.
Concreting of piles shall be carried our continuously. In exceptional cases of interruption of concreting the tremie shall not be taken out of the concrete under any circumstances. The tremie pipe shall be raised and lowered slowly from time to time to prevent it from getting stuck in the concrete while ensuring its lower and does not come out of concrete. The concreting shall be resumed before final setting time of concrete, which shall be established before the start of the piling operation. For achieving longer setting time f the
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concrete ,super plasticizers having retarding properties / retarders can be used . If any of there requirements are not met, the piles shall be rejected.
7.5.5 Removal of Concrete above Cut Off level
It is desirable that the concrete above cut-off level is removed before the concrete is set. His may be done manually or by specially or by specially made bailer or other device. Such removal of concrete helps in preventing the damage of the good concrete below the cut-off level, which results from chipping by percussion method.
The removal of concrete shall be within + 25 mm from the specified cut off level , preferably of the minus side. After removal of such concrete , the concrete shall be compacted with rammer with spikes or vibrated.
In case the concrete is not removed before setting, a groove shall be made on outer perimeter by rotary equipment before chipping by percussion method.
The minimum embedment of cast in-situ concrete piles into pile cap shall not be less then 50mm. Any defective concrete at the head of the completed pile shall be cut away and made good with new concrete, The clear cover between the bottom reinforcement in pile cap from the top of the pile shall be not less than 25mm. The reinforcement in the pile shall be exposed for full anchorage length to permit to be adequately bonded into the pile cap. Exposing such length shall be done carefully to avoid damaging the rest of the pile.
7.6 DRIVING EQUIPMENT
Piles or their casings may be driven with any type of drop hammer, diesel hammer or single acting steam or compressed air hammer, provided they penetrated to the prescribed depth to attain the designed resistance without being damaged. The weight or power of hammer should be sufficient to ensure a penetration of at least 5mm per blow unless rock has been reached, It is always preferable to employ the heaviest hammer practicable and to limit the stroke, so as not to damage the pile. The minimum weight of the hammer shall be 2.5 t. In the case of pre cast concrete piles the mass of the hammer shall not be less than the 30 times the mass of 300mm length of piles.
Steam or air hammers shall be furnished along with boiler or air compressor of capacity at least equal to the specified by the manufacturer of the hammers. It shall
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be equipped with an accurate pressure gauge at all the times. The valve mechanism and the other parts of steam, air or Diesel hammers shall be maintained in first class condition so that the length of stroke and number of blows per minute, for which the hammer is designed, will be obtained. Inefficient steam, air or diesel hammers shall not be permitted to be used on the work.
7.7 PILE TESTS
7.7.1 Initial Load test
7.7.1.1 The number of initial test shall be determined by the Engineer taking into consecration the bore log and soil profile, design length, pole diameter and design pile capacity. However, it shall not be less than two for each category.
7.7.1.2 Initial load test for axial load capacity, including uplift capacity if required on trial piles of the same diameter as of the design pile, shall be carried out after 28 days design strength is achieved. The testing shall be done as per the procedure laid down in IS: 2911, Part-IV. The load test shall be conducted for not less than 2 ½ times the design load. The initial load test shall be cyclic load test for piles deriving strength from end bearing and side friction. The maintained load test can be performed for end bearing piles which do not rely on friction and for piles socketed in rock;
7.7.1.3 If the Initial load test gives a capacity greater than 25 percent of the capacity calculated by static formula and if it is desired to take benefit of the higher capacity, another two load tests shall be carried out to confirm the earlier value and minimum of the tree shall be considered as initial laod test value. The number of initial test shall be determined by the Engineer taking into consideration the bore log and soil profile.
7.7.1.4 Lateral load tests shall be carried out for estimating the lateral load capacity of the piles. The test procedure shall be carried out as per IS 2911 part IV. However the permissible deflection shall be as per IRC:78.
7.7.1.5 In particular cases where upper part of pile is likely to be exposed later due to scour, then the capacity contributed by that portion of the pile during load test, shall be accounted for.
7.7.2 Routine Load Tests
Routine load test shall be carried out at actual locations of foundations of bridges to re-confirm or modify the allowable loads. The lateral load test may be conducted on two adjacent piles. However, results of routine load tests shall not be used for
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upward revision of design capacity of piles. The minimum number of tests to be conducted for confirming the capacity shall be as per Table below.
Total Number of Piles for the Minimum Number of Test Piles Bridge Upto 50 2 50-150 3 Beyond 150 2% of total piles (fractional number rounded to next higher integer number)
7.8 PILE CAP
Casting of pile cap should be at a level higher than low water level unless functionally required to be below low water level. In such cased dewatering shall be resorted to allow concreting in dry conditions. Pile caps shall be of reinforced concrete. A minimum offset of 150 mm shall be provided beyond the outer faces for the outermost piles in the group. If the pile cap is in contract with earth at the bottom, a leveling course of minimum 80 mm thickness of M15 nominal mix concrete shall be provided. In marine conditions or areas exposed to the action of harmful chemicals, the pile cap shall be protected with a coating such as bituminous based coaltar epoxy or epoxy based coating or with suitable anti corrosive paint. Concrete with high alumina cement, shall not be used in marine environment.
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 three days after casting of pile. The top of pile after stripping shall project at least 50 mm into the pile cap.
The top of concrete in a pile shall be brought above cut-off level to permit removal of all laitance and weak concrete before pile cap is laid. This will ensure good concrete at the cut-off level.
7.9 INSPECTION FOR BORED CAST IN SITU PILES
While concreting uncased piles, voids in concrete shall be avoided and sufficient head of concrete is to be maintained to prevent inflow of soil or water into the concrete. It is also necessary to take precautions during concreting to minimize the softening of the soil by excess water. Uncased cast in-situ piles shall not be allowed where mudflow conditions exist.
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The drilling mud such as bentonite suspension shall be maintained at a level sufficiently above the surrounding ground water level throughout the boring process, to ensure the stability of the strata which is being penetrated until the pile has been concreted.
Where bentonite suspension is used to maintain the stability of the borehole, it is essential that the properties of the material be carefully controlled at stages of mixing, supply to the borehole and immediately before concrete is placed. It is usual to limit.
i) The density of bentonite suspension to 1.05 g/cc
ii) The marsh cone viscosity between 30 and 40
iii) The pH value between 9.5 and 12
iv) The silt content less than 1 percent
v) The liquid limit of bentonite not less than 400 percent.
Theses aspects shall act as controlling factors for preventing contamination of bentonite slurry for clay and silt.
The bore shall be washed by bentonite flushing to ensure clean bottom at two stages viz. after completion of boring and prior to concreting after placing of reinforcement cage. Flushing of bentonite shall be done continuously with fresh bentonite slurry till the consistency of inflowing and out flowing slurry is similar.
For concreting of piles using tremie, Clause 1107 of these Specifications may be referred.
For very long or large diameter piles, use of retarding plasticizer in concrete is desirable For large diameter piles, it may be essential to conduct non-destructive pile integrity tests to evaluate integrity of the pile.
Where possible, it may be desirable to grout the base of pile with cement slurry under suitable pressure after concrete in the pile attains the desired strength. For this purpose, conduit pipes with easily removable plugs at the bottom end, should be placed in the bore along with reinforcement cage before concreting
7.10 TOLERANCES FOR BORED PILES
Variation in cross-sectional dimensions: +50 mm, -10 mm
Variation from vertical for vertical piles: 1 in 150
For vertical piles deviation at piling platform level: 75mm
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Variation of level of top of piles: + 25mm
7.11 TOLERANCES FOR PILE CAPS
Variation in dimensions: +50 mm, -10 mm
Misplacement from specified position in plan : 15mm
Surface irregularities measured: 5 mm with 3 m straight edge
Variation of level of top of piles: ±25mm
7.12 TESTS AND STANDARADS OF ACCEPTANCE
The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria and requirements.
The work shall conform to these Specifications and shall meet the prescribed standards of acceptance.
7.13 MEASUREMENT FOR PAYMENT
For cast in-situ driven and bored concrete piles of specified cross-section, the measurement shall be the length in metres of the accepted pile that remains in the finished structure complete in place. Reinforcement in cast in-situ driven and bored concrete piles shall be measured for payment as per MORTH Specifications.
Routine and Initial Pile Load Tests shall not be measured for payment.
For installation of the pile, i.e. by drilling in the case of precast concrete, timber, steel and cast in-situ driven piles, and by boring in the case of cast in-situ bored pile the measurement shall be the length in metres that remains in the finished structure complete in place, limited to that shown on drawings or ordered by the Engineer. No distinction shall be made for penetration through hard strata or rock and socketing into rock.
For steel liners/casing shown on the drawings to be permanently left in place, the measurement shall be by weight in tonnes that remains in the finished structure complete in place, limited to that shown on drawings or ordered by the Engineer.
For the pile cap, the quantity of concrete shall be measured in cubic metres as per Section 1700 of MORTH Specifications and reinforcement in pile cap shall be measured in tonnes as per Section 1600 of MORTH Specifications
The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria.
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The work shall conform to these Specifications and shall meet the prescribed standards of acceptance.
7.14 RATE
The contract unit rate for supplying precast concrete, timber or steel piles shall include cost of all labour, materials, tools and equipment, and other work involved in making or fabricating the pile complete as shown on the drawing, and where required its loading, transport, delivery to site, unloading and stacking at the place indicated by the Engineer. The cost of reinforcement including treatment as per Section 1600 of MORTH Specificatiol'1s in precast concrete shall be deemed to be included in the quoted rate for supply of piles. The contract unit rate shall also include costs of all labour, materials, equipments and all other incidentals involved in conducting routine and initial pile load tests, including installation of piles for initial load tests.
The contract unit rate for cast in-situ driven and bored piles shall include the cost of concrete and all other items as per Section 1700 of MORTH Specifications, The contract unit rate shall also include costs of all labour, materials, equipments and all other incidentals involved in conducting routine and initial pile load tests, including installation of piles for initial load tests.
The contract unit rate for reinforcement in cast in-situ driven and bored piles shall be as per Section 1600 of MORTH Specifications.
The contract unit rate for installation of piles shall include full compensation for furnishing all labour, materials, tools and equipment, and incidentals for doing all the works involved in driving timber, precast concrete and steel piles, driving or making bores for cast in-situ driven and bored concrete piles, cutting off pile heads, all complete in place to the specified penetration of piles. Providing temporary liner/casing and its withdrawal and placing reinforcement in position shall also be deemed to be included in the rate for installation of piles and no additional payment shall be made for the same.
The contract unit rate for permanent steel liners shall include cost of all labour, fabrication, treatment to the liner and placing the steel liner to the required depth as shown on the drawings and as ordered by the Engineer.
The contract unit rate for concrete in pile cap shall cover all costs of labour, materials, tools, plant and equipment, formwork and staging including placing in position,
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sampling and testing and all as per Section 1700 of MORTH Specifications. Unit rate quoted shall also include the treatment to be given to the surfaces of the pile cap. Reinforcement in the pile cap shall be paid for separately as per Section 1600 of MORTH Specifications.
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8.0 List of Approved Makes/Likely suppliers.
8.1 All materials and products shall conform to the relevant Standard Specification of MORTH, IRC, IS codes, Indian Railways, and other relevant codes/ standards etc. and shall use only with the Engineer's approved make and design.
8.2 The list of approved Makes/likely Suppliers for products and materials is given below. Decision of Engineer is final and binding on the Contractor. Other equivalent manufacturers can only be considered with prior approval of the Employer subject to testing of the material for equivalent specification and properties. Use of any product in the work is purely based on its merits, conformance to quality standards and demonstrated worthiness including durability etc and not just by virtue of getting listed now or then as an approved item.
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Sl.No. Material/ System Approved Makes / Likely supplier Ultratech, ACC, Gujarat Ambuja, Shree Lakshmi, J.K 1 Cement Cement, Grasim, (Birla Super), Lafarge 2 Reinforcement Bars Primary sources viz. TISCO, SAIL, RINL FOSROC, SIKA QUALCRETE, Araldite, CIBA 3 Epoxy GEIGY, CICO Technologies ltd, Structural Water proofing Ltd(CHRYSO GROUP OF Company) Empanelled Suppliers as per Ministry of Road Transport & Highways letter no. RW/NH-34059/1/96- 4 Expansion Joints S&R dated 20 Feb 2001& any amendments to the same FOSROC, Asian Lab, MC Baucheme, Sika, BASF, 5 Admixtures Pidilite, CICO Technologies ltd., Structural Water proofing Ltd(CHRYSO GROUP OF Company) Waterproofing FOSROC, SIKA, Krypton Build mat Co., Pidilite, 6 System CICO Civil Aid, Pile Dynamic, AIMIL, Geo Dynamic, Struct 7 Pile Integrity Test Geotech Research Laboratories Pvt. Ltd., 8 Anchor Fastener HILTI, BOSCH, Tyrolite, Canon 9 Structural Steel TATA, SAIL, RINL, Jindal, Essar 10 Pre-stressing Strand TATA SSL Ltd, Usha Martin Horizontal Tie bars /Shear Key System 11 BB Bars System, ETIC System, Macalloy System & Hold-down devices Rex Polyextrusion 12 HDPE Sheathing FOSROC, MBT, MC Baucheme, CICO Technologies Formwork Release 13 ltd., Structural Water proofing Ltd(CHRYSO GROUP Agent OF Company) Pre-Stressing Freyssinet, BBR, VSL, Dynamic, Killick Nixon, 14 System Tensacciai (Italy), Macalloy, Dwyidag, Usha martin Reinforcement Dextra, BBR, Moment 15 Couplers 16 Formwork suppliers L & T, Dywidag (Grips India) 17 Microsilica Fosroc, BASF Non-Shrink Fosroc, Roff, Sika, CICO, BASF 18 Compound Sriram Institute for Industrial Research and any other 19 Testing labs lab NABL approved subject to approval of the Engineer. Fosroc, Sika, MBT, CICO Technologies ltd., 20 Curing Compound Structural Water proofing Ltd (CHRYSO GROUP OF Company) 21 Electrodes Advani Orlikon / L&T (Electric) 22 STUDS Nelson/STUD Craft/Surecon
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B. ARCHITECTURAL FINISHING WORKS
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1.0 BLOCK MASONRY -SOLID, HOLLOW & LIGHT WEIGHT CONCRETE BLOCKS
1.1 SCOPE
These specifications cover the use of Concrete Block Masonry for the structural / non structural purposes.
1.2 GENERAL
The provision of the latest Indian Standards listed below form part of these specifications:
All relevant Standards as specified elsewhere in this Volume are also applicable. IS 269 Specification for ordinary and low heat portland cement IS 383 Specification for coarse and fine aggregates from natural sources for concrete. IS 455 Specification for portland slag cement IS 456 Code of Practice for plain and reinforced concrete. IS: 1200 Measurement for Building works IS: 1725 Specifications for solid cement blocks used in general building construction. IS: 1905 Code of practice for structural safety of buildings Masonry walls. IS:2116 Sand for masonry mortars. IS:2185 – P1 Specification for concrete masonry units: Hollow and solid concrete blocks. IS:2185 – P2 Specification for concrete masonry units: Hollow and solid light weight concrete blocks. IS:2185 – P3 Specification for concrete masonry units: Autoclaved cellular (aerated) concrete blocks. IS:2250 Code of practice for preparation and use of masonry mortar. IS 2572 Code of practice for construction of hollow concrete block masonry. IS 2645 Specification for integral waterproofing compound. IS:3115 Specification for lime based blocks.
IS:3414 Code of practice for design and installation of joints in buildings.
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IS:3466 Specification for masonry cement. IS:3952 Specification for burnt clay hollow blocks for walls and partitions. IS:4082 Recommendation on stacking and storage of construction material at site. IS:4098 Specification for lime-pozzolana mixture IS:4441 Code of practice for use of silicate type chemical resistant mortars. IS:4442 Code of practice for use of sulphur type chemical resistant mortars. IS:6042 Code & practice for construction of light weight concrete block masonry. IS 8112 Specification for 43 Grade ordinary Portland cement IS 9103 Specification for admixtures for concrete
1.3 MATERIAL
1.3.1 Cement
Ordinary Portland cement complying to IS 269 shall be used unless specified.
1.3.2 Aggregates
Aggregates shall conform to IS 383. Grading shall be as indicated in IS 383. Fineness modules of the combined aggregates shall be between 3.6 and 4.
1.3.3 Water
Water conforming to IS 456 and as approved by the EIC shall be used.
1.3.4 Admixtures
Additives or admixtures may be added to the cement or concrete mix conforming to the IS specifications. Admixtures shall be chloride free and melamine polymer based. Other additives or admixtures not being governed by Indian Standards shall be tested and checked that the same are not detrimental to durability. However any addition shall only be after approval of the EIC.
1.3.5 Solid Concrete Blocks
Concrete blocks used shall be solid and shall be referred to by its nominal dimension. The term nominal dimension includes the thickness of the mortar joint. All
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specifications of solid concrete blocks including specifications for actual dimensions, tolerances, sizes, shapes and webs, grades of blocks etc. shall conform to IS: 2185. All blocks shall be sound and free of cracks or other defects. Exposed construction face or faces shall be free of chips, or other imperfections. The maximum variation in length of the units shall not be more than + 5 mm and maximum variation in height and width of the unit not more than + 3mm.
1.3.6 Light weight concrete block
The light weight block shall be of approved manufacturer. The blocks shall have thickness of 200mm, 150mm, 100mm for load bearing walls, partitions and cladding work, etc. The blocks shall have a maximum density of 640 kg/cum. or less. All specifications of solid concrete blocks including specifications for actual dimensions, tolerances, sizes, shapes and webs, grades of blocks etc. shall conform to IS: 2185 Part-3 and the workmanship shall conform to IS:6042. All blocks shall be sound and free of cracks or other defects. Exposed construction face or faces shall be free of chips, or other imperfections. The maximum variation in length of the units shall not be more than + 5 mm and maximum variation in height and width of the unit not more than + 3mm.
a) Structural Strength requirement
(i) Compressive Strength: The light weight concrete block shall have a minimum compressive strength of 35kg/sq cm.
(ii) Bending Compression : 15 kg/sq. cm
1.4 MANUFACTURE
1.4.1 Concrete blocks
Concrete blocks may be hollow (open or closed cavity) or solid and shall be referred to by its nominal dimension. The term nominal dimension includes the thickness of the mortar joint. All specifications of solid concrete blocks including specifications for actual dimensions, tolerances, sizes, shapes and webs, grades of blocks etc. shall conform to IS : 2185.
1.4.2 Concreting
Concrete mix used for Hollow or Solid Concrete blocks shall be pre-designed to give a minimum crushing strength of 50 Kg/Cm2 or as specified in the Schedule of Quantity. Concrete shall be mixed in the mechanical mixer. Blocks shall be moulded, laid and compacted with automatic machines table vibrator. Care shall be taken to
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see that the mix mould is properly filled up. Block shall be protected until they are sufficiently hardened to permit handling without damage. The solid / hollow / light weight concrete blocks shall have a minimum crushing strength of 50 Kg/Cm2 or as specified in the Schedule of Quantity.
1.4.3 Curing & Drying
Hollow or Solid Concrete Blocks shall be cured in the curing yard by keeping them continuously moist for at least 14 days. Steam-cured blocks shall be preferred. Cured blocks shall be allowed to dry for a period of 4 weeks before being used. The blocks shall be allowed to complete their initial shrinkage before they are laid in the wall.
1.4.4 Physical requirements
All blocks shall be sound and free of cracks or other defects. For exposed construction face or faces shall be free of chips, or other imperfections, and the overall dimensions of the blocks shall be in accordance to tolerance as specified. Minimum compressive strength shall be 50 Kg/Cm2 or as specified in the Schedule of Quantity, maximum permissible water absorption shall not exceed the limit specified in I.S. : 2185, dimensional variations shall conform to I.S. 2185.
1.4.5 Testing
Tests as indicated in Appendices A to F of IS 2185 shall be conducted on samples of units selected according to the sampling procedure given here under to ensure conformity with the physical requirements as specified.
1.4.6 Sampling
A sample of 20 blocks shall be taken from every consignment of 5000 blocks or part thereof of the same size and same batch of manufacture. From these samples, the blocks shall be taken at random for conducting the test. The blocks shall be taken at regular intervals during the course of work, preferably while being loaded or unloaded. In case samples are to be taken from the stacks, blocks shall be taken at random from across the top of the stacks, the sides accessible and from the interior of the stacks.
1.4.7 Number of Tests
All the 20 blocks shall be checked for dimensions and inspected for visual defects. Out of the 20 blocks, 3 blocks shall be subjected to the test for block density, 8 blocks to the test for compressive strength, 3 blocks to the test for water absorption
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and 3 blocks to the test for drying shrinkage and later to the test for moisture movement. The remaining 3 blocks shall be reserved for retest for drying shrinkage and moisture movement if a need arises. Blocks shall be approved if requirements of conditions mentioned in 11.2 to 11.5 (as given below) of IS 2185 (Part I) are satisfied.
a) The number of blocks with dimensions outside the tolerance limit and / or with visual defects, among those inspected shall not be more than two.
b) For Block density and compressive strength, the mean value determined shall be greater than of equal to the minimum limit specified in Table 2 of IS 2185 (Part I). c) For drying shrinkage and moisture movement, all the test specimens shall satisfy the requirements of the test. If one of more specimens fail to satisfy the requirements, the remaining 3 blocks shall be subjected to these tests. All blocks shall satisfy the requirements. Drying shrinkage shall not exceed 0.1 percent.
d) For water absorption, the mean value determined shall not be more than 10 percent by mass.
1.5 WORKMANSHIP
a. In total dry climate top and sides may be slightly moistened to avoid absorption of water from mortar.
b. Joints shall not be bigger than 10mm and will be perfectly horizontal and vertical. Joints shall be raked 10mm deep while mortar is wet.
c. Cut blocks shall not be used. Special solid / hollow pre-cast blocks at site shall be cast well in advance to be used as spacers and to adjust breaking of vertical joints.
d. Cracks in block masonry are due to shrinkage or expansion of blocks or due to settlement, thermal expansion or changes in moisture content in the structural members enclosing the block walls. The following measures are recommended to prevent formation of cracks.
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1. While curing, the block masonry should be lightly sprinkled with water and not made excessively wet. 2. Expansion joints shall be provided in walls exceeding 30 m in length. 3. Reinforcement should be provided in the bed joints in block work, one course above and course below windows and above doors in order to distribute the shrinkage/ temperature stresses occurring at the corners of openings, more uniformly throughout the walls.
1.6 R.C.C. Stiffeners
For block masonry of 100 mm and below thick, RCC stiffeners / band of 100mm thick and width equal to block masonry and having 10mm dia. two bars with 6 mm dia links @ 200 mm c/c shall be provided at every 1000mm interval in the block masonry. The gap between the topmost layer of block and the soffit of the beam shall be packed by lightly hammering flat pieces of shahabad/ kota tiles and then the gaps will be covered by weld mesh before closing them by cement plaster. The weld mesh will be extended at least 150 mm on the R.C.C. beam and 150 mm on block masonry and nailed to them with strong nails. a. All block walls abutting concrete columns or walls shall be bonded to the same with approved 6mm dia 250 mm long galvanized M.S. dowels or approved G.I. butterfly ties left from the concrete columns while casting, at every alternate course of block. b. 150mm and above thick block masonry shall be laid in cement mortar mix of minimum 1:5 consistency and 100mm and below thick block masonry shall be laid in cement mortar mix of minimum 1:4 consistency. Cement and water used in mortar shall conform to the quality as described in section ‘Plain, Reinforced & Pre-stressed Cement Concrete’, whereas sand used for mortar shall be fine screened only. c. The light weight concrete block masonry should not be used below ground or in plinth. The block masonry work shall be built in stretcher course only. d. The gap between the topmost layer of block and the soffit of the beam shall be packed by lightly hammering flat pieces of shahabad/ kota tiles and then the gaps will be covered by weld mesh and grouted through PVC pipe inserts before closing them by cement plaster. The weld mesh will be extended at
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least 150 mm on the R.C.C. beam and 150 mm on block masonry and nailed to them with strong nails.
1.7 Tools & Equipment
All tools and equipment used shall be clean and free from set mortar, dirt or other injurious foreign substances.
1.8 Protection of Work
The blocks shall be kept under cover and protected from extreme conditions of temperature, relative humidity and wind until they are required for test. The test shall be conducted as soon as the sample has been taken. The blocks shall be kept under cover in a suitable shed and protected from extreme conditions of temperature, relative humidity and wind. The finished work shall be protected with covers. The area surrounding the block work shall be kept clean and tidy after completion of work. Care shall be taken during construction that edges of jambs, sills and projections are not damaged in case of rain. Damage, if any shall be made good to the satisfaction of the Employer’s Representative.
1.9 SCAFFOLDING
Scaffolding shall be erected with steel sections or pipes of adequate strength so as to be safe for construction operations. The contractor shall take all measures to ensure the safety of the work and working people. Any instructions of the Engineer in this respect shall also be complied with. The contractor shall be entirely responsible for any damage to properly or injury to persons resulting from ill erected scaffolding, defective ladders and materials or otherwise arising out of his default in this respect. Proper scaffolding shall be provided to allow easy approach to every part of the work. Overhead work shall not be allowed. Block work shall be carried out with double scaffolding only. Making holes of any kind for the purpose of supporting the scaffolding shall not be permitted.
1.10 MEASUREMENT
Block masonry shall be measured in sq.meter for the specified width.
1.11 RATES
Rates for concrete block masonry item shall include the following: a. Material and labour, for the completion of items as specified including any centering, shuttering, curing etc.
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b. Raking out of joints. c. Preparation of the tops and sides. d. Forming and preparing expansion, contraction or construction joints as detailed above or specified in the BOQ or drawings.
e. Making holes, openings, outlets, etc. embedding pipes, ends of beams, joints, slabs, trusses, sills, etc. whatever required during construction and neatly finishing the exposed surfaces and opening as per instructions of the EIC.
f. Curing and protection as specified.
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2.0 PLASTERING AND POINTING
2.1 SCOPE
These specifications cover the use of plastering for masonry and RCC work, pointing for brick and stone masonry work.
2.2 APPLICABLE INDIAN STANDARDS
The provision of the latest revisions of the following IS codes shall form a part of this specification to the extent they are relevant.
IS: 269 Specification for ordinary rapid hardening and low heat Portland cement
IS – 383 Specification for coarse and fine aggregate
IS – 460 (Part-1 & 2) Specification for test sieves
IS – 650 Standard sand for testing of cement
IS: 712 Building Limes
IS: 1200 (Part XII) Method of measurement of building and Civil Engg. Works - Plastering & Pointing
IS: 1542 Specification for sand for plaster
IS: 1630 Mason's Tools for Plaster work and pointing work.
IS: 1661 Code of practice for application of cement lime plaster finishes
IS – 2250 Tests for Mortar
IS 2645 Specification for integral waterproofing compound.
IS – 3085 Method of test for permeability of cement mortar and concrete
IS – 7969 Safety code for Handling & Storage of building materials
IS – 8112 Specification for high strength ordinary Portland cement. (43 Grade)
IS: 10067 Material Constants for Building Works
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Other I. S. Codes, not specifically mentioned here, but pertaining to plastering work, form part of these specifications.
2.3 GENERAL
2.3.1 Cement Mortar
Cement mortar shall have the proportion of cement to sand as specified and shall comply with relevant clauses of concrete specifications.
2.3.2 Scaffolding,
Scaffolding independent of masonry / RCC work i.e. double scaffolding shall be erected having two sets of vertical supports with steel sections or pipes of adequate strength so as to be safe for construction operations. The contractor shall take all measures to ensure the safety of the work and working people. Any instructions of the Engineer in this respect shall also be complied with. The contractor shall be entirely responsible for any damage to properly or injury to persons resulting from ill erected scaffolding, defective ladders and materials or otherwise arising out of his default in this respect. Proper scaffolding shall be provided to allow easy approach to every part of the work. Overhead work shall not be allowed. Making holes of any kind for the purpose of supporting the scaffolding shall not be permitted.
2.3.3 Tools and Accessories
Tools and accessories used in plaster work shall conform to IS: 1630. All tools shall be cleaned by scrapping and washing at the end of each day's work or after use. Metal tools shall be cleaned after each operation. All tools shall be examined to see that they are thoroughly cleaned before plastering is begun.
2.3.4 Programme of work in relation to plastering
The programme of other building operations before, during and after plastering shall be according to the instructions contained in clause 9 of IS: 1661.
2.3.5 General Precaution in plastering
All general precautions as specified in IS. 1661, Clause 9, shall be taken and preparation of the background shall be done as laid down in IS: 1661, Clause 13. Care shall be taken to see that other parts of the work or adjacent works are not damaged while plastering.
2.3.6 Preparatory work
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All joints in the face work that is to be plastered shall be raked out to depth equal to not less than the width of the joints or as directed by the Engineer. The raking shall be done taking care not to allow by chipping of masonry. In new work the raking out shall be done when the mortar in the joints is still green. Efflorescence if any shall be removed by brushing and scrapping. Smooth surfaces of concrete, old plaster, etc. must be suitably roughened to provide necessary bond for the plaster. All dirt, soot, oil paint or any other material that might interfere with satisfactory bond shall be removed. In the case of stone masonry, scrubbing on the walls to receive the plaster shall not be more than 12 mm.
The surface to be plastered shall be cleaned and scrubbed with fresh water and kept wet for 6 hours prior to plastering. It shall be kept damp during the progress of the work. The plastering shall not be commenced unless the preparatory work is passed in writing by the Engineer.
2.3.7 Chicken wire Mesh at Junction
All junctions of Masonry wall with R.C. structure e.g. column, beam, etc. which are to be plastered, shall be reinforced by fixing strips of approved G.I. Chicken wire mesh of minimum 300mm wide centrally over the length of junction. G.I. Chicken wire mesh of required width shall also be fixed over chasing for conduits, pipes, etc. on masonry walls before plastering is commenced. The mesh shall be nailed rigidly to the structure / masonry with G.I. nails of suitable type at approx. 400mm centers. The finished mesh shall be straight, rigid and laid without sagging.
2.3.8 Gauges
Patches of plaster 15cm x 15cm shall be put on about 3 m apart as gauges to ensure even plastering in one plane.
2.3.9 Workmanship
Plastering:
In all plaster work the mortar shall be firmly applied with somewhat more than the required thickness and well pressed into the joints and on the surface and rubbed and levelled with a flat wooden rule to give required thickness. Long straight edges shall be freely used to give perfectly plane and even surface. All corners must be finished to their true angles or rounded as directed by the Engineer. The surface shall be finished to plane or curved surface as shown on the plan or directed by the Engineer, and shall present a neat appearance. The mortar shall adhere to the
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masonry surface intimately when set and there should be no hollow sound when struck. Cement plastering should be done in squares or strips as directed. Plastering shall be done from top downward.
First or Backing Coat
The first coat of the specified thickness shall be applied as described above. The subsequent coat shall be applied after this coat has been allowed to set for 3 to 5 days depending upon weather conditions. The surface shall not be allowed to dry during this period.
2.3.10 Plastering to Ceiling
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 surface shall be poke marked with a pointed tool at spacing of not more than 50 mm centres, the pokes being made not less than 3 mm deep, to ensure a proper key for the plaster. The mortar shall be washed off and surface cleaned of all oil, grease etc., and well wetted before the plaster is applied.
2.4 PLASTERING IN TWO COATS
2.4.1 Base Coat
The base coat plaster shall be of cement mortar 1:4. Waterproofing compound of approved make shall be added according to the manufacturer’s' instructions to make the mortar waterproof.
The plaster with this mortar shall be laid as specified above with a thickness of not more than 12 mm for brick work and concrete surfaces, and 15 mm for rubble stone masonry. Keys shall be formed on the surface by thoroughly combing it with wavy horizontal lines about 12 mm apart and about 3 mm deep when the mortar is still pastic. The base coat shall be cured for not less than 2 days.
2.4.2 Final Coat / Finishing Coat
The cement mortar for sand faced plaster shall have washed Kharasalis or similar type of approved sand with slightly larger proportion of coarse material. The proportion of cement to sand shall be 1:4. The water is added gradually to make the mixture homogeneous. The thickness of finishing coat shall not exceed 7 mm. After application, the surface should be finished with a wooden flat, lined with cork and tapped gently to retain a coarse surface texture. When the finishing coat has hardened, the surface shall be kept moist continuously for 14 days.
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2.5 POINTING
2.5.1 General
When the type of pointing is not mentioned in the item, sunk pointing is described below shall be carried out.
2.5.2 Raking Out Joints
Where the joints have not been raked out when the mortar is green, the joint shall be chipped (without damaging the masonry) to such a depth that the minimum depth of new mortar measured from either the sunk surface of the finished surface of the finished pointing or from the edge of the brick shall not be less than 12 mm, thoroughly cleaned off all loose particles with a stiff brush and thoroughly wetted.
2.5.3 Pointing
The mortar shall be pressed into the raked out joints with a pointing trowel. The mortar shall not spread over the corners, edges or the surface of the masonry. With a pointing tool, the mortar shall be neatly pressed back to about 3 mm or as directed. The vertical joints shall be pressed back similarly to match the horizontal joints. The surface of masonry shall be cleaned of all mortar.
