HINDUSTAN PETROLEUM CORPORATION LIMITED, -...

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HINDUSTAN PETROLEUM CORPORATION LIMITED, E & P DEPTT, 2nd FLOOR, Gresham Assurance bldg, Sir P.M.Road, Fort, MUMBAI-1

TENDER DOCUMENT

FOR

SUPPLY & INSTALLATION

OF HIGHMAST LIGHT TOWERS AT

PARADEEP

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INDEX

Sr.No.

DESCRIPTION PAGES

FROM TO

1. TENDER COVER PAGE 1 1

2. INDEX 2 2

3. SCOPE 3 5

4. SCHEDULE OF QUANTITIES 6 12

5. TIME SCHEDULE 13 14

6. TECHNICAL SPECIFICATIONS 15 186

SPECIFICATIONS FOR HIGHMAST 16 22

DATASHEET FOR HIGHMAST 23 34

SPECIFICATION FOR CABLES, EARTHING

35 53

SPECIFICATION FOR CIVIL WORKS 54 137

SPECIFICATION FOR PILING WORKS 138 165

APPROVED MAKES 166 166

7. SPECIAL CONDITIONS OF CONTRACT 167 186

8. SAFETY, HEALTH & ENVIRONMENT 187 195

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1.0 SCOPE OF WORK 1.0 GENERAL 1.1 This defines the requirements for supply, installation, testing and commissioning

of high mast lighting system including connected civil foundation, supply of cables and laying of cables from bottom of high mast to top and supply and laying of cables from MCC room to the field FLP distribution boards and from DB to HM tower etc complete. The work has to be executed at: Hindustan Petroleum Corporation Limited Paradeep Terminal Opposite Paradeep Railway Station, Paradeep – 754145 Orissa. Phone:- (06722) 229225/ 229226

1.2 The high mast lighting system has been proposed to meet the general area lighting requirement of above ground tank farm area, T/T loading gantry area and other facilities.

1.3 The design data sheet comprising of lux requirements, set back distances, wind

speed etc; shall be approved by HPCL before commencement of the job.

1.4 The structural and foundation design is to be vetted by institutions like IIT, NIT or reputed engineering institution duly approved by HPCL..Force coefficient data shall be taken from wind tunnel test. The bidders who have not conducted a wind tunnel test need to conduct the same before adopting structural coefficient in the structural design. The illumination design is to be vetted by Illumination wing of Jadhavpur or Manipal collage of Engineering. The winch to be used shall have a type test certificate, if not shall be type tested at IIT or other reputed engg. Institutions duly approved by HPCL. All the raw material like High tensile steel etc shall have manufacturers test certificates to be furnished to HPCL/ HPCL approved TPI agency. The bidder should be ISO 9001 certified having their own marketing division and project cell with adequate qualified and experienced Engineers to carry out the job and must have experience of handling similar turnkey jobs in past and the proof of the same is to be furnished for issue of tender documents.

The bidder should be a high mast manufacturer and should have in-house civil, structural and product design facilities and the shaft is to be manufactured from ISO 9001, ISO 14001 and OSHAS 18001 certified factory taking care of all aspects of design, quality, environment and safety. The Luminaries supplier shall have their own in-house testing facilities for testing of photometry, other electrical and mechanical parameters of luminaries with facilities to prepare illumination design for outdoor areas.

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1.5 Supply and installation of complete high mast lighting system. Equipment and materials shall include, but not limited to the following.

• Supply of 30/20/25 m. High mast structure with Lantern carriage raising/lowering

mechanism.

• Supply of flood light fixtures, lamps.

• Supply of LED aviation obstruction lights.

• Design and providing civil pile foundation for high mast.

• Supply of power and control cables complete as required for power distribution to all high masts. The supply and laying of cables from MCC room to the field FLP distribution boards and from DB to HM tower etc complete is also in the scope of the bidder.

• Supply of flame proof feeder pillar boards weather-protected IP 55.

• Providing earth electrode, GI strip laying and earthing.

• EARTH PITS : Earth pit should be of pipe electrode type with all GI parts as per IS:3043 (latest edition) in line with attached drawing at the places as directed by EIC including testing with megger and submitting test certificates as per State Electricity Board rules. Rate to include carrying out modifications if required and retesting till the required values are achieved. Rate also includes construction of BM/CC chamber with CI cover plate.

• Installation testing and commissioning items.

1.6 Each high mast shall have feeder pillar distribution board located near the mast. Each feeder pillar will receive 3 phase, 415 V TPN supply. Tender scope includes cabling from feeder pillar box to high mast.

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IMPORTANT NOTES TO SCHEDULE OFQUANTITIES

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SCHEDULE OF QUANTITIES FOR PARADEEP

� �Sl No

Description Unit Qty

I SUPPLY ITEMS :

Supply of High Mast Tower System:

Design, supply of High Mast Tower lighting system which shall be in three sections, hot dip galvanised and designed to with stand a wind velocity 62.5m/s. The mast are to be constructed from HT Steel plates cut & folded to form a polygonal section, telecsopic jointed & welded with the exception of site joints. The two / three pieces of mast shall be joined at site using stressing equipment thus forming a sleeve joint. No site welding or bolting system will be permitted. Rate to include accessories for high mast including head frame, steel wire rope 6/8mm dia, trailing cable, double drum winch, Galvanised Lantern carriage arrangement suitable for carrying luminaries as per design including control gear boxes , lighting panel and counter weights if any. The mast shall have an integral power tool installed inside the base compartment for its operation. All accessories for bottom electrical panel & the power tool shall be flame proof. Luminaries are not included in the mast. The job shall be executed as per technical specifications, relevant/applicable codes, sound engineering practices and as directed by Engineer-in-charge complete. 1.4 The structural and foundation design is to be vetted by institutions like IIT, NIT or reputed engineering institution duly approved by HPCL..Force coefficient data shall be taken from wind tunnel test. The bidders who have not conducted a wind tunnel test need to conduct the same before adopting structural coefficient in the structural design. The illumination design is to be vetted by Illumination wing of Jadhavpur or Manipal collage of Engineering. The winch to be used shall have a type test certificate, if not shall be type tested at IIT or other reputed engg. Institutions duly approved by HPCL. All the raw material like High tensile steel etc shall have manufacturers test certificates to be furnished to HPCL/ HPCL approved TPI agency. The bidder should be ISO 9001 certified having their qualified and experienced Engineers to carry out the job and must have experience of handling similar turnkey jobs in past and the proof of the same is to be furnished for issue of tender documents. The bidder should be a high mast manufacturer and should have in-house civil, structural and product design facilities and the shaft is to be manufactured from ISO 9001, ISO 14001 and OSHAS 18001 certified factory taking care of all aspects of design, quality, environment and safety. The Luminaries supplier shall have their own in-house testing facilities for testing of photometry, other electrical and mechanical parameters of luminaries with facilities to prepare illumination design for outdoor areas.

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Supply of foundation bolts manufactured from special steel along with nuts, washers, anchor plates and templates.

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Supply of the following flood light type luminares and its control gear assenbly.

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Supply of flame proof control for mast hoisting arrangement. Rate to include supply & installation of 63 Amps MCB incomer, single dial timer contactor circuit, out going terminals & control circuit for power tool motor. EACH 12

Supply of LT XLPE insulated PVC sheathed armoured cable with Aluminum conductor,1.1 KV grade conforming to IS 7098 (part-I) with FRLS properties as tested vide IS 10810 (Part- 61) of following sizes as per attached technical specifications and as directed by EIC complete

MTR

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II ERECTION, TESTING & COMMISSIONING ACTIVITIES:

Erection of the high mast with the help of suitable tools and plants, wiring of luminaires with all wiring materials like XLPE FRLS insulated PVC sheathed flexible cable of suitable copper conductor cores of 1.5 sq. mm, lugs and all labour.

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Laying, Testing & Commissioning of LT XLPE insulated PVC sheathed FRLS armoured cable with Aluminum conductor,1.1 KV grade conforming to IS 7098(part-I) of following sizes as per attached techincal specifications and as directed by EIC complete. The job includes excavation upto a minimum depth of 0.75 m and minimum width of 0.3m. Laying and compaction 0f 150mm sand bed, laying of bare cable along with overlaying of 150mm sand bed, along with laying of bricks in transverse direction etc. complete to the satisfaction of EIC.

MTR

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End terminations of LT XLPE insulated PVC sheathed FRLS armoured cable with Aluminum conductor including providing terminal lugs, cable terminations, brass double compression glands, effecting connections to the equipment complete as required

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23 Installation, Testing & Commissioning of High Mast Feeder Pillar )�$2 � 12

24

Providing & fixing GI pipe earth pits using 2.5 mts long 40mm dia GI pipe. Job to include, providing and fixing 25x3mm GI flats, necessary excavation for chamber, brick masonry including plastering from both faces, CI cover with frame of 300x300mm opening, GI Funnel at the top of the pipe etc . Rate to include all necessary terminations, fixing etc complete as advised by EIC.

)�$2 � 24

III CIVIL WORKS

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25

Excavation up to 3.0 M Depth : Staking out, marking the outline for excavation, excavation in any type of soil including rcc floor/pcc floor either by machinery or manually etc up to 3.0 m below NGL for all depths including removal of stems and roots to full extent removal of all vegetation including bushes and grass, dewatering , shoring ,strutting etc., complete. The Job includes taking spot levels in grid pattern( 5 M X 5 M or less grid size), leveling, dressing and rolling the excavated surface wherever necessary. The job also covers loading, transportation and unloading all types of soils and other excavated materials to a designated dumping area inside /outside Terminal premises and leveling using roller ,complete as per specifications and instructions of Engineer in Charge. Rate to include the execution of the job as per latest codal provisions, attached Technical specifications and as directed by EIC.

CUM 650

26

Rubble Soling : Providing and laying 230 mm thick dry trap rubble stone soling including hand packing, filling the interstices with chips, spalls and binding with grit and selected murrum, watering, compaction by hand ramming and rolling with 2 MT/ 10 MT road roller below footings, floors etc.., complete as directed by EIC. Rate to include the execution of the job as per latest codal provisions, attached Technical specifications and as directed by EIC.

CUM 50

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PCC : Supplying and laying PCC 1:2:4, using 20 mm and down size crushed aggregate including providing shuttering for formwork, mixing, compacting by Vibrators, curing etc. complete for foundation beds of rafts, columns, pedestals and driveways etc. Cement shall conform to IS 8112 – 43 grade / 53 grade or IS 1489. Cement shall be Ultratech, ACC or approved make. Rate to include the execution of the job as per latest codal provisions, attached Technical specifications and as directed by EIC.

CUM 40

28

RCC M-25: Providing and laying RCC for footings and columns at all heights and depths using 20 mm and down size graded crushed aggregate including providing and fixing steel shuttering for form work with approved quality supports, scaffolding, machine mixing, compacting by mechanical vibrators, curing, etc complete. Concrete shall conform to IS 456-2000. Rate shall be exclusive of steel reinforcement, which shall be paid under a separate item. Cement shall conform to IS- 8112 43 grade/53 grade or IS 1489. Cement shall be Ultratech, ACC, Lafarge, Gujarat Ambuja. Party shall perform concreting jobs with standard mechanical mixers at site .Rate to include the execution of the job as per latest codal provisions, attached Technical specifications and as directed by EIC.

CUM 130

29

Bored Cast –In-situ Piles: �

Providing and casting of Bored cast-in-situ reinforced cement concrete piles with M25 design mix as per IS 456-2000 with a minimum cement content of not less than 400 kg/cum and a max water cement ratio of 0.45. The cement content shall be governed by Design mix or soil characteristics, which ever is higher. The job scope includes design of pile foundations including pile cap by reputed institute like IIT, Kharagpur or any other reputed Engineering Institutes/ Consultant duly approved by HPCL based on soil investigation report provided by HPCL and submit the same to HPCL before commencement of the job. The job includes boring up to required strata of the pile as per termination criteria of soil investigation report (to be provided to successful bidder) and approved design requirements of the pile foundation. The diameter of the pile shall be as per approved design.

CUM 380

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The job also include collecting, conveying, loading, transportation of muck, clay, other fluid particles along with soil to an unobjectionable place outside the terminal premises and HPCL will not be responsible for any irregularities by the party regarding dumping of the earth/muck/mud/debris. In case of any default by the party regarding the above, HPCL will be forced to take necessary action suitably. Cement shall be Portland Puzzolana Cement conforming to IS:1489. RCC shall be executed thru ready mix concrete from approved RMC Plants only like ACC, L&T etc. The scope of mix design is included in the scope of bidder and the same to be vetted by reputed engineering institute like IIT, Kharagpur or any other reputed Engineering Institutes/ Consultant duly approved by HPCL. Alternatively, A weigh batcher along with a batching plant can also be set up at the site duly certified for its performance with due components by third party agency is also permitted. No separate payment will be made on account of this and shall be deemed to be include in the quoted rates. The reinforcement for pile shall be Corrosion resistant steel and it shall be either “TISCON CRS” from TISCO or HSCR-M from Vizag Steel or HCR-M from SAIL only. The item is exclusive of the supply bending, erection of CRS steel. The same shall be paid in item no 31. The piling job to include providing casing pipe if required, bentonite slurry mixing plant and circulation plant, including filling of the bore hole with bentonite, hire and installation charges for all other tools, rigs & plants as necessary. The item is inclusive of all other sundry charges like oil, stores, testing equipments for routine load tests namely vertical , lateral as per codal requirements on working piles and others as deemed necessary as per enclosed specifications and standard engineering practices & relevant latest IS codes etc, complete as per approved drawings & instruction from EIC. Rate quoted shall include conducting routine load tests on working piles as per relevant codal provisions and replacement & re-casting of additional piles in case of failure in the load tests. Load tests to be repeated in case of failure as above complete as per codal provision and as directed by EIC. The reinforcement along with Pile concrete will be terminated 600 mm above pile cutoff level. The total approximate depth of boring may be 15 meters and actual depth shall be governed by soil investigation report. Payment will be made on actual quantity of concrete cast basis from termination strata to Cut-off level of the pile. Pile shall be terminated as per soil report/Design requirements or as advised by EIC. Rate to include casting of concrete of cast-in-situ piles 600mm above the cut-off level as indicated in the approved design drawings. This is included in the scope of this item and no additional payment will be made on this account. Rate to include chipping of concrete of cast-in-situ piles already cast to the correct lines and levels from the top of the piles to the cut-off level as indicated in the approved design drawings and exposing the reinforcing rods and disposal of the debris to an unobjectionable place outside the terminal premises. The exposed reinforcement shall be applied two coats of cement slurry as per the directions of EIC. No additional payment shall be made on account of the above. The pile shall protrude at least 75mm in to the pile cap and care to be taken to ensure he same while chipping the cast-in-situ pile. Rate to include development length of reinforcement at pile top which is to be embedded in the pile cap where ever necessary. The rate also to include supply and filling of the interstices between piles with lean mix PCC of 1:3:6 with 20mm down aggregate and make it ready to receive Pile cap and the average thickness of the same PCC shall be 50mm. No additional payment will be made on this account. The quoted rate shall include all necessary testing of building materials, mobilization, demobilization, cleaning of the site etc complete and job to be completed in all respect as per attached technical specification and as per direction of EIC .

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This item excludes the cost of supply and laying of reinforcement and the same will be paid under Item no: 31.0

30

RCC PILE CAP: Providing reinforced cement concrete M-25 design mix as per IS 456-2000 with a minimum cement content of not less than 400 kg/cum and a max water cement ratio of 0.45 using 20mm down size graded crushed granite aggregates including cost of centering, shuttering and all other charges for mixing, laying, consolidating and curing etc complete for pile caps as per approved drawings and as per standard specifications and as directed by Engineer In Charge. The cement content shall be governed by Design mix or soil characteristics, which ever is higher. Job also includes excavation to required depth for casting of pile cap and all other works required for completion of the job in all respect as per direction of EIC. This item excludes the cost of supply and laying of reinforcement and the same will be paid under item no: 31.0

CUM 100

31

Reinforcement Steel : Supply, fabrication, tying and laying in position TMT (Thermo Mechanically Treated) steel reinforcement conforming to IS 1786, Fe-500 (latest edition) manufactured by SAIL/TISCO/RINL .Job includes, cutting, cold bending, tying with 20 SWG black annealed binding wire and placing in position at all heights/line/levels etc., complete in all respects as per standard specification. Laps, chairs and spacer bars shall not be considered for measurement and payment purposes. Rate to include the execution of the job as per latest codal provisions, attached Technical specifications and as directed by EIC.

MT 40

32

Supply & Laying of RCC Hume Pipe of Class NP3 and 150 NB including collars, jointed with stiff mixture of CM 1:2 proportion, curing, aligning and joining etc. to correct slope including excavation, backfilling at all depths as per approved drawings for water / cable with all bye works complete as per specification and directions of Engineer.

MTR 150

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SUPPLY & INSTALLATION OF HIGHMAST

AT PARADEEP

PART LOCATION COMPLETION PERIOD FROM DATE OF PARADEEP TERMINAL ISSUE OF FOI /LOI/ PO 4 (FOUR) MONTHS NOTE:

1) Time for completion shall be reckoned from the date of issue of Fax/

Letter of Intent/Purchase Order by HPCL.

2) Time for completion shall include the time required for Design, vetting, QAP/ITP, mobilization, demobilization, carrying out the works as per requirements of Contract Document and instructions of HPCL Engineer-in-Charge.

3) The job scope is as defined in tender.

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SPECIFICATION FOR HIGH MAST LIGHTING SYSTEM 3.0 STANDARDS The supply of high mast, lighting fixtures, cables and other materials and the installation shall conform to the codes of Bureau of Indian Standards and other applicable International standards.

1. High mast Shaft – TR. No. - 7 – High Masts for Lighting and CCTV (2000 edition) of ILE, U.K, SABS 0225:1991

2. Wind Loading – IS 875 Part – 3 3. High Tensile Steel Sheets – BS EN 10025:2004 grade S355 J0 4. Mild Steel – IS 2062 5. Galvanization – BS EN ISO 1461 6. Stainless steel Wire rope – IS 3459 / 2266 7. Trailing Cable – IS 9968 Part – 1 8. Motor – IS 325

In case of any contradiction, the requirements of this specification shall govern. In addition, the installation shall conform to the stipulations of the latest editions of the following:

� Indian Electricity Rules & Act.

� Regulations laid down by the Chief Electrical Inspector of Uttar Pradesh, West Bengal, Orissa and Jharkhand.

� Fire Insurance regulations.

� Any other regulations laid down by Central/State local authorities.

4.0 EQUIPMENT SPECIFICATIONS: 4.1 HIGH MAST: 4.11 Structure: The High mast shall be of continuously tapered, polygonal cross section, at least 20 sided, presenting a good and pleasing appearance and shall be based on proven In-Tension design conforming to the standards referred to above, to give an assured performance, and reliable service. The structure shall be suitable for wind loadings as per IS 875 part3 1987. 4.12 Construction: The mast shall be manufactured using special steel plates, conforming to BS-EN10-025 and shall be delivered in multiple sections of effective length 10 metres. Thus a 30M, 25M & 20M mast shall be delivered in three sections & two sections to site. Each section shall be fabricated out of single plate duly folded and welded. There shall be only one longitudinal seam weld per section. Sections with more than one weld,

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circumferential or longitudinal, shall not be accepted. At site the sections shall be joined together by slip-stressed-fit method. No site welding or bolted joint shall be done on the mast. The minimum over lap distance shall be 1.5 times the diameter at penetration. The minimum top diameter shall be 150 mm. Bottom diameter and plate thickness shall be as per the structural requirements. Detailed design calculation of the mast shall be submitted for verification. The mast shall be provided with fully penetrated flange, which shall be free from any lamination or incursion. The welded connection of the base flange shall be fully developed to the strength of the entire section. The base flange shall be provided with supplementary gussets between the bolt-holes to ensure elimination of helical stress concentration. For the environmental protection of the mast, the entire fabricated mast shall be hot dip galvanised, internally and externally, having a uniform average thickness of 85 microns for plates with more than 5 mm thickness and 70 microns for 5 mm and less. Galvanising shall be done in single dipping method for better adhesion and life. 4.12.1 Door Opening: An adequate door opening shall be provided at the base of the mast and the opening shall be such that it permits clear access to equipment like winches, cables, plug and socket, etc. and also facilitate easy removal of the winch. The door opening shall be complete with a close fitting, vandal resistant, weatherproof door, provided with a heavy-duty double internal lock with special paddle key. The door opening shall be carefully designed and reinforced with welded steel section, so that the mast section at the base shall be unaffected and undue buckling of the cut portion is prevented. Size of door opening shall not be more than 1200 x 250 mm to avoid buckling of the mast section under heavy wind conditions. 4.13 Dynamic Loading for the Mast: The mast structure shall be suitable to sustain an assumed maximum reaction arising from a wind speed as per IS 875 (three second gust) or as specified in data sheet and shall be measured at a height of 10 metres above ground level. The design life of the mast shall be 25 years.

4.14 Lantern Carriage: 4.14.1 Fabrication: A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fittings and control gear boxes. The Lantern Carriage shall be of special design and shall be of steel tube construction, the tubes acting as conduits for wires, with holes fully protected by grommets. The Lantern Carriage shall be so designed and fabricated to hold the required number of flood light fittings and the control gear boxes, and also have a perfect self balance. The Lantern Carriage shall be fabricated in two halves and joined by bolted flanges with stainless steel bolts and nyloc type stainless steel nuts to enable easy installation or removal from the erected mast. The inner lining of the carriage shall be provided with

Page 18 of 199

protective PVC arrangement, so that no damage is caused to the surface of the mast during the raising and lowering operation of the carriage. The entire Lantern Carriage shall be hot dip galvanised after fabrication. 4.14.2 Junction Box. Weather proof junction box, made of Cast Aluminium shall be provided on the Carriage Assembly as required, from which the inter-connections to the designed number of the flood light luminaires and associated control gears fixed on the carriage shall be made. 4.15 Raising and lowering mechanism: For the installation and maintenance of the luminaires and lamps, it will be necessary to lower and raise the Lantern Carriage Assembly. To enable this, a suitable Winch Arrangement shall be provided, with the winch fixed at the base of the mast and the specially designed head frame assembly at the top. 4.15.1 Winch: The winch shall be of completely self sustaining type, without the need for brake shoe, springs or clutches. Each driving spindle of the winch shall be positively locked when not in use, gravity activated pawls. Individual drum also should be operated for fine adjustment of lantern carriage. The capacity, operating speed, safe working load, recommended lubrication and serial number of the winch shall be clearly marked on each winch. The gear ratio of the winch shall be 53: 1. However, the minimum working load shall be not less than 750 kg. (Please refer High mast data sheet for Safe working load of Winch). The winch shall be self-lubricating type by means of an oil bath and the oil shall be readily available grades of reputed producers. The winch drums shall be grooved to ensure perfect seat for stable and tidy rope lay, with no chances of rope slippage. The rope termination in the winch shall be such that distortion or twisting is eliminated and at least 5 to 6 turns of rope remains on the drum even when the lantern carriage is fully lowered and rested on the rest pads. It should be possible to operate the winch manually by a suitable handle or by an integral power tool. It shall be possible to remove the double drum after dismantling, through the door opening provided at the base of the mast. A test certificate shall be furnished by the Contractor from the original equipment manufacturer, for each winch in support of the maximum load operated by the winch. The winch shall be type tested through reputed institutions like IIT as consultants and the type test report shall be submitted along with offer. A test certificate is to be submitted along with supplies. 4.15.2 Head Frame: The head frame which is to be designed as a capping unit of the mast shall be of welded steel construction galvanised both internally and externally after assembly. The top pulley shall be of appropriate diameter, large enough to accommodate the stainless steel wire ropes and the multi-core electric cable. The pulley block shall be made of

Page 19 of 199

non-corrodable material, and shall be of die cast Aluminium Alloy (LM-6). Pulley made of synthetic materials such as Plastic or PVC is not acceptable. Self-lubricating bearings and stainless steel shaft shall be provided to facilitate smooth and maintenance free operation for a long period. The pulley assembly shall be fully protected by a canopy galvanised internally and externally. Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do not dislodged from their respective positions in the grooves. The head frame shall be provided with guides and stops with PVC buffer for docking the lantern carriage. 4.15.3 Stainless Steel Wire Ropes: The suspension system shall essentially be without any intermediate joint and shall consist of only non-corrodible stainless steel of AISI 316 grade. The stainless steel wire ropes shall be of 7/19 construction, the central core being of the same material. The overall diameter of the rope shall not be less than 6 mm. The breaking load of each rope shall not be less than 2350 kg. giving a factor of safety of over 5 for the system at full load as per the TR-7 referred to in the beginning of this specification . The end constructions of ropes to the winch drum shall be fitted with talurit. The thimbles shall be secured on ropes by compression splices. Two continuous lengths of stainless steel wire ropes shall be used in the system and no intermediate joints are acceptable in view of the required safety. No intermediate joints/terminations, either bolted or else, shall be provided on the wire ropes between winch and lantern carriage. 4.16 Electrical System, Cable and Cable Connections: Bottom electrical accessories of the mast shall be flame proof type suitable Gas group IIA/B. A suitable flameproof plug socket unit shall be provided at the bottom compartment. This unit shall have facilities for terminating incoming cable (up to 4 core 16 sq mm Al Armoured). Outgoing of this unit shall be trailing cable for the mast through plug. The electrical connections from the bottom to the top shall be made by special trailing cable. The cable shall be EPR insulated and PCP sheathed to get flexibility and endurance. Size of the cable shall be minimum 5 cores 4 sq mm copper. (Please refer Datasheet for Trailing cable size) The cable shall be of reputed make. At the top there shall be weatherproof Cast Aluminium IP 55 junction box to terminate the trailing cable. Connections from the top junction box to the individual luminaires shall be made by using 3 core 1.5 sq. mm flexible PVC cables of reputed make. Also, suitable provision shall be made at the base compartment of the mast to facilitate the operation of internally mounted, electrically operated power tool for raising and lowering of the lantern carriage assembly. 4.17 Power Tool for the Winch: A suitable, high-powered, electrically driven, internally mounted power tool with flame proof motor, with manual over ride shall be supplied for the raising and lowering of the lantern carriage for maintenance purposes. The speed and capacity of the power tool shall be to suit the system. The power tool shall be single speed, provided with a motor of the required rating. The power tool shall be supplied complete with suitable control.

Page 20 of 199

The power tool mounting shall be so designed that it will be not only self supporting but also aligns the power tool perfectly with respect to the winch spindle during the operations. Also, a handle for the manual operation of the winches in case of problems with the electrically operated tool, shall be provided and shall incorporate a torque limiting device. The power tool operation shall always be through a separate torque-limiting device to protect the wire ropes from over stretching. It shall be mechanical with suitable load adjusting device. The torque limitor shall trip the load when it exceeds the adjusted limits. There shall be suitable provision for warning the operator once the load is tripped off. The torque limitor is a requirement as per the relevant standards in view of the overall safety of the system. Each mast shall have its own power tool motor. 4.18 Lightning Finial One number heavy duty hot dip galvanised lighting finial shall be provided for each mast. The lightning finial shall be minimum 1.2 M in length and shall be provided at the centre of the head frame. It shall be bolted solidly to the head frame to get a direct conducting path to the earth through the mast. The lightning finial shall not be provided on the lantern carriage under any circumstances in view of safety of the system. 4.19 Aviation Obstruction Lights: Suitable LED Aviation Obstruction Lights of reliable design and reputed manufacturer shall be provided on top of each mast. 4.20 Earthing Terminals: Suitable earth terminal using 12 mm diameter stainless steel botls shall be provided at a convenient location on the base of the Mast, for lightning and electrical earthing of the mast.

4.21 Feeder Pillar Each mast shall be provided with flameproof feeder pillar fabricated out cast aluminum enclosure and finished with powder coated of shade 631 of IS-5. The feeder pillar shall comprise of incoming 63 Amps TPN MCB, single dial time switch, 45A TP contactor for the automatic switching of luminaries, power tool control with 2 no 9A contactors and raise lower push button, Incoming 35 / 70 sq. mm and outgoing 16 & 2.5 sq. mm terminals. 4.22 Incoming Power Cable All power and control cables shall be 1100 V grade and shall conform to the latest IS specification for M.V. Cables and accessories. A cable of size 4c x 10 sq mm XLPE insulated, PVC sheathed, FRLS, Aluminum armored for power supply ( max 10 M) and 4 c x 1.5 sq mm XLPE insulated, PVC sheathed, FRLS, Copper armoured cable for motor supply shall be provided from feeder pillar to base compartment of the high mast. Cable shall be taken to the base compartment of the high mast through provision made in the foundation. Power cable up to the feeder pillar from supply point shall be provided by HPCL.

Page 21 of 199

5.0 Luminaries Luminaires shall be specially designed with cast aluminium housing with frame, heat resistant clear toughened glass fixed to the frame with silicon gasket with electrochemically brightened, polished and anodised aluminium reflector with cast aluminium control gear box, copper ballast and 400 W HPSV Lamps. Make of luminaries shall be Bajaj/Phillips/ Crompton only.The luminaires shall be tested as per Indian standards and test reports shall be submitted along with the materials. The luminaires shall be suitable for installation on high masts. 6.0 Inspection and Testing: 6.1 The vendor shall arrange for Third party inspection and the cost for this shall be

indicated separately in the offer. Inspection may be carried out by any of the following parties.

1. LLOYDS. 2. EIL 3. IRS 4. DNV. 5. BVI 6. TUV

6.2 All tests shall be carried out at manufacturer’s work under his care & expense. 6.3 All routine tests as specified by the relevant standards/codes shall be conducted.

Type test certificates of a recognized testing organization shall be furnished with the offer. Vendor shall also submit a list of guaranteed technical particulars with the bids.

6.4 The vendor shall give at least 15 days notice to the purchaser regarding the date

of testing to enable him or his representative to witness the tests. Vendor shall furnish their detailed Q.A.P for high mast and other components to the purchaser for review. Routine tests shall be carried out on motor for winch drive. Tests shall be carried out on winch, wire rope for conformity to assigned ratings and specifications. Tests shall comply to relevant BIS or international standards. 7.0 SPECIFIC REQUIREMENTS 7.1 Locations of high mast towers are as shown in the enclosed plot plan. The area to

be illuminated is per enclosed layout plan. Vendor shall suggest the number of fittings to be used and furnish design calculation with regard to achieve lux level of the area.

7.2 All civil or structural works to be carried out as per the latest IS codes for the

same.

Page 22 of 199

7.3 After completion of job, vendor shall carryout the measurement of achieved illumination level and shall furnish test reports.

7.4 Vendor shall furnish the following along with the un-priced bid.

1. Technical details/description of the offered system with catalogues/brochures. 2. Filled in data sheet 3. Copies of Type test reports of winch, wire rope & Trailing cable etc. 4. Details of all bought out items and names of sub-vendors proposed

8.0 GUARANTEE The vendor shall guarantee the installation for a period of 12 months from the date of issue of completion certificate. Any damage or defect that may arise after or remain undetected shall be replaced and/or rectified by the vendor at no extra cost to the owner. Decision of the engineer-in-charge shall be final in this regard. The above guarantee shall be applicable for the quality of works executed as well as for the equipment/fittings/accessories supplied by the vendor. 10.0 SITE AND SYSTEM PARTICULARS: 10.1 Site conditions: The equipment and the material to be supplied and installed by the vendor shall be suitable for continuous and trouble free operation under the following site conditions: Temperature : Max. 40 º C & Min (-10) º C Design : 45 º C Relative Humidity : 87% (Max.) Seismic Condition : As applicable to the location. Atmosphere : Extremely cold conditions. Wind load : As per IS : 875 Wind direction : Refer overall plot plan Bearing capacity of soil : 10.2 System particulars: 10.2.1 The equipment and materials to be supplied by the vendor shall be designed for

the following power supply conditions.

Voltage : 415 V + 10% Frequency : 50 Hz + 3% Fault level : 50 kA System Neutral earthing : Solidly earthed

Page 23 of 199

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Page 35 of 199

CHAPTER- II

TECHNICAL SPECIFICATION

FOR

XLPE,FRLS LT CABLES

1.0 General 1.1 Scope This specification covers the basic requirements for design, manufacture,

inspection and testing at vendor’s works, of XLPE insulated cables upto 1.1KV for power, control and lighting purpose to be used in the Oil Terminal Project of M/s Hindustan Petroleum Corporation Ltd. (HPCL), at Paradeep in Orissa.

1.2 Codes and standards The design, construction, manufacture and performance of XLPE insulated

cables shall comply with all currently applicable statutes, regulations and safety codes of the locality where cables will be installed. The cables shall conform to the applicable Indian, IEC and British Standards.

The relevant Indian standards are: -

IS: 613 (1984) Copper rods and bars for electrical purposes IS:1885-(Part32) (1993)

Electro Technical vocabulary - electric cables

IS: 2633 (1986) Method of testing uniformity of coating on zinc coated articles.

IS:3961-(Part4) (1968)

Recommended current ratings for Polyethylene insulated cables.

IS: 3975 (1988) Mild steel wire, formed wires and tapes for armouring of cables.

IS: 5831 (1984) Specification for PVC insulation and sheath of electric cables.

IS: 6474 (1984) Specification for Polyethylene insulation and sheath of electric cables.

IS:7098-(PartI) (1988)

Specification for cross-linked Polyethylene insulated, PVC sheathed cables. (For working voltages upto and including 1100 volts)

IS: 8130 (1984) Conductors for insulated electric cables and flexible cords.

IS: 10418 (1982) Drums for electric cables. IS: 10462 (Part 1) (1983)

Fictitious calculation method for determination of dimensions of protective coverings of cables

IS: 10810 (Pt 58) Methods of test for cables : Part 58 Oxygen Index test IS: 10810 (Pt 61) Methods of test for cables : Part 61 Flame retardant test IS: 10810 (Pt 62) Methods of test for cables : Part 62 Flame retardant test

for bunched cables IEC:60540& 60540A Test methods for insulation & sheaths of electric cables

IEC: 230 (1966) Impulse tests on cables and their accessories IEC: 60332 (3 parts) Tests on electric cables under fire conditions IEC: 811 (5 parts) Test methods for insulating and sheathing materials of

electric cables.

IEC: 840 (1988) Tests for power cables with extruded insulation for rated voltages above 30KV upto 150KV

ASTM: D2863 Standard method for test for flammability of plastics using oxygen index method

IECAS-61-402 NEMA-WC5

Thermoplastic insulated wire & cable for transmission & distribution of electrical energy

IECAS-66-524 NEMA-WC5

Cross linked thermosetting poly ethylene insulated wire & cable for transmission & distribution of electrical energy

IEC: 840 (1988) Tests for power cables with extruded insulation for rated voltages above 30KV up to 150KV

1.2.3 The cables & accessories shall also confirm to the provisions of the Indian

Electricity Rules and other statutory regulations in force in the country. 1.2.4 In case of any contradiction between various referred standards/

specifications/ data sheets and statutory regulations, the following order of priority shall be given: - Statutory regulations - Data sheets - Unit Specifications - This Specification - Codes & Standards

2.0 General construction and material of construction

The cables shall be suitable for laying trays, trenches, ducts and conduits and for underground-buried installation with uncontrolled backfill and possibility of flooding by water & chemicals. Outer sheath of all PVC insulated cables shall be black in color and minimum value of the oxygen index shall be 29 at 27+/-2 0 C .In addition suitable chemicals shall be added in to the PVC compound of the outer sheath to protect the cable against rodent & termite attack. Sequential marking of the length of the cable in the meters shall be provided at every one meter. The embossing or engraving shall be legible or indelible. The overall diameter of the cables shall be strictly as per the values declared by the manufacturer in the technical information subject to a maximum tolerance of +/- 2mm up to overall diameter up to 60mm and +/- 3mm for above 60mm.

2.1 XLPE insulated FRLS cables All power and control cables shall be heavy-duty type, 1100V grade, with Copper/Aluminium Conductor, XLPE insulated, PVC inner sheathed, armoured and overall FRLS PVC sheathed. All cables covered in this specification shall be FRLS unless otherwise specified in the data sheet. The outer sheath of XLPE cables shall possess flame propagation properties meeting requirements

as per IS-10810 (Part-62) category AF. Exact type of the cable shall be as specified in the cable quantity list.

2.2 Conductor The conductor shall be composed of plain aluminium or high conductivity annealed copper wires complying with relevant Indian standards. The conductors of size above 6mm2 shall be stranded.

2.3 Insulation

The insulation shall be of cross linked polyethylene (XLPE) compound with anti oxidant stabilisers and shall conform to IS-7098, Part-1. (As applicable)

2.4 Filler and inner sheath (1) The filler and inner sheath shall be of the following: (a) Unvulcanized rubber, or

(b) Thermoplastic materials

(2) Unvulcanized rubber or thermoplastic material used shall not be harder than PVC used for insulation and PVC used for outer sheath. The material chosen shall be compatible with temperature ratings of the cable and shall have no harmful effect on any other component of the cable.

(3) The inner sheath shall be applied by extrusion method such that it fits closely on the laid-up cores and shall be possible to remove without damaging the insulation.

(4) Single core cables shall have no inner sheath.

2.5 Armouring

(1) Armouring shall be one of the following: -

(a) Galvanized round steel wire

(b) Galvanized steel strip (c) Any metallic non-magnetic wire/strip.

(2) Where the cable diameter below armour does not exceed 13mm, the armour shall consist of galvanized round steel wires. Where the diameter below armouring is greater than 13mm, the armour shall consist of either galvanized round steel wires or galvanized steel strips.

(3) The joints in armour wires or strips shall be made by brazing or welding

and any surface irregularities shall be removed.

2.6 Outer sheath

(1) The outer sheath shall be poly-vinyl chloride (PVC) compound conforming to the requirements of Type ST1/ST2 compound as per IS: 5831 and shall be of FRLS type only.

(2) Outer sheath of all PVC cables shall be black in colour and the minimum value of oxygen index shall be 29 at 27 � 2 deg. C. In addition suitable chemicals shall be added to the PVC compound of the outer sheath to protect the cable against rodent and termite attack.

(3) The outer sheath shall be applied by extrusion over the armouring.

2.7 Dimension / thickness of materials The thickness of insulation, inner sheath, outer sheath and dimension of wire/strips used for armouring shall be as per relevant standards. 3.0 Core identification Cores of cable shall be identified by colour coding of PVC insulation by adopting the following scheme. (1) 1 core : Red, black, yellow, blue or natural (2) 2 core : Red and black (3) 3 core : Red, yellow and blue (4) 4 core : Red, yellow, blue and black (5) 5 core : Red, yellow, blue, black and gray

(6) 6 core and above : The core identification shall be done by printing numbers or by providing colored strips all along cores. The insulation of cores shall be of the same colour and numbered sequentially. The numbers shall be printed in Hindu-Arabic numerals on the outer surface of cores. The numbers shall be repeated at regular intervals along the core and the spacing between consecutive numbers shall not exceed 50mm.

(7) For reduced neutral conductors, the insulation colour shall be black. 4.0 Identification of Cables

The cables shall be clearly and permanently marked with following information throughout the length.

(1) Voltage grade. (2) Manufacturer’s name or trade mark.

(3) Year of manufacture. Cross sectional area of conductor and no of cores. 5.0 Cable Drums

(1) Cables shall be supplied in non-returnable wooden drums of heavy construction. The wood used for construction of the drum shall be properly seasoned, free from defects and wooden preservatives shall be applied to the entire drum. All ferrous parts shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage.

(2) The vendor shall indicate in the offer, the maximum length of cable, which can be accommodated on one drum. The actual length supplied on each drum shall be within tolerance limit of +5%. The drum length shall be as per the cable quantity list.

(3) The cables shall be wound on drums of suitable barrel diameter, securely

battened, with the take-off and fully protected against mechanical damage. The cut ends of cable shall be sealed by means of non-hygroscopic sealing material to avoid ingress of water during transit or storage. Also, PVC /Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per thousand metre length.

(4) The following information shall be stencilled on each drum.

(a) Name of manufacturer, brand name or trademark. (b) Nominal cross sectional area of conductor (c) Number of cores. (d) Type of cable and voltage grade. (e) Cable code (f) Length of cable on the drum. (g) Number of lengths on drum (if more than one). (h) Drum number. (i) Direction of rotation of drum (by means of an arrow). (j) Reference standard (k) Approx. gross weight. (l) Job number. (m) Country of manufacture (n) Year of manufacture. A tolerance of +/- 3% shall be permissible for each drum. However, overall tolerance for each size of cable shall be limited to +/ - 2%. Offer with short / non-standard lengths are liable for rejection. If non- standard drum lengths are specified in the data sheet, then same shall be supplied.

6.0 Cable quantity

The bidder shall quote unit rates for all types of cables as indicated in the Job Schedule List.

7.0 Inspection and tests

(1) Inspection and testing shall be carried out in accordance with relevant standards. Routine tests shall be witnessed by HPCL approved Third Party Inspection Agency like BV/ EIL/ IRS/ DNV/ TUV. Test certificates for type test shall be furnished. Vendor shall quote unit rate for witnessing such type test by TPI Agency.