2.6 CURING
Curing shall be started after 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 as directed by the Engineer-in-Charge. 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 monitored.
2.7 MEASUREMENT AND RATE
Plastering shall be measured in sq. metre areas as per IS: 1200 (Part XII). The rate shall include erecting and removal of scaffolding all labour, all materials, equipment, plants, tools and all incidental expenses to complete plastering, pointing, rubbing out joints, cleaning, wetting, filling with cement mortar, troweling etc. and making of drip moulds, grooves, vattas, bands etc. including curing.
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3.0 FLOORING, SKIRTING, DADO & CLADDING
3.1 SCOPE
These Specifications covers flooring, skirting, dado or cladding works using different types of stone/ slabs/ tiles as detailed hereunder:
3.2 GENERAL
The provision of the latest revisions of the following IS Codes shall form a part of this specification to the extent they are relevant.
IS: 269 Specification for ordinary, rapid hardening and low beat Portland cement.
IS: 383 Specification for coarse and fine aggregate from natural sources for concrete
IS: 657 Specification for material for use in the manufacturer of magnesium oxychloride flooring compositions.
IS: 1130 Specification for marble (Blocks, slabs & Tiles).
IS: 1200 Part XI Method of measurements for Building and Civil Engg. Works, paving, floor finishes, dado & skirting.
IS: 1237 Specification for cement concrete flooring tiles.
IS: 1443 Code of practice for laying and finishing of cement concrete flooring tiles.
IS. 2541 Code of practice for use of lime concrete' in buildings.
IS: 2571 Code of practice for laying in situ cement concrete flooring
IS: 4082 Recommendation on stacking and storage of construction materials at site.
IS: 4457 Specification for Ceramic unglazed vitreous acid resistant tile.
IS: 8042 Specification for white port land cement
IS 8112 Specification for high strength ordinary portland cement
IS: 10067 Material Constants in Building Work
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IS: 13711 Ceramic Tiles : Sampling & basis of acceptance
IS: 13712 Ceramic Tiles : Definitions, classifications, characteristics and making
IS: 13753 Dust Pressed ceramic tiles with water absorption of E > 10% (Group - B III)
IS: 13754 Dust Pressed ceramic tiles with water absorption of 6% < E < 10% (Group - B IIb)
IS: 13755 Dust Pressed ceramic tiles with water absorption of 3% < E < 10% (Group - B IIa)
IS: 13756 Dust Pressed ceramic tiles with water absorption of E < 3% (Group - B I)
Other I.S Codes not specifically mentioned here, but pertaining to Floor Finishes form part of these specifications.
3.3 MATERIAL
Cement, sand, aggregate, water shall conform to the relevant BIS standards as specified in clause 3.2 above. Stone shall be hard, sound, durable and free from defects like cavities, cracks, sand- holes, flaws, injurious veins, patches of loose or soft materials and weathered portions etc.
3.4 SUB-BASE
3.4.1 Sub-base for all flooring shall be prepared and kept ready for further applications. All items shall be defined and detailed on the drawing. Measurements shall be as per the BOQ of these items.
Preparation of sub-base may be carried out by excavation or back filling in plinth. Back filling shall be with the selected earth in layer of 150mm to 200mm maximum and adequately watered and well-compacted to achieve at least 90% compaction at optimum moisture content. In case of excavation, the base shall be well-dressed to the desired level and inspected. All loose spots shall be excavated till the hard surface is reached and then filled as directed by the Engineer-in-Charge. Surface shall be watered with just sufficient water and rolled and compacted with vibratory compactor.
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3.4.2 Rubble soling
Good quality 150mm to 230mm thick rubble soling shall be carried out depending upon the grade of soil. Rubble used shall be at least 100mm for 150mm thick soling and 150mm for 230mm thick soling. Stone shall be hand packed as close as possible and bedded firmly with the broadest face downwards and the greatest length across, voids filled with chips and small stones. These shall be hammered down to achieve packing and the complete filling of interstices. To achieve the desired levels and slopes, pegs at suitable intervals (about 12m) shall be fixed. Soling shall be watered and again packed with sand or stone dust to fill interstices created by watering. Then it shall be rolled by power driven roller of 10MT capacity wherever possible or with vibratory compactor. Filling sand or stone dust, watering and compaction shall continue till full compactness is achieved to the satisfaction of the Engineer-in-Charge.
3.4.3 Base floor
This shall be regular reinforced concrete floor or plain cement concrete floor as specified. All specifications of concreting shall be the same as per Plain & Reinforced Concrete section of this volume.
3.5 CEMENT CONCRETE FLOORING
3.5.1 Materials
Cement concrete: The cement concrete shall generally conform to specifications for ordinary concrete. The coarse aggregates shall be carefully selected, sufficiently tough and hard stone pieces broken in a manner that will provide particles of approximately cubical shape affording good interlocking. The maximum size of coarse aggregate shall be 12 mm. The fine aggregate shall consist of properly graded particles. The proportion of mix shall be as specified in the item description. The least amount of mixing water that will produce a workable mix and will allow finishing without excessive trowelling shall be used. Generally a water cement ratio of 0.5 should suffice.
3.5.2 Workmanship
The sub-grade in all cases shall be formed to proper levels and slopes, well compacted and cured. The top surface shall be kept slightly rough.
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The surface of the sub-grade shall be cleaned off all loose materials and moistened immediately before laying the concrete floor. The concrete flooring shall be laid in alternate bays not exceeding 3.35 sq.m (about 36 sf.ft) each. The edge of each panel into which the floor is divided should be supported by aluminium dividing strips of adequate size to prevent sticking. Their depth shall be the same as that proposed for the finished floor as mentioned in the item. At least 48 hours shall elapse before the concreting in the adjacent bays is commenced. The concrete shall be laid immediately after mixing. While being placed the concrete shall be vigorously sliced and spaded with suitable tools to prevent formation of voids or honey comb pockets. The concrete shall be brought to the specified levels by means of a heavy straight edge resting on the side forms and drawn ahead with a sawing motion in combination with a series of lifts and drops alternating with small lateral shifts. While concreting the adjacent bays care shall be taken to ensure that the edges of previously laid bays are not broken by careless or hard tamping. Immediately after laying the concrete, the surface shall be inspected for high or low spots and any needed correction made up by adding or removing the concrete. After striking off the surfaces to the required grade concrete shall be compacted with a wooden float. The blows shall be fairly heavy in the beginning but as consolidation takes place, light rapid strokes shall be given to complete the ramming. The floating shall be followed by steel trowelling after the concrete has hardened sufficiently to prevent excess of fine material from working to the surface, The finish shall be brought to a smooth and even surface free from defects and blemishes and tested with straight edges. No dry cement or mixture of dry cement and sand shall be sprinkled directly on the surface of the concrete to absorb moisture or to stiffen the mix. After the concrete has been thoroughly rammed and has dried sufficiently to allow rendering to be worked up, surface shall be rendered with a thin coat of 1:1 cement mortar with fine sand and uniformly floated. If so directed by the Engineer-in- Charge, approved mineral colour pigment conforming to appendix-B of IS 657 shall be added to the cement mortar to give the required colour and shade to the flooring. When the cement mortar rendering is sufficiently stiff, lines shall be marked on it with strings or by any other device to give the appearance of tiles 30 x 30 cm or of any other size laid diagonally or square as directed by the Engineer-in-Charge. The junctions of floor and walls shall be rounded off if so directed, without any extra payment. After the concrete in the bays has set, the joints of the panels shall be filled with cement cream or with suitable bitumastic compound as shown on the drawings or
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directed by the Engineer-in-Charge. Vertical edge of the bays shall be neatly marked on the surface of the concrete with a pointed trowel after filling the joints. Finishing: When the rendering is somewhat stiff, neat cement may be sprinkled on sparingly through a paper pot on the surface and rubbed lightly to give smooth polished ordinary cement coloured surface. If coloured flooring is required by the Engineer-in-Charge the approved coloured cement shall be used. Surface shall be protected from direct sun when it is green. Curing: Curing shall start on the next day after finishing and shall be continued for 14 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 remanents of cement dust from the bags.
3.5.3 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.
3.5.4 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 and including the cost of strips. 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.
3.6 MARBLE / GRANITE STONE SLAB FLOORING
3.6.1 General
The item refers to provision of flooring of Indian Marble / Granite stone slabs of approved colour / pattern and shall conform to the specification as given below:-
3.6.2 Materials
3.6.2.1 Stone Slabs
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The stone slab specified in the item shall be got approved by the Engineer. At its thinnest part, no stone shall be thinner than the specified thickness. The stone slab shall be hard, sound, durable, resistant to wear, rectangular in shape or square if directed by the Engineer and of the specified width. The stone slab shall be of the type mentioned in the item and of the colour and quality approved by the Engineer. Slabs shall be hard, dense, uniform and homogenous in texture. They shall have even crystalline grain, and free from defects and cracks. The surface shall be machine polished to an even and perfectly plane surface and edges machine cut true and square. The rear face shall be rough enough to provide a key for the mortar. Uniformity of size shall generally be maintained for the stone slab used in any room. The stone shall be without any soft veins; cracks of floors and shall have a uniform colour. The edges shall be quite straight. The stone in slabs in external and internal wall veneer work shall be mirror polished where required, in the factory with silicon carbide abrasive starting from no. “00” up to no. 5 and then using buff/lead strip rolls with tin oxide for final mirror polish. For flooring and counter top the final tin oxide polish shall not be used. Samples of stone slabs to be used shall be got approved by the Engineer and the slabs to be used shall conform to the approved sample. The dimensions of the slab shall be as specified in the item.
3.6.2.2 Approval of Sample
Before starting the work, the contractor shall get samples of marble / granite slab approved by the Engineer-in-Charge. Approved samples shall be kept in the custody of the Engineer-in-Charge and the marble / granite slab supplied and used on the work shall conform to samples with regard to soundness, colour, veining and general texture.
3.6.2.3 Sampling
In any consignment of marble / granite, all the blocks / slabs / tiles of the same group, size and finish shall be grouped together to constitute a lot. Sample shall be selected and tested separately for each lot for determining its conformity or otherwise to the requirements of the specification. The number of marble / granite blocks / slabs / tiles to be selected for the samples shall depend upon the size of the lot and shall be in accordance with the Table (Sample size & Criteria for conformity) given below:
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Sample size and Criteria for Conformity. Number of Number of blocks slabs Permissible Sub sample Blocks / slabs / Tiles to be selected in number of size in Nos. /tiles in the lot sample defectives (1) (2) (3) (4) Upto 25 3 0 2 26 to 100 5 0 2 101 to 200 8 0 3 201 to 500 13 0 4 501 to 1000 20 1 5
Note: The marble / granite blocks/ slabs/ tiles in the sample shall be taken at random and in order to ensure to randomness of selection, random tables may be used.
Explanation 1: All the marble / granite blocks / slabs / tiles, selected in the sample, shall be examined for dimensions workmanship and general requirements.
Any block / slab / tile failing in any one or more of the above requirements shall be considered as defective. All lot shall be considered as conforming to these requirements if the number of defectives obtained is not more than permissible no. of defectives given in Col. 3 of the Table.
Explanation 2: The lot of marble / granite having been found satisfactory with respect to dimensions, workmanship and general requirements shall be tested for physical properties as given below. For this purpose a sub sample of the size given in Col. 4 of table shall be selected at random. These marble / granite blocks/ slabs / tiles in the sub sample shall be tested for moisture absorption, hardness and specified gravity. The lot shall be considered having satisfied the requirements of the physical properties if none of the marble / granite blocks / slabs / tiles tested for the requirements fails in any of these tests.
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Physical Properties
Sr. No.Characteristic Standards Method of Test (1) (2) (3) (4) 01 Moisture absorption after Max. 0.4% by weight IS : 1124 24 hrs immersion in cold water 02 Hardness Min 3 Mohs Mhos Scale 03 Specific Gravity Min 2.5 g/cc IS : 1122
3.6.2.4 Bedding
Cement mortar for the bedding shall be of the proportions as specified in the item. The proportions will be by volume on the basis of 50 Kg. bag of cement. The mortar may be hand mixed or machine mixed.
In hand mixed mortar, cement and sand in the specified proportions shall be thoroughly mixed dry on a clean impervious platform by turning over at least 3 times or more till a homogeneous mixture of uniform colour is obtained. Fresh & clean water shall be added gradually and thoroughly mixed to form a stiff plastic mass of uniform colour so that each particle of sand shall be completely covered with a film of wet cement. The mortar so prepared shall be used within 30 minutes of adding water. Only such quantity of mortar shall be prepared as can be used within 30 minutes. The mortar remaining unused after that period or mortar which has partially hardened or is otherwise damaged shall not be re-tempered or remixed. It shall be destroyed or thrown away.
3.6.3 Construction
3.6.3.1 Bedding
The base of cement concrete shall be laid and compacted to a reasonably true plain surface and to the required slopes and below the level of the finished floor to the extent of the thickness of the slabs and mortar bedding. Cement concrete bedding if provided shall be paid under a separate item. Cement mortar for bedding may be mixed manually or by a mechanical mixer. The amount of water added shall be the minimum necessary to give just sufficient plasticity for laying and satisfactory bedding. Care shall be taken in preparing the mortar to ensure that there are no hard
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lumps that would interfere with the even bedding of the stones. Before spreading the mortar, the sub-floor or base shall be cleaned of all dirt, scum or laitance and of loose material and then well wetted without forming any pools of water on the surface. In case of R.C.C. floors, the top shall be left a little rough. All points of level for the finished paving surface shall be marked out. The mortar shall then be evenly and smoothly spread over the base by the use of screed battens only over so much area as will be covered with slabs within half and hour. The thickness of the mortar bedding shall not be less than 12mm, not more than 25mm. The required slope shall be given to the bed.
3.6.3.2 Fixing stone slab
Before laying, the stone flags shall be thoroughly wetted with clean water. Neat cement grout of honey like consistency (white cement shall be used in the case of marble slabs) shall be spread on the mortar bed over as much area as could be covered with the slabs within half an hour. The specified type of stone slabs shall be laid on the neat cement float and shall be evenly and firmly bedded to the required level and slope in the mortar bed. Each stone slab shall be gently tapped with a wooden mallet till it is firmly and properly bedded. There shall be no hollows left. If there is a hollow sound on gentle tapping of the slabs, such slabs shall be removed and reset properly. The Mason shall make the joints of uniform thickness and in straight lines. The joints shall be filled solidly with pigmented grout for their full depth. The stone slabs shall be laid so as to give continuous parallel long joints with cross joints at right angles to them. The edges of the adjoining slabs shall be in one plane. Where the slabs cover open edges, of floor or window sills the edges shall be neatly rounded off. This shall be included in the rate. When diamond pattern paving is provided in the item, the slabs shall be square and laid to the diamond pattern with triangular shaped slabs to make up the edges. In plain pattern stones on each course shall break joints with those in the next. The pattern joints etc. shall be as per drawings or as directed by Engineer-In-Charge, to the entire satisfaction of Engineer –In- Charge.
3.6.3.3 Curing
The flooring shall be kept well wetted with damp sand or water for fourteen days. It shall be kept undisturbed for at lest seven days.
3.6.3.4 Cleaning
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All flooring shall be thoroughly cleaned and handed over clean and free from any mortar stains etc.
3.6.4 Measurement:
The contract rate shall be per square metre of the floor area covered by the flooring of the specified type. All work shall be measured net. The length and width of the flooring shall be measured net between the faces of skirtings or dados or plastered faces of walls. Paving under the dado, skirting or plaster shall not be measured.
3.6.5 Rate :
The rate for the item shall include the following: (a) All labour, materials and equipment, cleaning the sub-base, laying mortar bed and cement grout, fixing stone slabs specified above and making up the joints. (b) Any cutting and waste if required. (c) Pointing when included in the item. (d) Cleaning the floor from all stains, etc. (e) Polishing wherever required.
3.7 MARBLE / GRANITE STONE IN RISERS OF STEPS AND SKIRTING
3.7.1 Marble Stone Slabs and Dressing of Slabs shall be as specified above in clause 3.6 of Marble / Granite Stone Slab Flooring except that the thickness of slabs shall be as specified in the item description. A tolerance of + 3mm shall be allowed, unless otherwise specified in the description of the item.
3.7.2 Preparation of Surface
It shall be as specified above in clause 3.6 of Marble / Granite Stone Slab Flooring except where necessary the wall surface shall be cut uniformly to the requisite depth so that the skirting face shall have the projection from the finished face of wall as shown in drawings or as required by the Engineer-in-Charge.
3.7.3 The risers of steps and skirting shall be in grey or white cement admixed with or without pigment to match the shade of the stone, as specified in the description of the item, with the line of the slab at such a distance from the wall that the average width of the gap shall be 12mm and at no place the width shall be less than 10mm. The skirting or riser face shall be checked for plane and plumb and corrected. The joints shall thus be left to harden then the rear of the skirting or riser slab shall be packed with cement mortar 1:3 (1 cement: 3 coarse sand) or other mix as specified in the
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description of the item. The fixing hooks shall be removed after the mortar filling the gap has acquired sufficient strength.
The joints shall be as fine as possible. The top line of skirting and risers shall be truly horizontal and joints truly vertical, except where otherwise indicated. The risers and skirting slab shall be matched as shown in drawings or as instructed by the Engineer-in-Charge.
3.7.4 Curing, Polishing and Finishing
The face and top of skirting shall be polished. The stone in slabs in external and internal wall veneer work shall be mirror polished where required, in the factory with silicon carbide abrasive starting from no. “00” up to no. 5 and then using buff/lead strip rolls with tin oxide for final mirror polish. For flooring and counter top the final tin oxide polish shall not be used
3.7.5 Measurements
Length shall be measured along the finished face of riser or skirting, correct to a cm. Height shall be measured from the finished level of tread or floor, to the top (the underside of tread, in the case of steps) correct to 1mm. The areas shall be calculated in square metre correct to two places of decimal.
3.7.6 Rate
The rate shall include the cost of all materials and labour involved in all the operations described above.
3.8 MARBLE / GRANITE STONE SLAB CLADDING
Marble / Granite tiles and slabs shall be mirror polished, flame finished or as given any other surface treatment as specified. All exposed edges shall be similarly treated. The Marble / Granite stone in slabs in external and internal wall veneer work shall be mirror polished where required, in the factory with silicon carbide abrasive starting from no. “00” up to no. 5 and then using buff/lead strip rolls with tin oxide for final mirror polish. For flooring and counter top the final tin oxide polish shall not be used Machine polishing and sizing shall be done with only water as lubricant. Sawing also shall be preferably done with water as lubricant but as a special case, oil or kerosene may be permitted subject to the oil or kerosene being thoroughly dried in ovens. Tiles / slabs with stains or patches due to the use of oil or otherwise shall be rejected.
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Any tiles / slabs showing patches or stains after installation shall also be rejected and replaced. Tiles shall be transported to site well-packed in boxes. Slabs will be individually packed in cardboard paper. Tiles / slabs shall not be waxed or touched up with dyes / colours. The entire supply for each type of marble / granite, unless specifically permitted by the Consultant, shall be procured from one location in one quarry to keep variations to the minimum. The Contractor shall segregate and sort the tiles / slabs according to colour, texture and size to keep variations in the same in any one floor, wall or isolated area to the minimum. The Contractor shall, before fixing the marble / granite on floors or walls, lay whole areas of marble / granite loose on ground to select and match the marble / granite. Any tiles / slabs with a variation not acceptable to Consultant / ENGINEER shall not be used, and if used shall be removed and replaced. The Consultant’s decision in this respect shall be final and binding. Tight tolerances shall be checked and maintained throughout. Maximum variations shall be as follows:-
Sides ± 0.5 mm Thickness ± 0.5 mm slabs ± 0.3 mm tiles Angularity ± 0.2 % Flatness ± 2 mm
Linear items such as treads, skirting, sills etc. shall be of uniform thickness throughout. All visible edges shall be machine polished unless otherwise specified. Marble / granite shall be laid or fixed to the highest standard by highly trained masons to the entire approval of Consultant / Engineer. Any tiles / slabs broken, stained or damaged shall be removed / replaced. External wall cladding shall be fixed with approved stainless steel 316 grade serrated cramps and dowels. Marble / granite slabs for external cladding shall be minimum 30mm thick. The Contractor shall prepare shop drawings and get them approved by the Consultant before proceeding with any work. The Contractor shall put a mock-up of typical and non-typical panels and get it approved well before he commences fixing on site.
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The Contractor shall coordinate his site activities with other contractors working on site through Engineer and shall take particular care, in coordination with the Engineer, in ensuring that his methods of fixing do not damage or endanger the building structure, finishes and services in any way. The Contractor shall get his system of anchorage approved by the Consultant. No reinforcement bar in concrete shall be cut through during drilling or anchorage. The anchorage in solid concrete blockwork shall be specially designed taking into consideration the actual compactness and crushing strength of the blocks. 2 nos. pullout tests in blockwork shall be carried out prior to commencing work to prove the strength of anchorage with ample margin of safety. Prior to commencing work, the Contractor shall obtain approval of the Consultant for material and workmanship after submitting the following details:- (a) 3 representative samples for each type of marble / granite specified. (b) Physical characteristics:- Dimensional tolerances, water absorption (polished or unpolished as applicable) by weight, compression strength, Mohs hardness, unit weight. (c) Source of supply and availability in full quantity and uniformity of colour, tone and texture. (d) Company profiles of suppliers and labour sub contractor if any. (e) Procedure for fixing and samples of fixtures such as cramps, pins, dowels etc. If required the Contractor shall arrange visits to the quarries and to the works carried out by the proposed Sub Contractor.
3.8.1 Measurements:
The length and breadth shall be measured correct to a cm. In case of radially dressed or circular slabs used in the work, the dimensions of the circumscribing rectangles of the dressed stone used in the work, shall be measured & paid for. The area shall be calculated in Sqm. nearest to two paces of decimal
3.8.2 Rate:
The rate includes the cost of materials and labour required for all operations described above. The rate shall also include: a) Marble / Granite stone slab / tiles procured & delivered at Site, including wastage and breakage, polishing, chamfering, rounding, grooves, drip moulds and other linear works as per drawings and specifications. b) Stainless steel cramps, pins, dowels and other anchoring systems as per approved shop drawings and as specified.
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c) Backing mortar and pigmented cement grout where specified. d) Labour in transporting materials on site, fixing, carefully cutting, hand polishing, and touching up where required etc. e) Protecting Marble / Granite stone slab / tiles during construction until virtual completion of works. f) Temporary supports, templates, straight edges etc. g) Alignment and leveling in coordination with Engineer and Main Contractor. h) Joints with plastered and other surfaces. i) Cleaning on completion. j) Scaffolding / staging and safety precautions. k) Submissions of Samples. l) Mock-up (total area approx. 15 sqm.) m) Working to specified tolerances n) Shop drawings o) Pull out tests – 2 nos. – on anchors in blockwork. p) Provisions for adequate anchorage. q) Providing and applying protective water / stain resistant chemical coating / impregnation treatment.
3.9 ANTISKID VITRIFIED TILES FOR FLOORING
3.9.1 Standards
Description Minimum requirement Specification for coarse and fine I.S. 383 - 1970 aggregates Tests for mortar I.S. 2250 : 1981 Method of test of aggregates in I.S. 2386 - 1963 concrete Recommendation on stacking and storage of construction materials at I.S. 4082 : 1996 site. Specification for white port land cement I.S. 8042 - 1989 Ordinary portland cement 43 grade I.S. 8112 - 1989 Water I.S. 456 : 2000 & I.S. 3025 Antiskid Vitrified Tiles Shall conform to EN - 176 Group B1a and ISO 13006 stds.
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Description Minimum requirement Deviation in length Method of testing shall be as per EN 98 Deviation in thickness Method of testing shall be as per EN 98 Straightness of sides Method of testing shall be as per EN 98 Rectangularity Method of testing shall be as per EN 98 Surface flatness Method of testing shall be as per EN 98 Water absorption Shall not be greater than 0.05 % (Method of testing shall be as per EN 99) Moh's hardness Shall not be less than 6 (Method of testing shall be as per EN 101) Flexural strength Shall not be less than 27 N / sqmm. (Method of testing shall be as per EN 100) Abrasion resistance (Method of testing shall be as per EN 102) Skid resistance (coefficient of friction) 0.6 (Method of testing shall be as per ASTM C-1028) Breaking strength Shall not be less than 2500 N (Method of testing shall be as per ASTM C-678) Density Shall not be less than 2 gm / cm3 (Method of testing shall be as per DIN - 51082) Frost resistance Shall be frost proof (Method of testing shall be as per EN - 202) Chemical resistance Shall be resistant to chemicals(Method of testing shall be as per EN - 106) Thermal shock resistance Shall be resistant to thermal shocks (Method of testing shall be as per EN - 104) Colour resistance No damage (Method of testing shall be as per DIN - 51094) Thermal expansion Shall not be more than 9 x 10-6 (Method of testing shall be as per EN - 103) Stain resistance Shall be stain resistant (Method of testing shall be as per ISO 10545 -14) Glossiness Desired reflection effect as required by architect (Method of testing shall be with the use of glossometer)
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3.9.2 Materials
Tiles The tiles shall be unchamfered, fully vitrified, homogeneous, unglazed, ceramic satin matt finished tiles of nominal size of premium quality. The size and thickness of tiles shall be as per the architectural requirements.
3.9.3 Workmanship
The floor tiles shall be laid to the correct slope and levels. The mix of the mortar shall be to a minimum of 1:4 consistency. Bedding for tiles in flooring The amount of water added while preparing mortar shall be the minimum necessary to give sufficient plasticity for laying. Before spreading the mortar bed, the base shall be cleaned of all dirt, scum or laitance and loose materials and then well wetted without forming any pools of water on the surface. The mortar shall then be evenly and smoothly spread over the base by the use of screed battens to proper level or slope. The thickness of the bedding shall not be less than 12 mm (about 1/2") or more than 20 mm (about 3/4") in any one place. The tiles shall be laid on bedding mortar when it is still plastic but has become sufficiently stiff to offer a fairly firm cushion for the tiles. Laying of tiles The tiles before laying shall be soaked in water for at least 2 hours. Tiles, which are fixed in the floor adjoining the wall, shall be so arranged that the surface of the round edge tiles shall correspond to the skirting or dado. Neat cement grout of honey like consistency shall be spread over the bedding mortar just to cover so many areas as can be tiled within half an hour. The edges of the tiles shall be smeared with neat white cement slurry and fixed in this grout one after the other, each tile being well pressed and gently tapped with a wooden mallet till it is properly bedded and in level with the adjoining tiles. There shall be no hollows in bed or joints. The joints shall be kept as close as possible and in straight lines The joints between the tiles shall not exceed 1. 5 mm wide. The joints shall be grouted with a slurry of white cement. After fixing the tiles finally in an even plane, the flooring shall be covered with wet saw dust and allowed to mature undisturbed for 14 days.
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Cleaning After the tiles have been laid in a room or the day's fixing work is completed, the surplus cement grout that may have come out of the joints shall be cleaned off before it sets. Once the floor has set, the floor shall be carefully washed clean and dried.
3.9.4 Testing
If any tile is found to be warped, damaged or irregular in shape and size, it shall be refitted or replaced, properly jointed. The tiling work shall be tested for plumb, line and level. The surface of the floor and wall surfaces shall be frequently checked with a straight edge. Corners of walls shall be truly at right angles. The finished work shall not sound hollow when tapped with a wooden mallet.
3.9.5 Reference vendors / manufacturers
H & R Johnson (I) Ltd. NITCO Murudeshwar ceramics Granamite Euro or approved equivalent.
3.9.6 Measurement
The contract rate shall be per square metre of the floor area covered by the flooring of the specified type. All work shall be measured net. The length and width of the flooring shall be measured net between the faces of skirting or dados or plastered faces of walls. Paving under the dado, skirting or plaster shall not be measured.
3.9.7 Rate
The rate for the item shall include the following: (a) All labour, materials and equipment, cleaning the sub-base, laying mortar bed and cement grout, fixing tiles as specified above and making up the joints. (b) Any cutting and waste if required. (c) Pointing when included in the item. (d) Cleaning & protecting the floor from all stains, etc.
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4.0 PAINTING
4.1 SCOPE OF WORK
The work covered under these specifications consist of furnishing the various types of paints and also the workmanship for these items, in strict compliance with these specifications, which are given in detail here-in-after with the item of schedule of quantities. Copper, bronze, chromium plate, nickel, stainless steel, aluminium and model metal shall generally not be painted or finished except if otherwise specified.
4.2 STANDARDS AND SPECIFICATIONS
The provisions of the latest revisions with amendments, if any, of the following Indian Standards and other relevant codes shall form part of this specification to the extent they are relevant. Where the provisions of these Standards/ Codes are in conflict with the stipulations of this specification, the specification supersedes the respective Standard or Codes.
IS: 35 Zinc oxide for paints
IS: 63 Whiting for Paint & putty.
IS: 75 Specification for Linseed oil, raw & refined.
IS: 82 Method of sampling and test for thinners and solvent for paints
I.S. 101 (all parts) Methods of sampling and tests for paints, varnishes and related products I.S. 104 Ready mix paint, brushing, zinc chrome, priming I.S. 109 Cement primer codes I.S. 133 Enamel, Interior : (a) Undercoating (b) Finishing – Specification
IS: 159 Specification for ready mixed paint, brushing, acid resistant.
I.S. 164 Specification for ready mixed paint for road marking I.S. 168 Ready mixed paint, air drying, for general purpose – Specification
IS: 345 Specification wood filler, transparent, liquid.
IS: 426 Specification for paste filler for colour coats.
IS: 427 Specification for Distemper, dry colour, as required.
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IS: 428 Specification for Distemper, Oil Emulsion, colour as required.
IS: 533 Specification for Gum spirit of Turpentine (Oil of Turpentine)
IS: 710 Marine Plywood
IS: 1200 (Part XIII) Method of Measurement of Building & Civil Engg Works - White Washing, colour washing, distempering & other finishes.
IS: 1303 Glossary of terms relating to paints
IS: 1477 (Part 1) Code of practice for painting of ferrous metals in buildings Pre- treatment
IS: 1477 (Part 11) Code of practice for finishing of ferrous metals in buildings. Painting
IS: 2074 Red oxide zinc chromate primer codes
IS: 2338 (Part 1) Code of practice for finishing of wood and wood based materials Operations and workmanship for finishing.
IS: 2338 (Part 11) : Code of practice for finishing of wood and wood based materials, Schedule
IS: 2395 (Part 1) : Code of practice for painting concrete masonry and plaster surfaces. Operation & workmanship
IS: 2395 (Part 11) Code of practice for painting concrete, masonry and plaster surfaces Schedule.
IS: 2524 (Part 1) Code of practice for painting of non-ferrous metal in buildings Pre- treatment.
IS: 2524 (Part ll) Code of practice for painting of non-ferrous metal in buildings Painting.
IS: 3140 Code of practice for painting asbestos cement buildings.
IS: 3537 Specification for ready mixed paint, finishing, interior for general purposes to IS colour.
IS: 5410 Specification for cement paints, colour as required.
IS : 6278 Code of practice for white washing & colour washing.
I.S. 5411 (Part 1) Plastic Emulsion Paint for interior use I.S. 5411 (Part 2) Plastic Emulsion Paint for exterior use I.S. 9954 Pictorial surface preparation standards for painting of steel
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surfaces I.S. 13607 Ready mixed paint, finishing general purposes, Synthetic - specification I.S. 14589 Zinc priming paint, epoxy based two pack – specification I.S. 14925 Epoxy resin for paints – specification
Other IS Codes not specifically mentioned here, but pertaining to painting form part of these specifications.
4.3 MATERIALS
Paints, oils, varnishes etc. of approved brand and manufacture shall be used. Ready mixed paints as received from the manufacturer without any admixture shall be used.
If for any reason, thinking is necessary in case of ready mixed paint, the brand of thinner recommended by the manufacturer or as instructed by the Engineer-in- Charge shall be used. Approved paints, oils or varnishes shall be brought to the site of work by the contractor in their original containers in sealed condition. The materials shall be brought in at a time in adequate quantities to suffice for the whole work or at least a fortnights work. The materials shall be kept in the joint custody of the contractor and the Engineer-in-charge. 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-in-charge.
The contractor shall associate the chemist of paint manufacturers before commencement of work, during and after the completion of work who shall certify the suitability of the surface to receive painting and the paint before use etc.
The contractor shall arrange for safe and proper storage of all materials and tools The storage space if allotted within the building shall be adequately protected from damage, disfigurement and stains Paints shall be kept covered at all times and mixing s hall be done in suitable containers, All necessary precautions shall be taken by the Contractor to prevent fire.
4.4 COMMENCING WORK
4.4.1 Scaffolding
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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 on or touch the surface which is being painted. Where ladders are used, pieces of old gunny bags shall be tied on their tops to avoid damage or scratches to walls. For painting of the ceiling, proper stage scaffolding shall be erected. Painting shall not be started until and unless the Engineer-in-Charge has inspected the items of work to be painted, satisfied himself about their proper quality and given his approval to commence the painting work. Painting, except the priming coat, shall generally be taken in hand after all other builders work, practically finished. The rooms should be thoroughly swept out and the entire building cleaned up at least one day in advance of the paint work being started.