(2) Vendor shall submit blank formats where in the test results/readings are to be entered. This format shall give minimum acceptable value as per the relevant standards.

(3) Vendor shall submit blank formats where in the test results/readings are to

be entered. This format shall give minimum acceptable value as per relevant standard / purchaser’s requirement.

(4) The inspector shall have free access to the manufacturer’s works for the

purpose of inspecting the process of manufacture in all stages and he will have the power to reject any material which appears to him to be of unsuitable description or of unsatisfactory quality. The vendor shall give at least 2 weeks prior notice to the purchaser, regarding the date of testing to enable him or his representative to witness the tests.

(5) All routine tests, acceptance tests, type tests & additional type tests for

improved fire performance shall be carried out as listed in IS-7098 (Part-2).

(6) The test for resistance to Ultraviolet radiation: This test shall be carried out as per DIN 53387 or ASTM-G-53 on outer sheath. The retention value of tensile strength & ultimate elongation value after the test shall be minimum 60% of the tensile strength and elongation value before the test. The test certificates with respect to this test (not older than 1 year) from recognized testing laboratory to be furnished for review by PMC before dispatch clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to be carried out one for each order, provided the outer sheath remains the same.

(7) Acceptance tests as per IS-1554 Part-1 and IS-7098 Part-2 and the

following special tests to be performed on the cables as per the sampling plan. This tests are to be witnessed by PMC/ Owner before the dispatch of cables: a) Accelerated Water absorption test for insulation as per NEMA –WC-5 (For PVC insulated cables) and as per NEMA WC-7 (For XLPE insulated cables). Test certificates with respect to this test (not older than

one year) from recognized testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order.

(8) Dielectric Retention test: The dielectric strength of the cable insulation

tested in accordance with NEMA WC-5 at 75 ± 1o C shall not be less than 50% original dielectric strength. Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order.

(9) Oxygen Index Test: The test shall be carried out as per ASTM D2863 or

applicable Indian Standard specifications. Sampling to be done for every offered lot / size as per sampling plan.

(10) Flammability Test: The test shall be carried out on finished cable as per

IS-10810 (part 61 & 62). Sampling for this test is to be carried out one for each order, provided the outer sheath remains the same. The acceptance criteria for tests conducted shall be as under:

Part-61: The cable meets the specifications if there is no visible damage on the test specimen within 300 mm from its upper end. Part-62: The maximum extent of charred portion measured on the test sample should not have reached a height exceeding 2.5m above the bottom edge of the burner at the front of the ladder.

(11) Test for rodent & termite repulsion property: The vendor shall furnish details to analyze the property by chemical method. Sampling to be done for every offered lot / size as per the sampling plan.

8.0 Information required with the bid

Vendor shall furnish technical particulars / description and performance details of all cables, current carrying capacities and derating factors, for all conditions of cable laying.

�� !�"#��$��%�&�'��

DATA SHEET A NOTE: - This data sheet has been furnished by the Purchaser.

SR. NO.

DESCRIPTION TECHNICAL REQUIREMENTS

1.0 GENERAL 1.1 Suitable for AC/DC 1/3 Phase As required to suit system 1.2 Installation As required to suit 1.3 Length of cables As required (As per schedule of 1.4 Ambient temperature 45 o C 1.5 Relative Humidity 95% 1.6 Altitude Less than 1000 m 1.7 Plant Atmosphere Industrial corrosive, moisture laden 2.0 SYSTEM DETAILS 2.1 Rated Voltage 415 ± 10% 2.2 Rated Frequency 50 Hz ± 5% 2.3 Combined V & F variation 10% 2.4 Fault Level 65 kA for 1 sec at 415 V 2.5 System Earthing Solidly Earthed 3.0 CABLE CHARACTERISTICS 3.1 Cable type FRLS 3.2 Voltage Grade 1100 Volt

3.3 Material of Conductor Aluminium / Copper 3.4 Stranded Conductor Above 6 mm² 3.5 Solid Conductor 6 mm² and below 3.6 Cable Insulation XLPE 3.7 Screened Insulation 3.8 Inner Sheathed PVC type 3.9 Armour Required 3.10 Outer Sheathed FRLS PVC type 3.11 Earthed/Unearthed Earthed

3.12 Sizes for conductor Copper conductor for sizes up to and Including 4 Sq. mm and for

3.13 Control cables 2.5 Sq.mm stranded copper conductor, twisted pair/ shielded as

3.14 Power cables 3.5 core / 4 core as required 3.15 Cables connected in parallel Same type and cross-section 3.16 Separate control cables For CT/PT/ Interlocking/DC or AC

signals / Local control station 3.17 Multicore / multipair control Included with 20 % spare 3.18 Size of aluminium conductor Limited to 300 Sq.mm for each core 4.0 ARMOURING DETAILS 4.1 For Single-Core Cables Non-Magnetic Material (Aluminium) 4.2 For Multi-core Cables a) If Cable Diameter below Galvanized Round Steel Wire b) If Cable Diameter below Galvanized Round Steel Wire / 5.0 FRLS DETAILS 5.1 Min. Oxygen Index 29 at 27±2º C 5.2 Min. Temperature Index 21 at 250º C 5.3 Max. Hydrochloric Acid 20% by weight 5.4 Smoke Density 60% 5.5 Light Transmission 40%

XLPE Insulated FRLS LT VOLTAGE conforming to IS 7098 (part - I) CABLE

DATA SHEET B NOTE: - This data sheet B is to be filled in by the bidder for each LT CABLE and forwarded along with his offer.

SR. NO.

DESCRIPTION TECHNICAL REQUIREMENTS

1.0 GENERAL 1.1 Manufacturer’s type and 1.2 Type of Cable 1.3 Current rating in air/ground for 1.4 Temperature of conductor for 1.5 Armouring -Round wire/flat type 1.6 Normal delivery length of cable in 1.7 Drum dimensions 1.8 A.C. Resistance in Ohm / km at 1.9 Reactance in Ohm / km 1.10 Capacitance 1.11 Material of Conductor 1.12 Conductor Diameter 1.13 Outer diameter of cable 1.14 Under armour diameter of cable 1.15 Thermal resistivity 1.16 Bending radius for each cable 1.17 Oxygen Index 1.18 Fault current for each cable 1.19 Voltage drop for each cable 1.20 Weight for each cable 1.21 Material used for insulation 1.22 Data for FRLS material

CABLE LAYING:

1 General

Cable installation shall include power and control cables. These shall be laid in trenches/ cable trays as detailed in the cable layout drawings. Cable routing given on the cable layout drawings shall be checked in the field so as to avoid interference with structures, heat sources, drains, piping, air-conditioning duct etc. Any change in routing shall be done to suit the field conditions wherever deemed necessary, after obtaining approval of Engineer-in-charge.

1.1 Deleted

1.2 The lengths indicated in the cables schedule is only approximate. The contractor shall ascertain the exact, length of cable for a particular feeder by measuring at site. All cable routes shall be carefully measured .Before the start of cable laying, the contractor shall prepare cable drum schedule and get that approved by Engineer-in -charge to minimize/avoid straight through joints and then the cables cut to the required lengths, leaving sufficient lengths for the terminations of the cable at both ends. The various cable lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables. Extra loop length shall be given for feeder cables where required as per the directions of Engineer-in-charge to meet contingencies.

Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in cable tray along pipe sleepers or in over head trays as shown on cable layout drawings.

Overhead trays shall be installed 2700 nun (minimum) above grade level. At road crossings overhead trays shall be installed at 7000 mm (minimum) above grade level or cables shall be routed cable tray culvert/ Electrical road crossings as per layout drawings.

Sufficient care shall be taken while laying cables to avoid formation of twist, sharp bend etc. in order to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables

Cable installation shall provide minimum cable bending radii as recommended by cable manufacturer.

1.3 Cables shall be neatly arranged in the trenches / trays in such a manner that criss-crossing is avoided and final take off to the motor / switchgear is facilitated. Arrangement of cables within the trenches / trays shall be in line with cable layout drawings. Cable routing between cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate size. Pipe sleeves shall. be laid at an angle of maximum 45 to the trench wall. Bending radius of pipes shall not be less than 8D. It is to be ensured that both the ends of GI pipe sleeves shall be sealed with approved weather proof sealing plastic compound after cabling. In places where it is not possible, cables shall be laid in smaller branch trenches.

1.4 All cables shall be identified close to their termination point by cable tag numbers as per cable schedule. Cable tag numbers shall be punched on aluminum straps (2mm thick, 20 mm wide and of enough length) securely fastened to the cable and wrapped

around it. Each underground cable shall be provided with cable tags of lead securely fastened every 30 m of its underground length with at least one tag at each end before the cable enters/leaves the ground. In unpaved areas, cable trenches shall be identified by means of cable markers as per installation drawing. These cable markers shall be placed at location of changes in the direction of cables and at intervals of not more than 30 in and also at cable straight through joint locations.

1.5 All temporary ends of cables must be protected against dirt and moisture to prevent damage to the insulation. For this purpose, ends of cables shall be taped with an approved PVC end cap or rubber insulating tape.

1.6 Each row of cables shall be laid in place and before covering with sand. All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water inside building/lined trench. Every cable shall be given an insulation test in presence of Engineer-in-charge/Owner before filling the cable trench with sand Any cable which is found defective shall be replaced

1.7 Where cables pass through foundation walls, the necessary openings shall be provided in advance for the same by another agency. However, should it become necessary to cut holes in existing structures for example floor slab etc., the electrical contractor shall determine their location and obtain approval of the Engineer-in-charge before carrying out the same.

1.8 Cables for road crossings shall be taken through ERC (Electrical Road Crossing) is shown in the cable layout drawings. At road crossing and other places where cables enter pipe sleeves adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends.

1.9 Wherever cable trench crosses storm water, waste water channel/drain, cables shall be taken through PVC/RCC pipes. Where cables are required to cross drains of depth more than 1200 mm, cables shall be taken over the drain on cable trays supported suitably using ISMC 150/200 sections.

1.10 Ends of cables leaving trench shall be coiled & capped and provided with protective cover till such time the final termination to the equipment is completed.

2 Cables laid direct in ground

Cables shall be laid underground in excavated cable trenches where specified in cable layout drawings. Trenches shall be of sufficient depth and width for accommodation of all cables. Cables shall be properly spaced and arranged with a view of heat dissipation and economy of design. Maximum number of cable layers in trench shall be preferably limited to 5 layers.

Minimum depth of cable trench shall be 750 mm for low voltage. The depth and the width of the trench shall vary depending upon the number of layers of cables as per EIL installation Standards

Cables shall be laid in buried trenches at depth as shown in the cable layout drawings. It is to be insured by the contractor that the bottom of buried trenches shall be cleared of all rocks, stones and sharp objects before cables are placed.

The trench bottom shall be filled with a layer of sand. This sand shall be leveled and cables laid over it. These cables shall be covered with 150 mm of sand on top of the largest diameter cable and sand shall be lightly compacted. A flat protective covering of 75 min thick second class red bricks shall then be laid and the remainder of the trench shall then be back -filled with soil, rammed and leveled.

3 Cables laid in concrete trench

Cables shall be laid in 3 or 4 tiers in concrete trench as shown on layout drawings. Concrete cables trenches shall be filled with sand in hazardous area to avoid accumulation of hazardous gases and oil. RCC covers of trenches shall be effectively sealed to avoid ingress of chemical and oil in process area. Removal of concrete covers where required for the purpose of cable laying and reinstating them in their proper position after cables are laid shall be done by electrical contractor.

All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water

4 Above ground cables

4.1 Cables installed above grade shall be run in cable trays, clamped on walls, ceiling or structures and shall be run parallel or at right angles to beams , walls or columns. Cable routing shall be planned to be away from heat sources such as hot piping, gas, water, oil drainage piping, air-conditioning duct etc. Each cable tray shall contain only one layer of cables as far as possible for power cables. However control cables may be laid in double layer in the cable trays.

4.2 Individual cable or small group of cables (up to 3 to 4 cables) which run along structures / walls etc. shall be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars. Alternatively small group of cables can be taken through 100/150 mm slotted channel tray / ISMC 100. Cables shall be supported so as to prevent sagging. In general, distance between supports shall be approximately 300 mm for cables up to 25 mm diameter and maximum 450 mm for cables larger than 25 mm dia. to prevent the sagging of cables.

4.3 Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable trays shall be suitably clamped by means of G.I. saddles / clamps, whereas cables in horizontal run of cable trays shall be tied by means of nylon cords. Distance between supporting angles shall not exceed 600 mm.

4.4 All cable trays (other than galvanized trays) and supporting steel structures shall be painted before laying of cables. The under surfaces shall be properly degreased, derusted, descaled and cleaned. The painting shall be done with one coat of red oxide zinc chromate primer. Final painting shall be done with two coats of approved bituminous aluminum paint unless otherwise specified.

4.4 All cable trays (other than galvanized trays) and supporting steel structures shall be painted before laying of cables. The under surfaces shall be properly degreased,

derusted, descaled and cleaned. The painting shall be done with one coat of red oxide zinc chromate primer. Final painting shall be done with two coats of approved bituminous aluminum paint unless otherwise specified.

4.5 Where cables rise from trench to motor, lighting panel, control station, junction box etc., they shall be taken in (31 pipe for mechanical protection up to a minimum of 300 mm above grade. Cable ends shall be carefully pulled through conduit to prevent damage to cable.

4.6 All G.I. Pipes shall be laid as per layout drawings and site conditions. Before fabrication of various profiles of' pipes by hydraulically operated bending machine (which is to be arranged by the contractor) all the burrs from the pipes shall be removed. GI Pipes having bends shall be buried in soil / concrete in such a way that the bend shall be totally concealed. For G.I. pipes buried in soil, bitumen coating shall be applied on the buried lengths, Installation of G.I. pipes shall be undertaken well before paving is completed and necessary co ordination with paving agency shall be the responsibility of Electrical Contractor.

Following guide shall be used for sizing of G.I. pipe.

a) 1 cable in a pipe - 53% of pipe cross-sectional area occupied by cables. b) 2 cables in a pipe - 31 % of pipe cross-sectional area occupied by cables. c) 3 cables in a pipe - 43% of pipe cross-sectional area occupied by cables. d) 4 and above cables in a pipe - 40% of pipe cross-sectional area occupied by cables.

4.7 After the cables are installed and all testing is complete, conduit ends above grade shall be plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound. Alternatively rubber bushes shall be employed for the purpose of sealing.

5. TERMINATIONS

5.1 All PVC cables up to 1100V grade shall be terminated at the equipment by means of compression type cables glands suitable for the cable size. They shall have a screwed nipple with conduit electrical threads and check nut. The cables shall be identified close to their terminations points at both the ends of cable ( cable numbers shall be punched on aluminum straps 2 mm thick and securely fastened to the cable, wrapped around it ) and also along the route at recommended intervals, by cable tag numbers.

All cable entries for outdoor termination shall be preferably through bottom. Outdoor cable termination through top of equipment shall not be permitted.

5.2 Power cables cores wherever color coding is not available shall be identified with red, yellow and blue PVC tapes. Where copper to aluminum connections are made, necessary bimetallic washers shall be used.

5.3 In case of control cables, all cores shall be identified at both ends by their terminal numbers by means of PVC ferrules suitable for core size. Wire numbers shall be as per schematic/ wiring/inter-connection diagram. All unused spare cores of control cables shall be neatly bunched and ferruled with cable tag at both ends, for future use. For trip circuit identification additional red ferrules shall be used only in the particular

cores of control cables at the termination points in the Switchgear/ Control panels and Control Switches.

5.4 Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of nonmagnetic material/ aluminum sheet in case of single core cables. All unused cable entries on equipment/panels shall be plugged/sealed.

5.5 The cable shall be terminated at electrical equipment/switchboards through glands of proper size. The individual cores shall then be dressed and taken along the cables ways or shall be fixed to the panels with polyethylene straps. The cable glanding shall be done as per manufacturer’s instructions. Cable armor shall not be exposed after termination is complete. In case of termination of cables at the bottom of a panel over a cable trench having no access from the bottom close fit holes shall be drilled in the gland plate for all the cables in one line, and then gland plate shall be split in two parts along the centre line of holes. After fixing bottom plate, uncovered cable holes/gaps shall be sealed with cold setting compound.

5.6 Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool as per requirement. Insulation of the leads shall be removed before crimping. Conductor surface shall be cleaned and shall not be left open. Suitable conducting jelly shall be applied on the conductor lead. Lugs shall enclose all strands of cable core. Cutting of strands shall not be allowed.

5.7 The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands, lugs provided with the equipment vis-a-vis to the cable size indicated in cable schedule for taking corrective action.

5.8 The cable joints in power and control cables shall be avoided as far as possible. In case a joint is unavoidable, the following shall be insured:

The number of joints shall be restricted to minimum as far as possible. The location of joints shall be identified with permanent markers. No joints shall be allowed in hazardous areas without the approval of Engineer-in charge.

The jointing and termination of medium voltage power cables shall be carried out by trained personnel only. Jointing and termination of high voltage cables shall be done by skilled and experienced jointer duly approved by Engineer-in-charge. Only type tested termination kits of approved make shall be used.

5.9 No unauthorized repairs, modifications shall be carried out on the hazardous area equipment terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall be brought to the notice of Engineer-in-charge by contractor. After termination is complete, all the bolts, nuts, hard ware’s of terminal box shall be properly placed in its position and tightened.

5.10 Where required, cable sealing boxes intended to be used with the apparatus shall be filled with solid setting type bituminous compound unless otherwise specified.

6. TESTING AND COMMISSIONING

6.1 Field testing and commissioning of electrical installation shall be carried out as per specification.

6.2 Before energizing, the insulation resistance of every circuit shall be measured from phase to phase, phase to neutral and from phase/neutral to earth.

6.3 Where splices or terminations are required in circuits rated above 650 volts, insulation resistance of each length of cable shall be measured before splicing and or / terminating. After completion of splices and /or terminations measurements shall be repeated.

6.4 The insulation resistance of directly buried cables shall be measured before cable trenches are backfilled. Measurements shall be repeated after back filling.

• For cables up to 1.1 kV grade 1000 V Megger and for H.V.

• Cables 2.5 kV / 5 kV Megger shall be used.

6.5 D.C. High Voltage test shall be conducted on cables given below after installation.

All 1100 volts grade cables in which straight through joints have been made.

All cables above 1100 V grade.

The D.C. High Voltage test shall be performed as detailed below in the presence of the Engineer-in-charge or his authorized representative only.

Cables shall be installed in final position with the entire straight through joints complete. During the high voltage test, all other electrical equipment related to the cable installation, such as switches, instrument transformers, bus bars, etc., must be earthed and adequate clearance shall be maintained from the other equipment and framework to prevent flash over.

In each test, the metallic sheath/screen/armor shall be connected to earth.

6.6 All checks and tests shall be made as per standard test performs available with site

engineer.

All test readings shall be recorded and submitted to HPCL in triplicate sets.

6.7. Cable schedule, cable layout drawings, Interconnection drawings shall be marked by contractor for 'AS BUILT STATUS' and two sets of copies shall be submitted to HPCL.

EARTHING Scope: The scope under this section covers the following: -

a) Providing Earthing Station. b) Providing Main Earth Grid c) Earthing of all panels, DB’s and utilisation equipment.

Standards: The following standards and rules shall be applicable:-

1. IS: 3043-1987 : Amended upto date. Code of practice for Earthing

2. Indian Electricity Act 1901 and Rules issued there under. 3. OISD 147 Inspection and safe practice during electrical installation.

4. Regulations laid down by CEA/Electrical Inspectorate. 5. OISD 110 Recommended practices on static electricity.

Earthing Stations: Pipe electrode type earthing pits to be made as per IS 3043. Power conducting Apparatus: Metallic conduit shall not be accepted as an earth continuity conductor. A separate bare earth continuity conductor size of 12 SWG GI wires shall be used. The earth continuity conductor (ECC) shall be clamped to the conduit at one meter intervals using approved copper earth clamps. Non-metallic conduit shall have an insulated earth continuity conductor. All metal junction and switch boxes shall have an inside earth stud to which the ECC shall be connected. The insulated ECC shall be distinctly colored (green) for easy identification. The joint in the earth continuity conductor shall be done by welded lap joint with separate back plate of size larger than conductor itself. Armoured cables shall be earthed by distinct earth connections to the armouring at both the ends and the size of connection being as for the metallic conduit. 3 phase power panels and distribution boards shall have 2 distinct earth connections with brass studs of minimum 16mm dia. for two independent earth connections of the size shown or as co-related to the incoming cable size. Sizes of all earth connections shall be co-related to the incoming cables. All G.I. strips shall be hot dip galvanised with minimum zinc coating of 350 grams / sq.m.

3 phase apparatus shall have two distinct earth connections. For 1 Phase apparatus, the single earth connections shall be provided of the above size. For all light fittings and fans a single earth connections with 1.5 sq.mm. Copper shall be provided. An equipment-earthing grid is established. All earth connections to all panels; DB’s and Equipment shall be connected to the nearest point of the earthing grid. The installation shall be complete in all respects for efficient and trouble free service. All work shall be carried out in a first class quality and neat workmanship. Grounding conductors shall be handled carefully to avoid kinking and cutting of the conductors during their installation. All exposed ground conductors run shall be taken in a neat manner horizontal, vertical and parallel to the building walls or columns and shall not be laid haphazardly. All connections to the grounding grid shall be made with GI strip welded to grid and bolted at equipment ends. Earthing design impedance to ground shall not exceed 1 ohm. For all connections made to equipment or to the structures, the grounding conductor, connectors and equipment enclosures shall have good clean contact surfaces. Grounding conductor connection to all electrical equipment, switchgear, transformers, motors, panels, tray/conduit systems, equipment enclosures, distribution boards, equipment frames, bases, steel structure etc. shall be by pressure type or bolting type connectors. All lap, cross and tee connections between two grounding conductors both below and above ground shall be made by thermo welding process for GI or compression type connector when copper conductor is used. The various joints shall have adequate mechanical strength as well as necessary electrical conductivity not less than that of the parent conductors of the joints. All accessories for grounding installation shall be of good quality and design approved by the Owner / Consultant. All welded joints laid underground shall be treated with bitumen paint and covered with hassien tape. Grounding conductors, when crossing underground trenches, directly laid underground pipe and equipment foundation, if any, shall be at least 600 mm below the bottom elevation of such trenches / pipes. Testing: The following earth resistance values shall be measured with an approved earth meggar and recorded: -

1. Each Earthing Station 2. Earthing System as a whole (shall be less than one ohm)

3. Earth Continuity conductors.

CHAPTER- III


FOR

CIVIL WORKS

I.EARTH WORK AND BACKFILLING

1.0 SCOPE 1.1 This section of the specification covers the technical requirements for

excavation and filling & around structures, buildings, pipes, foundations, trenches, pits, drains, culverts, channels, cable ducts, underground facilities & similar works. It also covers filling areas and plinths with selected materials, conveyance and disposal of surplus spoils and/or stacking them properly as directed by the Consultant.

1.2 The contractor shall be fully responsible for proper setting out works,

profiling in excavation, stacking, etc. taking adequate safety measures etc. The Contractor shall carry out all works meant within the intent of this specification even if not explicitly mentioned herein. All works shall be executed to the satisfaction of the Consultant.

1.3 Existing trees, shrubs, any other plants, pole lines, fences, signs,

monuments, buildings, pipelines, drains, sewers or other surface or subsurface systems/ drainage facilities within or adjacent to the works being carried out which are not to be disturbed, shall be protected from damage by the Contractor. The Contractor shall provide and install suitable safeguards approved by the Consultant for this purpose.

1.4 During excavation, the Contractor shall take all necessary precautions

against soil erosion, water & environmental pollution, and where required undertake additional works to achieve this objective. Before start of operations, the Contractor shall submit to the Consultant for approval, his work plan and the procedure he intends to follow for disposal of waste materials etc. and the schedule for carrying out temporary and permanent control works. However, the approval of the Consultant to such plans and procedures shall not absolve the Contractor of his responsibility for safe and sound work.

2.0 GENERAL 2.1 The Contractor shall make his own surveying arrangements for locating

the coordinates and positions of all work and establishing the reduced levels (RL’s) at these locations based on two reference grid lines and one bench mark which will be furnished by the Owner. The Contractor has to provide at site all the required survey instruments, along with qualified surveyors, to the satisfaction of the Consultant so that the work can be carried out accurately and according to the specification and drawings.

2.2 The Contractor shall furnish all skilled and unskilled labour, plant, tools,

tackle, equipment, men and materials required for complete execution of the work in accordance with the drawings and as described herein and/or as directed by the Consultant.

2.3 The Contractor shall control the grade in the vicinity of all excavations so that the surface of the ground will be properly sloped or dyked to prevent surface water from running into the excavated areas during construction.

2.4 All materials obtained from excavation shall remain the Owner’s

property. All salvaged materials of archeological importance or of value (in the opinion of the Consultant) shall be segregated from the other materials and both stacked separately and in a regular manner at location indicated by the Consultant.

2.5 Excavation shall include removal of trees including roots & organic

remains, vegetation, grass, bushes, shrubs, plants, poles, fences etc. that are in the area to be excavated as well as beyond the excavation line so as to ensure safety of the excavated side slopes and of men and equipment operating in the area. Before start of excavation work, joint measurements of ground level shall be taken after clearing all grass, vegetation etc.

2.6 Excavation shall include the removal of all materials required to execute

the work properly and shall be made with sufficient clearance as decided by the Consultant to permit the placing and setting of forms, inspection and completion of all works to the satisfaction of the Consultant for which the excavation was done.

2.7 Classification of Earth Work: The earth work shall be classified under

the following main categories.

a) All types of soils, murrum, boulders. b) Soft rock. c) Hard rock.

2.7.1 Ordinary soils: This includes earth, murrum, top deposits of agricultural

soil, reclaimed soil, clay, sand or any combination thereof and soft and hard murrum, shingle etc., which is loose enough to be removed with spades shovel and pick axes. Boulders not more than 0.03 cum. in volume found during the course of excavation shall also fall under this classification.

2.7.2 Soft Rock: This shall include all materials which are rock or hard

conglomerate, all decomposed weathered rock, highly fissured rock, old masonry, boulders bigger than 0.03 cum in volume but not bigger than 0.5 cum and other varieties of soft rock which can be removed only with pick axes, crow bars, wedges and hammers with some difficulty. The mere fact that the contractor resorts to blasting and / or wedging and chiseling for reasons of his own, shall not mean the rock is classifiable as hard rock.

2.7.3 Hard Rock: This includes all rock other than soft rock mentioned in para 2.07.02 viz. Soft rock, occurring in masses, boulders having approximate volume more than 0.5 cum plain or reinforced cement concrete, which can best be removed by blasting or chiseling and wedging where blasting cannot be permitted owing to any restriction at site.

3.0 CODES AND STANDARDS 3.1 All standards, specifications, acts and code of practice referred to herein

shall be the latest editions including all applicable official amendments and revisions.

3.2. In case of conflict between this specification and those (IS standards,

codes etc.) referred to here in, the former shall prevail. 3.3 Some of the relevant Indian standards, Acts and Codes are referred to

here below:

IS: 383 1970 Specification for coarse and fine aggregates from natural sources for concrete.

IS 2720 (Part- 2)

1973 Methods of test for soils-Determination of water content

IS 2720 (Part4-4 )

1985 Methods of test for soils-Grain size analysis

IS 2720 (Part-5 )

1985 Methods of test for soils-Determination of liquid limit & plastic limit

IS 2720 (Part-6 )

1972 Methods of test for soils-Determination of shrinkage factors

IS 2720 (Part-7 )

1980 Methods of test for soils-Determination of water content-Dry density relation using light compaction

IS 2720 (Part-8 )

1983 Methods of test for soils- Determination of water content-Dry density relation using heavy compaction

IS 2720 (Part-14 )

1983 Methods of test for soils-Determination of dry index(relative density)

IS 2720 (Part-21 )

1977 Methods of test for soils-Determination of total soluble solids

IS 2720 (Part-23 )

1976 Methods of test for soils-Determination of calcium carbonate

IS 2720 (Part-24 )

1976 Methods of test for soils-Determination of cation exchange capacity

IS 2720 (Part-27 )

1977 Methods of test for soils-Determination of total soluble sulphates

IS 2720 (Part-29 )

1975 Methods of test for soils-Determination of dry density of soil in-place by core cutter method

IS: 3764 1992 Safety code for excavation work

IS: 4081 1986 Safety code for blasting and related drilling operations

IS: 4701 1982 Code of practice for earth work on canals IS: 9759 1981 Guide lines of dewatering during construction IS: 10379 1982 Code of practice for field control of moisture

and compaction of soils for embankment and sub grade

Indian Explosives Act 1940 as updated. 4.0 EXCAVATION IN SOIL 4.1 Side and bottom of excavation shall be cut sharp and true to line and

level. Undercutting shall not be permitted. When machines are used for excavation, the last 300 mm before reaching the required level shall be excavated manually or by such equipment that soil at the required final level will be left in its natural condition. Suitability of strata (at the bottom of excavations) for laying the foundation thereon shall be determined by the Consultant.

4.2. Excavation for foundation shall be to the bottom of lean concrete and as

shown on drawing or as directed by the Consultant. The bottom of all excavations shall be trimmed to required levels and when excavation is carried below such levels by error, it shall be brought back to the specified level by filling with concrete of nominal mix 1:3:6 (cement: coarse sand: 40 mm down aggregates) as directed by the Consultant.

4.3 The Contractor shall ascertain for himself the nature of materials to be

excavated and the difficulties, if any, likely to be encountered in executing this work., sheeting, shoring, bracing, maintaining suitable slopes, draining etc. shall be provided and installed by the Contractor, to the satisfaction of the Consultant.

4.4. All excavation for installation of underground facilities, such as pipe

lines, sewer line, drain lines etc. shall be open cuts. For deep and huge excavations and in other excavations, if required by the Consultant, the Contractor shall submit for Consultant’s approval an “Excavation Scheme” showing the methodology to be adopted for excavation in order to maintain the stability of side slopes, means for ensuring safety of existing facilities nearby, dewatering. However, the Contractor shall be fully responsible for the scheme irrespective of any approvals granted. Benching shall be provided for deeper excavation wherever required.

4.5 When excavation requires bracing, sheeting or shoring etc. the

Contractor shall submit drawings to the Consultant, showing arrangements and details of proposed installation. The Contractor shall also furnish all supporting calculations as called for and shall not proceed until he has received written approval from the Consultant. However, the responsibility for adequacy of such bracing, sheeting,

shorting etc. will rest with the Contractor, irrespective of any approval of the Consultant.

4.6 The Contractor shall have to constantly pump out any water collected in

excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, backfilling is completed. The Contractor shall remove all slush/muck from the excavated areas to keep the work area dry. Sludge pumps, if required, shall be employed by the Contractor for this purpose.

4.7 The Contractor shall remove all materials arising from excavations from

the vicinity of the work either for direct filling, stacking the subsequent filling or for ultimate disposal as directed by the Consultant. In no case shall the excavated soil be stacked within a distance of 1.5 m from the edge of excavation or one third the depth of excavation whichever is more. Material to be used for filling shall be kept separately.

5.0 EXCAVATION IN ROCK 5.1 General 5.1.1 All clauses from 4.1 to 4.7 shall be applicable to excavation in rock also.

In case of any discrepancy between the above mentioned clause and those specified in this clause then this clause shall govern.

5.1.2 For the work of excavation in rock, Contractor shall engage specialised

agency having experience of excavation in rock involving wedging and blasting. The agency shall be subject to approval of Consultant and the Contractor shall furnish details of relevant experience in support while seeking approval for the agency.

5.1.3 In case of overbreaks in rock excavation, the excavated level shall be

brought to the level shown on drawings with plain cement concrete of nominal mix 1:3:6 as described in para 4.02.00.

5.2 Excavation by Blasting 5.2.1 Blasting shall be resorted to only with the written permission of the

Consultant. All the statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc. pertaining to the acquisition, transport, storage, handling and use of explosives etc. shall be strictly followed.

5.2.2 The contractor shall obtain Licenses from Competent Authorities for

undertaking blasting work as well as for procuring, transporting to site and storing the explosives as per Explosives Act. The Contractor shall be responsible for the safe transport, use, custody and proper accounting of the explosive materials.

5.2.3 The Contractor may adopt any method of blasting as permitted according to explosives act/rule consistent with the safety and job requirements (after approval from the Consultant) and so as not to injure men or damage materials/structures during blasting operations.

5.2.4 The magazine for the storage of explosives shall be built by the

Contractor to the designs and specifications of the Explosives Department concerned and located at the approved site. No unauthorised person shall be admitted into the magazine which, when not in use, shall be kept securely locked. No matches or inflammable material shall be allowed in the magazine. The magazine shall have an effective lightning conductor and the following shall be hung in the lobby of the magazine.

a) A copy of the relevant rules regarding safe storage, both in English

and in the language(s) with which the workers concerned are familiar.

b) A statement of up to date stock in the magazine. c) A certificate showing the last date of testing of the lightning

conductor.

d) A notice stating that smoking is strictly prohibited.

5.2.5 The Contractor shall also observe any specific instructions given by the

Consultant. The Contractor shall be responsible and liable for damage to property and any accident which may occur to workmen or to the public or to materials on account of any operation connected with the storage, transportation, handling or use of explosives and the blasting operations. The Consultant or his authorised representative shall frequently check the Contractor’s compliance with these precautions and the manner of storing and accounting of explosives. The Contractor shall provide necessary facilities for this.

5.2.6 All materials, tools and equipments used for blasting operations shall be

of approved make and type. In special cases, the Consultant may specify the type of explosives to be allowed. The fuse to be used in wet locations shall be sufficiently water resistant so as to be unaffected when immersed in water for 30 minutes. The rate of burning of the fuse shall be uniform and precisely known to permit evaluation of the distance to which the firer should move before explosion takes place. Detonators shall be capable of effective blasting of the explosives.

5.2.7 The blasting powder, explosives, detonators, fuses etc. shall be fresh

and not damaged due to dampness or any other Cause. Explosives shall be kept dry and shall not be exposed to direct rays of the sun or be stored in the vicinity of fire, stoves, steam pipes, or heated metal etc. They shall be inspected before use and damaged articles shall be discharged totally and removed from site immediately.

5.3 Blasting Operations 5.3.1 The blasting operations shall remain in the charge of a responsible,

competent, authorised and experienced supervisor (called Man-in-Charge) and workmen who are thoroughly acquainted with the details of handling explosives and blasting operation and with the rules governing such work.

5.3.2 All rules under the Explosives Act and other local rules in force shall be fully observed. All blasting works shall be done in accordance with the stipulations contained in IS: 4081. Blasting shall only be carried out at certain specified times preferably during the mid-day lunchtime or at the close of work as directed in writing by the Consultant. The hours when blasting will be done, shall be made known to people in the vicinity. All the charges shall be prepared by the Man-in-Charge (as defined in 5.03.01) above) only. Proper precautions for safety of persons and property shall be taken.

5.3.3 Prior to blasting, red danger flags shall be displayed prominently around the area to be blasted and shall be kept in position until blasting work is completed. All people, except those who actually light the fuses, shall be prohibited from entering this area. The flags shall be planted 200 metres from the blasting site and all persons including workmen shall be evacuated from the flagged area atleast 10 minutes before firing. A warning whistle shall be sounded for this purpose.

5.3.4 Controlled Blasting shall be carried out within 200 metres of an existing structure unless otherwise permitted by the Consultant in writing. Where (generally with in plant area) controlled blasting is to be carried out in the proximity of other structures, then sand bags and/or earth bags etc. shall be used on top of the blast holes to prevent the rock fragments from causing damage to adjacent structures and property. At all stages of blasting operations, precautions shall be taken to preserve the rock in the soundest possible condition below and beyond the lines specified for the excavation. The quantity and strength of explosives used shall be such that it will neither damage nor crack the rock outside the limits of excavation. Any method of blasting which leads to overshooting shall be discontinued.

5.3.5 No explosive shall be brought near the work in excess of the quantity required for a particular amount of firing to be done and surplus left after filling holes shall be removed to the magazine. A careful and day to day account of the explosives shall be maintained by the Contractor in an approved manner and in an identified register, which shall be open to inspection by the Consultant at all time.

5.3.6 At a time not more than ten such charges shall be prepared and fired. The man-in-Charges shall blow the whistle in a recognised manner for cautioning the people. The number of blasts to be fired and actual

number of shots heard shall be compared and the person responsible shall satisfy himself by examination that all blasts have exploded before any person working in the area is permitted to re-approach the work site. Sufficient time shall be allowed to account for delayed blasts. The Man-in-Charge shall inspect all the charge. The withdrawal of the unexploded charge shall not be permitted under any circumstances. After tamping, the unexploded charge shall be flooded with water and the hole marked in a distinguishable manner. Another hole shall be jumped at a distance of 450 mm from the old hole and fired in the usual way. This process shall be continued till the original blast is exploded. The Man-in-Charge shall at once report to the Contractor’s office and the Consultant, all cases of misfire, the cause for the same and what steps where taken in connection therewith.

5.3.7 If misfire is found to be due to defective materials, the whole quantity in the box form which the defective materials was taken must be sent to the Authority directive by the Consultant for inspection to ascertain whether any of the remaining materials in the box are also defective.

5.4 Chiseling / Wedging

Where blasting is prohibited for any reasons or it is not practicable in the opinion of the Consultant, then the excavation shall be carried out by chiseling, wedging or any other approved method. The decision of the Consultant in this regard shall be final binding on Contractor.

5.5 Line drilling and pre-shearing

The number, size and location of holes shall be carefully worked out by the Contractor and shall be subject to the approval of the Consultant. Line drilled holes shall generally be 48 mm dia. and, if so directed, interior blasting holes shall also be made. The Contractor shall carry out test to determine the amount of explosives required to ensure an even break at the line drilled holes after the interior holes are blasted and irregularities in the vertical drilled line face shall be removed and trimmed by wedging, splitting, chiseling and barring.

6.0 EXCAVATION BELOW GROUND WATER TABLE 6.1 Wherever ground water table is met with during excavation, the

Contractor shall immediately report this fact to the Consultant who shall arrange to record the exact level of the water table before start of dewatering operation. The decision of the Consultant regarding sub-soil water level shall be final and binding on the Contractor. Ground Water Table for the purpose of this clause shall be taken as the level of standing water observed during the process of excavation. Capillary action of water in the surrounding soil mass shall not be considered for the above purpose.

6.2 The Contractor shall dewater and maintain dry working conditions by maintaining the water table below the bottom of the excavation level by well-point dewatering or deep well dewatering or any other method approved by the Consultant. He shall continue doing so till excavation, concreting, curing, and all other operation included in the scope of work, which require dry condition in the area are completed.

7.0 LIFT

The Contractor is required to excavate upto any depth as shown on the drawings or as directed by the Consultant. Lifting of excavated materials shall be done either by manual or mechanical or both means if called for by the Consultant.

8.0 CARRIAGE OF MATERIALS 8.1 The EIC shall indicate the disposal/ stacking areas for excavated

materials. The carriage of excavated materials shall be done by the methods mentioned below:

a) The excavated materials shall be carried beyond the initial lead of 50

m but upto 500 m by manual /animal labour or by mechanical means. If directed by the Consultant this material shall be used directly for filling purposes.

b) For leads exceeding 500 m the Contractor shall transport the

excavated materials by mechanical means only and as directed by the Consultant. The Contractor may be allowed to carry materials through Kuccha roads. Providing and maintaining of the Kuccha roads shall be the responsibility of the Contractor. The transported material shall be neatly stacked as directed by the Consultant.

8.2 Some excavated materials required for filling purposes, may have to be

carried upto a lead of 500 m and stacked as per instructions of the Consultant. Excavated materials carried beyond 500 m shall normally be for disposal purpose only. Double handling of materials shall be avoided as far as possible. However, depending on site condition excavated materials carried beyond a lead of 500 m may also be required to be brought back for filling purpose.

9.0 FILLING 9.1 Materials

9.1.1 Materials to be used for filling purpose shall be stone, sand or other

inorganic materials and they shall be clean and free from shingle, salts, organic matter, large roots and excessive amount of sod, lumps, concrete or any other foreign substances which could harm or impair the strength of the substances in any manner. All clods shall be suitably broken to small pieces. When the materials are mostly rock boulders,

these shall be broken into pieces not larger then 150 mm size. Sand used for filling shall be clean, medium grained and free from impurities. Fines less than 75 microns shall not be more than 20%. In any case, the materials to be used for filling purposes shall have the prior written approval of the Consultant.

9.1.2 If excavated materials are to be used for filling, then the Contractor shall select the materials from the stockpile, land and transport this material and execute the filling. This shall include excavation of earth, which may become hard due to lying in stockyard for a long period of time.

9.1.3 In case the materials have to be brought from pits/quarries, it shall be the Contractor’s responsibility for identification of such quarry areas, obtaining approval from their use from concerned authorities, excavation/quarrying loading and carriage of such material, unloading and filling at specified locations. The Contractor shall pay any fees, royalties etc. that may have to be pain for utilisation of borrow areas.