4.5 PREPARATION OF SURFACE
The surface shall be thoroughly cleaned. All dirt, rust, scales, smoke and grease shall be thoroughly removed before painting is started. Minor patches if any in plastered/form finished surfaces shall be repaired and finished in line and level in C.M. 1:1 and cracks & crevices shall be filled with approved filler, by the contractor at no extra cost to the Department. Masonry cracks shall be cleaned out and patch filled with mortar similar to the original surface and uniformly textured. Where this type of resurfacing may lead to the finishing paint being different in shade from the original surfaces, the resurfaced area shall be treated with minimum one coat of cement primer which should continue to the surrounding area for a distance of minimum 100 mm. The prepared surface shall have received the approval of the -in- Charge after inspection, before painting is commenced.
The surface shall be allowed to dry thoroughly before the regular coat of paint is allowed.
The surface affected by moulds moss, fungi, algaelicnens, efflorescence shall be treated in accordance with IS: 2395 (Part 1) before applying paint.
Surface with mildew or efflorescence shall be treated as below: a) M ild e w : All mildewed surface shall be treated with an approved fungicide such as ammonia wash consisting of 7g of copper carbonate dissolved in 80 ml liquor ammonia and diluted to 1 liter with water, or 2.5 percent magnesium silica fluoride solution allowed to dry thoroughly below the paint is applied.
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b) Efflorescence: All efflorescence shall be removed by scrubbing the affected surfaces with a solution of muriatic acid in water (1:6 to 1:8) and washed fully with clear water and allowed to dry thoroughly.
4.6 APPLICATION
Before pouring into smaller containers for use, the paint shall be stirred thoroughly in its containers. When applying also, the paint shall be continuously stirred in the smaller containers so that consistency is kept uniform. The external surfaces of the buildings under reference including the R.C.C. Jalli, fins and the panels above and below the window etc. shall be finished in different colours of approved shade. The contractor will make suitable samples at site for Departments approval before taking up the work in hand and they will be allowed to proceed with the work only after getting Departments approval for the same. The painting shall be laid on evenly and smoothly by means of crossing and laying off, the later in the direction of the grain in case of wood. The crossing & laying off consists of covering the area with paint, brushing the surface hard for the first time and then brushing alternately in opposite directions two or three time and then finally brushing lightly in direction at right angles to the same. In this process, no brush marks shall be left after the laying off is finished. The full process of crossing and laying will constitute one coat. Where so stipulated, the painting shall be done with spraying. Spray machine used may be (a) a high pressure (small air aperture) type or (b) a low pressure (large air gap) type, depending on the nature and location of work to be carried out. Skilled and experienced workmen shall be employed for this class of work. Paints used shall be brought to the requisite consistency by adding a suitable thinner. Spraying should be done only when dry condition prevails. Each coat shall be allowed to dry out thoroughly and rubbed smooth before the next coat is applied. This should be facilitated by thorough ventilation. Each coat except the last coat, shall be lightly rubbed down with sand paper or fine pumice stone and cleaned of dust before the next coat is laid. No left over paint shall be put back into the stock tins. When not in use, containers shall be kept properly closed. The final painted surface shall present a uniform appearance and no streaks, blisters, hair marks from the brush or clogging of paint puddles in the corners of panels, angles of moldings etc. shall be left on the work.
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In case of cement based paints/primers, the absorbent surfaces shall be evenly damped so as to give even suction. In any weather, freshly painted surfaces shall be kept damp for at least two days. In painting doors and windows, the putty around the glass panes must also be painted, but care must be taken to see that no paint stains etc. are left on the glass. Tops of shutters and surfaces in similar hidden locations shall not be left out while painting. Perspect covers of electrical switch boxes have to be painted from inside by removing them. Care shall be taken while removing them in position after painting with respective approved paints. In painting steel work, special care shall be taken while painting over bolts, nuts, rivets, overlaps etc. The additional specifications for primer and other coats of paints shall be as in accordance to the detailed specifications under the respective headings. Any damage caused during painting work to the existing works/surfaces shall be made good by the contractor at his own cost.
4.7 BRUSHES AND CONTAINERS
After work, the brushes shall be completely cleaned off paint and linseed oil by rinsing with turpentine. A brush in which paint has dried up is ruined and shall on no account be used for painting work. The containers, when not in use, shall be closed, kept air tight and shall be kept at a place free from dust. When the paint has been used, the containers shall be kept at a place free from dust. When the paint has been used, the containers shall be washed with turpentine and wiped dry with soft clean cloth, so that they are clean & can be used again.
4.8 MEASUREMENT
Painting, unless otherwise stated shall be measured by area in square metre. Length and breadth shall be measured correct upto two places of decimal of a metre. No deduction shall be made for opening not exceeding 0.05 sq.m. and no addition shall be made for painting to the beading, moulding edges, jambs, soffits, sills, architraves etc. of such openings. In measuring painting, varnishing, oiling, etc. of joinery and steel work etc. the coefficients as in the following table shall be used to obtain the areas payable. The coefficients shall be applied to the areas measured flat and not girthed in all cases. In case of painting of door shutter with push plates in plastic laminate, deduction will be made for area of such laminations.
4.8.1 Table of Coefficients
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Table of Coefficients to be applied over areas of different surfaces to get equivalent plain areas.
Sr. No. Description of Work. Multiplying Coefficients
1.0 Wood Work : Doors, Windows Etc.
1.1 Panelled or framed and braced doors, windows etc.
1.2 Ledged & battened or ledged, battened & 1.30 (for each side) braced doors, windows etc.
1.3 Flush doors etc. 1.20 (for each side)
1.4 Part paneled and part glazed or gauzed 1.00 (for each side) doors, windows etc.
1.5 Fully glazed or gauzed doors, windows 0.80 (for each side) etc.
1.6 Fully venetioned or louvered doors, 1.80 (for each side) windows etc.
1.7 Trellis (or Jaffri) work one way or two 2.00 (for painting all over) way.
1.8 Carved or enriched work: 2.00 (for each side)
1.9 Weather boarding: 1.20 (for each side)
1.10 Wood shingle roofing: 1.10 (for each side)
1.11 Boarding with cover fillets and match 1.05 (for each side) boarding.
1.12 Tile and slate battening: 0.80 (for painting all over)
2.0 Steel Work: Doors, Windows Etc.
2.1 Plain sheets steel door or windows: 1.10 (for each side)
2.2 Fully glazed or gauzed steel doors and 0.50 (for each side) windows
2.3 Partly paneled and partly gauzed and 0.80 (for each side) glazed doors and windows.
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Sr. No. Description of Work. Multiplying Coefficients
2.4 Corrugated sheeted steel doors or 1.25 (for each side) windows.
2.5 Collapsible gates 1.50 (for painting all over)
2.6 Rolling shutters of inter locked laths. 1.10 (for each side)
3.0 General Works:
3.1 Expanded metal, hard drawn steel wire 1.00 (for paining all over) fabric of approved quality, grill work and gratings in guard bars, balusters, railings, partitions and m.s. bars in window frames.
3.2 Open palisade fencing and gates 1.00 (for painting all over) including standards, braces, rails, stays etc. in timber or steel
NOTE: The height shall be taken from the bottom of the lowest rail, if the palisades do not go below it (or from the lower end of palisades, if they project below the lowest rail) upto the top of palisades but not upto the top of standards, if they are higher than the palisades.
3.3 Corrugated iron sheeting in roofs, side 1.14 (for each side) cladding etc.
3.4 A.C. Corrugated sheeting in roofs, side 1.20 (for each side) cladding etc.
3.5 A.C. Semi-corrugated sheeting in roofs, 1.10 (for each side) side cladding etc, or Nainital pattern using plain sheets.
3.6 Wire gauze shutters including painting of 1.00 (for each side). wire gauze.
4.8.2 Explanatory Notes on the Table of Coefficients
Where doors, window etc. are of the composite types other than those included in Para 3 of Clause 8.0 above, the different portions shall be measured separately with
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their appropriate coefficients, the centre line of the common rail being taken as the dividing line between the two portions. Measurements for doors, windows etc. shall be taken flat (and not girthed) over all including chowkhats or frames, where provided. Where chowkhats or frames are not provided, the shutter measurements shall be taken. Collapsible gates shall be measured for width from outside to outside of gate in its expanded position and for height from bottom to top of channel verticals. No separate measurements shall be taken for the top and bottom guide, rails, rollers, fittings etc. Rolling shutters of interlocked laths shall be measured for the actual shutter width and the height from bottom of opening to the centre of the shaft. No separate measurements shall be taken for painting guides and other exposed features within or outside the shutter area. The painting of top cover or hood shall however be measured separately. Coefficients for sliding doors shall be the same as for normal types of doors as mentioned in the table. Measurements shall be taken outside of shutters, and no separate measurements shall be taken for painting guides, rollers, fittings etc. Measurement of painting of doors, windows, collapsible gates, rolling shutters etc. as above shall be deemed to include painting all iron fittings in the same or different shade for which no extra will be paid. The measurements as above shall be deemed to include also the painting of edges, blocks, cheats etc. for which no extra will be paid. The coefficients for doors and windows shall apply irrespective of the size of frames and shutter members. When the two faces of a door, window etc. are to be treated with different specified finishes, measurable under separate items, the edges of frames and shutters shall be treated with the one or the other type of finish as ordered by the Engineer-in-Charge, and measurement of this will be deemed to be included in the measurement of the face treated with that finish. In the case where shutters are fixed on both faces of the frames, the measurements for the door frame and shutter on one face shall be taken in the manner already described, while the additional shutter on the other face will be measured for the shutter area only excluding the frame. Where shutters are provided with clearance at top or/and bottom, such openings shall be deducted from the overall measurements and relevant coefficients shall be applied to obtain the area payable.
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In case of trellis (or Jaffri) work, the measurements shall include the painting of the frame member for which no separate measurements shall be taken. Trellis door or window shutters shall also be measured under trellis work. Wherever air conditioning grill, lighting, fixtures etc. in false ceiling are painted along with, measurements shall be taken over all without deductions for opening in grills and no extra shall be paid for the grills. If grills, fixtures etc. are not painted, area of fixtures or grills as measured flat (not girthed) shall be deducted when it exceeds 0.05 sqm. individuals. Where walls and ceilings are painted in separate colours, the junctions of two paints shall be brought down on the walls in a straight line by about 6 mm to 12 mm. If so desired, if the junctions of walls and ceilings are not even. Nothing extra shall be paid to the contractor on this account. Beading wherever provided shall not be measured separately but shall be deemed to be included in the area of false ceiling etc. measured flat (not girthed). For painting open palisade fencing and gates etc., the height shall be measured from the bottom of the lowest rail, if the palisades do not go below it, (or from the lower end of the palisades, if they project below the lowest rail), upto the top of rails or palisades whichever are higher, but not up to the top standards when the latter are higher than the top rails or palisades. In the case of asbestos cement corrugated or semi-corrugated sheeting and iron corrugated sheeting in roofs, side cladding etc., the work shall be measured flat (not girthed) as fixed. For trusses, compound girders, stanchions, lattice girder and similar work, actual areas will be measured in sqm. and no extra shall be paid for painting on bolt heads, nuts, washers etc even when they are picked out in a different tint to the adjacent work. Painting of rain water, soil, waste, vent and water pipes etc. shall be measured in running metres of the particular diameter of the pipe concerned. Painting of specials such as bends, heads, branches, junctions, shoes etc. shall be included in the length and no separate measurements shall be taken for these or for painting brackets, clamps etc. Measurements of wall surfaces and wood and other works not referred to already shall be recorded as per actual and opening exceeding 0.05 sqm. shall be deducted to get the net payable area. Length and breadth shall be measured correct up to two places of decimal of a metre and area so worked out shall be correct up to two places of decimal of a square metre.
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In case the items of work requiring painting are inclusive of cost of painting, the painting carried out shall not be measure separately.
4.9 PRECAUTIONS
All furnitures, lightings, fixtures, sanitary fittings, glazing, floors etc. shall be protected by covering and stains, smears, splashings, if any shall be removed and any damage done shall be made good by the contractor at his cost.
4.10 RATES
Rates shall include cost of all labour and materials involved on all the operations described above and in the particular specifications given under the several items including:
a) Supplying & mixing paint as specified.
b) Scaffolding including erection and dismantling.
c) Preparation of the surface before painting
d) Application of Paint as specified.
f) Curing & protecting the painted surface
4.11 ACCEPTANCE CRITERIA AND TESTING
a) All painted surfaces shall be uniform and pleasing in appearance. b) All varnished surfaces shall be of uniform texture and high glossy finish. c) The colour, texture etc. shall match exactly with those of approved samples. d) All stains, splashes, and splatters of paints and varnishes shall be removed from surrounding surfaces.
4.11.1 Testing
a) As, each part of the work is under progress, i.e. preparation of surface, providing primer, providing different coats of finishing paints, it shall be passed by the Engineer. Variation from the drawings or specification or standard etc. shall not be accepted. The Contractor shall ascertain from the Engineer as to which parts will be inspected and passed from time to time. The Contractor shall provide all necessary arrangement for inspection of the painting work during its different working phase. The Contractor shall provide necessary scaffolding, approach for inspection of the above as per direction and satisfaction of the Engineer. All the necessary cost for scaffolding, approach, platform, lighting arrangement testing and inspection shall be
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borne by the Contractor. Such inspection and testing will not, however, exonerate the Contractor from his responsibilities for proper workmanship, material etc.
b) The Contractor shall carry out all sampling and necessary testing in accordance with the relevant Indian Standards and shall conduct such tests as called for by the Engineer. Where no specific testing procedure is mentioned in the relevant codes, the tests shall be carried out as per the prevalent accepted Engineering practice as per the direction of the Engineer. Tests shall be done in a laboratory, approved by the Engineer, and cost of testing shall be borne by the contractor. c) Material/workmanship unsuitable for acceptance shall he removed and replaced by the Contractor. The work shall be redone as per Specification of the contract and direction of the Engineer without any extra cost to the Employer.
4.12 PAINTING PRIMING COAT ON WOOD, IRON OR PLASTERED SURFACES
4.12.1 Primer
i) The primer for wood work, iron work or plastered surface shall be as specified in the description of the item. ii) Primer for Wood work / Iron & Steel / Plastered / Aluminium surfaces shall be as specified below: Sr No. Surfaces Primer to be used
a) Wood work (hard & soft Pink conforming to I.S. 3536-1966 wood): b) Resinous wood and ply wood: Aluminium primer
c) Iron & Steel, Aluminium and Zinc chromate primer conforming to I.S. galvanized Steel work: 104-1962.
d) Plastered surfaces, cement Cement Primer brick work, Asbestos surfaces for oil bound distemper and paint:
iii) The primer shall be ready mixed primer of approved brand and manufacture.
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4.12.2 Preparation of surface
a) Wood work: The wood work to be painted shall be dry and free from moisture. The surface shall be thoroughly cleaned. All unevenness shall be rubbed down smooth with sand paper and shall be well dusted. Knots, if any, shall be covered with preparation of red lead made by grinding red lead in water and mixing with strong glue sized and used hot. Appropriate filler material with same shade as paint shall be used where so desired by the Engineer-in- charge. The surface treated for knotting shall be dry before painting is applied. After the priming coat is applied, the holes and indentation on the surface shall be stopped with glaziers putty or wood putty (for specifications for glaziers putty and wood putty-refer as mentioned here-in-before). Stopping shall not be done before the priming coat is applied as the wood will absorb the oil in the stopping and the latter is therefore liable to crack. b) Iron and Steel Work: All rust and scales shall be removed by scrapping or by brushing with steel wire brushes. Hard skin of oxide formed on the surface of wrought iron during which becomes loose by rusting, shall be removed. All dust and dirt shall be thoroughly wiped away from the surface. If the surface is wet, it shall be dried before priming coat is undertaken. c) Plastered Surface: The surface shall ordinarily not be painted until it has dried completely. Trial patches of primer shall be laid at intervals and where drying is satisfactory, painting shall be taken in hand. Before primer is applied, holes and undulations, shall be filled up with plaster of paris and rubbed smooth.
4.12.3 Application
The primer shall be applied with brushes, worked well into the surface and spread even and smooth. The painting shall be done by crossing and laying off as described here-in-before.
4.12.4 Other Details
These shall be as per specifications for Painting as far as they are applicable.
4.13 PAINTING WITH ACRYLIC EMULSION/PLASTIC EMULSION PAINT
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This shall be polyvinyl based Acrylic/plastic emulsion paint of approved manufacture of the required shade, conforming to I.S. 5411-1969.
4.13.1 Primer
The primer to be used for the painting with acrylic emulsion on cement concrete surfaces, plastered surfaces, A.C. Sheets, timber and metal surfaces, if necessary, shall be of approved base and as per recommendations of the manufacturers.
4.13.2 Putty
Plaster filler to be used for filling up (putting) uneven surfaces, small cracks and holes etc. shall be of approved compound and as per recommendations of the manufacturers. No oil based putty shall be used. The putty should be made from a mixture of whiting and plastic emulsion paint or as per manufacturers recommendations.
4.13.3 Finishing coats
All the finishing coats shall be of matt finish or any other finish as required by the Engineer-in-charge. The number of finishing coats shall be as specified in the item.
4.13.4 Mode of Measurement
All the measurements for payment shall be taken on net surface area actually painted, unless otherwise specified. Deduction will be made from the areas for fixtures, grills, ventilation, outlets, electrical boxes and such obstructions not painted, if they are individually more than 0.05 sqm.
4.13.5 Job Requirements
i) Acrylic emulsion paint is required to be provided on plastered and concrete surfaces in portions of the building. The Department shall reserve the option to delete or increase quantities in full or part from the scope of contract during progress of work. ii) All wood surfaces are to be painted with semi glossy synthetic enamel paint with an approved primer. iii) All shades and colours of paints shall be subjected to review and prior approval of Engineer-in-Charge shall be taken before the application.
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4.14 SYNTHETIC TEXTURED PAINT IN PLAIN / STONE OR METALLIC FINISH.
4.14.1 General
Synthetic Textured Paint, reinforced by using fibres and shall be based on chemicals having acid and alkally resistant properties. It can be applied to any hard, plain surface both internally and externally. It does not require any further application or treatment once it is applied on the surface. Synthetic Textured Paint is available in ready-mixed form in any desired colour and can be applied by using a trowel. The synthetic Textured Paint avoids cracks formation as well as it provides a waterproofing coating on the surface treated.
4.14.2 Base Coat
An average 20mm thick cement plaster shall be provided as rendering coat which shall be roughened lightly with wire brush so as to form very mild keys on the rendered surface. The surface shall be allowed for curing for a period of minimum 14 days before the application of synthetic Textured Paint.
4.14.3 Applications
Synthetic Textured Paint is applied in three coats: (a) one coat of plaster by trowel and ; (b) Subsequent two coats of chemical overcoat by brush in approved colour and finished as specified (plain/stone or metallic).
4.14.4 Mode of Measurement
Length and breadth shall be measured correct upto two places of decimals of a metre. The area shall be worked out correct upto two places of decimals of a square metre.
4.14.5 Rate
The rate shall include all material, labour and use of tools to carry out the following operations:
a) Supplying & mixing paint as specified.
b) Scaffolding including erection and dismantling.
c) Preparation of the surface before painting
d) Application of Paint as specified.
f) Curing & protecting the painted surface
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4.14.6 Guarantee
The synthetic Textured Paint treatment shall be executed through an approved agency and written performance guarantee shall be submitted by the Contractor for a minimum period of Ten years through the agency. The contractor and the agency shall be jointly responsible for the performance of the treated surface until the expiry of the guarantee period.
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5.0 RAILINGS
5.1 SCOPE
This section refers to design, supplying, fabrication and installing in position composite hand railing for staircase, open area, balcony / terrace, corridor, cafeteria etc. at different floors, levels and locations.
5.2 CODES AND STANDARDS
The provisions of the latest revisions of the following I S Codes shall form a part of these specifications to the extent they are relevant. Table – Codes of Practice and Standards Specification Description IS: 800 Code Of Practice For Use Of Structural Steel In General Building Construction. IS: 875 Code of Practice for Design Loads of Buildings and Structures IS: 813 Scheme of symbols for welding. IS: 814 Covered electrodes for manual metal arc welding of Carbon and carbon-manganese steel.
IS: 816 Code of practice for use of metal arc welding in general mild steel construction.
IS: 817 Code of practice for training and testing of metal arc welders.
IS: 818 Code of Practice for safety and health requirements in electric and gas welding and cutting operations
IS: 822 Code of procedure for inspection of welds
IS: 823 Code of procedure for manual metal arc welding of mild steel
IS: 1161 Steel tubes for structural purposes
IS: 1181 Qualifying tests for metal arc welders
IS: 1182 Recommended practice for radiographic examination of fusion welded butt joints in steel plates IS: 3696 Safety codes for scaffolds and ladders
IS: 4923 Hollow steel sections for structural use
IS: 7205 Safety code for erection of structural steelwork
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Specification Description
ASTM A276 -06
ASTM A479/ Standard A Specifications for Stainless Steel Bar and shapes 479 M - 06a
ASTM E 1086 -94Standard Test Method for Optical Emission Vacuum Spectrometric Analysis of Stainless Steel
ASTM B-117 Standard practice for operating Salt Spray (fog) apparatus.
ASTM A 484 Standard Specifications for general requirement for Stainless Steel bars, Billets and Forgings.
ASTM A554 - 11 Standard Specification for Welded Stainless Steel Mechanical Tubing Material Testing & Inspection • Test Method: ASTM. (American Society for Testing and Materials). • Material confirms to ASTM A-276-06, ASTM A479/A479M-06a • Chemical Analysis Test Method ASTM E 1086-94 , ASTM B 117 • Dimensional tolerance as per ASTM A484/AA484M-06b • Specification used : AISI.(American Iron and Steel Institute) • All the materials testing are done through the NABL Certified Laboratory only.
5.3 MATERIALS
5.3.1 Stainless Steel railing / hand railing
Pipes used in all Railing shall be Stainless Steel as per SS 304 / 316 Grade with minimum tube thickness of 1.5 mm (or as mentioned in the Schedule of Quantities ) having tolerance level as per ASTM A554. All components in railing including baluster, pipes, caps etc. shall be in brush finish or as per the specified finish indicated in Schedule of Quantities.
5.3.1.1 Balusters
a. The balusters to have a standard height of 1050 mm or as specified in the drawings. b. All components used in the baluster to be manufactured using SS 304 / 316 grade material turned and finished on CNC and other automatic Machines. c. The base plate of the Baluster to be solid Stainless Steel of size 115 mm dia and 8 mm in thickness or as specified in the drawings.
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d. All connectors to be fixed to the Baluster using Allen Bolts. The baluster to have Zero welding except on the bottom plate. e. Balusters to be fixed using Stainless Steel M8 Fasteners with SS 304 / 316 grade Stainless Steel Caps f. The Baluster neck to be modular and can be tilted as per the handrail. The neck plate shall be minimum 2 mm thick in Stainless Steel 304 / 316 garde. g. Handrails shall be connected to the neck plate using Stainless Steel CSK M5x10 mm Screw only h. Balusters shall be installed with a centre to centre distance of 1 mt. or as indicated in the drawing.
5.3.1.2 Finish
All stainless steel shall have a non directional finish.
5.3.2 Wooden hand railing
Burma Teak wood shall be used in all wooden railing works and the profile of the sections shall be as shown in the drawing.
5.3.3 Appearance
Burma Teak wood shall generally straight grained with a coarse, uneven texture, medium luster and an oily feel. Yellow brown to dark golden brown heartwood and grayish or white sapwood. Plantation teak tends to be lighter in color but contains the same dimensional stability properties.
5.3.4 Physical Properties
Moderately hard and heavy, with low stiffness and shock resistance, moderate bending strength, moderate steam bending, and excellent decay resistance and dimensional stability. Individual hard and sound knots shall not be more than 12 mm in diameter and the aggregate area of all the knots shall not exceed one per cent of the area of the piece. The timber shall be free from decay, fungal growth, boxed heart, pitch pockets or streaks on the exposed edges, splits and cracks. The minimum density shall be 640 Kg/Cum. and the maximum permissible limit of moisture content shall be 12%. The wooden railing work shall be finished with polyurethane coating as approved by the Engineer.
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5.3.5 Glass
The glass used in the railing work shall be either one of the following specified below: a) Laminated toughened glass panels comprising of multiple panels of 10mm & 6mm thick clear toughened glasses sand-witched using 1.52 PVB film and fixed to the vertical balusters with glass clamping discs. b) 10mm thick clear toughened glass panels and fixed to the vertical balusters with glass clamping discs. c) Glass railing shall be of single panels per each flight or as shown in the drawing and all visible edges of the glass shall be machine polished.
5.3.6 Samples /Mock-up
Before taking up fabrication and erection on mass scale, the sample of railing materials being used etc. including mock-up of the system shall be got approved by the Engineer-in-charge.
5.3.7 Manufacturing Tolerances
a) A high degree of accuracy should be employed in the fabrication of the Hand rails, skirt rails and their support structure. b) Deviations in section length, width and diagonal dimension tolerances should not exceed ±2mm. c) The twist and warping should not cause any point of the element to be more than 1mm out of plane.
5.4 FABRICATION, ASSEMBLY AND INSTALLATION
5.4.1 General
a) Use no materials, equipment or practices that may adversely affect functioning, appearance and durability of completed items specified herein and related construction. Items shall comply with specified criteria without buckling, opening of joints, undue stress on fasteners, sealants and gaskets opening of welds, cracking of glass, leakage, noises, or other harmful effects. b) Conform strictly to materials, finishes, and shapes, sizes, thicknesses, and joint locations required by drawings and specifications. c) Match all materials to produce continuity of line, texture, and color. d) To fullest extent practicable, fabrication and assembly shall be executed in shop. Work not shop assembled shall be shop‐fitted.
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e) All components exposed in finished work shall be acceptably free from warping, oil canning effects, and telegraphing of welds, studs, and other fasteners. f) Pipes used in the work shall be seamless type. g) The wooden railing / hand rail work shall be carried out as described in the schedule of quantities and as per the drawing.
5.4.2 Welding
a) Welding of steel shall be done in accordance with the recommendations of related code of practice. Steel welding shall be done by skilled mechanics qualified by tests. b) All welding shall be done with electrodes and/or methods recommended by the suppliers of the metals being welded. The type, size, and spacing of welds shall be as shown on the approved shop drawings. Welding materials and methods shall be such as not to cause distortion, discoloration, or result in any other adverse effect on the required profiles and finishes of the specified work. c) Weld splatter and welding oxides on the exposed surfaces shall be removed. All exposed welds shall be finished to match and blend with adjacent parent metal prior to application of the final finish.
5.4.3 Glass
a) Glazing shall be performed without springing or forcing of glass. b) Install glass under the conditions recommended by respective product manufacturers.
5.4.4 Protection, Cleaning and Acceptance
a) Protect the Work of this Section from any materials, equipment or practices that may impair function appearance or durability of the work. b) Remove and replace or repair with approval of Engineer any portion of work including glass damaged prior to date of acceptance. c) Acceptance of completed work requires installation be sound, free from defects in materials and workmanship and clean. Clean is defined as free of any substance that cannot be removed by a normal cleaning with detergent and water.
5.5 METHODOLOGY & WORKMANSHIP
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5.5.1 General
a) Fit exposed connections together to form tight, hairline joints. Perform cutting, drilling, and fitting required to install handrails, skirt rails. b) Set handrails and railings accurately in location, alignment and elevation; measured from established lines and levels and free from rack. c) Adjust handrails and railings before anchoring to ensure matching alignment at abutting joints. d) Space posts at interval indicated, but not less than that required by structural loads. e) Fastening to In situ Construction. Use anchorage devices and fasteners where necessary for securing handrails and railings and for property transferring loads to in situ construction. f) The hand railing shall follow the inclination of stair in case of stair-case and shall be perfectly in line, level and plumb for all other railings. g) Any damage caused to treads/risers while fixing of balusters, posts, railings etc., the damaged tread and riser shall be removed and replaced by new ones at no extra cost to the Employer.
5.5.2 Anchoring Railing Ends
a) Anchor railing ends into concrete and masonry with round flanges connected to railing ends and anchored into wall construction with post installed anchors and bolts. Anchor railing ends to metal surfaces with flanges bolted to metal surfaces. Connect flanges to railing ends using non welded connections.
5.5.3 Attaching Handrails to Walls
a) Attach handrails to wall with wall brackets. Provide brackets with at least 40 mm clearance from inside face of handrail and finished wall surface. b) Locate brackets as indicated or, if not indicated, at spacing required to support structural loads. c) Secure wall brackets to building construction as follows:‐ i) For concrete and solid masonry anchorage, use drilled in expansion anchors ii) For steel framed gypsum board assemblies, use hanger or lag bolts set into wood backing between studs.
5.5.4 Installation Tolerances
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a) The hand railing, skirt railing shall be erected in proper alignment in relation to established lines and grids shown on the Shop Drawings. b) The width of any joint should not deviate from the nominal width by more than ±1mm. Any variation should be equally distributed with no sudden changes. c) Set posts plumb within a tolerance of 2 mm in 1 m.
5.6 TEMPORARY STORAGE & HANDLING
a) The material shall deliver and store packed materials in original packing with seals unbroken and labels intact till the same are intended to be used. b) The Contractor shall take necessary precautions during storage to prevent damage or contamination to the materials by water, foreign matter or other causes. c) Store materials in a dry, well ventilated, weather tight place, and protect from damage.
5.7 CLEANING & PROTECTION
5.7.1 Cleaning
a) Remove temporary coverings and protection of adjacent work areas. b) Clean installed products in accordance with manufacturer's instructions before acceptance by the Engineer. Do not use chlorine-based or abrasive cleaners. c) Remove from project site and legally dispose of all construction debris associated with this work.
5.7.2 Protection
a) Protect installed product from damage during subsequent construction activities.
5.8 MEASUREMENT
Hand railing shall be measured for payment in running meters of the railing system. The length shall be measured along the top centre line of the hand rail and shall be measured between ends of balusters, newels posts as the case may be upto two places of a decimal. Rate to include fabrication, leaving suitable pockets, grouting the same, fixing, all labour, materials, transporting, finishing, cleaning, protecting, scaffolding if necessary and as described in the schedule of quantities. Individual pipes, balusters,
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newels etc. shall not be measured separately and shall be included in the rates quoted.
5.9 REFERENCE VENDORS
Sr No Description Name of approved Vendors 1 SS Railing System Carl-F / Neki-Kich / Q-Railing/ Metalplas Engineering / Dorma 2 Stainless Steel Salem Steel / Indalco 3 Glazing Indo Ashai / Pilkington / Saint Gobain 4 Expansion anchors (with stainless HILTI SS 304 / 316 / FISCHER / steel bolts nuts and washers) MKT (Germany) 5 Chemical anchors HILTI / FISCHER / MKT (Germany) 6 PU Paint Akzonobel / Asian / Jotun
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6.0 STAINLESS STEEL SHEET CLADDING
6.1 MATERIAL
6.1.1 Stainless steel sheets:
Stainless steel elements shall be SS 304 / 316 grade as per the requirements and shall comply to the relevant AISI standards .They shall be non magnetic type with minimum wall thickness of 1.50 mm and of required finish. The stainless steel sheets shall be of approved make and quality and of required size, gauge and thickness as per design requirements / schedule of quantities. The sheets shall be used for cladding walls & columns and stainless steel pipes shall be utilized for railings. The framework for cladding should be designed in such a way that there are no surface deviations.
6.1.2 Stainless steel tubes and plates:
Stainless steel tubes & plates shall comply to the relevant AISI standards .They shall be non magnetic type with minimum wall thickness of 1.50 mm and of required finish.
6.1.3 Fasteners
6.1.3.1 The type, size, alloy, quantity and spacing of all fasteners and / or anchorage devices shall be as required for the specified performance standards.
6.1.3.2 Bolts, anchors and other fastening devices shall be of approved types as required for the strength of the connections, shall be self-locking, unless otherwise noted, shall be suitable for the conditions encountered, and shall be torque tightened, where required, to achieve the maximum torque tension relationship in the fasteners. Washers, nuts and all accessory items shall be of the same material as fasteners.
6.1.3.3 Fastening devices between aluminium and aluminium shall be Grade 304 / 316 of AISI non-magnetic stainless steel unless otherwise approved.
6.1.3.4 Fastening devices between aluminium and dissimilar materials shall be Grade 304 / 316 of AISI non-magnetic stainless steel unless otherwise approved.
6.1.3.5 Exposed fasteners are subject to Architect’s approval and shall be M.S. epoxy coated.
6.1.3.6 Self-locking fasteners shall be stainless steel of grade 304 / 316 with nylon inserts or Patches.
6.1.4 Solid Aluminium Sheets
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All solid aluminium sheet products shall be stretcher leveled flat and shall not be less than 3mm thick. The alloy and temper for solid aluminium sheet for painted finishes shall be of 3003 H14 or 5005 H34 grade.
6.1.5 Stainless Steel Plate, sheet and strips
Non-magnetic stainless steel in plate, sheet and strip shall conform to requirements specified in this specification and more stringent requirement listed below. Unless noted otherwise, grade 1.44xx (formerly 316) shall be used for visible components and components at areas not behind a vapour barrier, in all other circumstances grade 1.43xx (formerly 304) shall be used.