9.2 Filling Procedure 9.2.1 After completion of foundation, footings, walls and other construction

below the elevation of the final grades, and prior to filling, all temporary shoring, timber etc. shall be sequentially removed and the excavation cleaned of all trash, debris, and. perishable materials. Filling shall begin only with the written approval of the Consultant. Also, areas identified for filling shall be cleared of all soft pockets, vegetation, bushes, slash etc. In case of plinth and similar filling the ground shall be dressed and consolidated by ramming and light rolling.

9.2.2 Fill materials shall not be dropped directly upon or against any structure

or facility where there is danger of displacement or damage. Filling shall be started after the concrete/masonry has fully set and shall be carried out in such a manner so as not to cause any undue lateral thrust on any part of the structure.

9.2.3 All space between foundation (concrete or masonry) and the sides

excavation shall be filled to the original surface after making allowance for settlement, Fill shall be placed in horizontal layers not exceeding 200 mm loose thickness. Each layer shall be watered and compacted with proper moisture content and with such equipment as may be required to obtain a compaction/density as specified. Trucks or heavy equipment for depositing or compacting fill shall not be used within 1.5 meters of building walls, piers for operation. The methods of compaction shall be subjected to approval of Consultant under any circumstances.

9.2.4 Fill adjacent to pipes shall be free of stones, concrete etc. and shall be

hand placed and compacted uniformly on both sides of the pipe and where practicable up to a minimum depth of 300 mm over the top of pipes. While tamping around the pipes, care should be taken to avoid unequal pressure.

9.2.5 Filling shall be accurately finished to line, slope, cross section and grade as shown on the drawings. Finished surface shall be free of irregularities and depressions and shall be within 20 mm of the specified level.

9.2.6 Where filling with stone from excavated materials is specified, it shall be

from broken pieces of boulders. At first a 75 mm thick cushion of selected earth shall be laid over which the 200 mm thick graded stones shall be laid in loose layers of 200 mm then the interstices filled with properly graded fine materials consisting of selected earth brought from borrow areas. Each layer shall be watered and compared to the specified density before the next layer is laid. However, no cushion shall be required where filling is over non-rocky surface.

9.2.7 Where filling with 65 mm down graded stone obtained from excavated, it

shall be selected stone laid over and initial 50 mm thick cushion layer of selected earth and then stone laid in 200 m loose thick layers, interstices filled with the specified density before the next layer in laid. However, no cushion shall, be required where filling is over non-rocky surface.

9.2.8 Where clean stone fill is specified, it shall consist of clean selected

stone metal of 40-mm nominal size. It shall be laid in layers not exceeding 150 mm (loose) and lightly tamped before the next layer is laid. No compaction shall be required for this type stone filling.

9.3 Compaction 9.3.1 Where compaction to 95% Standard Proctor Density or more is called

for, it shall be by mechanical means only. Where access is possible, compaction shall be by 12 tonne rollers smooth wheeled, sheep foot or wobbly wheeled as directed by the Consultant. A smaller weight roller may be permitted by the Consultant in special cases, but in any case not less than 10 passes of the roller will be accepted for each layer. Each layer shall be wetted or the material dried by aeration to moisture content of 3-5% above the Optimum Moisture Content to be determined by the Contractor. Each layer shall be watered, rammed and compacted to the density as specified Consultant.

9.3.2 For compacting sand layer, water shall be sprayed over it to flood it and

it shall be kept flooded for 24 hours to ensure maximum compaction. Vibro-compactors shall also be used if necessary to obtain the required degree of compaction. Any temporary works required to contain sand under flooded condition shall also be undertaken. The surface of the consolidated sand shall be dressed to required levels or slope.

9.3.3 After the compacted fill has reached the desired level, the surface shall

be flooded with water for 24 hours, allowed to dry and then rammed and consolidated to avoid any settlement, at a later date. The compacted surface shall be properly shaped, trimmed and consolidated to an even

gradient or level. All soft spots shall be excavated, filled and consolidated.

9.3.4 The degree of compaction of compacted fill in place will be subject to

tests by the Consultant as the work progresses, and the contractor shall provide the necessary facilities to make such tests. If any test indicates that the compaction achieved is less than the specified degree of compaction, the Consultant may require fill placed subsequent to the last successful test to be removed and re-compacted by the Contractor. Compaction procedure shall be amended as necessary to obtain satisfactory results.

9.3.5 When semi-compacted fill is specified by the Consultant, the contractor

shall fill up such areas with available earth from stock piles of borrow pits or directly from excavation without special compaction except that obtained by moving trucks etc.

10.0 SAMPLING, TESTING AND QUALITY CONTROL 10.1 General 10.1.1 The contractor shall carry out all sampling and testing in accordance

with the relevant Indian Standards and/or International Standards and shall conduct such tests as are called for by the Consultant. Where no specific testing procedure is mentioned, the tests shall be carried out as per the prevalent accepted Consultant ringing practice to the directions of the Consultant. Tests shall be done in the field and at a laboratory approved by the Consultant and the Contractor shall submit to the Consultant, the test results in triplicate within three days after completion of a test. The Consultant may, at his discretion, waive some of the stipulations given below, for small and unimportant operations.

10.1.2 Work found unsuitable for acceptance shall be removed and replaced

by the contractor. The work shall be redone as per specification requirements and to the satisfaction of the Consultant.

10.1.3 Only as a very special case aid that too in non-critical areas, the

Consultant may accept filling work which is marginally unacceptable as per the criteria laid down. For such accepted work, payment shall be made at a reduced rate pro-rata to the compaction obtained against that stipulated.

10.2. Quality Assurance Program

The contractor shall submit and finalise a detailed field Quality Assurance Program within 30 days from the date of award of the Contract according to the requirements of the specification. This shall include setting up of a testing laboratory, arrangement of testing apparatus/equipment, deployment of qualified/experienced manpower,

preparation of format for record, Field Quality plan etc. On finalised field quality plan the Owner shall identity Customer hold points beyond which work shall not proceed without written approval from the Consultant.

10.3 Frequency of sampling and testing including the methods for conducting

the tests shall be as per IS codal provisions. The testing frequencies set forth are the desirable minimum and the Consultant shall have the full authority to carry out or call for tests as frequently as he may deem necessary to satisfy himself that the materials and work comply with the appropriate specifications.

10.4 Acceptance Criteria 10.4.1 Following Acceptance Criteria shall be as under:

a) All individual samples collected and tested should pass without any deviation when only one set of sample is tested.

b) For re-test of any sample two additional samples shall be collected

and tested and both should pass without any deviation. c) Where a large number of samples are tested for a particular test, 9

samples out of every 10 consecutive samples tested shall meet the specification requirement.

d) Tolerance on finished levels for important filling areas at approved

interval shall be + 20 mm. However, for an unimportant area, tolerance upto + 75 mm shall be acceptable at the discretion of the Consultant. However, these tolerances shall be applicable for localised areas only.

II. SOLING & HARDCORE

1.0 GENERAL 1.1 The work covered under this specification includes all type of soling work either by

rubble stones laid under floors / hard core under foundations, hand packed, complete as per under mentioned specification and applicable drawings.

2.0 RUBBLE STONE SOLING 2.1 The rubble stone shall be of best variety of black trap / granite / basalt

or other approved variety of stone available locally. The stone shall be hard, durable, free from defects and of required size and shall be approved by the Engineer in-charge before incorporation in the work.

2.2 Preparation of Surface & laying: 2.2.1 The bed on which rubble soling is to be laid shall be cleared of all loose

materials, levelled, watered and compacted and got approved by the Engineer In-charge before laying rubble soling. Cable or pipe trenches if shown in the drawing and as required by the Engineer in-charge shall be got done before the soling is started.

2.2.2 Over the prepared surface, the stone shall be set as closely as possible

and well packed and firmly set. The stones shall be of full height and shall be laid so as to have their bases of the largest area resting on the sub-grade. Soling shall be laid in one layer of 230mm or 150mm or other specified thickness and no stones shall be less than 230mm or 150mm depth or specified thickness of soling with a tolerance of 25mm.

2.2.3 After packing the stones properly in position, the interstices between

them shall be carefully filled with quarry spoils of stone chips of larger size possible to obtain a hard, compact surface. Spreading of loose spoils or stone chips is prohibited.

2.2.4 The entire surface shall be examined for any protrusions and the same

shall be knocked off by a hammer and all interstices shall be filled with approved murrum. Excess murrum if any over the surfaces shall be removed. Unless otherwise specified, the murrum shall be supplied by the contractor at his own cost from the selected areas. The surfaces shall then be watered and consolidated with mechanical or sufficiently heavy wooden tampers and log-rammers as approved by the Engineer in-charge to give the required slope or level and dense sub-base. After compaction, the surface shall present clean look. Adequate care shall be taken by the contractor while laving and compacting the rubble soling to see that concrete surfaces in contact with soling are not damaged.

3.0 HARD CORE FOR FOUNDATIONS 3.1 Where specifically mentioned in the drawings, hard core layer shall be

provided as a preparatory surface to receive blinding concrete/ leveling course.

3.2 Hard core layer shall comprise of well graded broken stones 80mm

nominal size with the following gradation:

IS Sieve designation % passing 80 mm 100 63 mm 85-100 40 mm 0-30 20 mm 0-5 10 mm 0-5

3.3 The hard broken stones layer shall be directly placed over the

compacted layer of under lying soil in layers. The stones shall be hand packed and crevices filled with broken stones.

3.4 Each layer shall be covered with clean river sand and thoroughly

worked into the crevices with a water jet. Additional layers of sand shall be placed on top and worked into the void spaces. The process shall be repeated until no more sand and water get into the voids.

3.5 Earth rammer shall be used to compact each layer if directed by

Consultant. 3.6 The thickness and area covered beyond the blinding concrete shall be

as indicated in the drawings or as indicated by Consultant.

III. PLAIN AND REINFORCED CONCRETE & ALLIED WORKS 1.0 SCOPE

1.1 This specifications covers the general requirements for concreting to be

used on jobs using on-site production facilities including requirements in regard to handling, storage of ingredients, proportioning, batching, mixing and testing and quality assurance. This also covers the transportation of concrete from the mixer to the place of final deposit and the placing consolidation, curing, protecting, repairing and finishing of concrete.

1.2 The work shall include providing of materials, all necessary plant and

equipment, providing adequate Consultanting supervision and technical personnel, skilled and unskilled labour, etc. as required to carry out the entire work as indicated on the drawings and/or described herein subsequently and/or as directed by the Consultant.

1.3 The Contractor shall carry out all works meant within the intent of this

specification even if not explicitly mentioned herein. All works shall be executed to the satisfaction of the Consultant.

2.0 GENERAL 2.1 The Contractor shall make his own surveying arrangements for locating

the coordinates and positions of all work and establishing the reduced levels (RLs) at these locations, based on two reference grid lines and one bench mark, which will be furnished by Owner. The Contractor has to provide at site, all the required survey instruments, along with qualified surveyors, to the satisfaction of the Consultant so that the work can be carried out accurately and according to the specifications and drawings.

2.2 The contractor shall establish a site laboratory for testing of material and

quality assurance as per the requirements of this specification. The laboratory shall be manned by qualified Consultant.

2.3 Any approval, instructions, permission, checking, review, etc.

whatsoever by the Consultant, shall not relieve the Contractor of his responsibility and obligation regarding adequacy, correctness, completeness, safety, strength, quality, workmanship, etc.

3.0 CODES AND STANDARDS

3.1 All work shall be carried out as per the stipulations contained in various

sections of these specifications and the latest Indian Standards, Acts, Codes and best practices.

3.2 All applicable standards, specifications, etc. and codes of practice shall

generally be the latest editions, including all applicable official

amendments and revisions. A complete set of all these documents shall generally be available at site, with the Contractor.

3.3 In case of conflict between the stipulations contained in various sections

of these specifications and stipulations of Indian Standards, Codes, etc. the requirements of stipulations contained in various sections of these specifications, shall prevail over that of Indian Standards, Codes, etc.

3.4 The following are the various relevant Indian Standards:

IS: 73 1992 Specification for paving bitumen IS : 216 1961 Specification for coal tar pitch IS: 269 1989 Specification for 33 grade Ordinary Portland cement IS: 280 1978 Specification for mild steel wire for general Consultanting purposes

IS: 383 1970 Specification for coarse and fine aggregates from natural sources

for concrete IS:432 (Parts I) 1982 Specification for mild steel medium tensile steel bars and hard

drawn steel wire for concrete reinforcement – Mild steel & medium tensile bars

IS: 432(Parts II) 1982 Specification for mild steel medium tensile steel bars and hard drawn steel wire for concrete reinforcement - Hard drawn steel wire

IS: 455 1989 Specification for Portland slag cement IS: 456 2000 Code of practice for plain and reinforced concrete IS: 457 1957 Code of practice for general construction of plain & reinforced

concrete for dams & other massive structures IS: 516 1959 Method of test for strength of concrete IS : 650 1991 Specification for standard sand for testing of cement IS: 702 1988 Specification for industrial bitumen IS : 737 1986 Wrought aluminium and aluminium alloy plate for general

Consultanting purposes IS: 800 1984 Code of practice for general construction in steel IS: 816 1969 Code of practice for use of metal are welding for general

construction in mild steel IS: 1161 1998 Specification for steel tubes for structural purpose

IS: 1199 1959 Methods of sampling and analysis of concrete

IS: 1200 (Part-II) 1974 Method of measurement of building and civil Consultanting works - Concrete works

IS: 1200 (Part-V) 1982 Method of measurement of building and civil Consultanting works - Form work

IS: 1200 (Part-VIII)

1993 Method of measurement of building and civil Consultanting works - Steel work & iron work

IS: 1200 (Part- XVIII)

1974 Method of measurement of building and civil Consultanting works - Demolition & dismantling

IS: 1322 1993 Specification for bitumen felts for waterproofing and damp proofing IS: 1363 (Part 1) 2002 Hexagon head bolts, screws and nuts of product grade ‘C’ –

Hexagon head bolts (size range M 5 to M 64) IS: 1363 (Part 2) 2002 Hexagon head bolts, screws and nuts of product grade ‘C’ –

Hexagon head screws (size range M 5 to M 64) IS: 1363 (Part 3) 2002 Hexagon head bolts, screws and nuts of product grade ‘C’ –

Hexagon nuts ( size range M5 to M 64) IS: 1489 (Part-I) 1991 Specification for Portland-pozzolana cement: Fly ash based

IS:1489 (Part-II) 1991 Specification for Portland Pozzolana Cement: Calcined clay

based. IS : 1566 1982 Specification for Hard-drawn steel wire fabric for concrete

reinforcement. IS : 1609 1991 Code of practice for laying damp proofing treatment using bitumen

felts. IS : 1786 1985 Specification for high strength deformed steel bars and wires for

concrete reinforcement. IS : 1791 1985 General requirements for batch type concrete mixer. IS: 1834 1984 Specification for hot applied sealing compound for joints in

concrete IS : 1838 (Part-I) 1983 Specification for preformed fillers for expansion joints in concrete

pavements and structures (non extruding and resilient type).- Bitumen impregnated fibe

IS: 2016 1967 Plain washers IS: 2074 1992 Specification for ready mix paint, air drying, red oxide zinc chrome IS : 2386 (Part 1) 1963 Methods of test of aggregates for concrete – Particle size & shape IS : 2386 (Part 2) 1963 Methods of test of aggregates for concrete – Estimation of

deleterious material and organis impurities IS : 2386 (Part 3) 1963 Methods of test of aggregates for concrete – Specific gravity,

Density, voids, absorption and bulking IS : 2386 (Part 4) 1963 Methods of test of aggregates for concrete – Mechanical

properties IS : 2386 (Part 5) 1963 Methods of test of aggregates for concrete – Soundness IS : 2386 (Part 6) 1963 Methods of test of aggregates for concrete – Measuring mortar

making properties of fine aggregates IS : 2386 (Part 7) 1963 Methods of test of aggregates for concrete – Alkali aggregate

reactivity IS : 2386 (Part 8) 1963 Methods of test of aggregates for concrete – Petrographic

examination IS : 2438 1963 Specification for roller pan mixer. IS : 2502 1963 Code of practice for bending and fixing of bars for concrete

reinforcement. IS : 2505 1992 General requirements for concrete vibrators, immersion type. IS : 2506 1985 General requirements for concrete vibrators, screen board type. IS : 2514 1963 Specification for concrete vibrating table. IS : 2571 1970 Code of practice for laying in-situ cement-concrete flooring. IS : 2645 2003 Specification for Integral cement water proofing compounds for

cement mortar and concrete IS : 2722 1964 Specification for portable swing weigh batchers for concrete.

(single and double type) IS : 2750 1964 Specification for steel scaffoldings. IS : 2751 1979 Code of practice for welding of mild steel plain and deformed bars

for reinforced concrete construction. IS: 2812 1993 Recommendation for manual tungsten inert gas arc welding of

aluminium and aluminium alloys IS : 3025 (Part 22)

1986 Methods of sampling and test (physical & chemical) for water & waste water - Acidity

IS : 3025 (Part 23)

1986 Methods of sampling and test (physical & chemical) for water & waste water - Alkalinity

IS : 3037 1986 Specification for bitumen mastic for use in water proofing of roofs IS : 3150 1982 Specification for hexagonal wire netting for general purposes. IS : 3370 (Part I) 1965 Code of practice for concrete structures for the storage of liquids –

General requirements IS : 3370 (Part II) 1965 Code of practice for concrete structures for the storage of liquids-

Reinforced concrete structures

IS : 3384 1986 Specification for bitumen primer for use in waterproofing & damp proofing.

IS : 3414 1968 Code of practice for design and installation of joints in buildings. IS : 3550 1965 Methods of test for routine control for water used in Industry. IS : 3558 1983 Code of practice for use of immersion vibrators for consolidating

concrete. IS : 3696 (Part I) 1987 Safety code for scaffolds and ladders - Scaffolding IS : 3696 (Part II) 1991 Safety code for scaffolds and ladders - Ladders IS : 4014 (Part I) Code of practice for steel tubular scaffolding – Definition &

amterials IS : 4014 (Part II) Code of practice for steel tubular scaffolding - Safety Regulation

for scaffolding IS : 4031 (Part 1) 1996 Methods for physical tests for hydraulic cement – Determination of

finess by dry sieving IS : 4031 (Part 2) 1999 Methods for physical tests for hydraulic cement – Determination of

fineness by specific surface by Blaine air permeability method IS : 4031 (Part 3) 1988 Methods for physical tests for hydraulic cement – Determination of

soundness IS : 4031 (Part 4) 1988 Methods for physical tests for hydraulic cement – Determination of

consistency of standard cement paste IS : 4031 (Part 5) 1988 Methods for physical tests for hydraulic cement – Determination of

initial and final setting times IS : 4031 (Part 6) 1988 Methods for physical tests for hydraulic cement – Determination of

compressive strength of hydraulic cement (other than masonry cement)

IS : 4031 (Part 7) 1988 Methods for physical tests for hydraulic cement – Determination of compressive strength of masonry cement

IS : 4031 (Part 8) 1988 Methods for physical tests for hydraulic cement – Determination of transverse and compressive strength of plastic mortar using prism

IS : 4031 (Part 9) 1988 Methods for physical tests for hydraulic cement – Determination of heat of hydration

IS : 4031 (Part 10)

1988 Methods for physical tests for hydraulic cement – Determination of drying shrinkage

IS : 4031 (Part 11)

1988 Methods for physical tests for hydraulic cement – Determination of density

IS : 4031 (Part 12)

1988 Methods for physical tests for hydraulic cement – Determination of air content of hydraulic cement mortar

IS : 4031 (Part 13)

1988 Methods for physical tests for hydraulic cement – measurement of water retentivity of masonry cement

IS : 4031 (Part 14)

1989 Methods for physical tests for hydraulic cement – Determination of false set

IS : 4031 (Part 15)

1991 Methods for physical tests for hydraulic cement – Determination of fineness by wet sieving

IS : 4130 1991 Safety Code for demolition of buildings. IS : 4218 (Part 3) 1999 ISO general purpose metric screws threads – Basic dimensions IS : 4326 1993 Code of practice for earthquake resistant design and construction

of buildings. IS : 4461 1998 Code of practice for joints in surface hydro-electric power stations. IS : 4656 1968 Specification for form vibrators for concrete. IS : 4671 1984 Expanded polystyrene for thermal insulation purposes IS : 4925 1968 Specification for batching and mixing plant. IS : 4990 1993 Specification for plywood for concrete shuttering work. IS : 4995 (Part I) 1974 Criteria for design of reinforced concrete bins for the storage of

granular and powdery materials – General requirement & assessment of bin loads

IS : 5256 1992 Code or practice for sealing joints in concrete lining on canals. IS : 5525 1969 Recommendations for detailing of reinforcement in reinforced

concrete work. IS : 5624 1993 Specification for foundation bolts. IS : 5871 1987 Specification for bitumen mastic for tanking and damp proofing IS : 6461 (Part 1) 1972 Glossary of terms relating to cement concrete – Concrete

aggregates IS : 6461 (Part 2) 1972 Glossary of terms relating to cement concrete – Materials (other

that cement and aggregates) IS : 6461 (Part 3) 1972 Glossary of terms relating to cement concrete – Concrete

reinforcement IS : 6461 (Part 4) 1972 Glossary of terms relating to cement concrete – types of concrete IS : 6461 (Part 5) 1972 Glossary of terms relating to cement concrete – Formwork for

concrete IS : 6461 (Part 6) 1972 Glossary of terms relating to cement concrete – Equipment, tools

& plant IS : 6461 (Part 7) 1973 Glossary of terms relating to cement concrete – Mixing, Laying,

Compaction, Curing and other construction aspects IS : 6461 (Part 8) 1973 Glossary of terms relating to cement concrete – Properties of

concrete IS : 6461 (Part 9) 1973 Glossary of terms relating to cement concrete – Structural aspects IS : 6461 (Part 10)

1973 Glossary of terms relating to cement concrete – Tests & testing apparatus

IS : 6461 (Part 11)

1973 Glossary of terms relating to cement concrete – Prestressed concrete

IS : 6461 (Part 12)

1973 Glossary of terms relating to cement concrete - Miscellenaneous

IS : 6494 1988 Code of practice for water proofing of underground water reservoirs and swimming pools.

IS : 6509 1985 Code of practice for installation of joints in concrete pavements. IS : 7193 1994 Specification for glass fiber base coal-tar pitch and bitumen felts. IS : 7293 1974 Safety code for working with construction machinery. IS : 7634 (Part 3) 2003 Code of practice for Plastic pipe selection, handling, storage and

installation for potable water supplies – Laying and jointing of PVC pipes

IS : 7861 (Parts I) 1975 Code of practice for extreme weather concreting – Recommended practice for hot weather concreting

IS : 7861 (Parts II)

1981 Code of practice for extreme weather concreting – Recommended practice for cold weather concreting

IS: 8042 1989 Specification for White Portland cement IS: 8043 1991 Specification for hydrophobic Portland cement IS: 8112 1989 Specification for 43 Grade Ordinary Portland Cement IS : 9103 1999 Specification for concrete admixtures IS : 9417 1989 Recommendations for welding cold-worked steel bars for

reinforced concrete construction. IS : 9595 1996 Recommendations for metal-arc welding of carbon and carbon

manganese steels. IS : 10262 1982 Recommended guidelines for concrete mix design. IS : 11384 1985 Code of practice for composite construction in structural steel and

concrete. IS : 12118 1987 Specification for two-part poly-sulphide based sealants – General

requirements IS : 12118 1987 Specification for two-part poly-sulphide based sealants – Methods

of test IS : 12200 2001 Code of practice for provision of water stops at transverse

construction joints in masonry and concrete dams IS : 12269 1987 Specification for 53 Grade ordinary Portland cement. IS: 12330 1988 Sulphate resisting Portland Cement IS : 12600 1989 Specification for low heat Portland cement

SP : 23 1982 Handbook of concrete mixes. SP : 24 1983 Explanatory Handbook on IS: 456 SP : 34 1987 Handbook on concrete reinforcement and detailing.

4.0 MATERIALS 4.1 General: 4.1.1 All the materials used in the manufacture of concrete shall be in

accordance with the Technical Specification for Properties, Storage and Handling of Common Building Materials, which shall be deemed to form a part of this specification.

4.1.2 The Consultant shall have the right to inspect the sources of materials,

the layout and operation of procurement and storage of materials, the concrete batching and mixing equipments and the quality control system. Such an inspection shall be arranged by the contractor and the Consultant s approval shall be obtained prior to starting the work.

4.2 Aggregates 4.2.1 Aggregate in general designates both fine and coarse inert materials

used in the manufacture of concrete. Coarse Aggregate is faction retained on 4.75 mm IS sieve. Fine Aggregate is faction which passes through 4.75 mm IS sieve.

4.2.2 Aggregate shall consist of natural sand, crushed stone and gravel from a source known to produce satisfactory aggregate for concrete and shall be chemically inert, strong, hard, durable against weathering, of limited porosity and free from deleterious materials that may cause corrosion to the reinforcement or may impair the strength and / or durability of concrete. Aggregates shall conform to I.S. 383

4.2.3 Properties: Aggregates with a specific gravity below 2.6 shall not be

used without special permission of the Consultant. Machine-made sand will be acceptable provided the constituent (rock/gravel) is sound, hard, dense and is acceptable to the Consultant. Sand, natural gravel and crushed rock shall be prepared for use by such screening or washing, or both, as necessary to remove all objectionable foreign matter.

4.2.4 The coarse aggregate and fine aggregate shall be tested from time to

time as required by the Consultant to ascertain its suitability for use in construction and the charges for testing aggregate shall be born by the contractor as specified herein after. Sampling of the aggregates for mix design and determination of suitability shall be taken under the supervision of the Consultant and delivered to the laboratory, well in advance of the schedule placing of concrete. Records of tests which

have been made on proposed aggregates and on concrete made from this source of aggregates shall be furnished to the Consultant in advance of the work for use, in determining suitability of the proposed aggregate.

4.2.5 The grading of aggregates shall be such as to produce a dense

concrete of specified strength and consistency that will work readily into position without segregation and shall be based on the “mix design” and preliminary test on concrete specified herein-after.

4.2.6 Grading of Coarse Aggregate : Coarse aggregates shall be either in

single or graded, in both the cases. The grading shall be within the following limits.

IS Sieve Designa

tion

Percentage passing for single sized aggregates of

nominal size

Percentage passing for graded

aggregates of nominal size 63

mm

40

mm

20

mm

16

mm

12.5

mm

10 mm 40

mm

20 mm 16

mm

12.5

mm

75mm 100 - - - - - - - - -

63mm 85-

100

100 - - - - 100 - - -

37.5mm 0-30 85-

100

100 - - - 95-

100

100 - -

19mm 0-5 0-20 85-

100

100 - - 30-70 95-100 100 100

16mm - - - 85-

100

100 - - - 90-100 -

11.2mm - - - - 85-100 100 - - - 90-100

9.5mm - 0-5 0-20 0-30 0-45 85-100 10-35 25-55 30-70 40-85

4.75mm - 0-5 0-5 0-10 0-20 0-20 0-5 0-10 0-10 0-10

2.36mm - - - - 0-5 0-5 - - - -

4.2.7 Foreign Material Limitations: The percentages of deleterious substances

in the coarse aggregate delivered to the mixer shall not exceed the following :

Substances Percentage by weight of aggregates

Uncrushed Crushed i) Material finer than 75 micron IS Sieve. 3.00 3.00 ii) Coal and lignite 1.00 1.00 iii) Clay lumps 1.00 1.00 iv) Soft fragments 3.00 -- v) Total of all the above substances 5.00 5.00

4.2.8 Grading of fine aggregate shall be within the limits indicated hereunder :

IS Sieve Designation

Percentage Passing for

Grading Zone-I

Grading Zone-II

Grading Zone-IIII

Grading Zone-IV

10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 95-100 2.36 mm 60-95 75-100 85-100 95-100 1.18 mm 30-70 55-90 75-100 90-100 600 micron 15-34 35-59 60-79 80-100 300 micron 5-20 8-30 8-30 20-65 150 micron 0-10 0-10 0-10 0-15

4.2.9 Foreign Material Limitations : The percentages of deleterious substances in

fine aggregate, delivered to the mixer shall not exceed the following : Substances Percent by weight

Uncrushed Crushed i) Material finer than 75 micro IS sieve 3.00 15.00 ii) Shale 1.00 -- iii) Coal and lignite 1.00 1.00 iv) Clay lumps 1.00 1.00 v) Total of all above substances

including items (I) to (iv) for uncrushed sand and items (iii) and (iv) for crushed sand

5.00 2.00

4.2.10 Fineness Modulus : The fine aggregate shall have a fineness modulus of

not less than 2.2 or more than 3.2. The fineness modulus is determined by adding the cumulative percentages retained on the following I.S. sieve sizes (4.75 mm, 2.36 mm, 1.18 mm, 600 micron, 300 micron and 150 micron) and dividing the sum by 100.

4.2.11 Storage of aggregates: All coarse and fine aggregates shall be stacked

separately in stock piles in the material yard near the work site in bins properly constructed to avoid inter mixing of different aggregates. Contamination with foreign materials and earth during storage and while heaping the materials shall be avoided. The aggregate must be of specified quality not only at the time of receiving at site but also at the time of loading into mixer. Rakers shall be used for lifting the coarse aggregate from bins or stock piles. Coarse aggregate shall be piled in layers not exceeding 1.00 metres in height to prevent conning or segregation. Each layer shall cover the entire area of the stock pile before succeeding layers are started. Aggregates that have become segregated shall be rejected. Rejected material after re-mixing may be accepted, if subsequent tests demonstrate conformity with required gradation.

4.3 Cement 4.3.1 The cement generally used shall be the Ordinary Portland cement 43 / 53

grade or PPC. However, any special type of cement such as High strength cement or sulphate resisting cement may be used under specific circumstances.

4.3.2 Cement unless otherwise specified or called for by the Consultant shall be

measured in 50 kg bags. Use of bulk cement will be permitted only with the approval of the Consultant. Changing of brands of type of cement within the same structure will not be permitted. Joint account of cement consumed at site for every day for items of work carried shall be maintained by the Contractor for verification to ensure effective control on quality of work.

4.3.3 A certified report attesting to the conforming of the cement to IS specifications

by the cement manufacturer’s chemist shall be furnished to the Consultant, if demanded. Should at any time the Consultant have reasons to consider that any cement is defective, then irrespective of its origin and / or manufacturers test certificate, such cement shall be tested immediately at a National Test Laboratory / Departmental Laboratory or such approved laboratory, and until the results of such tests are found satisfactory, it shall not be used in any work. Cement held in store for a period of ninety (90) days or longer shall be retested before use in work.

4.3.4 The contractor shall make his own arrangements for the storage of adequate quantity of cement. If supplies are arranged by the Department, cement will be issued in quantities to cover work requirements of one month or more, as deemed fit by the Consultant and it will be the responsibility of the contractor to ensure adequate and proper storage, which will provide complete protection from dampness, contamination and minimize caking and false set. Cement bags shall be stored in a dry enclosed shed (storage under tarpaulins will not be permitted), well away from the outer walls and insulated from the floor to avoid contact with moisture from ground and so arranged as to provide ready access. Damaged or reclaimed or partly set cement will not be permitted to be used and shall be removed from the site. The storage arrangements shall be such that there is no dead storage. No more than 12 bags shall be stacked in any tier. The storage arrangement shall be got approved by the Consultant. Consignments in cement shall be stored as received and shall be consumed in the order of their delivery.

4.4 Reinforcement 4.4.1 Steel reinforcement bars for concrete shall be either cold twisted high yield

strength deformed bars conforming to IS 1786 or TMT bars with strength requirements conforming to IS 1786 manufactured by SAIL, TATA or RINL. The grade of steel shall be as shown in the drawings, or as mentioned in the schedule of items or as directed by Consultant.

4.4.2 Storage: Steel reinforcement shall be stored in such a manner that they are not in direct contact with ground but stacked on top of an arrangement of timbers sleepers or the like. Bars of different classifications and sizes shall be stored separately. In cases of long storage or in coastal areas, reinforcement shall be stacked above ground level by at least 15 cm, and a coat of cement wash shall be given to prevent scaling and rusting at no extra cost to the owner. Fabricated reinforcement shall be carefully stored to prevent, distortion, corrosion and deteriorations.

4.4.3 Contractor shall submit the manufacturers test certificate for steel. Random

tests on steel supplied by contractor may be performed if the Consultant so desires as per relevant Indian Standards. All costs incidental to such tests shall be at contractors expense. Steel not conforming to specifications shall be rejected.

4.5 Water 4.5.1 Water used for mixing and curing shall be clean and free from injurious

amounts of oils, acids, alkalis, sugar, organic materials or other substances that may be deleterious to concrete or steel. Potable water is generally considered satisfactory for mixing concrete. The maximum permissible values of impurities shall be as given in clause no. 5.4 of lS:456.

4.5.2 In case of doubt regarding development of strength, the suitability of water for

making concrete shall be ascertained by the compressive strength and initial setting time tests specified in lS:456.

4.5.3 Average 28 days compressive strength of atleast three 150 mm concrete

cubes prepared with water proposed to be used shall not be less than 90% of the average strength of three similar concrete cubes -prepared with distilled water. The cubes shall be prepared, cured and tested in accordance with IS:456.

4.5.4 The initial setting time of a concrete test block made with the appropriate cement and the water proposed to be used shall not be less than 30 minutes and shall not differ by + 30 minutes from the initial setting time of control test block prepared with the same cement and distilled water. The test shall be carried out as per IS:4031.

4.5.5 Where concrete, made from water, proposed to be used does not satisfy the

above requirements and/or contains an excess of acid, alkali, sugar, salt or other deleterious, substances, then the Consultant may refuse to permit its use. Sea water shall not be used for curing and mixing in concrete.

4.5.6 Testing of water shall be done at intervals indicated by Consultant. The sample

of water taken for testing shall be typical of the water proposed to be used for concreting, due account being paid to seasonal variation. The samples shall not receive any treatment before testing other than that envisaged in the

regular supply of water proposed for use in concrete. The sample shall be stored in a clean container previously rinsed out with similar water. The following concentrations represent the maximum permissible values.

a) Limits of acidity : To neutralize 200 ml sample of water, using

phenolphthalein as an indicator, it should not require more than 2 ml of 0.1 normal NaOH. The details of test shall be as given in IS: 3025 (Part 22).

b) Limits of alkalinity : To neutralize 200 ml sample of water, using methyl

orange as an indicator, it should not require more than 10ml of 0.1 normal HCL. The details of test shall be as given in IS : 3025 (Part 23).

c) Percentage of solids shall not exceed the following :

Organic 0.02% (200 mg/litre) Inorganic 0.30% (3000 mg/litre) Sulphates (as SO4) 0.05% (500 mg/litre) Alkali chlorides (as cl) 0.20% (2000 mg/litre) for plain concrete

work & 0.10% (1000 mg/litre) for reinforced

concrete work Suspended matter 0.20% (2000 mg/litre)

4.6 Admixtures 4.6.1 Admixtures in concrete for promoting workability, entraining air for similar

purposes may be used only after the written permission from the Consultant is obtained. These shall be free from injurious amount of chloride, etc. Addition of admixtures should not reduce the specified strength or durability of concrete and should not have detrimental effect on reinforcement. The admixtures shall conform to lS:9103 and shall be of proven make and from a reputed manufacturer. Calcium chloride as accelerating admixture is not permitted to be used other than in mass concrete works. The Contractor shall produce latest test results carried out at approved Government Test Houses for the approval of the Consultant, before use.

4.7 Embedded parts 4.7.1 Steel for light structural work and for preparation of inserts and embedments

shall conform to IS:2062. 4.7.2 Bolts to be embedded in concrete shall, unless otherwise detailed in

drawings, conform to IS:5624. Material for bolts, shall, unless otherwise mentioned in drawings or the schedule of items, be corrosive resistant/coated steel conforming to IS:2062.

4.7.3 Nuts and locknuts shall conform to IS:1363 (Part 1 to 3) for diameters 6 to 39 and IS 3138 for Hexagon Bolts and Nuts (M-42 to M-150)”.

4.7.4 Plain washers shall conform to IS:2016 and spring washers shall conform to

IS:3063. 4.7.5 Steel pipe sleeves shall conform to Medium class of IS: 1161. 4.8 Filling material 4.8.1 General: Filling material shall conform to what is shown in drawing,

described in the Schedule of Items or otherwise directed by the Consultant. Earth or sand for filling under floors shall correspond to those described elsewhere in these specification.

4.8.2 Mastic Bitumen: Mastic Bitumen shall conform to IS: 3037 or IS: 5871 as

appropriate. 4.8.3 Flexible Boards: Flexible boards for use in expansion joints shall correspond

to the description given in drawing or the Schedule of Items or the instruction of Consultant.

5.0 GRADES OF CONCRETE 5.0.1 Concrete shall be in grades as tabulated below:

Grade Designation Specified Characteristic compressive strength at 28

days (N/mm2) M10 10 M15 15 M20 20 M25 25 M30 30 M35 35 M40 40

5.0.2 The characteristic strength is defined as the strength of material below

which not more than 5% of the test results are expected to fall. 5.0.3 In the designation of a concrete mix, latter M refers to the mix and the

number to the specified characteristic compressive strength of 15 cm cubes at 28 days.

5.0.4 Minimum grades of concrete to be followed shall be as per guidelines of

Table 5 of IS: 456 unless otherwise mentioned in the drawings/ schedule of items. Concrete leaner than those given above may be used for lean concerte, mudmat, or for foundations of masonry walls.

5.1 Concrete mix proportioning 5.1.1 Concrete mix proportions shall be selected based on the requirements of

workability, strength, and durability. The proportions of cement, aggregates and water shall be determined either by designing the mix only.Adopting nominal mix is limited to leveling courses only. Design mix concrete is designated as M20, M25, etc. and Nominal mix Concrete is designated as 1:2:4, 1:3:6, 1:4:8 or 1:5:10. The proportions referred to is by weight (mass) and not by volume. Use of volumetric mix concrete shall not be permitted.

5.1.2 Workability of concrete a) Workability of fresh concrete is mainly governed by placing conditions and

compaction. The degree of workability necessary to allow the concrete to be well compacted and to be worked into the corners of formwork and around the reinforcement shall be as stipulated under clause no. 7.0 of IS:456.

b) The workability of concrete shall be checked at frequent intervals. The

workability of concrete measured in accordance with IS:1199 for every sample taken for testing shall be recorded with the corresponding cube test result.

c) Not withstanding the above, the slump to be maintained for work in progress

shall be as per directions of the Consultant. d) Consultant may permit use of plastisizers for improving workability. Use of

certain other admixtures such has water proofing compounds also have an effect on workability and shall be considered during mix design.

5.1.3 Durability of concrete: a) The durability of concrete is mainly governed by the permeability of

concrete. Dense concrete is least permeable. In addition, cement content and water-cement ration and compaction of concrete play a major role in producing impermeable concrete.

b) Durability requirements is decided depending on the exposure

conditions as stipulated in clause 8.2 of IS 456. is to be taken into account while designing the mix. For given aggregates, the cement content should be sufficient to make sufficiently low water cement ratio and table 5 of IS: 456-2000 shall be taken as guideline for durability considerations.

c) Stipulations of minimum cement content and limiting water cement

ratio should be considered during design of mix. 5.1.4 Design Mix Concrete a) Design Mix Concrete shall be used for all reinforced concrete works. The

mix proportions shall be as per mix design, designed for each grade of

concrete, workability and durability requirements. The characteristic strength shall not be less than the appropriate values given in Table-2 of IS:456:2000.

b) In proportioning concrete, the quantity of both cement and aggregates shall

be determined by mass. Water shall be either measured by volume in calibrated tanks or weighed. All measuring equipment at site shall be maintained in a clean and serviceable condition, and their accuracy shall be periodically checked.

c) To keep the water-cement ratio to the designed value, allowance shall be

made for the moisture contents in both fine and coarse aggregates and determination of the same in accordance with lS:2386 Part (III) shall be made as frequently as directed by the Consultant..

d) With the permission of the Consultant, for any of the above mentioned

grades of concrete, if the water quantity has to be increased, proportionately cement quantity shall also be increased, to keep the ratio of water to Cement same as adopted in mix design for the corresponding grade of concrete. The extra cement required on account of this shall be at no extra cost to Owner.

e) At the beginning of the project, if so desired by the contractor, he/they may

be allowed by the Consultant , till the designed mix is obtained, to carry out the reinforced concrete work in foundation and plinth as per equivalent nominal mix against the specified design mix concrete as per IS codes. However, all other specification for design mix shall govern for nominal mix also and nothing extra shall be paid for use of extra cement or else on this account whether the cement is supplied by the Owner or procured by the contractor.