6.1.6 Extrusions
All aluminium extrusions shall conform to the system principal’s specification for tolerances which shall, in any case, be better than DIN standards. Any section not conforming to the tolerances shall be rejected. In general aluminium alloy for extrusions shall be 6063 T5 or T6 as per B.S.1474. However, the grade and tempering specifications shall be as recommended by the supplier for each application and shall be approved by the system principal. All aluminium sections shall be either anodised in approved colour to a minimum thickness of 35 microns or coated with PVDF as specified except for sections concealed from view behind cladding which may be mill-finished. All surfaces abutting the parent sections and designed to receive sealants shall have adequate sealant contact and adhesion. They shall be finished to match parent sections.
6.2 STORAGE
Stainless steel sheet surfaces are protected adequately during storage, transporting and processing.
6.3 FABRICATION
6.3.1 General
Sawing - with vertical panel saw, circular, compass or fret saw. Drilling holes for joining - with drill bits for aluminium sheet and plastic panels (for larger holes use a drill bit with locating point). Routing - with conventional routing equipment, to avoid pressure marks, please use plastic or wood vice jaws when chucking the work pieces.
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Shearing - with a guillotine (check correct insertion of top cover sheet), blanking tools to be padded. Bending- with folding table min. inside bending radius r = 15 x t (t = panel thickness) spring-back effect higher than with solid sheet Screwing- with conventional stainless wooden, sheet metal and metal screws. For outdoor use, please take panel expansion into account! Folding (routing technique)- manually after routing a V-groove on reverse side using a panel saw with milling attachment or a hand-milling cutter (see data sheet "Routing and Folding Technique"). Smoothing edges- using a file with a rasp-like cut to file roughly cut contours Lengthwise. Punching - with a steel band tool on punching base for panels of 2 and 3 mm in thickness (check correct insertion of upper cover sheet) - with conventional sheet punching machines (for panels of any thickness). Pressing - with a brake press min. inside radius r = 15 x t (t = panel thickness) spring-back effect higher than with solid sheet. Riveting -- with the usual equipment, using rivets or blind rivets. For outside use, please take panel expansion into account! Gluing
- with the usual metal adhesives for aluminium (no liability for front-end plastic edges) - using conventional double-faced tapes
6.3.2 Fabrication
The fabrication and installation of the cladding systems shall be carried out as per manufacturer’s instructions with invisible / concealed fastenings, aluminium sub- structure, silicon sealants properly tooled etc. All cladding sheets of one kind shall be obtained in one lot from the manufacturers. Each sheet shall be guaranteed for a minimum flatness of 1 mm from the true face after installation under no-wind conditions. Deviations from the true alignment of adjoining sheets shall not be cumulative. Full load deflections shall be kept to the minimum possible. Each sheet shall be capable of withstanding wind pressure without any permanent deformation. The cladding system shall be adequately ventilated. The air-gap between the cladding sheets and the concrete / block wall shall be atleast 50 mm to allow proper
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ventilation of the rainscreen system. The cavity shall be closed by a perforated bird / vermin-proof closer at bottom and by a flashing at top. The fabrication processes including cutting, grooving, benching, folding, joining, rout- in as well as installation shall be performed as per manufacturer’s instructions. The sheets shall be backed by approved aluminium supporting framework, fixed to walls with aluminium brackets.
6.4 INSTALLATION
General: All assemblies shall be fabricated and assembled in accordance with the drawings and the requirements of these specifications. Deviations of any nature, without approval of the Engineer shall not be permitted.
Tolerances: Furnish a schedule of fabrication tolerances for all major wall cladding components. In addition to the fabrication tolerances, provide for and schedule thermal movement including assembly and installation tolerances for all major and/or applicable wall cladding components and/or assemblies.
6.4.1 Workmanship
All work shall be performed by skilled workmen, specially trained and experienced in the applicable trades and in full conformity with the applicable provisions of the listed References and Standards and/or otherwise noted on the drawings or as specified herein. All work shall be carefully fabricated and assembled with proper and approved provisions for thermal expansion and contraction, fabrication and installation tolerances and design criteria. All forming and welding operations shall be done prior to finishing. Unless otherwise noted. Approved electrodes compatible to the parent material shall be used for welding. Where two different types of metal elements like stainless & mild steel are to be welded together, the welding process and choice of electrodes shall conform to the code requirements of mutual compatibility. All work shall be true to detail with sharp, clean profiles, straight and free from defects, dents, marks, waves or flaws of any nature impairing strength or appearances; fitted with proper joints and intersections and with specified finishes. All work shall be erected true to plumb, level, square to line, securely anchored, in proper alignment and relationship to work of other trades and free from waves, sags or other defects.
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6.4.2 Joints in Metal Work
All exposed work shall be carefully matched to produce continuity of line, design and finish. Joints in exposed work, unless otherwise shown or required for thermal movement, shall be accurately fitted, rigidly secured with hairline contacts and sealed watertight. Where two or more sections or metals are used in building up members, the surface in contact shall be brought to a smooth, true and even surface and secured together so that the joints shall be absolutely tight without the use of any point materials. Extrusions shall be finished to eliminate any edge projection or misalignment at joints. Furnish physical samples of all joinery elements as for comparative appraisal and approval of the production materials. Physical samples of all typical wall intersection assemblies shall be colour coded on surfaces and/or areas to receive sealants.
6.4.3 Shop Assembly
As far as practicable, all fitting and assembly of the work shall be done in the shop. Work that cannot be permanently shop assembled shall be temporarily assembled in the shop and marked with the approval of Engineer before disassembly to ensure proper assembly later in the building.
6.4.4 Sleeves
Unless otherwise noted, all aluminum sleeves shall be extruded sections designed to accurately interlock with adjacent sections and incorporate serrated surfaces for the Amount of total deviation and/or misalignment in any direction for vertical members: 3 mm maximum in a height of 4 m (non-cumulative) and maximum 7 mm in full-height of cladding/curtain walling.
6.4.5 Anchorage
a) Anchorage of the stainless steel sheet cladding system to the structure shall be by approved methods and in strict accordance with approved shop drawings. After the SS cladding system are properly positioned, all connections so designated on approved shop drawings shall be rigidly fixed by welding or other positive means. b) All anchorage assemblies and their related components shall be thoroughly scheduled and described on the shop drawings so that anyone can evaluate an installation and ensure its compliance with the contract documents. Designate trades responsible for furnishing and/or installing materials if other
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than the Sub-Contractor. Descriptive items shall include the access removal movement and tolerances of related building and the SS cladding system direction and magnitude of thermal expansion, materials, sizes, quantities and any special instruction as may be required. All primary SS cladding, anchorage assemblies inclusive of frame/structural mullion shall receive a 100% inspection.
6.4.6 Use of sealing materials
a) Sealing materials shall be used in strict accordance with the Manufacturer’s printed instructions and shall be applied only by workmen specially trained or experienced in their use. Before applying sealant, all mortar, dirt, dust, moisture and other foreign matter shall be completely removed from surfaces it will contact. Adjoining surfaces shall be masked when required to maintain a clean and neat appearance. Sealing compounds shall be tooled to fill the joint and provide a smooth finished surface. b) The manufacturer(s) of the applicable materials shall, when required render technical assistance prior to the application of any sealant and witness the first applications as well as periodic site inspections thereafter. The contractor shall witness and document all inspections performed by the sealant manufacturer and provide close supervision of all workmen used to apply the sealant.
6.4.7 Tensioning of Bolts
All bolts shall be correctly tensioned. The tension shall be specified on shop drawings. At least 10% of bolts shall be mechanically checked for corrected tension.
6.5 PROTECTION AND CLEANING
a) The Contractor shall adequately protect all aluminum sections, glazing, cladding sheets, components and accessories from damage during shipment, storage, erection and after completion of the work by use of protective film/foil of approved non-staining quality, b) At such time as may be directed by the Engineer, the Contractor shall remove all protective coverings and/or coatings and clean surfaces free of all soil and discoloration. Only those cleaning agents that are acceptable to the applicable aluminum, glass and coating manufacturers, shall be used and where doubt exists, spot tests shall be made to satisfy the Engineer.
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7.0 TENSILE MEMBRANE (FABRIC) ROOFING SYSTEM
7.1 SCOPE OF WORKS
The scope of work contained in this specification together with all the drawings which form part of the contract documents provide the instructions necessary to carry out that part of the contract which includes design, supply, fabrication, installation, protection, guarantees, testing and maintaining upto the defects liability period for tensile membrane (fabric) roofing system, structures and associated works & accessories.
7.2 GENERAL
Generally all labour, tools, plant and materials necessary to complete the design, supply and installation of all tension membrane to the building. The work shall be executed in the best trade practice by specialized tradesman, all strictly in accordance with the manufacturer’s written instructions.
7.2.1 Design Parameters
ii) Wind load as per IS 875 (Part III) – 1997 iii) Earthquake resistant design as per IS –1893 –1984 – Zone III Lateral Building movement (EQ governs) as per latest codes available. iv) The structure is designed as per IS 456 –2000 v) Loading as per IS 875 (Part I) – 1987, IS 875 (Part II) – 1987 vi) The structural design shall comply with applicable codes and regulations. vii) Design engineering documentation of complete tensioned membrane structure will meet all applicable codes. viii) The structure shall be designed in accordance with the IBC Building Code with the design wind speed conforming to IS 875 (Part III) – 1997. ix) Engineering: (a) Based on the structural calculations as defined in this section, prepare structural design drawings defining the complete structure, precise interface geometry determination, reaction loads imposed on foundations, anchoring loads, connection details, interfaces and seam layouts. (b) Structural calculations for the fabric structure shall include: Large deflection numerical shape generation that will insure a stable, uniformly stressed, three dimensionally curved shape that is in static equilibrium with the internal prestress forces and is suitable to resist all applied loads.
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Large deflection finite element method structural analysis of the membrane system under all applicable wind, seismic and snow loads. Finite element method structural analysis of the support frame system. Member sizing calculations of all primary structural members. Connection design including bolt, weld and ancillary member sizing. Biaxial Fabric test specification, interpretation and fabric compensation determination. Accurate generation of the two dimensional compensated fabric templates required to generate the three dimensional equilibrium shapes.
7.3 CODES AND STANDARDS
In addition to the design parameters as per clause 7.2.1 above, all materials and workmanship shall conform to the requirements of the current Australian Standards and any relevant codes mentioned therein as follows:- AS 1170 Rules for minimum design loads and structures, Part 2. AS 1530 Methods for fire tests on building materials, components and structures. AS 1250 1981 Steel Structures Code. AS 1252 1983 High Strength Steel bolts with associated nuts and washers for structural engineering. AS 1394 1984 Round Steel Wire for Ropes. AS 1544 Structural Steel Welding Code – Part 1 – 1985 Welding of Steel Structures. AS 1627 Metal finishing – Preparation and Pre-treatment of surfaces – Part 0 – 1977 and other relevant parts. AS 1650 1981 Galvanised Coatings. AS 1656 1974 Steel wire Ropes AS 2312 1984 Guide to the Protection of iron and steel against exterior atmospheric corrosion. AS 2319 1984 Rigging Screws and Turnbuckles AS 2741 1984 Shackles AS 3569 1989 Steel Wire Ropes AS 2001 Methods of Test for Textiles (various parts; see below) AS 1441 Method of Test for Coated Fabrics. AS 1530 Parts 2 & 3 Methods for Fire Tests on Building Materials, components and Structures. AS 1111 1980 ISO Metric Hexagon commercial bolts & screws. AS 1112 1980 ISO Metric Hexagon Nuts including thin Nuts. Slotted Nuts and Castle Nuts.
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AS 1131 Dimensions of Hot Rolled Structural Steel Sections AS 1163 Structural Steel Hollow Sections. AS 1227 General requirements for supply of hot rolled steel plates, sections, piling & bars for structural purposes.
AS 1428.1 1988 General Requirements for Access – Buildings AS 1552 1973 Classification of Covered Electrodes. AS 1553 1983 Low Carbon Steel covered Electrodes for Manual Metal Arc Welding. AS 1796 1983 SAA Welding Certification Code. Additional standards and codes as set out in the detailed instructions.
7.4 MATERIALS
All materials shall be approved, of the types specified, the best obtainable quality, free from all defects and shall comply with the requirements of the Standard specification for the particular materials and together with fixings, sealants and accessories shall be of substance and temper best suited to the function and particular conditions for which they are used. Any caulking shall be of the type recommended by the supplier for the particular conditions and be applied strictly in accordance with the manufacturer’s written instructions.
7.4.1 Approved Architectural Fabric Membrane Materials
7.4.1.1 PVC (Polyvinyl Chloride)
a) Raw Material: Polyester b) Construction: PVC/PVDF Coated Polyester c) Tensile Strength: to meet requirements of engineer d) Light Transmission: 8% - 14%, depending on required strength e) Color: White f) Expected service life: 7 – 10 years g) Flame retardant: NFPA 701 h) Composure: Solid and water repellent i) Seams: RF Sealed with sufficient strength to develop 90 percent of full strength of fabric j) Recyclable material construction
7.4.1.2 PTFE (Polytetrafluoroethylene) coated Fiberglass
a) Base Fabric: Woven "EC6" glass. b) Coating: PTFE.
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c) Tensile Strength: as required by engineer d) Combustibility: Non-combustible substrate when tested in accordance with ASTM E 136. e) Intermittent Flaming: Class A, when tested in accordance with ASTM E 108. f) Flame Spread: Class A, when tested in accordance with ASTM E 84. g) Flame Retardancy: Passing NFPA 701. h) Solar Transmission: 19 percent, minimum. i) Seams: Welded, with sufficient strength to develop 90 percent of full strength of fabric j) Expected Service Life: 20 to 25 years. k) Color After Exposure to Sunlight: White. l) Composure: Solid and water repellent m) Neoprene gaskets will be used to protect PTFE against contact with metal components
7.4.1.3 HDPE (High Density Polyethylene)
a) Mesh fabric made from UV stabilized HDPE b) Fire Retardancy: NFPA 701 c) Sewn with PTFE thread in a zig-zag stitch to prevent failure under tension d) Color: As approved by architect/owner from available selection
7.4.1.4 ePTFE (Expanded Polytetrafluoroethylene)
a) Tear strength: as required by engineer b) Light Transmission: 30% - 40% with respect to associated required strength c) Color: White d) Flame retardant: NFPA 701 e) Flame spread: Class A (ASTM E84) f) Composure: Solid and water repellent g) Seams: RF Sealed with sufficient strength to develop 90 percent of full strength of fabric h) 25 year expected life - 15 year full warranty i) Recyclable material construction
7.4.2 Structural Steel Framing
i) Structural frame shall be fabricated from structural steel using standard shapes. The steel shall conform to IS:1169 for standard profiles and IS:2062.
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ii) The fabrication of the steel shall be in accordance with guidelines set forth in the Specifiction for Section 10.0 Steel Work. All welds shall be in accordance with manufacturers design and performed prior to shipping. No welding shall be performed in the field unless authorized in writing by the Engineer. iii) The structural members shall be fabricated in as large segments as possible to minimize field joints. iv) All segments of the assembly will be welded or stamped with the appropriate part number in a manner that will still be visible after powder coating is applied. v) Grind all corners and sharp edges. vi) The steel shall be epoxy powder coated to a minimum of 150 micron. vii) Steel will require abrasive blasting and primer before application of the polyester powder paint finish.
7.4.3 Aluminum Membrane Plates and Clamps.
i) Aluminum shall conform to alloy 6061-T6 ii) All components will be welded or stamped with the appropriate part number in a manner that will still be visible after powder coating is applied. iii) The aluminum shall be polyester powder coated to a minimum of 60 micron.
7.4.4 Cables and end Fittings
7.4.4.1 Galvanized Cables and Fittings:
a) All structural wire rope shall be made from Wire Rope conforming to AISI Steel Cable Manual requirements with a Class A galvanized coating or approved substitute. The cable should be IWRC improved plow steel. All cable terminations and connectors shall be hot-dipped galvanized for corrosion protection. Cables should be designed with a minimum safety factor of 2 on breaking strength. b) Cables which are designated to be prestretched shall be prestretched per ASTM A603 for wire rope. Cables of the same type shall have the same modulus of elasticity. c) All cables and end fittings shall be delivered clean and dry. d) All swaged and speltered fittings shall be designed and attached to develop the full breaking strength of the cable. Thimble end fittings shall develop a minimum of 110% of the cable breaking strength. e) Swaged end fittings, pins, nuts and washers shall be electro-galvanized.
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f) Speltered end fittings shall be hot dipped galvanized. g) Attach a tag indicating the cable length and mark number to each cable assembly. h) The design load is the load in the cable under prestressed load condition per the recommendation of the engineer on record i) Cables shall be tensioned to double the design load before length is cut j. Cables shall be tensioned to the design load when measuring the cut length that is indicated on the shop drawings
7.4.4.2 Stainless Steel Cables and Fittings:
a. Cables shall be 1x19 Stainless Steel Open Strands, Grade 316 b. Cables and fittings will be fabricated per the standard operating procedures of the following approved manufacturers: Frontier Technologies Ronstan International c. Attach a tag indicating the cable length and mark number to each cable assembly. d. The design load is the load in the cable under prestressed load condition per the recommendation of the engineer on record e. Cables shall be tensioned to double the design load before length is cut f. Cables shall be tensioned to the design load when measuring the cut length that is indicated on the shop drawings
7.4.5 Bolts and Related Fasteners
i) Fasteners and hardware accessories shall be of types and sizes best suited for the purpose as recommended by the engineer on record. ii) Fasteners used on main structural members shall be hot-dipped galvanized high strength bolts including nuts and washers, and conforming with ASTM A325 or A490 as applicable. All other fasteners shall be adequately sized and treated for corrosion protection. iii) Concrete anchor bolts shall conform to A307 and be Hot-dipped Galvanized.
7.5 SHOP DRAWINGS
Shop drawings mean complete drawings showing all details of fabrication, assembly, installation, fixing and waterproofing methods of specific items or components include all necessary explanatory notes and specifications.
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The Contractor warrants that he will produce all detailed shop drawings for checking and/or approval by the Engineer at such times as required by the Contract Programme. In no case shall the Contractor proceed with fabrication and production of any components until the said drawings are checking and/or approved by the Engineer.
7.6 INSTALLATION
7.6.1 Seam Layout
Submit to the Engineer for approvals a seam layout indicating the proposed location and width of all seams to be included in the complete membrane.
7.6.2 Wrinkles
There shall be no wrinkles in the completed membrane which in the Engineer’s opinion are visually objectionable whether viewed internally or externally. Some tolerance on uniformity of the tensioned fabric against wrinkling is accepted. The following limits on the degree of wrinkling shall be used as a guide :- ii) Isolated wrinkles upto 200mm long at seams and stress points – one (1) only 100 square metres. iii) Isolated wrinkles approximately a panel width in length – none (0) only per 100 square metres. iv) Continuous line of small wrinkles over one metre in length – one (1) per 100 square metres. v) General wrinkle across dimension of canopy section – none. vi) For the purpose of these tolerances, a wrinkle shall be a fold in the fabric canopy in the pre-stressed condition in still air and which is visible from the ground below the canopy.
7.6.3 Patches
There shall be no patches in the completed membrane which in the Engineer’s opinion and given reasonable commercial considerations involved in rectification, detract significantly from the overall aesthetic effect of the complete installation. Minor patching resulting from events on site during erection shall be permitted as follows and only to be carried out where the damage to be rectified is relatively minor and the effect of the patching is not visually dominant. The permissible patching is as follows :- Maximum area of 50mm diameter per 100 square metres. Maximum number of patches is one per 100 square metres.
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Patching shall be carried out in an approved manner using appropriate seaming equipment and techniques.
7.6.4 Fixing Details
The fixing materials used to attach the membrane to the supporting stainless steel framework shall be of the highest quality compatible with the minimum anticipated life of the membranes. Minimum requirements are as follows :- Fasteners: Stainless Steel Grade 316.
7.6.5 Patterning Design
Membrane form finding design analysis and patterning shall be by computer finite element analysis conducted by an engineer experienced in the field of tensile engineering. Submit shop drawings to and obtain approval of the design from the Engineer prior to ordering or cutting for fabrication.
7.7 FABRICATION
7.7.1 General
The Contractor is to employ the greatest care in cutting of the fabric. All cut edges of the fabric panels shall be continuous curves free from irregularities. The fabric shall be cut along marked lines to any accuracy of +/-2 mm. The structure shall be fabricated under factory shop conditions. The Contractor shall carefully plan his assembly to ensure that seams are always shingle laid and that a cut edge does not face uphill. All welded seams, reinforcements, assemblies, rope reinforced edges and other details are to be executed in accordance with the approved drawings. Any hole punching indicated on the drawings shall be performed by the Contractor. At positions where bolt or other penetrations of the fabric is shown or required, holes shall be punched using a sharp 1mm oversized punch. Holes shall be neat and have uniform edges. Rope edges shall be formed using hard polypropylene or polyester rope of minimum diameter 12mm. The structure shall be fabricated using field splices only where shown and approved by the Engineer. Where splices are not specified and the Contractor proposes the use of same, describe in full in the tender offer including details of location and design. All add-on details to the fabric shall use the same seaming procedures as for structural seams.
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The Contractor shall exercise great care in marking, cutting, aligning, checking, welding seams and additions as well as general handling and soiling prevention procedures to produce a smooth uniform surface with even curved edges and interfaces lacking wrinkling, cuts, abrasions, stains or marks, surface imperfections or welding aberrations.
7.7.2 Fabric Joints
Joints shall be formed at under pressure at the appropriate temperature and to a tolerance of + 2mm. Adjacent panels shall be lapped by 75mm, FEP ribbon inserted between the two panels then heat and pressure applied. All excess matter FEP ribbon, markings etc. shall be removed from the membrane before packing. All fabricated joints shall have a minimum of 90 percent of the total strength of the coated fabric in strip tensile testing. All structural joints must maintain the integrity of the coating and ensure complete isolation of the base fabric from air and moisture. Joints shall be symmetrical as specified by the cutting pattern. No short pieces or selvage shall be permitted.
7.7.3 Packing
The Contractor shall be wholly responsible for employing particular measures to prevent any damage occurring to the fabric coating or to the base cloth. The fabric shall be folded in such a manner as to minimize sharp creases and folds. All materials shall be packed in substantial crates and shall be designed to protect the materials contained against hazard both during transit and whilst stored at the site.
7.8 CONSTRUCTION
7.8.1 Specialized Agency for Erection
The Erection of Tensile Membrane (fabric) Roofing System shall only be carried out by an approved specialist agency experienced in this work. The Tensile Membrane (fabric) Roofing agency engaged to carry out the Tensile Membrane (fabric) Roofing installation should have at least 5 years of relevant experience and have completed Tensile Membrane (fabric) Roofing of similar nature and equivalent scale to the works as shown in the tender documents. The Contractor shall submit an outline of recent works (illustrated by appropriate drawings, sketches, photographs and/or brochures) by the firm to illustrate the competence, experience and suitability of the firm.
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The firm must be able to provide shop details belonging to a proprietary system. The Engineer reserves the right to reject any or all agencies proposed by the Contractor. The contractor shall propose two or more agencies so that no delay is occurred in case of rejection of his sub- agency by the Engineer. The delay in this process shall be accountable only to the contractor.
7.8.2 Erection
7.8.2.1 Method of Erection
The Contractor shall prepare a full and comprehensive assembly procedure guide prior to installation. Comply with the TFS Manufacturer recommendations, the approved shop drawings and the applicable Code requirements.
7.8.2.2 Weather Conditions:
Proceed with installation of the fabric and associated work only when existing and forecasted weather conditions will permit work to be performed in accordance with manufacturers recommendations. The Tensioned Fabric Structure shall not be installed when wind conditions are deemed in excess of manufacturer’s determination of safe wind speed erection conditions. It shall be the manufacturer’s sole discretion to determine acceptable and safe wind condition for installation.
7.8.2.3 Framing and structural members:
Anchor bolts shall be accurately set. Uniform bearing under base plates shall be provided using non shrink grouting compound where applicable. Members shall be accurately set to assure proper fitting and covering. As erection progresses, the work shall be securely fastened to resist the dead load and wind and erection stresses. Erected structural frame work shall be adequately guyed and secured to resist all possible loads due to wind and the installation process.
7.8.2.4 Fabric
Prior to start of installation; check all surfaces of framing members and other rigid construction elements to be in contact with fabric to ensure that all edges are smooth and well rounded. Remove any potential causes for snagging or tearing of the fabric. Properly install all connections and provide all materials and equipment required for the erection and stressing of the fabric. Unroll the fabric in such a manner as to avoid snagging or dragging the fabric over sharp objects during installation. Adequate fabric prestress shall be confirmed by the fabric structure manufacturer and the
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appearance of the fabric membrane roof shall be smooth and wrinkle free. Creasing or folding the fabric around sharp corners shall be avoided at all times.
7.8.2.5 Fabric tensioning system
Cables shall be free of all kinks and bends. Care shall be taken not to damage cables during installation. Bolt holes shall be 1/16” larger then the bolt, unless otherwise indicated. After installation, restore marred or abraded surfaces to original condition using same paint or coating as factory-applied finishes, when the results are acceptable to the Architect, otherwise replace damaged equipment.
7.8.2.6 Handling
All surface areas to be in contact with the fabric shall be checked for smoothness. All edges shall be smooth and well rounded. No creasing or folding of the fabric around sharp corners is to be permitted. The fabrics shall not be abraded in any manner.
7.8.2.7 Cleaning
The fabric elements shall be cleaned and dried after erection.
7.8.2.8 Final Inspection
The Contractor shall give seven working day’s notice to the Engineer on completion of installation of fabric structure and shall execute immediately any adjustments, making good damage or defects etc. as instructed by the Engineer.
7.9 RATE & MEASUREMENTS
The entire system shall be measured in Sqm. corrected to two decimal for the finished work in specified area of the tensile fabric in the general plane of the fabric after installation (not girthed). The rate includes for the entire installation including necessary stainless steel and structural steel frame work, all accessories etc. complete as instructed by the Engineer.
7.10 GUARANTEE
The contractor shall be fully responsible for and shall guarantee proper performance of the entire installed system for a period of 10 (Ten) years from the final completion of works. The entire installation shall be to the best international standard and shall specially take account of wind loads, storms, air pollution, thermal stresses and the like.
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The Contractor shall furnish a minimum of 10 year Performance Warranty for the entire installation carried out in approved pro-forma. Contractor to fulfil the quality standards stipulated in this document. The performance guarantee shall cover for replacement of any or all members and components by the Contractor at his own cost in case of any deficiency or failure in performance of the curtain wall component as per the design requirement during the warranty Period.
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8.0 HORTICULTURE WORKS
8.1 MATERIALS - GENERAL
8.1.1 Soil for ground
Good earth/garden soil shall be friable loam material, fertile, typical or the cultivated topsoil’s of the locality, containing at least 2% of decay organic matter. Topsoil shall be taken from a well drained aerable site and shall be reasonably free of subsoil, stones, weeds, earth, clods, sticks, roots or other objectionable extraneous matter or debris and shall contain no toxic materials. Representative samples shall be tested for fertility and general texture (sieve test) by the contractor or by a recognized commercial or government agency. No topsoil shall be delivered in frozen or muddy condition.
8.1.2 Manure
CITY COMPOST Manure - Manure should be well rotten and of standard quality (Preferably Dynamic lifter). Manure shall be well mixed with soil in proportion as proposed by consultant. The supply of the manure shall be in branded 50kg bags including transportation upto site & internal transportation at desired. Manure shall be free of weeds, straw leaves or inorganic debris. It shall not be less than 8 months and more than 24 months old.
8.1.3 Sand
Coarse sand taken from a dry river or sandy area shall be well washed and leached, and shall not contain any toxic chemical harmful to plants. Sand must be free of cobbles, stones, earth, roots, weeds and other foreign material. Sand will be incorporated and mixed topsoil.
8.1.4 Planting Medium
The ratio of the planting medium of the garden soil, sand, manure shall be: 3:1:1 on ground. The ratio of the mix to be used on terrace will be - 3:2:2:2:1 (Garden Soil 30%, sand 20%,Agropeat 20%,Vermiculite 20% & Charcoal 10%
8.1.5 Fertilizer
Shall be complete fertilizer consisting of nitrogen, phosphorous and potash (NPK17:17:17 (5kgs/M3). It shall be applied by weight in two applications. The first application shall be within one week before planting harrowed into the top 6 inches of
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soil. The second application shall be done, as the Horticulturist -in-charge / Landscape Architect will think is needed at a later stage.
If pH exceeds 7.5 ammonium sulphate or equivalent fertilizer should be added. Sufficient Limestone or equivalent fertilizer shall be added to bring it to a range of pH 6.5 to 7.5 in case pH is below 6.5
8.1.6 Root Barriers/HDPE edges
The root barriers will be of HDPE sheets in 50 to 100m rolls of 0.3m depth and 0.7mm thickness fixed between two types of lawn or lawn and planting as shown in the drawings. It should be 20mm above the finished grade of the lawn to prevent invasive runners from mixing with other lawn. Typical properties of the root barrier membrane are: PROPERTY VALUE STANDARD Material HDPE - Dimension (length) 100 m - Dimension (depth) 300, 600, - 1000 & 1500 mm Thickness 0.70 ± 0.05 mm - Break strength ASTM D638 - machine direction 2600 t/m2 - transverse direction 2700 t/m2 Break elongation ASTM D638 - machine direction 600 % - transverse direction 700 % Tear strength ASTM D1004 - machine direction 14 N - transverse direction 15 N Puncture strength 36.5 N ASTM D4833 Hydrostatic resistance 200 t/m2 ASTM D751-A
Multi-axial tensile stress 1600 t/m2 ASTM D5617-A
Elongation at rupture 20.8% ASTM D5617-A
8.1.7 Drain Cell
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Size 305X305X20mm,100% recycled polypropylene, weight -250gms/sq.ft. The compressive load will be above 1200KN Opening - above 70% are easy to install, by interlocking them horizontally and vertically. Replacement if broken during execution and maintenance period included
8.1.8 Geo-textile Fabric
Laying & Fixing the Geo-Fabric 150 GSM,- 100% recycled polypropylene, of thickness 1.3mm, -Tensile strength at breaking more than 4.5KN/m. CBR plunger strength more than 0.6 KN, and Tearing strength more than 0.12KN, Breadth Tolerance to be 0.5%, and Elongation at breaking 25-100%, EOS O90 0.07-0.2mm, Vertical Permeability Kx (10-1 ~10-3) CM/S, including cutting & Fixing, etc. charges for complete finish work (measurement taken only of actual work done excluding wastage) .Supply &transport of geotextile as per the specification given here.
8.1.9 Coir Mat on Slope
a) Supply & transport of coir mat as per the specification. Rate to include transport, base-preparation, installation, labour etc. b) Begin at the top of the slope and anchor Coir Mat in a 12” deep initial anchor trench. c) Backfill trench and tamp earth firmly. d) Unroll matting down slope Overlap edges of adjacent parallel rolls 6” and anchor with stable at 12” centers. e) When Coir Mat must be spliced, place end over end(shingle style) with 12”overlap and anchor using two staggered rows of staples at 6”centers. f) Lay mat loosely and anchor sufficiently to maintain direct contact with the soil. g) For slopes 2:1 and steeper use a minimum of 3 staples per square yard and for slopes flatter than 2:1 using a minimum of 2 staples per square yard. h) Anchor, fill and compact end of the matting in 12” x 6” terminal anchor trench.
8.1.10 Light Weight Material Filling
a) Option-a—Brick bat Filling 4" thick Brick Bat of good quality, well burnt of size 2" to 4" by proper arrangement & filling gaps in between the perforated pipes for subsurface drainage (as per consultant) by river Sand of approved grain size, Broken bricks &
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crush of bricks & for filter media, achieving a clean finished given level, etc everything complete all as directed by engineer in charge/ Landscape Architect b) Option-b- Cinder Filling required area with well burnt wood pieces or cinder that are neutral in their effect on the soil or plants. The Cinder pieces should not have sharp edges. After laying achieving a clean finished given level etc as directed.
8.1.11 HDPE sheet
Available in custom size and length. Colour - Natural laid over waterproofing layer. Non-corrosive, Non-Toxic. Low coefficient of friction, Corrosion resistant ,Abrasion and impact resistant, Anti-Weather and Anti-Aging, Self-lubricating. Wear Resistant. Great liner material for industrial material handling applications, UV Resistant High Operating Temperature High Tensile Strength, High Viscosity, Flame Retardant Reprocessed. Supply &transport of as per the specification Job to include transport, base-preparation, installation, labour etc. This is laid under the mounds on the Podium for area of 6x6m under the mounds.
8.2 MATERIALS – PLANT/LAWNS
8.2.1 Plant Material
Trees, Shrubs, Ground Covers, Creepers, etc.
8.2.2 Plant List
Plants are listed in the drawings. The plant list is enclosed herein.
8.2.3 Nomenclature
The names of the plants confirm to standardized botanical names.