5.1.5 Mix design: Mix design shall generally be done at any of the approved

laboratory. The foolowing is the guideline to be followed: a) IS:10262 shall be followed as general guidance for mix design. The

minimum value of target strength of design mix of various grades of concrete shall be as per clause no. 9.2 of IS:456. However, the Consultant may allow change in target strength values based on adequate numbers of works test results.

b) Minimum cement content from durability consideration for different

exposures and sulphate attack shall be as given in Table-4 and 5 of IS:456. In case higher value is obtained from strength consideration, same shall be provided.

c) Preliminary tests/trial mix, as specified or as required by the Consultant,

shall be carried out sufficiently ahead of the actual commencement of the work with different grades of concrete made from representative samples of aggregates and cement expected to be used on the works. These tests are to be conducted to arrive at the grading of aggregates, water-cement ratio,

workability and the quantity of cement required to give Preliminary (target) compressive strengths as specified in clause 9.2 of IS 456.

d) At least four trial mixes are to be made and minimum six test cubes taken

for each trial mix noting the slump for each type of mix. The cubes shall then be properly cured and three cubes for each mix shall be tested in a laboratory (approved by the Consultant) at 7 days and others at 28 days for obtaining the compressive strength. The test reports shall be submitted to the Consultant. The design mix particulars shall indicate, with the help of graphs and curves etc. the extent of variation in the grading of aggregates which can be allowed. While designing mixes, over wet mixes shall be avoided. For the structures, where assessment of early strength is required the concrete cubes shall also be tested for early age strength at 1 day and 3 days for establishing the values.

d) The Contractor shall submit the test reports of mix design to the Consultant

for his review, indicating design criteria, analysis and proportioning of materials, etc. On the basis of the above test reports, a mix proportion by mass and the water-cement ratio, shall be determined by the Contractor such that concrete prepared with this mix will yield the desired characteristic strength and shall have suitable workability. The mix design to be adopted on the works shall be subject to the approval of the Consultant. The proportions, once decided for different grades of concrete, shall be adhered to, during all concreting operations as long as the quality of the materials does not change. If, however, at any time, the quality of materials being used has changed from those for Preliminary mix design, or there is a change either in the required strength of concrete, or water-cement ratio or workability, the Contractor shall have to make similar trial mixes and Preliminary tests to ascertain the revised mix proportions and water-cement ratio to be used for obtaining the desired strength and consistency.

e) The entire cost of all the trial mixes including all the preparatory works for

trial mixes, preparation of test cubes and their testing shall be borne by the Contractor.

5.1.6 Nominal mix Concrete a) Nominal mix concrete shall be used only for plain cement concrete works

and where shown on drawings or specifically allowed by the Consultant. Such concrete shall not require preparation of trial mixes and all such concrete shall be mixed in a mechanical mixer. Proportions for nominal mix concrete shall be according to Table-9 of IS:456.

b) The proportion of mix may be slightly adjusted within limits, keeping the total

value of aggregates to a given quantity of cement constant to suit the sieve analysis of both the aggregates. Cement shall on no account be measured by volume, but it shall always be used directly from the bags (i.e. 50 kg/bag). The proportion of cement, sand, aggregate and water for concrete of proportion 1:5:10, 1:4:8, 1:3:6 & 1:2:4 by volume shall generally consist of quantities as given below :

Proportion of Ingre

Quantity of materials used per bag of cement Cement Fine

aggregate (sand)

Coarse aggregate

Total of fine and coarse aggregates

Water

1:5:10 1 170 kg. 340 kg. 800 kg. 60 ltrs. 1:4:8 1 130 kg. 272 kg. 625 kg. 45 ltrs. 1:3:6 1 102 kg. 204 kg. 480 kg. 34 ltrs. 1:2:4 1 68 kg 136 ltrs. 350 kg. 32 ltrs.

c) The quantity of water used shall be such as to produce concrete of

consistency required by the particular class of work and shall be decided by the use of slump cone. Sufficient care should be taken to see that no excess quantity of water is used. The final proportion of the aggregate and quantity of water shall be decided by the Consultant on the basis of test in each case. The for each class of work shall in general be as follows:

Type of concrete Max slump (in mm) Mass concrete 50 Concrete below water proofing treatment 50 Coping 25 Floor paving 50

d) As a general guidance the Nominal mix concrete of mix proportion 1:5:10

shall approximately correspond to grade M5, 1:4:8 shall correspond to grade M7.5, 1:3:6 to grade M10 and 1:2:4 to grade M15 of IS:456.

e) If fine aggregates are moist, the amount of surface water shall be

determined. Also an allowance shall be made for bulking in case of volume batching, in accordance with IS:2386 (Part-Ill). Allowance shall also be made for surface water present in the aggregates, when computing the water requirement. In the absence of exact data the amount of surface water may be estimated as follows:

Aggregate Approximate quantity of surface water

Percentage by mass

l/ cum

Very wet sand 7.5 120 Moderately wet sand 5.0 80

Moist sand 2.5 40 Moist gravel or crushed

rock 1.25-2.5 20-40

f) If nominal mix Concrete made in accordance with specified proportions does

not yield the specified strength of the corresponding grade and fails to satisfy the requirements of “acceptance criteria for concrete” as specified in IS:456, such concrete shall be treated in the following manner:

i) In case the Consultant is satisfied that lower strength of concrete is

attributed to material and workmanship of the Contractor, then such

concrete shall be replaced by concrete of specified strength. The Consultant may, however, also accept such lower strength concrete but such lower strength concrete shall be classified as belonging to the appropriate lower grade proportion.

ii) In case the Consultant is satisfied that lower strength of concrete is not

attributable to the Contractor, he may direct in writing to increase the cement content to obtain specified strength at no extra cost to Owner. The use of richer mix shall be continued until the Consultant instructs otherwise.

g) Nominal mix proportion shall not be classified as higher grade proportion

either on the ground that the test strengths are higher than the minimum specified or in the case where the Consultant directs use of additional cement over the quantity specified for the particular mix proportion to achieve the minimum specified strength.

h) However, only in some exceptional cases including concreting in some

isolated areas, the Consultant may allow the quantity of aggregates to be determined by an equivalent volume basis after the relationship between weight and volume is well established by trials and the same shall be verified frequently.

6.0 PREPARATORY WORKS 6.1 Preparation of earth for foundation 6.1.1 Earth surface on which direct placement of concrete is to be placed shall be

rammed and consolidated as directed by the Consultant such that it does not crumble and get mixed with concrete during or after placement. If the foundation is quite wet, the same shall be kept dry and then sufficiently consolidated, if necessary, a thin top layer of the wet soil shall be removed and replaced by sand or other suitable materials as directed by the Consultant without any extra cost to the Owner.

6.1.2 All earth surfaces upon which or against which concrete is to be placed,

shall be well compacted and free from standing water, mud or debris. Soft, yielding soils shall be removed and replaced with suitable earth and well compacted as directed by the Consultant. Where specified, lean concrete shall be provided in the earth stratum for receiving concrete. The surface of absorptive soil against which concrete is to be placed shall be moistened thoroughly so that no moisture will be drawn form the freshly placed concrete.

6.1.3 The earth surface over which concrete is to be placed direct, shall not be

kept abandoned at the specified level and concrete shall be placed immediately following the final preparation of the formation otherwise suitable measures shall be taken, as directed by the Consultant without any extra cost to the Owner.

6.2 In case the drawings indicate hard core below the blinding concrete, the same shall be provided as per relevent specifications.

6.3 Preparation of rock strata for foundation 6.3.1 To provide tight bond with rock foundation concrete shall not be deposited

on large sloping rock surface. Where required by Consultant or as indicated on the plans, the rock shall be cut to form rough steps or benches to provide roughness or a more suitable bearing surface.

6.3.2 Rock stratum shall be prepared by picking, barring, wedging and similar

methods which will leave the rock in an entirely sound and unshattered condition.

6.3.3 Shortly before concrete is placed, the rock surface shall be cleaned with

high pressure water and air jet even though it may have been previously cleaned in that manner.

6.3.4 Prior to placing concrete, the rock surface shall be kept wet for a period of 2

to 4 hours unless otherwise directed by the Consultant. 6.3.5 Before placing concrete on rock surfaces, all water shall be removed from

depressions to permit through inspection and proper bonding of the concrete to the rock.

6.4 Preparation of concrete surfaces 6.4.1 Preparation of concrete surface upon which additional concrete is to be

placed later, shall preferably be done by scarifying and cleaning while the concrete is between its initial and final set. This method shall be used wherever practicable and shall consist or cutting the surface with picks and stiff brooms and by use of an approved combination of air and water jet as directed by Consultant. Great care shall be taken in performing this work to avoid removal of too much mortar and the weakening of the surface by loosening of aggregate. When it is not practicable to follow the above method, it will be necessary to employ air tools to remove laitance and roughen the surface.

6.4.2 The final resulting surface shall be a pitted surface, from which all dirt,

unsound concrete, laitance and glazed mortar have been removed. 6.5 Preparation of construction joints 6.5.1 All such joints shall have continuous square bond grooves to produce a

substantial and water-tight key. Where the placement of concrete has to be resumed on a surface which has hardened, it shall be roughened, cleaned by wire or bristle brushing, compressed air, water jet etc., and thoroughly wetted.

6.5.2 For vertical construction joint, neat cement slurry shall be applied on the surface immediate before the placement of concrete.

6.5.3 For horizontal joints, the surface shall be covered with a layer of freshly

mixed mortar about 10 mm thick composed of cement and sand in the same proportion as the cement and sand in the concrete mix and applied immediately before placing of the concrete. On this surface (i.e. on the surface of joints) a layer of concrete not exceeding 150 mm in thickness shall first be placed and shall be well rammed against old work, particular attention being paid to corners and close spots. To ensure water tightness, care shall be taken to put concrete properly against the old surface.

6.5.4 In placing concrete against formed construction joints, the surfaces of the

joints, where accessible, shall be coated thoroughly with the specified bed joint bonding mortar immediately before they are covered with concrete or by scrubbing with wire brooms, dipped into the fresh concrete. Where it is impracticable to apply such a mortar coating, special precautions shall be taken to ensure that the new concrete is brought into intimate contact with the surface of the joint by carefully puddling and spading with aid of vibrators and suitable tools.

6.6 Bonding mortar 6.6.1 After rock or concrete surfaces upon which new concrete is to be placed

have been scarified, cleaned and wetted as specified herein. It shall receive a bonding treatment, immediately before placement of the concrete.

6.6.2 The bonding medium shall be a coat of cement sand mortar. The mortar

shall have the same cement sand proportion as the concrete which shall be placed on it. The water cement ratio shall be determined by placing conditions and as approved by Consultant.

6.6.3 Bonding mortar shall be placed in sufficient quantity to completely cover the

surface about 10mm thick for rock surface and about 5mm thick for concrete surfaces. It shall be brushed or broomed over the surface and worked thoroughly into all cracks, crevices and depressions. Accumulations or puddles of mortar shall not be allowed to settle in depressions and shall be brushed out to a satisfactory degree as determined by Consultant.

6.6.4 Mortar shall be placed at such a rate that it can be brushed over the surface

just in advance of placement of concrete only as much area shall be covered with mortar as can be covered with concrete before initial set in the mortar takes place. The amount of mortar that will be permitted to be placed at any one time, or the area which is to cover, shall be in accordance with directions of Consultant in-charge.

6.6.5 Staging shall be checked for its soundness as a whole and for adequacy of the joints and its foundations. Formwork joints shall be inspected for soundness of connections. All joints shall be either vertical or horizontal and shall be such as to avoid loss of liquid through the formwork.

7.0 FORMWORK AND STAGING 7.0.1 The Contractor shall supply, fabricate, erect and dismantle (after use) all

staging that is required for all activities covered under the specifications. He shall prepare the scheme and submit along with the supporting calculations for approval of the Consultant.

7.0.2 Prior to construction of form work for any item where soil will not act as

bottom form, approval shall be obtained from Consultant as to the suitability of the soil.

7.1 Materials 7.1.1 Formwork shall compose of steel, best quality wood or non-absorbant -type

plywood. Timber shall be free from significant knots and shall be of medium grain as far as possible and hard woods shall be used as caps and wedges under or over posts. Timber shall be well seasoned, free from sap, shakes, worm holes, warps or other surface defects and shall have smooth finish.

7.1.2 Staging, unless specified otherwise, shall generally be of mild steel tubes,

steel beams and channels etc. or strong sal ballies 150 mm in diameter or above. Bamboos, small diameter ballies etc., shall not be used unless approved by the Consultant in specific cases.

7.2 Classification of formwork 7.2.1 Ordinary: This shall be used in places where ordinary surface finish is

required and shall compose of steel and/or approved good quality seasoned wood. Plywood shuttering can also be used by the Contractor.

7.2.2 Plywood: This shall be used in exposed surfaces as shown on drawings or

as directed by the Consultant where a specially, good finish is required. Such surfaces shall be formed using approved brand of heavy quality water resistant plywood to produce a perfectly levelled, uniform and smooth surface. Reuse of such forms may be permitted only after inspection and approval by the Consultant, for each such reuse.

7.3 Quality of formwork and staging 7.3.1 Formwork shall consist of all materials required for forming the boxing to

pour concrete, Including steel/wood/plywood forms, ties, anchors, hangers, inserts, etc. Formwork shall be so constructed that vertical and horizontal adjustments can be made as required. The design and Consultanting of formwork including staging as well as its erection and dismantling shall be the responsibility of the Contractor.

7.3.2 The staging shall be true and rigid and thoroughly braced in both directions

as well as cross braced, strutted and propped such that it will not deform unduly under weight of concrete and other loads due to men, equipment, etc. Vertical members or props should not be supported on an unpropped lower suspended floor or beam unless it is ensured by the Contractor that the lower floor or beam can safely carry the loads. No propping shall take place until the Consultant’s approval has been given to the Contractor’s scheme submitted along with supporting calculations.

7.3.4 The forms and staging shall be sufficiently strong to carry without undue

deformation, the dead weight of the concrete as a liquid as well as anticipated working loads. Where the concrete is vibrated, the formwork shall be strong enough to withstand the effects of vibration, without appreciable deflection, bulging. distortion or loosening of its components. The joints in the formwork shall be sufficiently tight to prevent any leakage of mortar. The formwork shall be such as to ensure a smooth uniform surface free from honeycombs, air bubbles, bulges, fins and other blemishes. Any blemish or defect found on the surface of the concrete, must be brought to the notice of the Consultant immediately and rectified as directed by him.

7.3.5 To achieve the desired rigidity, ample studs, braces, bolts, spacer blocks,

wires, clamps, ties, straps, shores, etc. shall be used to hold the form in proper position without undue distortion. These shall be approved by the Consultant but they must in no way impair the strength of concrete or leave stains or marks on the finished surface. Where there are chances of these fixtures being embedded, only mild steel or concrete of adequate strength shall be used. Bolts passing completely through liquid and or earth retaining walls/slabs, basement walls etc. for the purpose of securing and aligning the formwork, shall not be permitted.

7.3.6 For exposed interior and exterior concrete surfaces of beams and columns,

plywood : other approved forms thoroughly cleaned and tied together with approved corrosion resistant devices shall be used. Rigid care shall be exercised ensuring that all column forms are plumb and true and thoroughly cross braced to keep them so.

7.3.7 Bevelled strips 25x25 mm shall be provided to form angles and in corners of

columns and beam boxes for chamfering of corners if shown on drawings or directed by the Consultant. Temporary openings for cleaning, inspection and for pouring concrete shall be provided at the base of vertical forms and at other places, where these are necessary and as may be directed by the Consultant. The temporary openings shall be so formed that they can be conveniently closed rigidly when required and must not leave any mark on the concrete.

7.3.8 If it is so desired by the Consultant, the Contractor shall prepare, before

commencement of the actual work, designs and drawings for formwork and staging and get them approved by the Consultant. Formwork shall -be so designed and positioned that it can be removed without damage to concrete.

7.3.9 The Contractor shall maintain necessary camber in centering for all floor

slabs and beams in all spanning directions, so as to offset the deflection and assume correct shape. The camber shall have the crown of not less than 8 mm for every 5 metres span unless otherwise shown on the drawings. For cantilever, camber at free end shall be 1 in 100.

7.3.10 The Contractor shall provide the shuttering for complete stretch of work upto

expansion joints for the structures like shell, folded plate etc. and/or as directed by the Consultant.

7.4 Cleaning and treatment of forms 7.4.1 All forms shall be thoroughly cleaned of old concrete, wood shavings, saw

dust, dirt and dust sticking to them before these are fixed in position. All rubbish, loose concrete, chippings, shavings, saw dust etc. shall be scrupulously removed from the interior of the forms before concrete is poured. Wire brushes, brooms, compressed air jet and/or water jet etc. shall be kept handy for cleaning, if directed by the Consultant.

7.4.2 Before formwork is placed in position, the form surfaces, that will be in

contact with concrete shall be treated with approved non-staining oil or composition which is insoluble in water and not injurious to concrete. Care shall be taken that the oil or composition does not come in contact with reinforcing steel or stain the concrete surfaces. Burnt oil shall not be allowed to be used specially where the concrete surface will require finishing and/or plaster.

7.5 Removal of forms 7.5.1 The Contractor shall begin the removal of formwork only after approval of

the Consultant. He shall place on record the dates on which the concrete is placed in different parts of the work and the dates of the removal of formwork there from. This record shall be checked and countersigned by the Consultant. The Contractor shall be responsible for the safe removal of formwork but the Consultant may delay the time of removal if he considers it necessary. Any work showing signs of damage through premature removal of formwork, shall be entirely removed and reconstructed by the Contractor at no extra Cost to Owner.

7.5.2 The formwork shall be so designed and erected that the forms for slabs and

the sides of beams, columns and walls may be removed first, leaving the beam bottoms and their supports in position. Re-propping of beams shall not be done except with the approval of the Consultant. Formwork for columns and walls at each stage of concreting shall be erected only upto the particular lift of construction. Wedges, spacer bolts, clamps or other suitable means shall be provided to allow accurate adjustment of the formwork and to allow it to be removed gradually without jerking the concrete.

7.5.3 Forms of various types of structural components shall, under normal

circumstances, not be removed before the minimum periods specified in Cl. 11.3 of IS:456, which shall also be subject to the approval of the Consultant. However, in any case formwork shall not be struck until the concrete has

reached a strength, at least twice that of the stress to which the concrete may be subjected -to at the time of removal of forms. The removal of form work shall generally be as per the following guidelines:

Part of Structure

Earliest Concrete age at stripping Ordinary Portland cement concrete

Portland Pozzolana cement concrete

Walls, columns and vertical sides of beams

16 to 24 hours or as directed by the Consultant-.

3 days

Slabs (Props left under) 3 days 7 days Beam soffits (Props left under) 7 days 10 days Removal of props to slabs i) Spanning up to 4.5 m. ii) Spanning over 4.5 m.

7 days 14 days

10 days 14 days

Removal of props to beams and arches i) Spanning up to 6 m. ii) Spanning over 6 m.

14 days 21 days

14 days 21 days

Cantilever slabs 14 days 14 days 7.5.4 The number of props left under, their sizes and disposition shall be such

as to be able to safely carry the full dead load of the slab, beam or arch as the case may be together with any live load likely to occur during curing or further construction.

7.5.6 Where the shape of the element is such that the formwork has reentrant

angles, the formwork shall be removed as soon as possible after the concrete has set, to avoid shrinkage cracking occurring due to the restraint imposed.

7.5.7 Contractor shall record on the drawings or a special register, the date

up in which the concrete is placed in each part of the work and the date on which the shuttering is removed there from.

7.5.10 In case of cantilever slabs, the removal of forms shall begin from the

outer edge and proceed towards the support, where as in the case of slabs supported on two/four sides, the removal of forms shall begin from centre to supports.

7.5.11 The formwork shall be so made as to produce a finished concrete, true

to shape, lines, plumb and to dimensions as shown on the drawings. The Consultant may call for finished work at any time to set standards of workmanship. Once approved, these will become the accepted Sample.

7.5.12 In case PPC/PSC is used instead of OPC, the removal of shuttering/

support shall be after 50% more time from that being applied for OPC, unless otherwise permitted by the Consultant. For concrete temperature above 40°C, stripping time shall be increased.

7.5.13 In case of special structures, such as shells, folded plates, etc, the sequence of removal of forms shall be as per drawings or as directed by EIC.

7.6 Re-use of forms

Before reuse, all forms shall be thoroughly scraped, cleaned, all nails and adhering substances removed, holes and leaks satisfactorily plugged, joints examined and where necessary repaired and inside surfaces treated as specified herein before. Formwork shall not be used/re-used, if declared unfit or unserviceable by the Consultant.

7.7 Dimensional Tolerance for Formwork 7.7.1 Tolerances is a specified permissble variation from lines, grade or

dimensions given in drawings. Unless otherwise specified, the following tolerances will be permitted.

Footings for columns, piers, walls, buttresses and similar members

1 Variation of dimensions in plan (+) 50 mm./(-) 10 mm 2 Misplacement or eccentricity 2% of footing within the

direction of misplacement but not more than 50 mm

3 Reduction in thickness 5% of specified thickness subject to a maximum of 50 mm.

In case of inclined surfaces, the deviation in the alignment of inclined surfaces, shall not exceed 3 mm with reference to the theoretical alignment, for a length of 1000 mm measured vertically, subject to a maximum of 10 mm.