8.2.4 Quality and General Requirements of Plants
a) Plants shall be typical of their species and variety, have normal growth habits, well developed branches, densely foliated with vigorous and fibrous root systems. b) Plants shall be free from defects and injuries. Bark shall be free from abrasion. c) Plants shall be freshly dug and nursery grown. Plants shall be grown under climatic conditions similar to those in locality of project, or acclimated for at least 2 years to conditions of project location. Nursery grown plants shall be at least once transplanted.
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d) Each bundle of plants and all separate plants be properly identified by weatherproof labels securely attached there to before delivery to project site. e) No. of plants shall be delivered to the project site, except for required samples, until inspection has been made in the field or at the nursery, or unless specifically authorised in writing by the ARCHITECT. f) B & B (Balled and Burlap) plants must be moved with the root system as solid units in balls of each firmly wrapped with burlap. The diameter and depth of the balls of earth must be sufficient to encompass the fibrous and feeding root system necessary for the health development of the plant. No plant shall be used when the ball of earth surrounding its roots have been badly cracked or broken preparatory to or during the process of planting or after the equipment required in connection with its transplanting has been removed. The plant and ball shall remain intact as one unit during all operations. g) Container grown stock shall be grown in containers long enough for the root system to have developed sufficiently to hold its soil together, firm and whole. No plant shall be loose in containers. h) All plants shall be hardy under climatic conditions similar to those in the locality of the project. When plants of kinds or sizes are not available substitution may be made upon request by the Contractor if approved by the LANDSCAPE ARCHITECT. i) All trees, soon after planting shall be properly supported to ensure their safety against wind or other factor, which may effect if adversely. As minimum of 3 stakes per tree shall be provided by the contractor.
8.2.5 Size of Plants
a) All plants shall be equal to or exceed the sizes given in the plant list, which are minimum acceptable sizes. Plants shall be measured before planting, with branches in normal position. b) Trees shall be of minimum length as specified and shall be straight and symmetrical with a crown and having a persistent main stem. The size of the crown shall be in good overall proportion to the height of the tree shall be measured from the top of the root ball or pot. In case of palms, ht. will be measured from top of root bell to the point of branching of leaves. c) Shrubs shall be well formed with a crown typical of the species and variety. Shrub height dimensions shall be the average height of the top of all stems and not of longest stem preferably to be supplied in 8” pots.
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d) Ground cover, plants shall be least 12” and will be supplied in suitable poly bags or pots.
e) Creepers and vines shall have at least 4 runners, and shall be supplied in 8 inch earthen or other suitable pots.
8.3 HORTICULTURE WORKS
8.3.1 Scope of Work
The Planting Contractor shall provide all horticultural operations and services specified on the drawing schedule of quantities as specified herein or both, for plant nursery and for early procurement, maintenance and planting plants at positions on site and during subsequent planting maintenance period. Provide labour, equipment, services and transport. Provide fertilizers, chemicals and manure and stakes as specified. Preparation of planting locations. Prepare plant pits, back filling; prepare “saucers” for watering, adding soil after settlement. Spraying before planting. Staking, supporting, wrapping and tying plant materials. Transplanting, if any. Disposal of debris and unused materials. Guarantee of trees and plants for a period of 12+24 months. Free visiting, inspecting and consulting for the period of 12+24 months.
8.3.2 Plant Materials/Lawns
Area – All exterior ground area, except surfaces occupied by structures and paying as well as areas indicated to be undisturbed or planted (trees, shrubs, ground covers, creepers, vines, annual plants etc.) shall be planted as shown on drawing. i) Ground Preparation a) Grading – Grade lawn areas to finish grades, filling as needed or removing surplus dirt and floating areas to a smooth, uniform, grade as indicated. All lawn areas shall slope to drain. b) Where no grades are shown, areas shall have a smooth and continual grade between existing contours (such as walks, curbs, catch basins, elevation at steps or building) and elevation shown on plans. Roll, scarify, rake and level as necessary to obtain true, even lawn
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surfaces, all finish grades shall meet approval of the LANDSCAPE ARCHITECT or his authorized representative, before lawn is laid.
c) Chemical fertilizer shall be spread on areas to be seeded at the rate of 20 lbs. per 100 square feet the fertilizer shall be 50% organic and shall be applied from a suitable spreader. d) City compost-Manure shall be well-rotten unleached, free from sawdust shavings, refuse an harmful chemicals, manure shall contain no lumps which will not pass a 2 inch sieve. Spreading of 1 inch thick layer of manure on the ground and mixing with the good earth. e) After incorporation of fertilizer in the soil, the lawn bed, shall be graded to remove all ridges and depressions, and surface cleared of all stones 1 inch or more in diameter and of other debris. At least I inch layer of manure is to be spread on the ground and mixed with earth for grassing. Ref. given specification for lawn bed preparation. f) Planting of rooted cuttings grass at a regular distance of 5cm centre to centre. After 15 days 1st mowing should be done. Laying grass carpet directly on prepared ground, rolling lightly with a roller and fixing appropriate signage to warn people of unstabilised lawn to prevent walking over them. ii) Planting Operations a) Time of planting – Planting operations shall be conducted under favourable weather conditions, the contractor will be notified by the LANDSCAPE ARCHITECT representative when areas of work are sufficiently clear of construction work for the contractor to commence work on planting. The ground cover for slopes and stabilisation will have to be done after the monsoon to allow for the plants to grow before the next monsoon and stabilise the slope b) Planting shall be done by experienced workmen familiar with planting procedures under the supervision of a qualified foreman. Planting should be carried out as soon as acclimatized to site conditions. Where planting must be delayed, care should be taken to protect the plants from pilfering or damage from people or animals. Plants with bare roots should be heeled-in as soon as received or otherwise protected from drying out, and others set closely together and protected from the wind. If planting is to be delayed for more than a
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week, packaged plants should be unpacked, the bundles opened up and each group of plants heeled in separately and clearly labeled. If for any reason the surface of the roots becomes dry the roots should be thoroughly soaked before planting. c) Plant Pits shall be excavated with vertical sides, except for those designated to be planted in beds. Plant pits shall be of the following sizes. d) Palms and Trees – 0.9m dia, 0.9m depth. min. for small trees, for large trees as specified in tender, tree pits shall be large enough to accommodate the root ball – 1/3 root depth on all sides. Trees staked for support. e) Shrubs & Climbers bed – 0.45m depth of bed & incase of individual shrubs, 0.45m dia & 0.45m depth. f) Ground Cover and lawn bed – The bed shall be dug a depth of 30 cms. THE LANDSCAPE ARCHITECT shall inspect and approve plant pits before the contractor proceeds with placing of plants. Topsoil shall be made ready for planting before plants are delivered to the site. The pits / beds shall be given anti termite treatment before backfilling.
iii) Placing of plants Plants shall be centre of pits plumb and straight. The LANDSCAPE ARCHITECT shall inspect and approve placing of plants before the contractor proceeds with further operations. iv) Final Considerations Topsoil shall be compacted around basin of balls to fill all voids. Roots shall be properly spread out and topsoil carefully worked in among them.
8.3.3 Completion
On virtual completion the ground shall be formed over and left tidy, before commencement of maintenance.
8.3.4 Maintenance
The landscape contractor shall maintain all planted areas within the landscape contract boundaries for 12+24 months until the areas are handed over in whole or in phases. Maintenance shall include replacement of dead plants, watering, weeding, cultivating, control of insects, fungus and other diseases by means of
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spraying with an approved insecticide or fungicide, pruning, and other horticulture operations necessary for the proper growth of the plants and for keeping the landscape contract area neat in appearance. a) Lawn Maintenance Maintenance shall consist of watering, weeding, fertilizer, liming, disease and pest control, aerating, protective spraying, replacement of unacceptable material and any other procedure consistent with good horticultural practice necessary to ensure normal, vigorous and healthy growth of all planted area. For the first 30 days, it requires approximately 500 gallons of water for every 100 square feet every day for each application to penetrate the soil to a depth of 4 to 6 inches. After the, same quantity of water shall be applied on alternate dates. Keep all planting areas free from weeds and undesirable grasses. Mow all grass areas at regular intervals which will keep grass height from exceeding 2.5 inches. Remove all grass clippings during or immediately after mowing. Make periodic test during the maintenance period to determine the degree of compaction existing in all lawn areas. If soil is compacted to a degree that water and air penetration is impaired, the Contractor shall aerate these areas to the satisfaction of the LANDSCAPE ARCHITECT. Maintenance shall also include all temporary protection fences, barriers and signs and all other work incidental to proper maintenance. Upon completion and inspection of all repairs or renewals necessary in the judgment of the LANDSCAPE ARCHITECT, the LANDSCAPE ARCHITECT shall certify in writing to the clients. b) Watering : The contractor should allow for the adequate watering in of all newly planted trees and shrubs immediately after planting and he shall during the following growing season, keep the plant material well watered. c) Fertilizing : Fertilizing shall be carried out when directed by Landscape Architect by application in rotation of the following fertilizers. - Organic well-rotted dry manure : 0.05 cum or 1 tassla - Urea 25 gm All shrubs which are supplied shall be well soaked prior to planting. Frequent watering of summer planted container-grown plants is essential. d) Pruning and repairs :
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Upon completion of planting work under the contract all trees should be pruned and all injuries repaired where necessary. The amount of pruning shall be limited to the minimum necessary to remove dead or injured twigs and branches and to compensate for the loss of roots and the result of transplanting operations. Pruning shall be done in such a manner as not to change the natural habit or special shape of the trees. e) Tree Guards : Where tree guards are necessary, care should be taken to ensure that they do not impede natural movement or restrict growth. They should be monitored and removed once the tree is stable. f) Protective Fencing : According to local environment plants shall be protected adequately from vandalism until established.
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9.0 LIST OF APPROVED MAKE / MANUFACTURERS
9.1 GENERAL NOTES
i) Products with relevant I.S. markings from the I.S. Licensed manufacturers, who are in the market for the last three years with valid I.S. License, shall be considered for approval. Only “First” quality materials shall be used. ii) Employer reserves the right to choose any of the approved make/vendors as per this list. iii) In case of products not indicated in this list, only BIS marked products shall be used subject to prior approval of Engineer-in-charge. iv) Specification of manufacturer’s item shall be checked against tender item / specifications before selecting any product or brand name. In case of any discrepancy, tender item / specifications shall prevail and any such brand of item shall not be used which is not conforming to tender specifications even if it is listed in this list. v) For use of material from a BIS listed / certified manufacturer, the contractor shall furnish a copy of the valid BIS certificate to the Employer before procuring the material. vi) In case of non-availability of any item / material among approved manufacturers / brands, alternate manufacturers / brands conforming to BIS / BS etc. shall be proposed along with required credentials for Employer’s approval. vii) Employer reserves the right to accept/reject any new brand(s) proposed by the tenderer / contractor. viii) Samples of all materials, fittings etc. to be incorporated in the work shall be submitted by the contractor and got it approved from the Engineer-in-Charge, before supply in bulk at site of work. Wherever particular make or its equivalent is mentioned in the item schedule, the decision of the Engineer-in-Charge in selection of particular make or its equivalent shall be final and binding on the contractor. The approved samples will be kept in custody of the Engineer-in-Charge till completion of the work. Materials not conforming strictly to the approved samples will be rejected. S.No. Item Manufacturer 1.0 CIVIL WORKS 1.1 Stainless Steel A Salem Steel B Indalco 1.2 Aluminum Extrusion A Hindalco
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S.No. Item Manufacturer B Indal C Jindal D Bhorukha 1.3 Cement Concrete Blocks A Prayosa B Automatic C Ved PMC D LANWIN 1.4 High Tensile bolts A Unbrako B GKW C Fischer D Hilti 1.5 Joint Fillers (Cementitious) /Injection Grout A BASF B Laticrete C Balendura Group D Fosroc E Saint Gobain Weber F Sika 1.6 Plaster additive A BASF B Laticrete C Fosroc 1.7 Readimix Plaster A Ultratech Cement ltd B Roofit C Ramco OR Approved Equivalent 1.8 Glass A Saint Gobain B Glaverbel C Pilkington 1.9 Granite Sealer A Laticrete 1.10 Stainless Steel Sheets A Rimex B Jindal C Sailam 2.0 FLOOR FINISHING 2.1 Vitrified Tiles A RAK Ceramics B Asian C Euro D SPL Ltd. E H & R Johnson (I) Ltd. F Murudeshwar Ceramics Ltd.
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S.No. Item Manufacturer G Kajaria Ceramics Ltd. 2.2 Wooden Deck flooring A Xylos Arterior India Pvt. Ltd B Square Foot C Ego Flooring D Pergo Flooring
3.0 PAINTING WORKS Plastic /Acrylic Emulsion Paint 3.1 Internal and External Emulsion Paints A ICI Paints / ICI India Ltd. B Berger Paints C Asian Paints D Shalimar Paints E Nirolac Paints 3.2 Decorative Textured Coating A Damani Dye Chem B Luxture Surface Coatings Pvt.Ltd. C Bakelite Hylam Ltd. D NCL Alltek and Seccolor Ltd. E Acro Paints Ltd. F UNITILE G Spectrum Paints D Jotun 3.3 Primer (Metal, Wood, Cement) A Asian B Nerolac C ICI D Jotun E Berger F Nippon 3.4 Anti-Corrosive Paints A Asian B Nerolac C ICI D Jotun E Berger F Nippon 3.5 Paints (Cement, Wood, Metal) A Asian B Nerolac C ICI D Jotun E Berger F Nippon 3.6 Steel Protection System
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S.No. Item Manufacturer A Akzonobel B Jotun 4.0 ANCHOR FASTENERS 4.1 Mechanical Anchor Fasteners A Hilti India Pvt.Ltd. B Fischer Fixing Systems (MICO) Ltd. C MKT (Germany) 4.2 Chemical Anchor Fasteners A Hilti India Pvt.Ltd. B Fischer Fixing Systems (MICO) Ltd. C MKT (Germany)
5.0 SCREWS A Hilti B Philips C GKW 6.0 SS Railings System A Carl-F B Neki-Kich C Q-Railing D Metalplas Engineering E Dorma 7.0 Tensile Fabric System A Sioen Industries B Serge Ferrari
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C. ELECTRICAL WORKS
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1.0 ELECTRICAL EQUIPMENTS
The following Technical Specifications are made applicable for the Stated Job and shall be rigidly adhered to while supplying and installing the materials at site.
1.1 Codes And Standards:
1) The following Codes and Standards shall be applicable for continuous performance of all electrical equipments to be supplied, delivered at site, erected, tested and commissioned. The Electrical equipments offered shall comply to the relevant Indian Standard Specifications, Fire Insurance Regulations, Tariff Advisory Committee's Regulations, and in particular to Indian Electricity Rules in all respects with all its latest amendments up-to-date.
2) For guidelines to the tenderers, few of the Indian Standards are indicated below:
IS 8084 / 1976 Interconnecting bus-bars for A.C voltage above 1KV up to & including 36KV.
IS 13032 / 1991 A.C miniature circuit breaker board for voltage not exceeding 1000V specification.
IS 3043 / 1987 Code of practice for earthing.
IS 3427 / 1997 A.C metal enclosed switchgear & control gears for rated voltage above 1KV up to & including 52KV.
IS 3837 / 1976 Accessories for rigid steel conduits for electrical wiring.
IS 13947 / Part3 / 1993 Specification for low voltage switchgear & control gear.
IS 13947 / Part1 / 1993 Specification for low voltage switchgear & control gear.
IS 4615 / 1968 Switch socket outlets (Non-Interlocked type).
IS 5216 / Part1, 2 /1982 Guide for safety procedures & practices in electric work.
IS 5578 / 1984 Guide for marking of insulated conductors.
IS 5820 / 1970 Specification for precast concrete cable covers.
IS 6381 / 1972 Specifications for construction & testing of electrical apparatus with type of protection ‘e’.
IS 10322/ Part1, 2/1982 Specification of luminaries.
IS 10322 /Part3, 4/1984 Specification of luminaries.
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IS 10322/Part5 (Sec1, 2)/1985 Specification of luminaries.
IS 10322/Part5 (Sec3 to 5)/1987Specification of luminaries
IS 13947 / Part1 / 1993 Specification for low-voltage switchgear & control gear.
IS 13703 / Part4 / 1993 Specification for low voltage fuse for voltages not exceeding 1000V AC or 1500V DC.
IS 2551 / 1982 Danger notice plates.
IS 2268 / 1994 Call bells / Buzzers.
IS 732 / 1989 Code of practice for electrical wiring installation.
IS 3854 / 1997 Switches for domestic & similar purpose.
IS 2309 / 1989 Code of practice for lighting production.
IS 2418 / Part1 to 3/1977 Tubular fluorescent lamps for general lighting service.
IS 1937 / Part3 / 1983 Conduits for electrical installations.
IS 13032 / 1991 AC miniature circuit breaker board for voltage not exceeding 1000V.
IS 2667 / 1988 Fittings for rigid steel conduits for electrical wiring.
IS 2675 / 1983 Enclosed distribution fuse boards cutouts for voltage up to 1000V.
IS 2706 / Part1 to 5/1992 Current transformers.
IS 15086 / Part1 / 2001 Surge arresters.
IS 13925 / Part1 / 1998 Shunt capacitors for AC power systems having a rated voltage above 1000V.
IS 5578 / 1984 Guide for marking of insulated conductors.
IS 418 / 1978 Tungsten filament general service electrical lamp.
IS 694 / 1990 PVC insulated cable & cords for power / lighting.
IS 13010 / 2002 A.C watt-hour meters.
IS 732 / 1989 Electrical wiring installation (up to 650V).
IS 10870 / 1984 Code of safety for hexane.
IS 1248 / Part1 / 1993 Direct acting indicating instruments & their accessories.
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IS 1248 / Part2, 6 /1983 Direct acting indicating instruments & their accessories.
IS 1248 / Part7, 8/1984 Direct acting indicating instruments & their accessories.
IS 1248 / Part9/1983 Direct acting indicating instruments & their accessories.
IS 1293 / 1988 3 Pin plugs & socket outlets.
IS 1554/Part1 to 3/1988 PVC insulated cables – heavy duty.
IS 13947/Part 1 to 5/1993 Low voltage switchgear & control gear.
IS 1651 / 1991 Lead acid cell batteries.
IS 9537 / Part 5 / 2000 Conduits for electrical installation.
The entire electrical installation work shall be strictly complied with the Codes Standards, Rules and Regulations framed under the Indian Electricity Act. Further, it shall be carried out as per the Regulations and Rules setout by "Tariff Advisory Committee and/or Fire Insurance Regulations". Any other IS Codes As applicable at the time of execution over and above whatever stated above. Some of the Rules framed under Indian Electricity Rules of 1956 and all amendments thereof more particularly complied to: 35, 43, 44, 44-A, 45 (Part-I), 50, 51, 59, 61 (a), 61 (c), 62, 63 (2), 65, 66, 67, 68, 69 and 92 (2).
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2.0 L.T. EQUIPMENTS
2.1 Scope:
This Specification covers the design, manufacture, testing and supplying of all substation equipment’s required to be installed to complete of the sub-station in all respect and to complete the installation in working condition
2.2 Applicable Standards:
All relevant Indian Standards shall be made applicable with latest amendments. Also any other specific application is required, and then the same shall be complied to.
2.3 440 Volts grade Warning Boards
440 Volts Red Warning Boards of made up of Aluminium sheet and having size of 150 mm x 150 mm x 3 mm thick painted with self illuminated fluorescent “RED” Colour paint shall be fixed at prominent places. These shall have minimum 2 languages inscribed on it, mainly Local Language, and English. The Warning Boards shall also have the usual Electrical Shock inscriptions as well as the small mark of Danger on it. These shall be fixed out side of all the electrical rooms and as per directions of Consultant/ Engineer in charge.
2.4 Rubber Matting
In the front operational part of Medium Voltage Panels a Rubber Matting shall be placed. The Rubber Matting shall be of approved quality of size not less than 1000 mm (wide) x 20 mm (thick). The length of the rubber matting shall be such as to cover the entire working area in front of all the equipment’s placed in the Main LT Room. These shall further comply to relevant standards under Indian Electricity Rules and Codes of Standards. The mats shall be so designed to withstand 1100 Volts for 1 minute and leakage of current shall not exceed 160 mA/square meter.
2.5 Fire buckets, extinguishers and charts
Fire buckets, Fire extinguishers and charts shall be supplied as per the list given below. The fire buckets shall be made up of galvanized Iron Sheets of approved thickness and painted Red with letters of 'FIRE' written on it. 5 such buckets shall form one set and they shall be hung by means of hook arrangement from a stand prepared out of Round steel bars with supporting frame. This frame work shall also be painted 'RED'.
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The fire buckets shall be filled with clean, dry and peddle free sand ready for immediate use for extinguishing fires. There shall be two such sets kept ready one in the switchyard under a proper weather protection shed and the other inside the HV/LV Room. The number of Fire extinguishers shall be as per the insportate. These shall be CO2 type and shall be tested at least once in six months on the site, after erection. This shall be as per relevant Indian Standards of minimum 6.8 Kgs. Instructions charts of restoration of persons suffering from Electric shocks in English, Hindi and Marathi shall be displayed in an enclosed wooden/glass frame work, one in the LV Room and the other in the H.V. Room.
2.6 The Contractor has to also ensure the following things during the execution of the job or before starting of any wok/job.
1) The Rate quoted by the contractor shall include all the associated civil work like cutting, chasing walls, making holes in wall/ceilling for cables and conduits, cable trays, grouting of panels, DB’s etc and making good of the same.
2) The Contractor should employ full time Degree holder site Engineer having minimum Twelve Years experience in the field. Further he should also employ Two Nos. full time Diploma holder site supervisor having minimum Seven years experience.
3) The Contractor should produce copies of the Supervisors & Workmen licences prior to start of any work at site.
4) When there are differences between Specifications and Schedule of quaintness, the superior of the two will be applicable. No additional payment will be entertained. Also Consultants decision in this matter will be final and binding on both the parties.
5) All changes made by the Architects/Consultants even after approval of shop or working drawings are to be incorporated in the said drawings without any extra cost. The owner will not entertained any claim on this account. Also the contractor has to submit minimum six copies for approval purpose.
6) All the Measurements shall be taken as per IS standards.
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7) All Tool, Tackle, lifting or any other equipment needed for completion of the job is to be included in scope. No extra payment will be made to the contractor on this account.
8) The Contractor has to submit Seven Copies of the As Built Drawings plus Four CD for record purpose. Also the contractor has to submit one set of drawings on Reproducible tracing film.
9) The Contractor has submit Six copes of Operation and Maintenance manuals. Out of Six copies, One copy should be Original.
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3.0 415 VOLTS, LOW TENSION PANEL AND POWER CONTROL CENTRES AND DISTRIBUTION BOARDS
3.1 Scope
This Specification covers the design, manufacture, testing and supplying at site all LT Distribution Panels in all respect and to complete the installation in working condition
3.2 Applicable Standards
All relevant Indian Standards shall be made applicable with latest amendments. Also any other specific application is required, then the same shall be complied to.
3.3 440 Volts grade Warning Boards :-
All the warning Boards shall be 440 Volts Red in colour and made up of Aluminium sheet and having size of 150 mm x 150 mm x 3 mm thick painted with self illuminated fluorescent “RED” Colour paint shall be fixed at prominent places. These shall have minimum 2 languages inscribed on it, mainly Local Language, and English . The Warning Boards shall also have the usual Electrical Shock inscriptions as well as the small mark of Danger on it. These shall be fixed on The Main L.T Panel and All the Distribution Panels as per directions of Consultant.
3.4 General Specification of Equipment :-
The scope of work comprises of Designing, Obtaining Approval of the Consultants and Fabricating as per approved Drawings, Testing at Works, Packing and Forwarding, Supplying, at Site, Checking at site, Touching Up all Damaged portions, and assessing the Electrical Contractor while commissioning of the Panels at site. Further Touching up of damaged powder coated painting shall be carried at site after the installation of all panels is completed by the contractor. The Main L.T. Panel, Power Control Centres, distribution boards shall be metal clad, totally enclosed, rigid, floor mounting, air-insulated, cubicle type for use on 415 volts, 3 phase 50 cycles system. The equipment shall be designed for operation in high ambient temperature and high humidity tropical atmospheric conditions. Means shall be provided to facilitate ease of inspection, cleaning and repairs in the installations where continuity of operation is of prime importance.
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3.5 Standards
The equipment shall be designed to conform to the following requirements and to the latest amendments in the codes or relevant IEC applicable standards. a) IS 8623 - Part II of 1993 Factory Built Assemblies of switchgear and control gear. b) IS 13947 - Part I General requirements for switchgears and control gear for voltages not exceeding 1000 Volts. c) IS 13947 Part I - Degrees of protection provided by enclosures for low voltage switchgear and control-gear. d) IS 11353 - Marking and arrangement of bus-bars. e) IEC 660947-1 – General specification for Low voltage Switchgears f) IEC 60947-2 – For ACB and MCCB g) IEC 60947-3 – For Switches (Isolators and SDF) h) IEC 60947-4 For Contactors and BMR i) IEC 60898 – For MCB
3.6 Individual equipments housed in the power control center shall conform to the following IS specifications :
a) Air Circuit Breakers - IEC 647-2 and IS 13947-2 b) Molded Case Circuit Breakers - IEC 60947-2 and IS 13947-2. c) HRC Fuse-links - IS.9224 Part II d) Current Transformers- IS.2705 Part I, II & III of 1992. e) Voltage Transformers - IS.3156 Part I,II,III &IV of 1992. f) Relays - IS.3231 Part I, II, & III of 1987 g) Indicating Instruments - IS. 1248 Part I of 1993 h) Control Switches & Push Buttons - IS 13947 Part V Sec -1 i) AC Contractors - IS.13947 Part IV Sec - 4
3.7 Construction
3.7.1 The Main LT Panel, Power Control Centres, Distribution boards shall be :-
a) of the metal enclosed, indoor, floor mounted, free standing type. b) be made up of the minimum 14 Gauge White CRCA Sheets vertical sections, which, when coupled together shall form continuous front operated dead back type switchboards except for Main L.T Panel which shall have back access. c) Provide dust and vermin proof design. All the Panels should be designed in such a manner that the in Panel Temperature should not rise more than 30 degree
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Centigrade over an ambient of 45 degree Centigrade. The Vendors has to provide the temp sensors. If the temp of the cubicle increase more than 15 degree over an ambient the Exhaust Fan should be started and even after that the temp of the Bus Bars reaches to 85 degree the Alarm should be stared and should the command to the Main Breaker to Trip . All this provision has be done by the bidder without any extra cost. The Small Exhaust fans with the louvers should be provided for the Main Bus Bar chambers and all the cable alleys. All the fans should have the provision to start and stop by way of MCB. All the fans should be suitable for continuous duty. All panels cable alleys should have dust proof ventilators with the provision to mount impedance compensated fans d) be readily extensible on both sides by the addition of vertical sections after removal of the end covers or as otherwise as called for in the schedule of quantities.
3.7.2 The Main L.T Panel, Power Control Centres and Distribution Boards shall be constructed only of materials capable of withstanding the mechanical, electrical and thermal stresses, as well as the effects of humidity, which are likely to be encountered in normal service.
3.7.3 Each vertical section shall comprise :-
3.7.3.1 A front framed structure of rolled/folded sheet steel channel section, of minimum 14 Gauge thickness, rigidly bolted together. This structure shall house the components contributing to the major weight of the equipment, such as Air circuit breaker, Moulded Case Circuit Breakers, main horizontal bus-bars, vertical risers and other front mounted accessories.
3.7.3.2 he structure shall be mounted on a rigid base frame fabricated using Galvanized Iron channel of minimum 100 mm height. The design shall ensure that weight of the components is adequately supported without deformation or loss of alignment during transit or during operation. The thickness of the Galvanising should be minimum 65 microns and it should be hot dipped. a) A rear or front cable chamber housing shall be designed in such a manner that enough space is available for clamping of the cable cores terminating the same on the terminals. The design shall ensure generous availability of space for case of installation and maintenance of cabling, and adequately safety for working in one vertical section without coming into accidental contact with live parts in an adjacent section.
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b) Galvanised Powder Coated Sheets of 18 gauge shall be provided inside all the horizontal and vertical Bus bar chamber and cable alleys. After the removal of the Bus Cover these painted sheets should be visible this is to be provided for ventilation purpose and to avoid direct access to Bus Bars or live parts after the removal of the Bus-bar covers. The size of the holes shall be less than 12.5 mm in diameter. This sheets should also go under seven tank painting process and should be power coated Egg Shell white in color. This sheets shall be fixed using magnetic locks and the ball catch fixed to the Main body. c) All the doors should be fitted with neoprene gaskets with fasteners designed to ensure proper compression of gaskets. When covers are provided in place of doors, generous overlap shall be assured between sheet steel surfaces with closely spaced fasteners to preclude the entry of dust. d) No Black sheets shall allowed. All sheets shall be white CRCA. If it is found at any stage that Black sheets have been used, The panel shall be summarily rejected.
3.7.4 The height of the panel should not be more than 2100 mm. The total depth of the panel should be adequate to cater for proper cabling space and should not be less then 1000 mm for ACB sections and 450 mm for MCCB sections. The Minimum size of the Compartments for the various sizes of MCCBs/ACBs shall be as shown in the General Arrangement drawings . The Contractor may modify to suit the site conditions.
3.7.5 Doors and compartment partitions shall be fabricated using 14 Gauge thick sheet steel. Sheet steel shrouds and partitions shall be of minimum 14 Gauge thickness. All sheet steel work forming the exterior of switch boards shall be smoothly finished, leveled and free from flaws. The corners should be rounded. All the Sheet steel forming the exterior of the switch board should be fabricated using 14 gauge White CRCA Sheets. The entire Panel shall be fabricated using 14 Gauge white CRCA Sheets only.
3.7.6 The apparatus and circuits in the Power Control Centres shall be so arranged as to facilitate their operation and maintenance and at the same time to ensure the necessary degree of safety.
3.7.7 Apparatus forming part of the Power Control Centres shall have the following recommended minimum clearances for un insulated or should be as per relevant IS Codes.
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a) Between Phases - 25 mm.
b) Between Phases and Neutral - 25 mm.
c) Between Phases and Earth - 25 mm.
d) Between Neutral and Earth - 25 mm.
When, for any reason, the above clearances are not available, suitable insulation shall be provided. Clearances shall be maintained during normal service conditions. Creepage distances shall comply to those specified in relevant standards.
3.7.8 All insulating material used in the construction of the equipment shall be of non-hygroscopic material, duly treated to withstand the effects of high humidity, high temperature tropical ambient service conditions.
3.7.9 Functional units such as circuit breakers and fuse switches shall be arranged in multi-tier formation. All the Air Circuit Breakers shall housed in a single tier formations Only. Nothing shall be housed above and below the Bus- Coupler. The above and below compartments of the Bus-Coupler/Or shall be kept empty.
3.7.10 Metallic/insulated barriers shall be provided within vertical sections and between adjacent sections to ensure prevention of accidental contact with :
3.7.10.1 Main bus-bars and vertical risers during operation, inspection or maintenance of functional units and front mounted accessories.
3.7.11 All doors/covers providing access to live power equipments circuits shall be provided with tool operated fasteners to prevent unauthorized access.
3.7.12 Provision shall be made for permanently earthing the frames and other metal parts of the switchgear by two independent connections.
3.8 METAL TREATMENT AND FINISH :-
All steel work used in the construction of the switch board should have undergone a rigorous metal treatment process as follows.
3.8.1 Effective Cleaning by hot alkaline degreasing solution followed by cold water rinsing to remove traces of alkaline solution.
3.8.2 Pickling in dilute sulfuric acid to remove oxide seals and rust formation, if any, followed by cold water rinsing to remove traces of acidic solution.
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3.8.3 A recognized phosphating process to facilitate durable coating of the paint on the metal surface and also to prevent the speared of rustling in the event of the paint film being mechanically damaged. This again, shall be followed by hot water rinsing to remove traces of phosphate solution.
3.8.4 Passivating in de-oxalite solution to retain and augment the effects of phosphating.
3.8.5 Drying with compressed air in a dust free atmosphere.
3.8.6 Two coats of granule finished Powder Coating of Siemens gray having shade No. RAL 7032 is to be done from inside and outside of the panel on the phosphate panels on all exterior and interior side, by wet on wet process, with an interval of 2-3 minutes between coats. One coat involves 2 phases horizontally/ vertically over the entire surface on all exterior and interior side. In any case the thickness of the Paint should not be less than 65 Microns. All the panels shall be Granule finished powder coated painted with Siemens Gray having shade No RAL 7032 from Outside and Inside and dried up in oven.
3.9 BUS-BARS :-
3.9.1 The material of the Bus-Bars shall be electrolytic grade Copper and should have purity more than 99.95% and Conductivity more than 97 IACS. All the Bus Bars should be Tinned Copper throughout the length. The Oxygen contents in Copper should not be more than 10 parts in million. The Copper should be cold drawn and annealed up to 30%. All the Bus Bars should be tested as per relevant IS and latest IEC standard. The Bus Bar manufacture should submit the certificate from original supplier of Bus Bar for purity and oxygen contents in Copper. These shall confirm to I.S 613 of 2000 (Rev III) or the latest amendments. The size of the Bus bars used should be indicated by the Bidder in his Bid and shall be subject to the Consultants approval. For all the Molded Case Circuit Breakers (MCCBs) more than 63 Amps the connections should be done using Tinned Copper Bus bars . The connections to MCCBs having rating 63 Amps and below can be done using FR Copper flexible of Lapp makes given in the document. To arrive at the bus bar size, the calculations will be based on 1000 Amps. Per sq. inch. The size of the bus bar thus arrived at shall be chosen to the nearest mm. The sizes of the shall be chosen in such a manner that the sizes of the terminals and the sizes of the are matches with each other.
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3.9.2 The shall be suitably braced with non-hygroscopic SMC supports. The Neutral as well as the earth bar should also be cable of withstanding the stresses of electrical fault. Ridges shall be provided on the SMC supports to prevent tracking between adjacent .
3.9.3 Large clearances and creepage distances shall be provided on the system to minimized the possibility of a fault.
3.9.4 High tensile bolts and spring washers shall be provided at all joints.
3.9.5 The cross section of the bus-bars and risers for various ratings shall have been decided on the basis of temperature rise tests results carried out on some other Panels for the stated sections.
3.9.6 Connections from the main bus-bars to functional circuits shall be arranged and supported so as to withstand without any damage or deformation the thermal and dynamic stresses due to short circuit currents.
3.9.7 Bus-bars shall be color coded for easy identification of individual phases and neutral.
3.9.8 All the shall be provided with color coded heat sink sleeves through the full length. Intermittent color bands are not acceptable. The Earth Bus bar shall be provided with green color heat shrink sleeve. The size of the Earth shall be same as the size of the neutral bus bar but in any case it should not be less than 50 x 6 mm Tinned Cooper strip with Heat Shrinkable PVC Sleeve for Main L.T Panel and 25 x 6 mm Tinned Copper Strips for Small Panels.
3.10 AIR CIRCUIT BREAKERS :-
3.10.1 All Air Circuit breakers shall be Triple Pole with Neutral link or Four Pole as specified in the Bill of material or in drawing. All the Breakers shall be air break, horizontal draw out type, designed to be maintained.
3.10.2 The breakers shall comply fully with IEC 947-2 Or IS 13947-2 and should have microprocessor base trip unit and shall have ICs=ICu=ICw
3.10.3 A short circuit breaking capacity of not less than 65 KA RMS at 440 Volts 50 Hz AC.
3.10.4 A short circuit making capacity of 136 KA.
3.10.5 A short-time withstand circuit of 65 KA for 1 Second.
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3.10.6 All the Circuit Breaker shall confirm to disconnection function and should have fault indication L.E.D
3.10.7 Air Circuit Breakers having rating 2500 Amps or Below shall have Maintenance free Electrical life of minimum 6000 operations.
3.10.8 The circuit breakers shall be fitted with detachable arc chutes on each pole designed to permit rapid dispersion, cooling and extinction of the arc. All the accessories shall be snap fitted in design and it should be possible to convert Manually operated Breaker into Electrically operated breaker at site without any major modification.
3.10.9 Arcing contacts shall be of hard wearing material of copper tungsten or silver tungsten.
3.10.10 The operating mechanism shall be of robust design, with a minimum number of linkages to ensure maximum reliability. Manually operated circuit breakers shall be provided with spring operated closing mechanism which are independent of speed of manual operation. Electrically operated breakers shall have a motor wound spring charged closing mechanism. Breaker operation shall be independent of the motor which shall be used solely for charging the closing spring.
3.10.11 The Breaker shall be Trip free type an should be provided with anti pumping function.
3.10.12 The Microprocessor Based Releases fitted on the Breaker shall confirm to the following
a) Long Time Current Setting and with adjustable Tripping Delay
b) Over Load Signal (LED)
c) Short Time Pick Up and Tripping Delay.
d) Adjustable Instantaneous Pick up.
e) Earth leakage or Earth Fault Pickup and Tripping Delay
f) Earth leakage or Earth Fault Test Button
g) Long Time rating Plug Screw
h) Test Connector.
i) Lamp + Battery test and indication Reset
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j) Indication of tripping Cause.
k) High Resolution Screen
l) Measurement Display
m) Maintenance indicators (% Contact Wear Indication)
n) Protection Settings (Over & Under Voltage, Over Under Frequency, Current in balance, Phase Sequence, & Reverse Power)
o) Navigation buttons
p) Hole for Setting lockout pin on cover
q) Communication option
r) Indication option via programmable contacts.
s) Reverse Power Alarm
t) Phase Sequence.
u) Tripping History and Alarm History recorded in two separate history files and same should be displayed on Screen.(for last 10 faults as stand alone breaker without communication)
v) All the above parameters should be able to communicated with the PC
w) It should be possible to change IDMT Charities (EIT/VI/DT/SIT &HF) for achieving the discrimination with up stream HV Breaker or a Fuse
3.10.13 Circuit breakers shall be individually housed in sheet metal cradle fabricated using MS Zinc passivated sheets. The breaker along with its operating mechanism shall be mounted on a robust carriage moving on guide rollers within the cradle. Isolating contacts for both power and control circuits shall be of robust design and fully self-aligning. The assembly shall be designed to allow smooth and easy movement of the breaker within its cradle .
3.10.14 Operating Mechanism
The operating mechanism shall be of the Open/Closed/Open stored-energy type. The closing springs shall be able to be manually charged by operating the front lever
The circuit breaker shall be of trip free type and shall be provided with built in mechanical Anti Pumping device. Closing coil & other auxiliary devices shall be
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available in sufficient number for the purpose of indication, alarms, annuciations on switch boards as well as on respective remote control panel in control room & for the purpose of interlocking scheme shall be provided
There shall be four distinct & separate position of the circuit breakers on the cradle as – Service / Test / Isolated / Maintenance. The first three position shall be positive , achieved only through the racking motion of draw out mechanism & not by trail & error. There shall be indicator clearly showing the above 3 conditions
Circuit breaker shall be convertible from Manual to Electrical breaker at site.
3.10.15 The breaker shall have four distinct position within the cradle.
3.10.16 Service/Test/Isolate and Maintenance. The position shall be positive achieved through the racking handle motion. Their shall be indicator showing the above mentioned four conditions and should be possible to interlock the breaker at each position.
3.10.17 All Air Circuit Breakers should have molded case design with Class II front facia. All Air Circuit Breakers shall have indication of Mechanical wear of Contacts, enabling visible indication of Contact life.
3.10.18 Provision shall be available for the padlocking of the circuit breaker access flaps in any of three positions.
3.10.19 Automatically operated safety shutters shall be provided to screen the fixed isolating contacts when the breaker is drawn out from the cassette.
3.10.20 Auxiliary switches directly operated by the breaker operating mechanism and having 4 NO and 4 NC contacts, shall be provided on each breaker. The auxiliary switch contacts shall have a minimum rated thermal current of 10 Amps.
3.10.21 All the Air Circuit Breakers shall confirm to EMC and shall be immune to harmonics to avoid the nuisance tripping of the Breaker. Further all the Breaker shall be provided with RS 485 Communication port with facility to Operate the Breaker from Remote. The Vendor to provide the necessary software suitable to Profy Bus open Prtocol.
3.10.22 The trip unit fitted on the Breaker shall have Thermal memory to store Temperature rise data in case of the respective faults.
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3.10.23 All the Breakers shall have the facility of zone selectivity interlocking and their shall be indication of percentage loading of current in each phase of the Circuit Breaker. All Air circuit Breaker shall comply with IEC – 60947-2 & all incoming Air Circuit breaker should be four pole, electrical draw out type capable of setting Neutral Protection to N or N/2 to ensure precise neutral Protection. Breaking Capacity of Breaker in Main LT Panel shall be Ics = Icu = 65 KA at 440V & Ics = Icu = Icw (for 3 Sec)
3.10.24 All the breakers should not have any de rating up to 90 degree centigrade on the Main Bus bar terminals ( 45 degree ambient plus 45 degree rise at the bus bars) and 55 degree ambient inside the cubicle. The breakers shall confirm to the following power loss table. The Manufacture to confirm the same in writing and should be able to show the Test if required by the Consultant. Further all the Microprocessor based releases to be tested for 110 degree centigrade. i.e it should not malfunction and the results produced by the releases should be type tested.
Power loss per pole values(watt) Ratings Min Max 800 93 100 1000 150 230 1250 200 230 1600 210 385 2000 315 465 2500 510 600 3200 570 710 4000 660 900 5000 700 1050 6300 1100 1600
3.10.25 Protection and Measurement Function :
Protection Functions:
All shall have Microprocessor based releases capable of sensing true RMS value of Current based on Digital Technology
All ACB shall confirm to EMC & shall be immune to harmonics to avoid Nuisance tripping
Protection unit shall offer following as standard in all breakers excluding bus couplers
Long time protection with adjustable time delay.
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Instantaneous or Short ckt protection with time delay. The short circuit setting (Isd) should necessarily be the function of the set current(Ir) of the ACB.
Earth fault protection with settable absolute values& this protection will be only where specified in BOQ or in Drawing
For all ACBs above 1250A, the maximum earth fault setting should not exceed 1250A
All the adjustments should be on line & the circuit breaker need not be switched off while adjusting the settings.
The control unit shall have thermal memory throughout the range to store temp rise data in case of repetitive Overloads or earthfault for protecting the cables & loads.
The Trip unit should also give the IDMTL long time protection, minimum & maximum voltage & frequency, voltage & current imbalance, phase sequence & reverse power protection.
Breaker shall have facility of Zone selective interlocking
Measurement Functions
Measurement function should be independent of protection functions & there shall be A power meter with graphical display & bar graph for showing the percentage loading in each phase built in the trip unit.
Communication Function
Main incoming breaker shall be equipped with communication output port & the circuit breaker shall be capable of communicating the following data via a bus:
Circuit-breaker status (open/closed, connected/disconnected/test, tripped on a fault, ready to close);
Control-unit settings;
Tripping causes;
The measurements processed by the control unit: current, voltage, frequency, power, power quality.
It shall be possible to remotely control the circuit breaker.
It shall be possible to remotely modify circuit-breaker settings:
Settings of the protection functions and the alarms.
Communications functions shall be independent of the control unit.
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Main incoming breaker shall also have Event Logging facility for last ten faults, events storing & counting the no of operations & contact wear (electronic)
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3.11 MOULDED CASE CIRCUIT BREAKER:-
All the MCCBS Shall be suitable for fault braking Capacity as mentioned in the Single line Diagrams but in any case should not be less than 16 KA. All the MCCBs shall be provided with variable Over Current, Short Circuit releases . The variable Earth fault release is optional. The same shall be provided if called for in the schedule of quantity. The MCCBS having rating 250 Amps and the above the releases shall be Microprocessor based only and the MCCBS of lower ratings the releases shall be Thermo magnetic type. All the MCCBS shall have ICs=100% of ICu. All the MCCBS shall conform to disconnection function as per IEC947-2 Section 7.1.2. All four pole MCCBS above 250 Amps shall have capability of setting Neutral to N or N/2. All accessories of MCCBS shall be snap fitted type . All MCCBS should have flexibility of Line Load reversibility. Manufacture should submit let through energy curves and discrimination charts and cascading table for the approval of the consultant prior to ordering the MCCBS. All the MCCBS should be designed in such a way that no live parts is accessible. All the MCCBS should comply to IEC 60947-2 and IS 13947-2. All the MCCBS should have three clear positions ON/OFF and TRIP. The Manufacturer to Provide direct or extended Rotary handle with door interlock facility for all the rating of the MCCBS. All the MCCBS should be suitable for total discrimination. The MCCBs having rating more than 250 Amps shall have communication option which should able to display the status of each breaker and its setting, Control the circuit breakers and display the faults. All MCCB's shall be double break the current limiting type enabling full use of current limitation. Operating mechanism shall be of the quick make quick break type, with the speed of operation independent of the operator, and mechanically trip free from the operating handle so as to revert the contacts from being held closed against short-circuit and overload conditions. The operating mechanism shall be constructed to operate all poles in a multi-pole breaker simultaneously during opening, closing and tripped conditions.
Protection Function
All Moulded Case Circuit Breakers should have Microprocessor based releases capable of sensing true RMS values of Current based on digital Technology & should have Centralised variable short circuit & overload setting
Electronic trip units shall comply with appendix F of IEC60947-2 standard (measurement of rms current values, electromagnetic compatibility, etc.).
All electronic components shall withstand temperatures up to 125°C. ‘
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Earth fault protection if required should be an integral part of the release & should be adjustable
The control unit shall have thermal memory to store temp rise data in case of repetitive
Overloads or earth fault for protecting the cables & loads.
The accessories like shunt trip, closing trip coils should be continuously rated to avoid the Burning due to sustained command.
The MCCBs should be with Class-2 front facia in order to avoid any live part exposure in case the front cover is opened for the accessory mounting.
All the Moulded Case Circuit Breakers should have load Monitor LED and Adjustable Magnetic Threshold above 200 Amps. All the MCCB,s Should have Trip Unit Interchangeability at site.
The MCCB shall be 3 pole / 4 pole as the need be. In case of 4 pole MCCB, the 4th pole shall be 100% rated.
The MCCB shall be available in fixed / draw-out version as the need be.
It shall be possible to fit accessories on the MCCB such as aux contact, trip indication contact, rotary handle, undervolt coil or shunt trip coil, etc. In case of rotary handle, the same shall have built-in door interlock, defeat & padlocking facility. The rotary handle shall be same as that for SDF or MPCB for better aesthetics.
The MCCB shall be manually operated or motor operated as the need be. It shall be possible to convert the MCCB from manually operated to motorised MCCB and vice- versa.
Electrical
All the MCCB shall be suitable for 440 V ac system voltage.
The MCCB shall be suitable for impulse withstand of 8 kV.
The MCCB shall have short circuit breaking capacity Icu of 18 or 40 or 70 kA rms. The MCCB breaking capacity shall have Icu = 100% of Ics for the entire range.
The MCCB shall have no de rating up to 50C service temperature. In case the MCCB needs de rating, manufacturer shall declare the de rated current carrying capacity at 50C service temperature.
The MCCB shall be current limiting and shall have line-load interchangability without any loss of capacity.
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The MCCBs above 100 A, shall have adjustable and properly calibrated overload and short circuit settings.
Trip Unit
The MCCBs up to 630 A shall be with thermo-magnetic trip unit. 800 A & above, the trip unit shall be microprocessor based. Static trip unit shall not be acceptable.
The trip unit shall be capable to accept any change in the setting on-line, without need to switch off the MCCB.
The trip unit shall have overload and short circuit protection. It shall be possible to change the trip unit from thermo-magnetic to microprocessor based and vice-versa.
3.12 MINIATURE CIRCUIT BREAKERS (MCB)
3.12.1 All the Miniature Case Circuit Breakers shall comply fully with IEC 8828-1996 and should have uniform breaking capacity of 10 KA.
3.12.2 All the MCB shall comply with Isolation function.
3.12.3 “C” Curve MCBS shall be used for Lighting and other small loads and “D” Curve MCBS should be used for Capacitors and UPS Loads.
3.12.4 All the accessories of the MCB should be Snap fit type in design.
3.12.5 The Power loss per pole of the MCB shall be less than as specified in relevant codes of IEC standards and Manufactures shall submit the test certificate for the same.
3.13 Switch-Disconnector Fuse –
3.13.1 The SDF shall conform to the latest IS specification IS – 13947 (3)
3.13.2 The SDF shall be suitable for 550 V ac system voltages.
3.13.3 The SDF shall be 3 pole with neutral. In case required, facility shall be available to have switched neutral.
3.13.4 It shall be possible to fit accessories on the SDF such as aux contact, castle-key interlock, etc. The rotary handle shall have built-in door interlock, defeat & padlocking facility. The rotary handle shall be same as that for MCCB or MPCB for better aesthetics.
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3.13.5 The SDF shall have quad break mechanism and roller contact system for longer life.
3.14 HRC Fuse –
3.14.1 The HRC fuse shall conform to the latest standard IS – 13703.
3.14.2 The HRC fuse shall be suitable for 500 V ac system voltage.
3.14.3 The HRC fuse shall have non-deteriorating type characteristics.
3.14.4 The HRC fuse shall be of operating class gG.
3.14.5 The HRC fuse shall be of link type construction as per DIN standard.
3.14.6 The HRC fuse shall have breaking capacity of minimum 120 kA.
3.14.7 The HRC fuse shall have trip indication flag / pop.
3.14.8 The fuse characteristics shall be such that it allows close selectivity between downstream or upstream fuses with a ratio of 1 : 1.25. Manufacturer to specify this ratio for the fuses offered.
3.15 Contactors –
3.15.1 The contactors shall conform to the latest IS specification IS – 13947 (4)
3.15.2 The contactors shall be suitable for 690 V ac with impulse withstand capacity of 8 kV.
3.15.3 The contactors shall have no de rating up to 55C service temperature. In case the contactors need de rating, manufacturer shall declare the de rated current carrying capacity at 55C service temperature.
3.15.4 The contactors shall be suitable for various duties viz AC1, AC2, AC3 & AC4.
3.15.5 For applications such as capacitor switching or crane duty etc, special definite purpose contactors shall be used.
3.15.6 Contactors above 45 A shall have arc chamber interlock to prevent ON operation if arc chamber is not in place.
3.15.7 Vendor to specify 10 seconds rating for the contactors offered.
3.15.8 Contactors above 16 A, shall have replaceable contacts. The spare kits shall be available.
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3.15.9 The contactor – overload relay combination shall be type tested for type-2 co- ordination at 50 kA.
3.16 Overload relays –
3.16.1 The overload relays shall conform to the latest IS specification IS – 13947 (4)
3.16.2 The overload relays shall be suitable for 690 V ac.
3.16.3 The overload relays shall have no de rating up to 55C service temperature. In case the overload relays need de rating, manufacturer shall declare the de rated current carrying capacity at 55C service temperature.
3.16.4 The overload relay shall be bi-metallic type with built-in single-phase preventor and 1NO+1NC aux contacts.
3.16.5 The overload relay shall have trip test and auto / manual reset facility.
3.16.6 For critical motors, wherever specified, microprocessor based overload relay shall be used. Static relays shall not be allowed.
3.16.7 For motors above 75 kW, a microprocessor based motor protection relay shall be used. Static relays shall not be allowed. The relays shall offer at least following protections
3 ph balanced overload - Locked rotor
Phase imbalance - Earth fault
Single phasing - Thermistor
Trip cause indication by LED & - Trip class setting
3.17 Motor Protection Circuit Breakers –
3.17.1 The MPCB shall conform to the latest IS specification IS – 13947 (4)
3.17.2 The MPCB shall offer overload, single phasing and short circuit protection.
3.17.3 It shall be possible to fit accessories on the MPCB such as aux contact, trip indication contact, rotary handle, under volt coil or shunt trip coil, etc. In case of rotary handle, the same shall have built-in door interlock, defeat & padlocking facility. The rotary handle shall be same as that for SDF or MCCB for better aesthetics.
3.17.4 The MPCB shall have rotary handle mechanism with ON, OFF & TRIP positions.
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3.17.5 The MPCB shall have no de rating up to 55C service temperature. In case the MPCB needs de rating, manufacturer shall declare the de rated current carrying capacity at 55C service temperature.
3.17.6 The contactor – MPCB combination shall be type tested for type-2 co-ordination at50 kA.
3.17.7 The MPCB shall sense the overload faults, however the tripping shall be by the contactor only. MPCB shall trip only on short circuit faults.
3.18 Current Transformers :-
3.18.1 Current transformers shall comply with the requirements of IS.2705. They shall have ratios, outputs and accuracy’s as specified/required.
3.18.2 Indicating/Integrating Meters :-
3.18.3 All indicating instruments shall be of flush mounting industrial pattern, conforming to the requirements of I. S.
3.18.4 The instruments shall have non-reflecting bezels, clearly divided and indelibly marked scales, and shall be provided with zero adjusting devices in the front.
3.18.5 Integrating instruments shall be of flush mounting switchboard pattern, complying with the requirements of I. S.
3.19 Relays :-
3.19.1 Circuit breakers shall be provided with integrally mounted Microprocessor based Releases. The Releases shall have a set of 3 phase characteristics which shall be adjustable over wide range to provided discrimination between a multiplicity of devices.
3.19.2 Microprocessor based relays shall be used for all applications including auto changeover. These relays shall be draw out type with built-in test facilities. All the Microprocessor Relays shall conform to IEC 60255-5. LED indication shall be provided in these relays capable of being reset without opening the relay case.
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3.20 Control Switches :-
3.20.1 Control switches shall be of the heavy duty rotary type with escutcheon plates clearly marked to show the operating position. They shall be semi-flush mounting with only the front plate and operating handle projecting.
3.20.2 Circuit breaker control switches shall be of the spring return to neutral type, while instrument selector switches shall be of the stay-put type.
3.20.3 All the Indicating lamps shall be of the LED type. All the Lamps shall be color LED lamps. Lamps and lenses shall be easily replaceable from the front. All the Lamps should be Tested and certified as per IS 13947 (Part II) 1993. All the lamps shall be provided with leakage voltage glow protection. All the lamps shall be Immune to vibrations. The Power Consumption of the lamps should not be more than 0.5 Watts at 230 Volts A.C. The Lamps should be suitable for –30% to + 20% of operating Voltage. The Lamps Housing material shall be Flame Retardant ABSTRYNOL with ribbed Poly Carbonate Lens. The Enclosure shall be IP 65 as per IS 13947- (1) of 1993. The Rated Insulation Voltage shall be 500 Volts and Insulation shall be above 500 Mega Ohms. The Termination shall be Totally enclosed/finger Touched proof glass filled nylon and suitable for 2.5 sq. mm FRLS wires with M 3 brass screws. All the Lamps shall be provided with color LEDs.
3.21 Push Buttons :-
3.21.1 Push buttons shall be of the momentary contact, push to actuate type, fitted with self reset contacts and provided with integral escutcheon plates marked with its functions.
3.22 Cable Terminations :-
3.22.1 Cable entries and terminals shall be provided in the switchboard to suit the number, type and size of aluminium conductor power cables and copper conductor control cable specified in the detailed specifications.
3.22.2 Provision shall be made for top or bottom entry of cables as required. Generous size of cabling chambers shall be provided, with the position of cable gland and terminals such that cables can be easily and safely terminated. The minimum depth of the panel shall be restricted to suit for this purpose.
3.22.3 Barriers or shrouds shall be provided to permit safe working at the terminals of one circuit without accidentally touching that of another live circuit.
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3.22.4 Cable risers shall be adequately supported to withstand the effects of rated short circuit currents without damage and without causing secondary faults.
3.22.5 Cable sockets shall be of copper and of the crimping type as specified.
3.23 Control Wiring :-
3.23.1 All control wiring shall be carried out with colour coded 1100 Volts grade single core FR wires of approved make conforming to IS 694 of 1990. All the wires should be Uniley in construction with more than 99.99% purity Copper. All the wires stranding should be of fine wires CLASS-5 Construction in accordance with VDE 0295 or IEC 60228. The Oxygen contents in Copper should not be more than 10 parts in million. The
3.23.2 Copper should be cold drawn and on line annealed. All the wires should be tested as per relevant IS and latest IEC standard. The Wire manufacture should submit the certificate from original supplier for purity and oxygen contents in Copper. The outer PVC insulation should be Flame Retardant as per IEC 332.1 The colour coded wires should be used. For Potential Circuits “Red”, “Yellow” and ”Blue” Colour wires to be used. For Neutral Black Colour is to be used. For Earth Yellow/Green Wires is to be used. For Control’s Wiring Gray Colour wires are to be used. For CT and PT 2.5 sq. mm wires are to be used.
3.23.3 Wiring shall be neatly bunched, adequately supported and properly routed to allow for easy access and maintenance.
3.23.4 Wires shall be identified by numbered ferrules at each end. The ferrules shall be of the ring type and of non-deteriorating material. They shall be firmly located on each wire so as to prevent free movement.
3.23.5 All control circuits fuses shall be mounted in front of the panel and shall be easily accessible.
3.24 Terminal Blocks :-
3.24.1 Terminal blocks shall be of 500 volts grade of the suitable type. Insulating barriers shall be provided between adjacent terminals. All the Terminal Block shall be approved make.
3.24.2 Terminal blocks shall have a minimum current rating of 10 Amps. Provisions shall be made for label inscriptions.
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3.25 Labels :-
3.25.1 Labels shall be of anodized aluminum, with white engraving on black background. They shall be properly secured with fasteners.
3.26 Tests :-
3.26.1 The Following tests shall be conducted on all the Panels and Distribution Boards before the same are dispatched to the site from the vendors place. All the Tests shall be carried out in accordance with relevant IS codes and in presence of the Representative of Owner/ Consultant .
3.26.2 Visual inspection of Panels and checking the bill of materials as per the approved drawings and Mechanical ON/OFF operation of the components.
3.26.3 Checking of Protective Measures and electrical continuity of the protective circuits.
3.26.4 High Voltage Test by applying 2.5 kV, 1 minute for checking insulation of equipment and the Material used and recording the leakage current .
3.26.5 Megger tests before and after High Voltage Test at Vendors Factory.
3.26.6 Heat Run Test On Main L.T Panel .
3.26.7 Primary Injection Test for Checking of all Meters and Relays.
3.26.8 Testing of all the Microprocessor Releases at vendors factory and at site before commissioning of the ACBs and MCCBs. The Release should be tested by OEM only and necessary settings of releases to be done at site in consultation with Consultants.
3.26.9 Millie Volt Drop Test across the Bus-Bars Joints/ACB/MCCB/SFU/MCB and any other Equipment.
3.26.10 Testing of Barkers through Remote operation for ON/OFF and connectivity and operation of Barkers Through the Software and RS 485 Port.
3.26.11 Physical verification of all components.
3.26.12 Any other tests as desired by Owner / Consultant.
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4.0 LT POWER CABLES - GENERAL DESCRIPTION:
Electrolytic grade of Aluminium / high conductivity annealed copper conductor, as per IS : 8130, XLPE insulation, all sector shaped cores laid up with PP filler and PP tape (in case of extruded PVC inner sheath), taped/ extruded PVC inner sheath as per IS : 5831, armoured as per IS : 3975 and overall Flame Retardant ST2 PVC sheath as per IS:5831, 1100 Volts grade cable as per IS : 7098 (I).
4.1 LT CONTROL CABLES - GENERAL DESCRIPTION :
Plain annealed electrolytic grade of Copper conductor, as per IS : 8130, PVC insulation as per IS : 5831, cores laid up, STI PVC inner sheath as per IS : 5831, armoured as per IS : 3975 and overall STI PVC sheath as per IS : 5831, 1100 Volts grade cable as per IS : 1554 (I).
4.1.1 CONDUCTOR
Conductor shall be stranded above 10 sqmm in case of Aluminium cables, and above 6 sqmm in case of copper cables, below which it shall be solid conductor. On customer demand stranded conductor can be supplied. Stranded conductor are shaped and compacted to reduce dimension and give a smoother profile.
Strand details shall be as below :
1.5 to 10 sqmm (CU) - 7 Strands
6 to 10 sqmm (AL) - 1 Strands
16 to 50 sqmm (CU/AL) - 7 Strands
70 to 150 sqmm (CU/AL) - 19 Strands
185 to 300 sqmm (CU/AL) - 37 Strands
400 to 630 sqmm (CU/AL) - 61 Strands
800 to 1000 sqmm (CU/AL) - 91 Strands.
4.1.2 INSULATION
Insulation shall be of cross linked polyethylene with IR value more than 100 Mega. Ohm/km for power cables and shall be of PVC type A with IR value more than 50 Mega Ohm/km for PVC cables.
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XLPE : Insulation having dielectric strength between (25 – 30 KV/MM)
PVC Type A : Insulation having dielectric strength between (30 – 36 KV/MM).
4.1.3 INNER SHEATH
Inner sheath of ST-2 PVC along with Polypropylene (PP) fillers, in case of Taped Inner Sheath. For extruded PVC inner sheath (if required) PP Fillers shall be provided with a binder of PP Tape.
4.1.4 ARMOUR:
ISI Marked armour, as per IS : 3975 should be provided over inner sheath to guard against mechanical damage. Armour should be galvanized steel wire/ strip. In case of single core cables used in A.C Systems, armouring should be non magnetic hard drawn aluminium wire/ strip. Round steel wire should be used where diameter over inner sheath is less than 13mm and flat steel strip armour when diameter over inner sheath exceeds 13 mm. Round wire can be provided on specific request.
Armour coverage to be more than 95% to achieve better mechanical projection and low armour resistance.
4.1.5 OUTERSHEATH:
Outer sheath is of extruded ST-2 Flame Retardant PVC compound, black in colour as per IS : 5831. Having Oxygen index value of min 30%.
Outer sheath shall be resistant to terminate and rodent attack.
4.2 HT POWER CABLES – GENERAL DESCRIPTION :
Electrolytic grade Aluminium / annealed copper conductor, as per IS : 8130, conductor screen of semi-conducting compound. XLPE insulation, insulation screen
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of semi-conducting compound (All these three extruded in single tandem process of triple extrusion), copper tape screen (only above 6.6 KV (E) ), cores laid up with PP fillers & PVC fillers and tape, PVC inner as per IS : 5831, armoured as per IS : 3975 and overall Flame Retardant ST2 PVC Sheath as per IS : 5831, from 3.3 KV (E) grade cable as per IS : 7098 (II).
4.2.1 CONDUCTOR :
Circular compacted stranded conductor of Electrolytic grade Aluminium / annealed copper as per following strand details.
35 to 50 sqmm - 7 Strands
70 to 150 sqmm - 19 Strands
185 to 300 sqmm - 37 Strands
400 to 630 sqmm - 61 Strands
800 to 1000 sqmm - 91 Strands.
4.2.2 CONDUCTOR SCREENING :
Shall be black extruded semi-conducting compound and extruded in tandem with insulation.
4.2.3 INSULATION :
Insulation shall be of cross linked polyethylene, extruded in tandem with both conductor screen and insulation screen. Insulation shall be free from voids, dust particulars and external elements.
4.2.4 CONDUCTOR & INSULATION SCREENING :
Insulation screen shall be black semi-conducting compound and be provided along with core insulation in tandem triple extrusion process.
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4.2.5 CORE SCREENING :
Copper tape screening to achieve full coverage shall be provided over the cores for voltage grade from 6.6 KV (E) to 33 KV (E). Number of tapes and thickness of tape shall be chosen to meet required short circuiting rating. Core shall have binder / identification tape with number / colour coding or both.
4.2.6 INNER SHEATH :
Inner sheath of ST-2 PVC along with Polypropylene (PP) fillers & PVC fillers (with a binder tape of PP tape in case of extruded PVC).
4.2.7 ARMOUR :
ISI Marked armour, as per IS : 3975 should be provided over inner sheath to guard against mechanical damage. Armour should be galvanized steel wire/ strip. In case of single core cables used in A.C Systems, armouring should be non magnetic hard drawn aluminium wire
Armour coverage to be more than 95% to achieve better mechanical projection and low armour resistance.
4.2.8 OUTERSHEATH :
Outer sheath is of extruded ST-2 Flame Retardant PVC compound, black in colour as per IS : 5831. Having Oxygen index value of min 30%.
Outer sheath shall be resistant to terminate and rodent attack.
4.2.9 MARKING OVER OUTER SHEATH :
Progressive sequential marking, size marking, voltage grade, manufacturers name at every one meter shall be provided on the outer sheath.
4.2.10 PACKING :
Cables shall be supplied in non-returnable wooden or returnable steel drums of heavy construction as per IS : 10148. Wooden drums are properly seasoned,
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sound and free from defects. Drum shall be treated with antioxidants, and painted with good quality paint to increase the life of the packing drum.
4.2.11 DRUM LENGTHS :
Standard lengths for each size of power and control cables shall be 500/1000 mtrs. The cable length per drum shall be subject to a tolerance of +/-5% of the standard drum length.
A clear space at Min. 40mm shall be left between the cables and the lagging.
Each drums shall carry the manufacturers name, the purchaser’s name, type, size and length of the cable, sequential marking detail, net and gross weight stenciled on sides of drum. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.
Packing shall be sturdy and adequate to protect the cables from any injury due to mishandling or other conditions encountered during transportation, handling and storage. Both cable ends shall be sealed with PVC end caps.
Cable drum above 1600 mm should be provided with MS bush plate for spindle hole.
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4.3 TESTING AND INSPECTION
4.3.1 ROUTINE TEST :
a) Conductor resistance test.
b) High voltage test.
c) Partial discharge test (for screened cable only)
d) (to be carried out on full drum length).
4.3.2 TYPE TEST :
a) Tests on conductor
Annealing test for copper
Tensile test (for aluminium)
Wrapping test (for aluminium)
Resistance test
b) Test for armouring wire/ strips
Tensile strength & elongation at break
Thickness of zinc coating (Dip Test)
Torsion/ Winding test
Resistivity Test
Mass of Zinc coating test
c) Test for thickness of insulation and sheath
d) Physical tests for insulation
Tensile strength & elongation at break
Ageing in air oven
Hot set test
Shrinkage test
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Water absorption (gravimetric)
e) Physical test for outer sheath
Tensile strength & elongation at break
Ageing in air oven
Shrinkage test
Hot deformation
f) Insulation resistance (volume resistivity test)
g) High voltage test
h) Flammability test
i) Bleeding and blooming test (for outer sheath).
j) Partial discharge test.
k) Bending test.
l) Impulse withstand test.
4.3.3 ACCEPTANCE TEST :
a) Annealing test (for copper)
b) Tensile test (for Aluminium)
c) Wrapping test (for Aluminium)
d) Conductor resistance test
e) Test for thickness of insulation and sheath
f) Hot sheath test (for insulation)
g) Tensile strength and elongation at break test (for insulation & sheath)
h) Partial discharge test (for screen cable only)
i) High voltage test.
j) Insulation resistance test.
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4.3.4 SPECIAL TESTS FOR FRLS CABLES :
a) Oxygen Index Test as per ASTM-D-2863
b) Temp. Index Test as per ASTM-D-2863
c) Acid Gas Generation test (HCL) as per IEC-754(I)
d) Smoke Density test as per ASTM-D-2843
e) Flammability tests
i. As per IEC 332-P-I ii. As per IEC 332-P-3 iii. Swedish Chimney As per SS-424-14-75 (Class F 3) IEEE – 383.
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5.0 EARTHING
5.1 Scope:
5.1.1 Earthing system to be provided shall comprise of earth electrode of copper plate or hot dipped Galvanised plates in earth pits, earth bus/grid of copper flats or GI Flats or Aluminium flats as called for and bare copper earth wires or Galvanised earth wires or aluminium earth wires as called for, for acting as earth continuity conductor.
5.1.2 Lightning Protection system shall comprise of earth electrode of Cu or GI plate in earth pits, earth bus of down conductors of Cu or GI flats.
5.1.3 Earthing of Compound, Flood Lighting and Road Lighting poles shall be done by using Cu or GI plates in earth pits near pole and 7/16 size galvanised strained wire for connecting to the pole or as specified in the Schedule or in drawings.
5.1.4 Entire earth system shall conform to the Code of Practice as per IS. 3043 of 1987.
5.2 General Requirement :
5.2.1 Enclosures and frame work of all current carrying equipment and accessories, structural steel/columns shall be adequately earthed to a single earthing system, unless separate earthing systems are specifically stipulated. All electrical equipment shall be earthed at two distinct points.
5.2.2 Earth loads and risers shall follow as direct and short a path as possible. Suitable risers shall be provided as directed if equipment is not available when earthing is installed.
5.3 Earth Electrodes in Earth Pits :
Plate electrodes of Copper shall be 600 x 600 x 6 mm thick and 600 x 600 x 12 mm thick for GI unless otherwise specified.
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5.4 Earth Bus and Earth Continuity Conductor :
5.4.1 Earth bus is a copper strip or flat of specified size interconnecting all earth electrodes
5.4.2 Switchgears and Power Distribution Boards shall be earthed by a copper flat strip
5.4.3 Panels, fused DBs and motors up to 30 KW rating shall be earthed by a continuity conductor, as specified. Minimum size of continuity conductor shall be 25 x 3 mm bare copper strip, soft drawn.
5.4.4 Road Lighting Poles shall be earthed with Cu stranded wire conductor while for lighting and power wiring bare copper conductor shall be provided unless otherwise specified to use insulated conductor.
5.5 Earth Bus Station :
Earth Bus Station shall be provided to facilitate tapping of earth continuity conductor from earth bus/grid very conveniently. It will comprise of a 400 mm long 50 x 6 mm bare copper strips/flat fixed with rawl plugs/bolts securely on wall/column above floor level. Spacers of 20 mm to 25 mm shall be provided to keep the flat away from wall and facilitate connections of earth conductor for which 6 mm dia holes 8 to 10 numbers are provided with proper size brass nuts, bolts, and washers. Earth bus shall be connected to it.
5.6 Lightning Protection System :
5.6.1 Air termination shall be five prong type copper Rod with round head and the same shall be securely clamped/installed to withstand severe weather conditions and provide protection against lightning. Horizontal air termination conductors shall be Cu or GI flat/strip and shall be provided where specified.
5.6.2 Earth Electrodes for lightning protection system shall be Copper plate installed in earth pits as per IS.
5.6.3 The down conductors from air terminals shall be done in tinned Cu or GI Flat/strip, of size as specified in the schedule of quantities or drawings, but shall not be less than 12.5 x 3mm as required. The down conductors shall follow
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a direct path to the earth electrode without any sharp bend, turn or kinks. These down conductors shall not be connected to other earthing conductors above ground level but the metallic parts in the vicinity of lighting protection conductor such as ladders, pipes, etc. shall be effectively connected and bonded.
5.6.4 A test joint as per IS shall be provided for every down conductor within 1500 mm above ground level.
5.6.5 Hardware and clamps shall be similar as used for the earthing systems.
5.7 Artificial Treatment of Soil :
If the earth resistance is too high and the multiple electrode earthing does not give adequate low resistance to earth, then the soil resistivity immediately surrounding the earth electrodes shall be reduced by adding sodium chloride, calcium chloride, sodium carbonate, copper sulphate, salt and soft coke or charcoal in suitable proportions.
5.8 Resistance to Earth :
The Contractor shall measure the resistance of the individual earthing pit and report to the Architect/Consultants. The Contractor will make after due consultation with Architect/Consultants, No. of Earth pits, such that, the overall resistance in the earth mat does not exceed 1.0 ohm.
5.9 Earthing Station
5.9.1 Plate Electrode Earthing :
Earthing electrode shall consist of a tinned copper plate not less than 600 x 600 x 6 mm thick, or, 600 x 600 x 6 mm G.I. as called for in the drawings. The plate electrode shall be buried as far as practicable below permanent moisture level but in any case not less than 3 mts. below ground level. Wherever possible earth electrode shall be located as near the water tap, water drain or a down take pipe as possible. Earth electrodes shall not be installed in proximity to a metal fence.
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It shall be kept clear of the buildings foundations and in no case shall it be nearer than 1 meter from the outdoor face of the wall. The earth plate shall be set vertically and surrounded with 150 mm thick layer of charcoal dust and salt mixture. 20 mm G.I. pipe shall run from the top edge of the plate to the ground level. The top of the pipe shall be provided with a funnel and a mesh for watering the earth through the earth. The main earth conductors shall be connected to the electrode just below the funnel, with proper terminal lugs and checks nuts. The funnel over the G.I. pipe and earth connections houses 300 mm wide and 300 mm deep. The masonry chamber shall be provided with a cast iron cover resting cover a C.I. frame embedded in masonry.
5.9.2 Pipe Electrode Earthing :
Earthing electrode shall consist of a G.I. Pipe (Class 'B') Indian Tube Company make/ zenith or approved equal, not less than 40 mm dia and 5 meters long. G.I. Pipe electrode shall be cut tapered at the bottom and provided with holes of 12 mm dia. drilled at 75 mm interval upto 2.5 meters length from bottom. The electrode shall buried vertically in the ground as far as practicable below permanent moisture level with its top not less than 200 mm below ground level. The electrode shall be in one piece and no joints shall be allowed in the electrode. Wherever possible earth electrodes shall be located as near water tap, water drain or a down take pipe. Earth electrode shall not be located in proximity to a metal fence. It shall be kept clear of the building foundations and in no case shall be nearer than 2 meters from the outer face of the wall. The pipe earth electrode shall be kept vertically and surrounded with 150 mm thick layer of charcoal dust and salt mixture upto a height of 2.5 meters from the bottom. At the top of the electrode a funnel with a mesh shall be provided for watering.
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6.0 LIGHTING FIXTURES
6.1 Scope:
Manufacture, Test, Supply and Delivery at site, Erection in proper position testing and commission the specified Light Fittings. All the fittings shall have Electronic Ballets of Approved make.
6.2 Standards:
Lighting Fittings covered against this specifications shall comply with the relevant latest Indian Standards and Codes and more specifically to IS 2418 for tubular fluorescent lamps, and IS 1771 for Industrial Fittings with metallic reflector.
6.3 Construction:
6.3.1 The atmosphere where these fittings are to be installed will be humid and conducive to chemical corrosion. All light fittings shall be with IP67 IP rating. The fittings shall be suitable for 240 Volts. Single phase A.C. supply (+)/(-) 5% and frequency 50 Hz. (+)/(-)3%.
6.3.2 The complete fittings and its accessories such as Drivers, Ballets, Side holders shall be fixed and pre wired. All fittings shall be provided with one internal and one external earthing terminal of appropriate diameter GI/Passivated Brass complete with one spring and two flat washers. The fluorescent fittings shall be complete with high frequency ballast, lamp holders, terminal block (4 way), etc. and fully wired upto terminal block.
6.3.3 Lighting Fittings Components/Accessories :-
a) Electronic Ballast :-
All the Electronic ballast shall be compact in design, electronic type and high frequency type having low power loss, good heat dissipation, with no humming. The HF ballast should not interfere with the Computers. The H.F Ballests should not have any “H” mark on it. The Electronic Ballast should have total harmonic distortion less than 10%. The Electronic Ballast should have constant light out put
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i.e in case of variation in supply voltage the light out put of the lamp should remain constant. The Ballast should have following compliances and approvals.
RFI Less than 30 MHz EN 55015
RFI more than 30 MHz EN 55022 A
Harmonics EN 61000-3-2
Immunity EN 61547
Safety IEC 928
Performance IEC 929
Vibration & Bump Tests IEC 68-2-6FC & IEC 68-2-29Eb
Quality Standard ISO 9001
Environmental Standard ISO 14001
All the Ballast’s should be flicker free warm start. The ballast should have constant light output irrespective of mains voltage fluctuations within 202-254 Volts. In case of the Mains fluctuations within 202-254 Volts the luminous flux should not change more than +/- 4%. The ballast should have Low harmonics distortion The total harmonic distortion should be less than 10%. The Earth leakage Current should be less than 0.5 mA per ballast and ignition time should be less than 2 sec. Further the ballast should have over voltage protection i.e. it should able to sustain for 48 hrs at 320 Volts AC and 2 hours at 350 Volts AC. The Ballast should either of Philips make having Cat No. EB-PERFORMER (EB-P 220-240 1/36 RS) for Single Tubes or EB-PERFORMER (EB-P 220-240 2/36 RS) for double tubes or approved equilvent make.
b) Lamp Holders: These shall be rotary, spring loaded resilient type, either moulded from Urea- Formaldehyde.
c) LED Lamps & Drivers: The LED lamps shall be of High Lumen out put and of approved colors as per BOQ and of Philips or any other approved make similar to Philips True Light and of stated wattage. The LED drivers shall be suitably selected as per
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manufacturer's recommendations. The drivers required for lamps shall be integrated suitably within the light fitting or can be kept at suitable distance in ( a IP67 protected enclosure ) from LED light fitting.
All LED light fittings located outdoors shall have IP rating IP67.
7.0 CABLE TRAYS
7.1 Perforated Cable Trays of ladder type and associated accessories tees, bends, elbows and reducers shall be fabricated from 12 gauge (2.5 mm) mild steel. Prefabricated Cable trays of perforated type and associated accessories tees, elbows and reducers shall be fabricated from 14 gauge (2 mm) White CRCA Sheets. Cable trays shall be made of corrosion resistant material or if made of material shall be adequately protected against the corrosion.
7.2 Cable trays accessories shall be painted with One Shop coat of Red oxide zinc chromate primer and two side coats of Aluminium alkyd paint.
7.3 Cable trays shall not have sharp edges, burrs or projections that may damage the insulation jackets of the wiring.
7.4 Cable trays shall not have side rails or equivalent structural members cable trays shall include fittings or other suitable means for change in direction and elevation of runs.
7.5 Cable Tray Mounting
Unless otherwise specifically noted on the relevant layout drawing, all cable tray mounting works to be carried out the following :
a) Cable tray mounting arrangement type to be as marked on layout drawing.
b) Assembly of tray mounting structures shall be supplied fabricated, erected & painted by the electrical contractor.
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c) Tray Mounting structures shall be welded to plate inserts or to structural beams as approved by the Project Manager.
d) Wherever embedded plates & structural beams are not available for welding the tray mounting structure electrical contractor to supply the MS plate & fix them to floor slab by four anchor fasteners of minimum 16 mm dia having minimum holding power of 5000 Kg, at no extra cost.
e) Maximum loading on a horizontal support arm to be 120 Kg/metre of cable run.
f) Width of the horizontal arms of the tray supporting structures to be same as the tray widths specified in tray layout drawings, plus length required, for welding to the vertical supports.
g) The length of vertical supporting members for horizontal tray runs will be to suit the number of tray tiers shown in tray layout drawings.
h) Spacing between horizontal support arms of vertical tray runs to be 300 mm.
i) Cable trays will be welded to their mounting supports.
j) Minimum clearance between the top most tray tier and structural member to be 300 mm.
k) Cable in vertical race ways to be clamped by saddle type clamps to the horizontal slotted angles. Clamps to be fabricated from 3 mm. thick aluminium strip at site by the electrical contractor to suit cable groups.
l) The structural steel (standard quality) shall be according to latest revision of IS : 2062 & IS 808 Rev III of 1989 . Welding shall be as per latest revision of IS : 816 Rev I of 1969. All structural steel to be painted with one shop coat of red oxide and oil primer followed by a finishing coat of aluminium alkyd paint where any cuts or holes are made on finished steelwork these shall be sealed against oxidation by red oxide followed by the same finishing paint. Steel sheet covers wherever indicated to be similarly painted.
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8.0 POINT WIRING USING PVC CONDUITS
8.1 Scope of Work:
The scope of this section comprises of supply, delivery, store at site, prepare the conduit assembly, fix and erect in proper position, rigid PVC conduits of minimum 2.0 mm wall thickness and as per IS 9537 Part III. Concealed work check before casting of slab, measure and tie the assembly to reinforcements, complete with providing GI pull wires.
8.1.1 Applicable Standards:
The relevant sections of Indian Standard Specifications as more particularly stated herein and broadly to all the codes, statues and regulations as applicable shall be strictly enforced and adhered to. More particularly following codes should be strictly followed.
IS 9537 Part III : Rigid non metallic conduits for Electrical work. IS 2274 : Wiring Practice. IS 3043 : Code of Practice of Earthing.
8.2 Rigid PVC Conduit Work:
8.2.1 Material
a) The minimum wall thickness of Rigid PVC Conduits permitted for concealed conduiting shall be 2.0 mm thick and shall be suitable for heavy duty.
b) The tubing must be perfectly circular, without any burrs or kinks.
c) The Conduits shall be of such type, so as to be capable of making tight fitting joints.
d) The minimum size of Rigid PVC Conduits allowed in concealed work shall be of 20 mm and above.
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8.2.2 Conduit Accessories :
a) All conduit accessories that are to be used in concealed work shall be of Rigid PVC type conforming to latest and relevant IS codes.
b) Conduit Accessories shall be capable of clean and tight fittings.
c) All junction boxes of one way or above shall be of high dome type with a depth of minimum 65 mm and minimum 2 mm wall thickness.
d) In concealed work, inspection types of bends are not allowed, normal bends/elbows may be permitted after specific approval.
8.2.3 Conduit Assembly Work :
a) The Contractor shall submit to the Architect/Consultant detail layout plan of conduit network containing particulars regarding size and routes of conduits, number of wires carrying in each conduit, inspection and junction boxes provided along with the routes of the conduits. The number of wires in each conduit shall not exceed as specified in the table of conduit capacity. All the conduits are supported using minimum 16 gauge M.S. Spacers and G.I Saddles fabricated using 16 gauge sheets and fixed using GI Screws.
b) Initially all drawings for concealed conduit work shall be inspected. Any discrepancies or otherwise occurring due to site conditions or change in internal layouts or in walls shall be reported. After rectification of the same, then the measurements and marking shall be done for the conduit assembly, on the shuttering of the slab.
c) All conduits shall be assembled. Wherever straight runs exceeds 3 mts., additional pull boxes or junction boxes shall be provided. However, the entire assembly shall be so assembled in order to facilitate renewal of wires etc. in the future.
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d) Wherever fluorescent light fixtures are shown in the layout, the conduit shall be terminated in a high dome junction box at the centre of the fixture, unless otherwise specified or indicated in drawings.
e) In the concealed conduit work, all junction boxes, bends, elbows shall have PVC tapes on either side to ensure security of the accessories in its place. They shall also be PVC taped at all joints in order to prevent cement, water or slurry entering the Rigid PVC conduit assembly.
f) All precautions should be taken in concealed work, to ensure no entry of cement slurry or blocking of conduits due to concreting.
g) For all circuit wiring, i.e. from Lighting Distribution Boards to Individual Switchboards, minimum 25 mm Rigid PVC conduits and minimum 2.0 mm wall thickness conduits shall be used.
h) All PVC conduits drops that are to be taken for the purpose of joining the Distribution Board or Switch Boards shall be taken out of the shuttering with a clean hole. Sand then shall be provided at the bottom most part of the entry in the shuttering. The projected part of the PVC conduit shall have a coupling over the same.
i) The entire PVC conduit assembly shall be properly secured and bonded by means of steel wires, twisted and fixed to the reinforcements. Additional fixing shall be done near joints, junction boxes, pull boxes etc.
j) The entire Rigid PVC conduit assembly then shall be checked for rigidity and no movement shall be allowed in the assembly. k) The entire Rigid PVC conduit assembly shall be provided with proper GI pull wires of minimum 14 gauge.
l) Adequate number of PVC, pull boxes of suitable sizes shall be provided in the PVC conduit assembly.
m) It shall be the entire responsibility of the Contractor to supervise the concealed conduit assembly work during the casting of the slabs. Adequate precautions
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should be taken to spread fine sand covering the opening of the PVC conduit boxes or junction boxes at the bottom of the slab.
n) Where the conduit passes through the flooring the same shall be passed through galvanised pipe of suitable size fixed in the flooring, so that conduits, cables or wires can be renewed at any time without breaking the floor.
o) Where the conduit runs in brick walls same should be necessarily fixed by using MS clamps. In the straight run the distance between the two clamps shall not exceed 500 mm and additional clamps should be provided near bend and junction box.
p) The entire jointing in PVC conduit assembly shall be done using PVC solvent cement only. Wherever the conduits are terminated in PVC switchboard boxes or PVC, socket outlets boxes, the use of collars, male female type of adaptors shall be only used.
8.2.4 Conduit Capacity:
The maximum capacity of a conduit for drawing in Flame Retardant Low Smoke (FRLS) wires shall be in accordance with IS 2274. The minimum size of conduit to be used shall not be less than 20 mm (approx.) and not more than two circuits connected to same phase be bunched in one conduit. Two different phases are not allowed in one conduit.
Commonly used sizes of 650/1100 Volts Flame Retardant Low Smoke (FRLS) wires and conduit capacities are as tabulated below:-
Size of Wire Capacity of the Conduit Voltage Grade (sq. mm.) 20 mm 25 mm 1.5 650/1100 5 Nos. 8 Nos. 2.5 650/1100 5 Nos. 6 Nos. 4.0 650/1100 3 Nos. 5 Nos. 6.0 650/1100 2 Nos. 3 Nos. 10.0 650/1100 ...... 3 Nos.
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8.2.5 Point Wiring
The wiring shall be of the looping in system as different from the tree system. Connectors should not be used without specific prior approval. Looping in on the phase side shall be at the switches and that on the neutral side at the ceiling roses. Every light point, fan point and plug point shall have individual control switch unless stated otherwise. Earthing shall be provided for all the points according to the statutory requirement wherever necessary. The number of points per circuit shall not exceed 8 in any case.
a) The point wiring in conduit consists of wiring from the branch distribution board in conduit with its ancillary work, such as inspection bends, junction boxes and FRLS wires upto the fixed terminals of ceiling roses, connectors, batten holders, etc. depending upon the type of point.
b) For easy identification, wires with different colours shall be used for phase and neutral as far as practicable.
c) The control switches for lights, fans, wall sockets and fan regulators shall suitably be grouped on sheet steel cases of all welded design fabricated out of 1.2 mm (approx.). Generally, the bakelite sheet shall be 3 mm thick where SP Piano type flush mounting switches are to be accommodated and in all other cases it shall be 5 mm thick. The bakelite sheet cover shall be fitted above the sheet steel case and shall be leveled on the outer edges. Control accessories for one circuit only shall be grouped on a sheet steel case. Not more than 2 ceiling fan regulators shall be mounted on a sheet steel case. Suitable earthing terminal shall be provided on the sheet steel case. All the conduits entering and leaving D.B. shall be bonded together with 4 sq.mm bare aluminium/copper wire and earth clips (as mentioned in the schedule.).
d) Point Wiring by using Flame Retardant Low Smoke (FRLS) Wires:- This shall be similar to point wiring in conduit system. The fixing of cables shall, however, be according to the specifications.
e) All the Flame Retardant Low Smoke (FRLS) wires shall have a grade 650/1100 Volts for lighting and power wiring.
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8.2.6 Mains and Sub-Mains Wiring:
This shall include the cost of all Flame Retardant Low Smoke (FRLS) wires conduit, conduit accessories, clamps spacers, Flame Retardant Low Smoke (FRLS) wires on battens depending upon the type of wiring, all masonry work, such as cutting, neat finishing of walls, floor openings etc. Only approximate lengths are included in the Schedule of Quantities and Rates, but the actual lengths of the mains and sub-mains executed will be measured between terminating points and will be paid for. Where the mains and sub-mains pass through the flooring, or through the wall, the same shall pass as specified in 3(b) above. Mains and Sub-Mains risers in conduit shall be bonded together with 4.0 sq.mm. bare aluminium/copper as specifically mentioned in Schedule and earth clips on each floor landing/mid-landing. The Flame Retardant Low Smoke (FRLS) wires are provided as mains and sub-mains, the same shall be fixed as per specifications.
8.3 Switches, Sockets & Ceiling Roses
8.3.1 Ceiling Roses:
These shall be of bakelite and of approved make and colour and shall not contain fuse terminals. These shall be provided with brass ceiling plate and M. T. Brass screws and washers with cord grip for termination of wires.
8.4 Plate type, moulded design - switches on white Urea Power pressed cover plates:
These shall be of single pole, double pole, two ways, one ways or otherwise as called for in the Schedule. These shall be manufactured as per relevant IS Codes and shall amply to Indian Electricity Rules. The minimum rating shall be 5 Amp at 250 V AC.
8.5 Socket Outlets with Plugs
These shall be with porcelain base, in 2 Pin and earth design of best quality, suitable for single phase, 250 volts supply. The earth pin shall be effectively connected to the nearest conduit or earth connections in distribution board with not less than 3 mm2 (No. 14 SWG) copper wire. The socket outlet shall be complete unit shall be with ratings of 5 Amps. 250 Volts or 15 Amps 250 Volts to suit individual requirement
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as stated in Schedule of Quantities and Rates. The socket outlets shall be in flush mounting or on plate designs as called for in the Schedule.
8.6 Interlocked Metal Clad Switch Fuse Units
The Metal Clad switch fuse unit shall be of the heavy duty type, quick make and quick break action, of approved pattern and capable of carrying continuously the current specified. All the switch fuse units shall have 'U' type contacts on fuse carriers and the switch fuse units of capacities 30 Amps. and above shall be provided with spring type contacts on the fuse bases. Unless otherwise specifically brought out in the Schedule the metal cases shall be of cast iron and shall be provided with knock-outs for incoming and outgoing pipes or cables and earthing terminals. The cover of the switch shall be interlocked with the switch handle so that the cover cannot be opened unless the switch is 'OFF' and the switch cannot be made on unless the cover is fixed.
The fuse shall be either rewirable type or HRC type as detailed in Schedule of Quantities and Rates. The Switches with HRC fuse links shall be supplied with insulated fuse removers.
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9.0 MARKING OF PANELS AND NOMENCLATURE:
All Panels shall borne the Nomenclature as suggested in the tender. The same shall be embossed on steel plates and not painted. All Panels shall also bear the name of the Consultants of the project. All panels shall also indicate the line diagram and the method of receiving Power from upstream Panel /Switch.
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10.0 INSTALLATION OF MAIN L.T. PANEL
The Main L.T. Panel shall be installed in the electrical room allotted at site. The panels shall be properly assembled if dispatched in sections. All bus bars fish plates will be thoroughly cleaned, greased and bolted to instructions. The Main Panel will be mounted on base frame of adequate size using 100 x 50 x 6 mm ISMC channels fabricated to meet the design of the base frame of the Main L.T. Panel. The fabricated frame shall be welded in design and will undergo metal treatment process as stated in the specifications elsewhere. The base-frame shall have adequate size Anchor Fasteners which shall be grouted in the flooring. The base- frame of the panels will then be aligned with the fabricated base-frame already grouted. The whole structure will be rigid and will not in any way move while operating any of the switchgears. If found necessary, then, additional supports by way of angles horizontally bolted to the panel and grouted in the nearby wall shall be done. The entire erection of the panel shall have a neat and aesthetic appearance.
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11.0 INSTALLATION OF POWER CONTROL CENTERS AND A.P.F.C. PANEL.
The PCCs and APFC shall be installed in the electrical room allotted at site. The panels shall be properly assembled if dispatched in sections. All busbars fish plates will be thoroughly cleaned, greased and bolted to instructions. The Main Panel will be mounted on base frame of adequate size using 100 x 50 x 6 mm ISMC channels fabricated to meet the design of the base frame of the PCCs or APFC Panel. The fabricated frame shall be welded in design and will undergo metal treatment process as stated in the specifications elsewhere. The base-frame shall have adequate size Anchor Fasteners which shall be grouted in the flooring. The base-frame of the panels will then be aligned with the fabricated base-frame already grouted. The whole structure will be rigid and will not in any way move while operating any of the switchgears. If found necessary, then, additional supports by way of angles horizontally bolted to the panel and grouted in the nearby wall shall be done. The entire erection of the panel shall have a neat and aesthetic appearance.
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12.0 Installation of Sub-Power and Sub-Lighting Distribution Boards and Power & Lighting Distribution Boards
12.1.1 Before erecting the SLDB and SPDB and LDBs and PDBs at site, a thorough inspection shall be done by the Contractor and reported to the Architect / Consultants if any difficulties are envisaged for erection. Thereafter, an erection sketch shall be prepared, indicating the dimensions and the clearances between the Boards. A similar marking will also be made at site.
12.1.2 All Power and Distribution Boards shall be tested for mechanical endurance. After checking wiring and cable connections the entire boards, shall be erected in places indicated and marked on the plan. All touching up work of points shall then be done and foundation bolts granted. All necessary holes and civil works shall be done as per directions. The Panel after duly testing shall be put to commission for trial. All the lighting and power distribution boards shall be mounted directly on wall.
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13.0 SPECIFICATION FOR INSTALLATION OF L.T. CAPACITORS
L.T. Capacitor shall be neatly arranged and installed in tier formation. Proper checks should be done to ensure proper banking and number of L.T. Capacitors banked together. The Capacitors after installation and cable joints, shall be finally checked for any leakage etc. The L.T. Capacitors banks shall be fixed on angle iron frame work firmly granted in the floor and fixed as MS Channels frames. All Joints shall be checked for proper connections and after conducting all tests, the Capacitor Banks shall be commissioned. The Capacitor Banks shall be commissioned. The operation of banks shall also be tested and terminal voltages discharge should be tested and noted prior to commissioning.
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14.0 INSTALLATION OF MV/LV CABLES:
14.1 General:-
14.1.1 MV Cables shall be inspected prior to laying, laid tested and commissioned in accordance with drawings, specifications, relevant Indian Standards Specifications and cable Manufacturer's instructions. The Cable shall be delivered at Site in original drums with manufacturer's name clearly written in the drum.
14.1.2 The recommendations of the cable manufacturer with regard to jointing and sealing shall be strictly followed.
14.2 Inspection
14.2.1 All cables shall be inspected upon receipt at site and checked for any damage during transit.
14.2.2 While selecting cable route for external lighting, sewage effluent pipes, Fire Hydrant Pipes etc. shall be avoided; where this is not feasible, special precautions as decided by the Architect / Consultants, shall be taken.
14.3 Proximity to communication cables:-
14.3.1 Power and communication cables shall as far as possible cross at right angles. Where power cables are laid in proximity to communication cables the horizontal and vertical clearances shall not normally be less than 60 cms.
14.4 Laying methods:
14.4.1 Cables shall be laid direct in ground, in pipes/ closed ducts, in open ducts or on surface depending on environmental and site conditions.
14.4.2 During the preliminary stages of laying the cables, consideration should be given to proper location of he joint position so that when the cables are actually laid the joints are made in the most suitable places. As far as possible water logged locations, carriage ways, pavements, proximity to
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telephone cables, gas or water mains, inaccessible places, ducts pipes racks etc. shall be avoided for joint position.
14.5 Laying direct in ground:-
14.5.1 General:
This method shall be adopted where the cable route is along roads etc. and where no frequent excavations are encountered and where re-excavations is easily possible without affecting other services.
14.5.2 Trenching:-
a) Width of trench:
The width of the trench shall first be determined on the following basis: i. The minimum width of trench for laying single cable shall be 35 cm.
ii. Where more than one cable is to be laid in the same trench in horizontal formation, the width of trench shall be increased such that the inter- axial spacing between the cables, except where otherwise specified shall be at least 20 cm.
iii. There shall be a clearance of at least 15 cm between axis of the end cables and the sides of the trench.
b) Depth of Trench :-
The depth of the trench shall be determined on the following basis: i. Where cables are laid in single tier formation, the total depth of trench shall not be less than 75 cm. for cables up to 1.1 KV and 1.20 m for cables above 1.1 KV.
ii. When more than one tier of cables is unavoidable and vertical formation of laying is adopted, depth of trench in above shall be increased by 30 cm for each additional tier to be formed.
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14.6 Excavation of Trenches
14.6.1 The trenches shall be excavated in reasonably straight lines. Wherever there is a change in direction, suitable curvature shall be provided complying with the requirements of the manufacturer.
14.6.2 Adequate precautions should be taken not to damage any existing cable(s), pipes or other such installation in the proposed route during excavation. Wherever bricks, tiles or protective covers or bare cables are encountered, further excavation shall not be carried out without the approval of the Architect / Consultants.
14.6.3 If there is any danger of a trench collapsing or endangering adjacent structures, the sides should be well shored up with timbering and/or sheeting as the excavation proceeds. Where necessary, these may even be left in places when back filling the trench.
14.6.4 Excavation through lawns shall be done in consultation with the staff of the department/owner concerned.
14.6.5 The bottom of the trench shall be level and free from stone, brick bats etc. The trench shall then be provided with a layer of clean, dry sand cushion of not less than 8 cm in depth.
14.7 Laying of Cable in trench :-
14.7.1 The time of issue of cable for laying the cores shall be tested for continuity and insulation resistance.
14.7.2 When the cable has been properly straightened, the cores are tested for continuity and insulation resistance and the cable is then measured. In case of PVC cables suitable moisture seal tape shall be used for this purpose. All wastage to be contractors account.
14.7.3 Cable laid in trenches in a single timer formation shall have a covering of clean, dry sand of not less than 17 cms. above the base cushion of sand before the protective cover is laid.
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14.7.4 In the case of vertical multi-tier formation after the first cable has been laid, a sand cushion of 30 cms. shall be provided over the initial bed before the second tier is laid. If additional tiers are formed, each of the subsequent tiers also shall have a sand cushion of 30 cms. as stated above. The top most cable shall have a final sand covering not less than 17 cms. before the protective cover is laid.
14.7.5 At the time of original installation, approximately 3 m of surplus cable shall be left on each end of the cable and on each side of underground joints (straight through /Tee/Termination) and at entries and places as may be decided by the Architect / Consultants. The surplus cable shall be left in the form of a loop. Where there are long runs of cable length, loose cable may be left at suitable intervals as specified by the Architect / Consultants.
14.7.6 Unless otherwise specified, the cables shall be protected by second class bricks of not less than 20 cm x 10 cm x 10 cm (nominal size) protection covers placed on top of the sand, (bricks to be laid breadth wise) for the full length of the cable to the satisfaction of the Architect / Consultants. Where more than one cable is to be laid in the same trench, this protective covering shall cover all the cables and projects at least 5 cm. over the sides of the end cables.
14.8 Back filling
14.8.1 The trenches shall be then back filled with excavated earth free from stones or other sharp edged debris and shall be rammed and watered, if necessary, in successive layers not exceeding 30 cm. Unless otherwise specified, a crown of earth not less than 50 mm. in the center and tapering towards the sides of the trench shall be left to allow for subsidence. The crown of earth however should not exceed 10 cm. so as not to be a hazard to vehicular traffic.
The temporary reinstatements of roadways should be inspected at regular intervals, particularly during the wet weather, and any settlement should be made good by further filling as may be required. After the subsidence has ceased, trenches cut through roadways or other paved areas shall be restored to the same density and material as the surrounding area and repaved to the satisfaction of the Architect / Consultants.
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14.8.2 Where road turns or lawns, have been cut to kerb stones displaced, the same shall be repaired and made good except turning / asphalting to the satisfaction of the Architect/Consultants and all surplus earth or rock removed to places as specified.
14.9 Route Marker
14.9.1 Route marker shall be provided along straight runs of the cables at locations approved by the Architect/Consultants and generally at intervals not exceeding 100 m. Markers shall also be provided to identify change in the direction of the cable route and also for location of every underground joint.
14.9.2 Route markers shall be made out of 100 mm x 100 mm x 5 mm GI/Aluminum plate, welded or bolted on to 35 mm x 35 mm x 6 mm angle iron 60 cm. long. Such plates marker shall be mounted parallel to and 0.5 m or so away from the edge of the trench.
14.9.3 The word `cable` and other details such as voltage grading size etc. as furnished by the Architect /Consultants shall be inscribed on the marker.
14.10 Single Core Cables:-
Three single core cables forming one three phase circuit shall normally be laid in close trefoil formation and shall be bound together at intervals of approximately 1 m. The relative position of the three cables shall be changed at each point, complete transposition being effected in every three consecutive cable lengths. The joints shall be clearly marked in an approved manner to indicate the circuit and phases. The arrangement for laying a number of parallel cables shall be as detailed of IS : 1255/1967.
14.11 Laying in Pipes/Closed Ducts :-
14.11.1 In locations such as road crossing, entry to buildings, on poles, in paved areas etc. cables shall be laid in pipes or closed ducts.
14.11.2 Stone ware pipes, GI, CI or Spun reinforced concrete pipes shall be used for such purposes. In the case of new construction, pipes as required shall be laid along with the Civil Works, and jointed as per the instructions of the Architect / Consultants. The size of the pipe shall be decided by the Architect /
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Consultants and shall not be less than 10 cm in diameter for a single cable and not less than 15 cm for more than one cable. These pipes shall be laid directly in ground without any special bed except for SW pipe which shall be laid over 10 cm. thick cement concrete 1:5:10 (1 cement : 5 coarse sand : 10 graded stone aggregate of 40 mm nominal size) bed. No sand cushioning or tiles need be used in such situations. Unless otherwise specified, the top surface of pipes shall be at a minimum depth of 1 m. from the ground level when laid under roads, pavements etc.
Where steel pipes are employed for protection of single core cables feeding AC load, the pipe should be large enough to contain both cables in the case of single phase system and all cables in the case of poly-phase system.
14.11.3 Pipes for cable entries to the building shall slope downwards from the building and suitably sealed to prevent entry of water inside the building. Further, the mouth of the pipes at the building end shall be suitable sealed to avoid entry of water.
14.11.4 All chases and passage necessary for the laying of service cable connections to buildings shall be cut as required and made good to the original finish and to the satisfaction of the Architect / Consultants.
14.11.5 Cable grips/draw wires and winches etc. may be employed for drawing cables through pipes/closed ducts etc.
14.12 Laying of Cables in open ducts/Trenches:-
14.12.1 Trenches with suitable removable covers shall be preferred in sub-stations, switch rooms, plant rooms, etc
14.12.2 The cable ducts should be of suitable dimensions so that the cables can be conveniently laid. If necessary, cables may be fixed with clamps on the walls of the duct or taken in troughs in duct. The duct should be covered with removable slabs or chequered plates.
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14.12.3 Ducts may be filled with dry sand after the cable is laid and covered as above or finished with cement plaster specially in high voltage applications.
14.12.4 Splices or joints of any type shall not be permitted.
14.12.5 As far as possible laying of cables with different voltage ratings in the same duct shall be avoided.
14.12.6 Where considered necessary, hooks or racks shall be provided for supporting the cables in masonry/concrete cable ducts, cable troughs. Otherwise cables shall be laid direct in the trench or trough etc. While deciding the layout of cables in such ducts, care should be exercised to ensure, that, unnecessary crossing of cables is avoided.
14.13 Laying on Surface:-
14.13.1 The cables may be laid in troughs or brackets at regular intervals or directly cleated to wall/ceiling. When laid over bracket supports, the cables shall be clamped to prevent undue sag.
14.13.2 Cable clamps shall be made from materials such as mild steel or Aluminum only. In case of single core cables the clamps shall be non-magnetic materials. A suitable non-corrosive packing shall be used for clamping unarmored cables, to prevent damage to the cable sheath.
14.14 Cable Identification Tags:-
14.14.1 Wherever more than one cable is laid/run side by side, marker tags as approved, inscribed with cable identification details shall be permanently attached to all the cables in the manholes/open ducts etc. These shall also be attached to various cables laid direct in ground at suitable intervals as decided by the Architect / Consultants before trenches are filled up.
14.14.2 All cables before laying shall be tested with a 500 Volts megger for 1.1 KV grade or with a 2,500/5,000 Volts megger for cables of higher voltages. The
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cable cores shall be tested for continuity, absence of cross phasing, insulation resistance to earth/sheath/armor and insulation resistance between conductors.
14.14.3 All cables shall be subjected to above mentioned tests during laying, before covering the cables by protective covers and back filling and also before the jointing operations.
14.14.4 In the absence of facilities for pressure testing, it is sufficient to test for one minute with 1,000 Volts megger for cables for 1.1 KV grade and with 2,500/5,000 Volts megger for cables of higher voltages.
14.15 Completion Plan and Completion Certificate :-
14.15.1 The work shall be carried out in accordance with the drawings enclosed with the tender and also in accordance with the modifications thereto from time to time approved by the Architect / Consultants.
14.15.2 At Completion, all layout drawings should be on Auto-cad and on 1:100 scale. The contractor is required to submit 5 sets of as built drawings on A-1 Size white paper along with 5 sets of Rewritable CDs. The Virtual Completion certificate can be issued to the contractor only when he submit all the shop drawings, As built drawings, Operation and Maintenance Manual to owner, Architect/Consultant and PMC.
14.15.3 Layout of Cable Work.
14.15.4 Length, size, type and grade of cables.
14.15.5 Method of laying i.e. direct in ground, in pipes etc.
14.15.6 Location of each joint with jointing method followed.
14.15.7 Route marker and joint marker with respect to permanent land marks available at site.
14.15.8 Name of work, Job Number, accepted tender reference, date of completion, names of Division and Sub-Division, names of Contractor with their signature and scale of drawing.
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14.16 Earthing Grid and Earth Stations :-
14.16.1 The earthing system shall comply with the relevant standard as laid down in the Fire Insurance and Indian Standard Specifications.
14.16.2 The Earthing stations for Pipe and Plate Earthing shall be as per drawings. Entire Civil works, Salt, Charcoal in proper proportions, Watering chamber with wire mixing etc. shall be done. The Earth tapes wherever indicated shall be obtained by using Earth Megger. The results should comply with the Standards bid down by the Indian Standard Specifications.
14.16.3 The Lightning Arrestors shall be fixed on angle from frame work secured to the building walls at the top most painted and at all other points wherever indicated on the plan. They shall be connected to earth by using G.I. tapes of appropriate size. The entire unit shall have completed earth grid running around the unit and the same shall be inter-connected. The entire works of earthing should be complete in all respects such as welding the GI tape joints, tapping etc. There shall be no place where earthing strips are not connected to earth stations. G.I. tape shall be fixed on walls or laid in prepared trenches or chiseled in ground and redone etc. as per directions.
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15.0 TESTING
15.1 General
At the completion of the work, the entire installation shall be subjected to the following tests
a) Insulation Continuity Test. b) Insulation Resistance Test. c) Earth Continuity Test. d) Earth Resistivity Test. Besides the above tests, any other test specified by the Local Authority shall also be carried out.
15.2 Testing of Wiring
All the wiring system shall be tested for continuity of circuits, short circuits and earthing after the wiring as completed and before energizing.
15.3 Insulation Resistance Test
The insulation resistance shall be measured by applying between earth and the whole system of conductors, or any section thereof, with all fuses in place and all switches closed and except in concentric wiring all lamps in position of both poles of the installation otherwise electrically connected together, a direct current pressure provided that it does not exceed 60 volts for medium voltage circuit. Where the supply is derived from AC three phase system the neutral pole of which is connected to earth, either direct or through added resistance, pressure shall be deemed to be that which is maintained between the phase conductor and the neutral. The insulation resistance measured as above shall not be less than 50 divided by the number of points on the circuit provided that the whole installation shall not be required to have an insulation greater than one mega ohm.
The insulation resistance shall also be measured between all conductors connected to one phase conductor of the supply and all the conductors connected to the middle wire of the neutral or to the other phase conductors of the supply. Such a test shall be carried out after removing all metallic connections between the two poles of the installation and in those circumstances the installation shall not be less than that specified above. The insulation resistance between the case of frame work of housing and power appliances, and all live parts of each appliance
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shall not be less than that specified in the relevant Indian Standard Specifications or where there is no such specification shall not be less than half a mega ohm.
15.4 Testing of Earth Continuity Test
The earth continuity conductor metallic envelopes of cable shall be tested for electric continuity and the electrical continuity and the electrical resistance of the same along with the earthing lead but excluding any added resistance or earth leakage circuit breaker measured from the connection with the earth electrode to any point in the earth continuity conductor in the completed installation shall not exceed one ohm.
15.5 Testing of Polarity of Non linked single pole switches
In a two wire installation a test shall be made to verify that all non-linked single pole switches have been fitted in the same conductor throughout and such conductor shall be labeled or marked for connections, to an outer or phase conductor or to the non-earthed conductor of the supply. In the three of four wire installation a test shall be made to verify that every non-linked single pole switch fitted in a conductor to one of the outer or phase conductor of the supply. The entire electrical installation shall be subject to the final acceptance of Architect / Consultants as well as the local authorities.
15.6 Earth Resistivity Test
Earth Resistivity Test shall be carried out in accordance with Indian Standard Code of Practice for earthing IS 3043 - 1966. All tests shall be carried out in the presence of the Architect / Consultants/PMC.
15.7 Testing, Manufacturer’s Tests Pre-commissioning Tests and Complete Commissioning
15.7.1 The general intent of this specification is to mention all the relevant tests to be done and results to be furnished to Owner/Consultant/PMC by the contractor, prior to commissioning of the electrical work. These are guidelines, however, the Contractor shall carryout all such tests and complete all formalities as per relevant Indian Standard Specifications, Fire Insurance Requirements and/or
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Electricity Rules and Regulations as per Government as per Government Gazette and Publications.
15.7.2 Testing of Equipments
All equipments before installing on the site work shall be tested and all such results produced to the Owner. Nothing shall absolve the Contractor from re- performing any tests that the Contractor may be called upon specifically by the Architect / Consultants.
15.7.3 Manufacturer’s Tests
The Contractor shall specifically perform all tests such as type, routine tests on all equipments such as Medium Voltage Panels, Light Fixtures etc. The details of such tests shall be furnished by the Contractor to the Owner/ Architect / Consultants and obtain their approval in the matter. All costs incidental to such tests shall be deemed to have been included in the specific them for that equipment and no extra charge shall be payable by the Owner.
15.7.4 Pre-commissioning Tests
All tests underlined herein and/or called by the local Electrical Authorities, Government Officials and as laid down in relevant Indian Standard Specifications and/or Rules and Regulations stated in Indian Electricity Act shall be strictly complied megger, on M.V. side the reading shall not exceed 1 ohm and for H.V. side not exceeding 0.5 ohm.
15.7.5 Commissioning
a) The Contractor shall obtain the written permission and sanction of commissioning the equipment from Electrical Inspector of I.E.& L. Department of Government of Maharashtra State, if required under the specific rules of the Government.
b) All costs, visit fees etc. incidental to such obtaining sanctions shall be to the Contractors` Account, except statutory fees payable under relevant Indian Electricity Act or Rules.
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c) Contractor shall furnish all the necessary test and tests-reports to the Electrical Supply Authorities and furnish all formalities required to comply as per the Rules and Regulations on laid down for release of Electrical Supply to the Building. If called on, the Contractor shall carry out all such tests and prove the results to the entire satisfaction of the local and electric supply authorities. All costs and expenses incidental to the release of electric supply shall be to the Contractors account and no demand whatsoever shall be made to the Owner, except for any security deposits that the supply authorities would deem it necessary for charging of the line etc.
15.7.6 All such documents forwarded and/or letters and/or correspondence exchanged to this regard shall be made available for inspection and the Contractor shall furnish 3 sets of such documents and drawings for the Owner`s records.
15.7.7 After release of electric supply to Owner, the Contractor shall furnish six sets of all tests and test reports declared to the Supply authorities and shall record the initial reading of the L.T. Meter and shall furnish all such documents, officially exchanged between the Contractor and the Supply authorities for the record of Owners.
15.7.8 Contractor shall also attend and furnish the relevant completion certificate from the Electrical Inspector, I.E & L. Department, Government of Maharashtra and/or any other authority thereof, such as Pollution Control Board, various Government Bodies, Electrical Inspector, and supply Authorities whichever may be applicable.
15.7.9 The Contractor shall maintain a close liaison with the Supply Authorities and keep informed to the Architect / Consultants/Owners of the entire developments and planning i.e. being done by the Supply Authorities. It is the primary responsibility of the Contractor to approach Supply Authorities for obtaining Electrical Loads Sanctions. All formalities connected with this work shall be to the account of the Contractor except for official fees or deposits or any other statutory obligations.
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16.0 LIST OF APPROVED BRANDS/MAKES OF EQUIPMENTS REQUIRED UNDER THIS TENDER.
The following are the list of approved brands/makes of equipments required under this tender. Please note that wherever there is a multiple choice of brands/makes approved, any one make as nominated by the Owners/Consultants will have to be supplied by the Contractor without any extra cost to the owners. No deviation in this will be accepted by the owners.
S.No Details of Materials / Equipment Manufacturer’s Name .
MEDIUM VOLTAGE EQUIPMENT
1. Power Distribution Panel Antelec Advance Panels & Switchgear Milestone Engg. Sudhir Engineering RITTAL
2. Air Circuit Breaker ( 3/4 Pole ) ABB GE Power Controls Schneider Electric Siemens 3. Moulded Case Circuit Breaker ABB - T-max (T2/T4) frame (MCCB) GE Power Controls -record plus Schneider Electric - compact NXS Siemens -3VL/ Indo Asian
4. Motor Protection Circuit ABB Breaker(MPCB) GE Power Control Legrand Schneider Electric Siemens/ Indo Asian
5. Automatic Transfer Switch (ATS) ASCO
6. Final distribution board \ ABB Miniature Circuit breakers GE Power Controls (MCB)\ Residual Current Hager Circuit Breakers (RCCB)) Legrand Schneider Electric Siemens / Indo Asian
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7. Power/Aux. Contactor / ABB Capacitor GE Power Control Duty Contactor Larsen & Toubro Schneider Electric Siemens
8. Change Over Switch Elcon Socomec Larsen & Toubro 9. Control Transformer/Potential Automatic Electric Transformers Gilbert & Maxwell Indcoil Matrix Kappa Pragati
10. Current Transformer (Epoxy Automatic Electric Cast Resin) Gilbert & Maxwell Indcoil Matrix Kappa Pragati
11. Protection Relay
a. Numeric Type ABB Areva Larsen & Toubro Prok Devices Pvt. Ltd. Schneider (SEPAM) Siemens Woodword
b. Electromagnetic Type ABB Areva Larsen & Toubro 12. Indicating Lamps LED type and Altos Push Button Larsen & Toubro (ESBEE) Schneider Electric Siemens Teknik Vaishno
13. Overload relays with built in ABB Single Phase preventer GE Power Controls Larsen & Toubro Schneider Electric Siemens
14. a. Electronic Digital Meters Automatic Electric (A/V/PF/Hz/KW/KWH) with El Measure LED/ Display \ Dual Energy L & T Meter \ Static Meter Matrix
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Rishabh Schneider Electric(Conzerve) Socomec
b. Prepaid Meters & Actaris accessories HPL Schneider Electric(Conzerve) Secure Socomec
c. Electro-Magnetic Meters Automatic Electric Rishabh 15. Power Capacitor EPCOS Electronicon (Cap Electric) GE Larsen & Toubro Neptune Ducati Shreem Schneider Electric (Meher ) Subodhan Unistar
16. Autoamtic Power Factor BELUK (Germany) Correction Relay Conzerv (Numeric Type) Electronicon (Cap Electric) Neptune Ducati Power Field Shreem
16.1 Thyristerised APFC Control ABB Panel Larsen & Toubro Neel Controls Power Field Power Matrix Shreem Schneider Electric (Meher )
16.2 Detuned Reactor ABB EPCOS Larsen & Toubro Neel Controls Nepune Ducati Power Matrix Schneider Electric (Meher )
16.3 Thyristor Fuse Cooper Bussman Ferraz Shawmut Siemens
17. FRLS PVC insulated XLPE CCI aluminium/copper conductor Polycab armoured MV Cables upto 1100 Ravin Cables V grade RPG
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18. LT Jointing Kit / Termination 3M Raychem REPL
19.1 Cable Glands Double Baliga Lighting Compression with earthing links Comet Cosmos
19.2 PVC Glands Control Well Lapp
20. Bimettalic Cable Lug Comet Cosmos Dowell’s (Biller India) Hax Brass (Copper Alloy India)
21. FRLS PVC insulated copper Finolex conductor stranded flexible wires Polycab R R Kabel
22.1 Mettalic / GI Conduit (ISI AKG approved) BEC Vimco
22.2 Lead Coated Flexible GI Conduit Flexicon PLICA India Pvt. Ltd.
23. PVC Conduit & Accessories (ISI AKG approved) BEC D Plast Dimond Polypack Precision Universal VIP
24. Switch & Socket Anchor (Roma Viola) Clipsal (Opal Series) Crabtree M K India (Wraparound / Blenze) Legrand (Arteore) Wipro (NorthWest)
25. Terminal Blocks Connect Well Elmex Wago 26. Industrial Socket a. Splash Proof Clipsal CG-Scame ELCON-PCE
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Gewiss MDS Legrand Spelsberg (Cap Electric) Schneider Electric
b. Metal Clad BCH HANSEL MDS
27. Ceiling Fan Anchor Crompton Greaves Havells Orient Usha
28. Lighting Fxiture a. LED / CFL / PL / Metal Crompton Halide) / Fluorescent Philips Wipro Gewiss
b. External Lighting Fixture Crompton Philips Wipro Gewiss
c. Aviation Obstruction Light Actos (LED Type) Bajaj Binay
29. Electronic Ballast for GE Fluorescent with Active power Osram factor correction Opal (To be selected as per fixtures’ Philips manufacturer) Thorn Tridonic Wipro (APF)
30. Lighting Control Equipments/ ABB Dimmers Anchor (Panasonic) Dynalite Philips Helvar Lutron MK (Honeywell) Schneider Electric Wipro
31. Anchor (Panasonic) Occupancy sensors L&T Lutron MK (Honeywell)
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Philips Schneider (Clipsal) Wipro
32. Selector Switch, Toggle switch Kaycee Salzer (Larsen & Toubro)
33. Timer ABB BCH GE Power Control Larsen & Toubro Legrand Schneider Electric Siemens
34. Batteries with battery charger Amar Raja Amco Exide Global (Rocket) Hitachi HBL-Life Max Power Shinkobe
35. LT Servo Automatic Voltage Automatic Electric Stabilizer & Isolation Neel Controls Transformers Recon
Datson K rated Isolation Transformers Numaric Emerson
36. Inverter Autopro (Professional Lighting) Luminous Megatech Vivitar Electronics
37. Cable Trays (Factory Asian Ancillary Corporation Fabricated) / Raceways Elcon Globe Indiana Profab Engineer Rico Steel Slottco West Coast Engineering
38. Fire Sealant & Fire Retardant BTHM Engineering Paint Birla 3 M HILTI Promat
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17.0 TECHNICAL SPECIFICATIONS FOR PA SYSTEM
17.1 Applicable codes and standards
Unless specifically mentioned otherwise, all the applicable Codes and Standards published by the Bureau of Indian Standards and their subsequent revision / BS Standards shall govern in respect of design, workmanship, quality and properties of materials and method of testing; standards listed below shall be applicable, in particular:
NBC - 2005 ; National Building Code of India Part IV for Fire Protection System TAC : Fire alarm system
NFPA 72 : National fire alarm and signaling code
IS-2189 : Installation & Maintenance of Fire Detection and Alarm System
IS-2175 : Detectors
IS-694 : Copper wire
IS-9968 (Pt-1) : Rubber Insulated Braided Wire
IS-1554 (Pt-1) : PVC Insulated Cables
17.2 Objectives
The main objective of the P.A. System shall be used to convey clear and audible instructions to all the people on all floors / buildings incase of occurrence of fire / other emergency to reach a place of safety in the open, outside the buildings. The sound output should not be so loud that people nearest to the speakers feel uncomfortable, nor so weak that people away cannot discern what is being broadcast. This is achieved by working the system at 60 to 75% power output and distributing speakers uniformly all over floor area.
17.3 General description of the system
The system comprises of a microphone suitable for voice communication / Announcements through speakers on various locations on bridge. All PA system
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devices located outdoors shall have IP rating IP67 or shall be enclosed in IP67 rated enclosure.
The system shall consist of : a. Control consoles with Microphones b. Amplifiers c. Speakers d. Connecting cables and Racks for mounting above. The local control console shall be located in existing facility.
17.4 SPEAKERS
The following type of speakers shall be used in public address system for the project. 12 watt wall/column mounted speakers shall mount on the structural members of bridge at strategic locations.
17.5 CONDUITS
These shall be 16 swg mild steel, welded, thread type and having perfectly circular tubing and capable of being cleaned and tight fitting joints. Conduits shall be laid either surface or in recess as required. All conduits / junction / fittings should be painted with approved color and shall be marked for easy identification.
17.6 WIRES
The wiring shall be approved make and as specified in the bill of quantities.
17.7 SAMPLES
The contractor shall submit the samples of all equipments for approval by architects / consultants before installation.
17.8 INSPECTION, TESTING & COMMISSIONING
Inspection, testing & commissioning shall be done as per NFPA 72 guide line and print out to be submitted loop/zone wise with proper certification.
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17.9 MAKE OF EQUIPMENT
P.A. SYSTEM 1. BATTERY : HITACHI / DRYSIL / JOHNSON / PANASONIC / EXIDE / STANDARD 2. COPPER CONDUCTOR CONTROL : POLYCAB / CCI / NICCO / FINOLEX / RPG
CABLE / WIRES
3. COMMUNICATION WIRES : POLYCAB / CCI / NICCO / FINOLEX / RPG
4. M S CONDUITS : BHARATH / GB / PRINCE
5. PVC CONDUITS : VIP / PRECISION / NELCO
6. P.A. SPEAKERS : BOSCH/ Honeywell
7. P.A.CONSOLE : BOSCH/ Honeywell
8. P.A. AMPLIFIERS : BOSCH / Honeywell
9. COMPUTER : IBM / COMPAQ / HP / DELL
10. PRINTER : TVSE / HP / WIPRO / EQUI.
11. UPS : Americal Power Corp. (APC)/ Merlin Gerin/ EATON/APC/Microtek/Liebert
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18.0 TECHNICAL SPECIFICATIONS FOR CCTV SYSTEM
18.1 INTRODUCTION
Surveillance CCTV system is required to ensure effective surveillance of an area as well as create a tamperproof record for post event analysis. The System shall provide an online display of video images on monitors located in Central Control Room. . System should facilitate viewing of live and recorded images and controlling of all cameras by the authorized users present in the LAN. System should provide inter- operability of hardware, OS, software, networking, printing, database connectivity, reporting, and communication protocols. System expansion should be possible through off-the-shelf available hardware.
All CCTV system devices located outdoors shall have IP rating IP67 or shall be enclosed in IP67 rated enclosure.
18.2 GENERAL SPECIFICATIONS
Proposed CCTV system shall be an open standard based integrated system with IP network centric functional and management architecture aimed at providing high- speed manual/automatic operation for best performance.
System shall use video signals from various types of outdoor POE/IP cameras installed at different locations, process them for viewing on workstations/monitors at Central Control Room/local control rooms and simultaneously record all the cameras after compression using MPEG 4 or better standard. Joystick or Mouse-Keyboard controllers shall be used for Pan, Tilt, Zoom, and other functions of desired cameras.
System shall have combination of Bullet & PTZ IP/POE Cameras, Network Video recorders (NVR/CAMERA SERVER), Network attached storage (NAS) / Raid backup device for recording, Application software, Colour Video Monitors, Keyboards with Joystick controllers / Mouse-Keyboard, software based Video Matrix Switcher, workstation for System Administration / Management / Maintenance etc.
The NVR / CAMERA SERVER can be embedded type or server based. However the NVR / CAMERA SERVER software shall run on common off the shelf available servers (Camera server & Database server). Each NVR / Camera Server shall be able to handle 60 or more cameras.
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Network Video Recorder/Server shall offer both video stream management and video stream storage management. Recording frame rate & resolution in respect of individual channel shall be programmable.
System should ensure that once recorded, the video can not be altered, ensuring the audit trail is intact for evidential purposes.
System shall provide sufficient storage of all the camera recordings for a period of 30 days or more @ 25 FPS, at 4 CIF or better quality using necessary compression techniques for all cameras
The video shall be compressed using MPEG-4 or better standard and streamed over the IP network.
.Encoders shall digitize analog video, compress the digital video using various compression algorithms (MPEG - 4 or better standard), and transmit the compressed digital video over packet-based IP network. Encoders shall have less than 200 ms of latency and shall support dual stream – MPEG 4
The recording resolution and frame rate for each camera shall be user programmable
The Area under surveillance shall be monitored and controlled from Central/Local Control Room(s) through workstations and Joystick controllers.
Surveillance CCTV System shall operate on 230 V, 50 Hz single-phase power supply. Power for all the equipment will be conditioned using on-line UPS with minimum 30 minutes or more back up. If any equipment operates on any voltage other than the supply voltage and supply frequency, necessary conversion/correction device for supply shall be supplied along with the equipment.
System must provide built-in facility of watermarking or Digital certificate to ensure tamperproof recording so that these can be used as evidence at a later date, if so desired. The recording shall support audit trail feature.
All camera recordings shall have Camera ID & location/area of recording as well as date/time stamp. Camera ID, Location/Area of recording & date/time shall be programmable by the system administrator with User ID & Password.
System shall be triplex i.e. it should provide facility of Viewing, Recording & Replay simultaneously.
The offered system shall have facility to export the desired portion of clipping (from a desired date/time to another desired date/time) on CD or DVD. Viewing of this
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recording shall be possible on standard PC using standard software like windows media player etc.
System shall have provision of WAN connectivity for remote monitoring
There shall be a Control System with Video Control Software to manage all the video surveillance devices.
Digital video surveillance control software should be capable to display and manage the entire surveillance system. It should be capable of supporting variety of devices such as cameras, video encoders, video decoders, PTZ controller, NVR, NAS boxes/Raid backup device etc. The software should have inbuilt facility to store configuration of encoders / decoders and cameras. The software should Support flexible 1/2/4 Windows Split screen display mode or scroll mode on the PC monitor or on preview monitor as per site requirement. The software should be able to control all cameras i.e. PTZ control, Iris control, auto / manual focus, and color balance of camera, Selection of presets, Video tour selection etc
The software is required to generate reports of stored device configuration. The control software is required to provide alarm and alarm log. The log shall be able to be achieved, printed and displayed using a device filter, a device group filter and/or a time window. 5.8 The software should have user access authority configurable on per device or per device group basis. The user shall have the facility to request the access of any camera and can control the camera for a reservation period. Control of camera is released after the reservation period.
It should have recording modes viz. continuous, manual, or programmed modes on date, time and camera-wise. All modes should be disabled and enabled using scheduled configuration. It should also be possible to search and replay the recorded images on date, time and camera-wise. It should provide onscreen controls for remote operation of PTZ cameras. It should have the facility for scheduled recording. Different recording speeds (fps) and resolution for each recording mode for each camera should be possible.
The software for clients should also be working on a browser based system for remote users. This will allow any authorized user to display the video of any desired camera on the monitor with full PTZ and associated controls.
Retrieval: The CCTV application should allow retrieval of data instantaneously or any date / time interval chosen through search functionality of the application software. In case data is older than 30 days and available, the retrieval should be possible. The
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system should also allow for backup of specific data on any drives like CD/DVD/Blu ray Recorders or any other device in a format which can be replayed through a standard PC based software. Log of any such activity should be maintained by the system which can be audited at a later date.
Backup: Online backup should be maintained to protect against storage failure.
18.3 DETAILED TECHNICAL SPECIFICATIONS:
A) IP/POE Bullet Camera
UL Listed IR Vandal proof bullet Camera (IP67) Verifocal Lens with necessary
mountings to fix it on the site :-
1/3-inch progressive scan CMOS sensor, 1280(H) x 960 (V) 1.3 MP resolution, built-
in IR of 30 mtrs range, 2,8 to 12 mm lens, ONVIF compliant, with SD card slot for
onboard storage,H.264 compression, Advanced Digital Wide Dynamic Range,3D
DNR , Weather proof IP66 , PoE and 12 V DC redundant DC Power supply Camera
shall be FCC, CE, UL and RoHS compliant
B) IP/POE PTZ Camera
UL Listed IR Vandal proof PTZ Camera (IP67) 1/3-type Exmor CMOS sensor, 1.3 Megapixels, Lens Focal Length 30x Zoom
Field of View (FOV) 2.3° - 65°, Auto-focus Zoom LensFocal length f = 3 - 120 mm, DNR (Dynamic Noise Reduction) technology for clear images with virtually no motion blur under ,IR range with upto 200m IR distance.
low illumination, Frame Rate 1080P (1 - 25/30fps)
720P (1 - 25/30fps)
Pan Range 360° continuous
Tilt Range 0° to ±90°
IR distance 100 m (Detection), POE +
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C) Server with data storage
Commercial grade server from IBM/Dell/HP/Lenovo for hosting video management
application upto 60 cameras and having the minimum specification as :- processor :
6 core 2.13 GHz, 16 GB RAM, 17TB HDD, complete with RAID, power supply,
Windows 2012+ OS, Anti virus ,SQL as required.
D) Cables
Suitable fibre optic cables along with necessary LIUs & Pigtails shall be used for connecting the field switches & server.
CAT6 cables along with suitable POE connectors shall be used for connecting POE cameras & field switches.
18.4 MAKE OF EQUIPMENT
CCTV SYSTEM
1. COPPER CONDUCTOR CONTROL : POLYCAB / CCI / NICCO / FINOLEX / RPG CABLE
2. COMMUNICATION WIRES : POLYCAB / CCI / NICCO / FINOLEX / RPG
3. M S CONDUITS : BHARATH / GB / PRINCE
4. PVC CONDUITS : VIP / PRECISION / NELCO
6. IP/POE CAMERAS : Johnson Controls/ Honeywell
7. Server : IBM/Dell/HP/Lenovo
8. Monitor/ Screens : Sony/Panasonic/Samsung/LG
9. UPS : Americal Power Corp. (APC)/ Merlin Gerin/ EATON/APC/Microtek/Liebert
10. Network Switches : AMP/Legrand/CISCO/IBM
11. CAT6 & Fibre Optic Cables : AMP/Legrand/Equivalent
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19.0 TECHNICAL SPECIFICATIONS FOR FRP POLES LIGHTING
Height - 3.5m above finished floor/ground level
Shape - Round/Square
Colour - Suitable for colour theme as per Architect's Approval
Mounting Arrangement - With fixed MS Powder Coated Base Plate/Anchor Base.
Wind Load - As per site wind load conditions
UV Resistance - as per As per IS 14887 or ASTM G53
Junction Box - Internal/Integral
As per Standards- AASHTOL LTS-5, ANSI 136.20/IS 875 (PART3)
19.1 MAKE OF EQUIPMENT
Bajaj/ Equivalent
20.0 TECHNICAL SPECIFICATIONS FOR LIGHTING SCHEME
3D lighting simulation of lighting scheme have to be submitted for Architects' Approval.
The lighting system shall be capable of providing all possible lighting scenes as per Architect's requirements.
The lighting scheme will be finalized after Architect's approval to the 3D lighting simulation of lighting scheme.
The light fitting suitable for the lighting scheme & control system shall be identified & selected.
(The procurement of light fittings shall be initiated only after Architect's Approval to the 3D lighting simulation.)
21.0 Additional Points in: Electrical, Lighting and PA Works i. Dynamism for lighting:-The contractor has to program the lighting system as per Architect's Scheme. Contractor has to identify the light fitting suitable for the lighting scheme & control system and has to submit 3D lighting simulation for Architects' Approval. ii. Accessibility for Maintenance: Contractor has to make necessary arrangements like hooks/ supports for easy accessibility & maintenance of lighting system. iii. During construction and DLP (5 Years) any causality in shall be contractors responsibility iv. During DLP , any faulty light fitting and other items shall be replaced as per DLP clause (5 Years),Since this bridge DLP is 5 years, it also cover entire electrical
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maintenance as per tender, after completion period of 5 years, contractor has to take clearance / NOC from electrical /lighting or concerned AMC department. v. The contractor has to consider the Operation period for lighting system as the DLP period and One ITI electrician and one supervisor shall be deployed during DLP for operation and these staffs shall have knowledge of lighting control system and reporting to concerned AMC / SRFDCL as per instruction by engineer in charge. vi. Safety for pedestrian:-The contractor has to install the fittings to the metal structure considering safety of pedestrians. The light fittings shall be concealed in the metal frame with proper supports & the same shall be flushed to the face of the steel structure without any gap all around. The cables & earth conductors shall be properly clamped to the structure so that they will not protrude out. vii. Electrical and lighting work shall be executed by reputed and experienced class-A approved contractor.
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