8.0 REINFORCEMENT PLACEMENT 8.0.1 All reinforcement for concrete works shall be provided as per the drawings or

as indicated in the schedule of items. The Contractor shall prepare and furnish to the Consultant, bar bending schedules for all RCC works for his review and approval. No work shall commence without the approval of the bar bending schedules by the Consultant in writing.

8.0.2 The contractor shall plan the procurement of steel well in advance and

complete the surface treatment, if specified in a planned manner. In case of non availability of certain diameters Consultant may permit substitution of bars. However such substitutions shall be the last resort and shall not be a reason for delay. The Contractor shall modify the bar bending schedule, and specific approvals of Consultant obtained.

8.0.3 All bars shall be thoroughly cleaned before being fabricated. Pitted and defective bars shall not be used. All steel for reinforcement shall be free from loose scales, rust coatings, oil, grease, paint or other harmful matters immediately before placing the concrete. To ensure this, reinforcements with rust coatings shall be cleaned thoroughly before bending/placement of the same.

8.1 Bending and placing 8.1.1 Bending shall be as under: a) Reinforcing bars supplied bent or in coils, shall be straightened before these

are cut to size. Straightening of bars shall be done in cold and without damaging the bars. This is to be considered as a part of reinforcement bending and fabrication work.

b) Unless otherwise specified, reinforcing steel shall be bent in accordance with

procedure specified in lS:2502 and/or as approved by the Consultant. Bends and shapes shall comply strictly with the dimensions shown on the approved bar bending schedules and they shall be rechecked by the Contractor before bending and he shall be entirely responsible for their correctness. Bars correctly bent, shall only be used. Unless specified otherwise or directed by the Consultant, the detailing of reinforcement shall be in accordance with lS:5525 and SP:34.

c) Bending of longitudinal bars for laps shall be done with 1:6 slopes. The ends of

column bars at the top of columns shall be bent horizontally at the just below the beam bars permitting full development length of beam bars. The beam column junction reinforcement shall be tied by U-stirrups to develop full moment connection with good confined concrete.

d) No reinforcement shall be bent when in position in the work without approval of

the Consultant, whether or not it is partially embedded in concrete. Where reinforcement bars are bent aside, at construction joints and afterwards bent back into their original positions, care shall be taken to ensure that, at no time, the radius of the bend is less than 4 times the bar diameters for plain mild steel or 6 times the bar diameters for deformed bars. Care shall also be taken while bending back bars, to ensure that the concrete around the bar is not damaged.

e) Welding of bars to obtain continuity shall not be allowed, particularly for cold

twisted bars, unless specifically approved by the Consultant. If welding is approved, the work shall be carried out as per IS:2751 and lS:9417, according to the best practice and as directed by the Consultant.

8.1.2 Placing in Position shall be as under: a) Spacing of bars shall be as indicated in the drawings. Minimum distance

between reinforcing bars shall be in accordance with clause 26.3.2 of IS:456. a) All reinforcement shall be accurately fixed and maintained in position as shown

on the drawings by such approved means as steel chairs, and/or concrete spacer blocks as per IS:2502. Bars intended to be in contact at crossing points, shall be securely bound together at all such points by two numbers annealed steel wire of 0.9 mm to 1.6 mm size conforming to IS:280 in such a manner that they do not slip over each other at the time of fixing & concreting. The tying of bars shall be in criss-cross manner.

b) Binders shall tightly embrace the bars with which these are intended to be in

contact and shall be securely held. The vertical distance between successive layers of bars shall be maintained by provision of spacer bars. These shall be so spaced that the main bars do not sag perceptively between adjacent spacers. Bundled bars shall be provided wherever shown on the drawing to facilitate concreting. Location of laps and development lengths, shall be as indicated on the drawings or as directed by Consultant.

c) The placing of reinforcement shall be completed well in advance of concrete

pouring. The reinforcement shall be checked by the Consultant, for accuracy of placement and cleanliness. Necessary corrections, as directed by the Consultant shall be carried out. Care shall be taken to ensure that projecting ends of ties and other embedded metal do not encroach into the concrete cover. Where concrete blocks are used for ensuring the cover and positioning of reinforcement, these shall be made of mortar 1:2 (1 cement:2 sand) by volume and cured for at least seven days. The sizes and locations of the concrete blocks shall be approved by the Consultant. The 28 days crushing strength of cover blocks shall be at least equal to the specified strength of concrete in which the blocks will be embedded.

d) Laps and anchorage length of reinforcing bars shall be in accordance with

IS:456, unless otherwise specified. If the bars in a lap are not of the same diameter, the smaller diameter will guide the lap length. Laps shall be staggered as far as practicable and as directed by the Consultant and not more than 50% of bars shall be lapped at a particular section. Mechanical connections, for splicing reinforcement bars in congested locations may be used by the Contractor, only if approved by the Consultant. Reinforcement bars shall not be lapped unless the length required exceeds the maximum available lengths of bars at site.

e) Unless otherwise specified by the Consultant-, reinforcement shall be placed within the following tolerances :

Tolerance in spacing

For effective depth 200 mm or less + 10 mm

For effective depth more than 200 mm. + 15 mm

8.2 Cover to reinforcement

8.2.1 The correct cover shall be maintained by cement mortar briquettes are other approved means. Reinforcement for footings, grade beams and slabs on sub

grade shall be supported on precast concrete blocks as approved by the Consultant-. The use of pebbles or stones shall not be permitted.

8.2.2 Unless shown otherwise on the drawings, minimum clear concrete cover for reinforcement (exclusive of plaster or other finishes) shall be as follows:

a) At each end of a reinforcing bar, not less than 25 mm, nor less than

twice the bar diameter, b) For a longitudinal reinforcing bar in a column, 40 mm or bar diameter

whichever is more. 25 mm cover may be adopted for columns of minimum dimension 200 mm or under and with longitudinal reinforcement diameter not exceeding 12 mm.

c) For longitudinal reinforcing bars in a beam, not less than 25 mm or

less than the bar diameter. d) For reinforcement in slabs and walls; not exposed to weather or

ground not less than 15 mm nor less than the bar diameter.

e) For bottom reinforcement in footings; 75 mm, if concrete is laid against the ground or 50 mm if laid on a layer of lean concrete.

f) For retaining walls, grade beams, top and sides of footings and

similar surfaces exposed to weather or ground; 50 mm for bars larger than 16 mm and 40 mm for bars upto 16 mm.

g) For liquid retaining structures; 40 mm or diameter of main bar,

whichever is larger.

h) For any other reinforcement not less than 15 mm, nor less than the

diameter of such bar.

8.2.3 Special requirements in corrosive atmosphere: Unless special protective

coatings are used, the following measures shall be adopted for structures exposed to sever conditions. a) Increased cover thickness may be provided when surfaces of

concrete members are exposed to the action of harmful chemicals, acid vapour, saline atmosphere, sulphur smoke, etc. such increase may be between 15 to 50 mm beyond the figures indicated above as may be specified by consultant.

b) For reinforced concrete members totally immersed in sea water, the cover shall be 40 mm. more than specified in 8.02.02

c) For reinforced concrete members, periodically immersed in sea water or subject to sea spray, the cover of concrete shall be 50 mm. more than that specified in 8.02.02.

d) For concrete of grade M 25 and above, the additional thickness of cover specified in (a), (b) and (c) above may be reduced to half. In all such cases the covers should not exceed 75 mm.

e) Protection to reinforcement in case of concrete exposed to harmful surroundings may also be given by providing a dense impermeable concrete with approved protective coating, as specified on the drawings. In such case the extra cover, mentioned in (c) and (d) above, may be reduced by the Consultant-, to those shown on the drawing.

Unless otherwise specified the tolerance for cover from the required nominal cover shall not deviate by (+) 10/ (-) 0 mm.

8.2.4 The bars shall be kept in correct position by the following methods :

a) In case of beam and slab construction precast cover blocks in cement mortar 1 : 2 (1 cement : 2 coarse sand) about 4 x 4 cm section and of thickness equal to the specified cover shall be placed between the bars and shuttering so as to secure and maintain the requisite cover of concrete over reinforcement.

b) In case of cantilevered and doubly reinforced beams or slabs, the vertical distance between the horizontal bars shall be maintained by introducing chairs spacers or support bars of steel at 1.0 metre or at shorter spacing to avoid sagging.

c) In case of columns and walls the vertical bards shall be kept in position by means of timber templates with slots accurately cut in them; or with block of cement mortar 1 : 2 (1 cement : 2 coarse sand) of required size suitably tied to the reinforcement to ensure that they are in correct position during concreting.

d) In case of other R.C.C. structure such as arches domes, shells, storage tanks etc. a combination of cover blocks, spacers and templates shall be used as directed by Consultant-.

8.3 Inspection & testing

8.3.1 Erected and secured reinforcement shall be inspected and approved by Consultant-prior to placement of concrete.

8.3.2 Sample bent bars shall be checked to ensure that they conform to the

bar bending schedules. Reinforcement in position shall be checked for proper positioning, and rigidity, cover, spacing of bars, placement of chairs and spacers. etc. Also it shall be checked that all bars at crossings are properly tied.

8.3.3 Each batch of reinforcement procured shall be accompanied with

manufacturer’s test certificate. In addition, Consultant may direct the reinforcement to be tested independently. Reinforcement shall tested in reputed testing laboratory, approved by Consultant. The frequency of testing shall be as stipulated by Consultant. The cost of testing shall be borne by the contractor.

9.0 EMBEDDED PARTS 9.0.1 Embedded steel parts shall be supplied, fabricated and erected by the

Contractor as as indicated in drawings. 9.0.2 Embedded steel parts shall be supplied, fabricated and erected by

the contractor and shall include items such as, but not limited to, foundation grillages, anchor bolts, pipe sleeves, equipment mounting plates, steel rolled sections with or without properly welded lugs, plate inserts, edge protection angles, as shown on the drawings, auxiliary framing for equipment supports, pegstay plugs for door and window frames, miscellaneous frames, etc. Cold worked deformed steel bars shall not be used for lugs.

9.1 Foundation bolt assembly

9.1.1 Foundation bolt assembly shall comprise of foundation bolts, stiffener

plates, washers, nuts, lock nuts, pipe sleeves, etc. Contractor’s scope shall include supply, fabrication, erection and installation in position as per drawings.

9.1.2 The fabrication and erection of bolt assemblies shall include threading,

cutting, grinding, drilling, welding, etc. complete. The bolts shall have coarse pitch screw thread in the diameter range, 8 to 64 mm and 6 mm pitch screw for diameter greater than 64 mm, as per IS : 4218.

9.1.3 For fabrication of any particular size of bolt indicated on the drawing, the

diameter of the threaded portion of the bolt shall be considered as the diameter of the bolt unless otherwise mentioned in the drawings.

9.1.4 Fabrication & erection shall be carried out as per lS:800. Welding shall

conform to IS:816 and IS:9595,

9.1.5 Every bolt shall be provided with a steel washer, under the nut. The washer shall be flat and minimum outside inscribed circle have a diameter 2.50 times that of the bolt and of suitable thickness. All nuts shall be of steel with well formed hexagonal heads, unless specified otherwise, forged from solid metal and shall be dipped in hot boiled linseed oil as soon as these are made. The nuts shall fit good on the bolts.

9.1.6 During erection, the Contractor shall provide necessary template,

temporary bracings, supports, etc. to ensure proper positioning of the assemblies and holding them firmly during concreting or until they are grouted and the grout has set. All materials shall be erected in plumb and in level (unless otherwise specified) and at true locations as shown on the drawings. Threads shall be protected by using PVC tape. All threads for bolts and inserts shall be greased at intervals and kept covered to prevent damage.

9.2 Embedded plates, pipes, etc.. 9.2.1 The Contractor shall fabricate, transport to site and erect accurately in

position all embedded steel parts either by welding, bolting or any other means as approved by the Consultant. Exposed surfaces of embedded parts other than holding down bolts, unless otherwise stated, are to be painted with two coats of approved anticorrosive paint (as per lS:2074) and/or bituminous paint as directed. The threads of holding down bolts shall be greased and protected with waterproof tape.

9.2.2 During erection, the Contractor shall provide necessary strong

temporary bracings and supports to ensure proper installation of the embedded parts which shall be erected at the true location as shown on the drawings and these shall be in plumb and level (unless otherwise shown on drawings). The Contractor shall furnish the Consultant with fabrication and assembly drawings prepared for embedded steel parts showing the erection procedure, for major items, wherever necessary.

9.2.3 Fabrication & erection shall be carried out as per IS: 800. Welding rods

& site/field welding shall conform to IS: 816 and IS: 9595. IS:7634 (part-Ill) shall be followed for PVC pipe works.

9.2.4 Exposed surfaces of embedded materials shall be painted with one coat

of anticorrosive paint or bituminous paint, as desired, without any extra cost to the Owner. If welding is to be done subsequently on the exposed surfaces of the embedded parts, the painting for a length of 50 mm beyond each side of the weld line shall be cleaned off

10.0 MIXING OF CONCRETE

10.0.1 Concrete shall be mixed in a mechanical mixer conforming to IS:1791.

However, mixing shall preferably be done at a single central batching plant, conforming to IS:4925, situated within the area allocated for the Contractor’s particular use as directed by the Consultant. The plant shall

have a mechanically operated mixer of an approved size and type, capable of ensuring a uniform distribution of the materials throughout the mass and the mass is uniform in colour and consistency.

10.0.2 Water shall not be added into the drum of the mixer, until all the cement

and aggregates constituting the batch are already in the drum and dry mixed for at least one minute and are uniformly distributed. Water shall then be added and mixing of each batch shall be continued until there is a uniform distribution of the materials and the mass but in no case shall mixing be done for less than one and half minutes and for at least 40 revolutions after all the water and materials are in the drum. When absorbent aggregates are used or when the mix is very dry, the mixing time shall be extended as directed by the Consultant. Mixers shall not be loaded above their rated capacity as this prevents thorough mixing.

10.0.3 The entire contents of the drum shall be discharged before the

ingredients for the next batch are fed into the drum. No partly set or remixed or excessively wet concrete shall be used and it shall be immediately removed from site. Each time if the work stops for more than 30 minutes, the mixer shall be thoroughly cleaned and when the next mixing commences, the first batch shall have 10% additional cement.

10.0.4 All plain concrete should be preferably mixed in a drum type powder

driven machine with a loading hopper which will permit the accurate measure of various ingredients. In exceptional circumstances and/or work in remote areas, hand mixing may be allowed by the Consultant, subject to adding 10% extra cement at no extra cost to Owner. The mixing shall be carried out on watertight platform and mixing shall be continued till a uniform colour and consistency of the mix is achieved.

10.1 Batching of Concrete 10.1.1 Cement shall always be batched by weight. A separate weighing device

shall be provided for weighing cement. Where the weight of cement is determined by accepting the weight per bag, number of bags shall be weighed separately to determine the average net weight of cement per bag and the same shall be checked regularly.

10.1.2 Aggregates shall always be batched by weight.In particular cases, or

where weigh-batching is not possible proportioning by volume batching may be allowed by the Consultant, provided Contractor guarantees the uniformity of aggregates through out the period of construction. For this purpose, the Contractor shall submit to the Consultant sufficient data indicating the weight/volume relationship of aggregates for different types of concrete and after such approval, periodic checks on the weight/volume relationship of the aggregates shall be made by the Contractor to the satisfaction of the Consultant.

10.1.3 Where the aggregates are moist and volume batching is adopted, allowance shall be made for bulking in accordance with IS 2386 (Part-III). Suitable adjustments shall be made for the variation in the weight of aggregates due to variation in their moisture contents.

10.1.4 Water may be measured either by weight or by volume. When

measured by volume, it shall be by well calibrated conical shaped jar or vessel or from a calibrated tank fitted to the mixer. It is very important to maintain the water cement ratio constant at its correct value. For the correct determination of amount of water to be added in the concrete mix, to maintain the water cement ratio constant, the amount of moisture content in both coarse and fine aggregates shall be taken into consideration, be as frequently as possible. The frequency for a given job being determined by the Consultant according to weather conditions.

10.1.5 Any solid admixture, to be added, shall be measured by weight, but

liquid or semi-liquid admixture may be measured by weight or volume. 10.1.6 The accuracy of batching shall be within the following tolerance:

0.5% by weight 10.2 Ready mix concrete supplied by commercial ready mix concrete plants

shall be used only with the approval of EIC. No extra will payable on this account on account of providing Ready mix concrete for various jobs.

11.0 TRANSPORTATION OF CONCRETE 11.0.1 Concrete shall be handled and conveyed as rapidly as practicable, from

the place of mixing to the place of final laying, by approved means, before the initial setting of the cement starts. Concrete shall be conveyed in such a way that there is no segregation or loss of any of the ingredients and maintaining the required workability. If segregation does occur during transport, the concrete shall be remixed. During very hot or cold weather, if directed by the Consultant, concrete shall be transported in deep containers which will reduce the rate of water loss by evaporation in hot weather and heat loss in cold weather, at no extra cost to Owner.

11.0.2 Conveying equipment for concrete shall be mortar tight, well maintained

and thoroughly cleaned before commencement of concrete mixing. Such equipment shall be kept free from set concrete. Chutes shall not be used for transport of concrete without the written permission of the Consultant. The chute in case permitted to be used shall be of such size and design as to ensure practically continuous flow. Slope of the chute shall be so adjusted that the concrete flow without the use of an

excessive quantity of water and without segregation of its ingredients. The delivery end of the chute shall be as close as possible to the point of deposit.

11.0.3 Concrete may be conveyed and placed by mechanically operated

equipment, e.g. pumps or pneumatic placers only with the written permission of the Consultant, who shall also review the entire scheme for which comprehensive details shall be furnished by the Contractor.

11.0.4 All equipment used for mixing, transporting and placing of concrete shall

be maintained in clean condition. All pans, buckets, hoppers, chutes, pipe lines and other equipments shall be thoroughly cleaned after each period of placement.

12.0 CONCRETE PLACING

12.1.0 Final inspection and approval prior to concrete placement:

12.1.1 Before the concrete is actually placed in position, the inside of the form

work shall be inspected to see that they have been cleaned and oiled. Temporary openings shall be provided to facilitate inspection, especially at bottom of columns and wall forms, to permit removal of saw dust, wood shavings, binding wire, rubbish, dirt etc., Opening shall be placed or holes drilled so that these materials and water can be removed easily. Such openings / holes shall be later suitably plugged.

12.1.2 The various traders shall be permitted ample time to install drainage and

plumbing lines, floor and trench drain, conduits, hangers, anchors, inserts, sleeves, bolts, frames and other miscellaneous embedments to be cast in the concrete as indicated on the drawing or as necessary for the proper execution of the work. All such embedments shall be correctly positioned and securely held in the forms to prevent displacement during depositing and vibrating of concrete.

12.1.3 Prior to concrete placement, all works shall be inspected and approved by

Consultant , and if found unsatisfactory, concrete shall not be poured until all defects have been corrected at contractors cost. Approval by Consultant of any and all materials and work as required herein shall not relieve contractor from his obligations to produce sound concrete in accordance with the drawings and specifications

12.1.4 Formwork and reinforcement shall be approved in writing by the Consultant

before concrete is placed. Concrete shall be placed only after all preparations for casting have been approved by the Consultant and approval given to proceed with the casting in writing on pour card to be maintained by the Contractor for this purpose and to be submitted alongwith the Contractor’s bills.

12.2 Placement 12.2.1 Concrete shall be placed and compacted in its final position before the

cement reaches the initial set and normally concrete shall be compacted in its final position within 30 minutes of leaving the mixer.

12.2.2 Where direct placement is not possible, the Contractor shall provide

suitable arrangements such as chutes, tremie, elephant trunks, etc. to confine the movement of concrete as directed by the Consultant. Concrete shall not be dropped from a height or handled in a manner which may cause segregation.

12.2.3 If concrete is placed by pumping, the consistency shall be the minimum

necessary for such conveyance of concrete. Before commencement of regular pumping, the pipeline shall be lubricated by cement mortar (1:2), and once pumping commences, stoppages shall be avoided.

12.2.4 The placing of concrete shall be a continuous operation with no interruption

in excess of 30 minutes between the placing of continuous portions of concrete. Concrete shall be placed in continuous horizontal layers of 150 mm or higher thickness as directed by the Consultant and thoroughly compacted before placing next layer. The thickness of each layer shall be such that it will be deposited before the previous layer has stiffened. When placing concrete through reinforcing steel, care shall be taken to prevent segregation of the coarse aggregates.

12.2.5 Slabs, beams and similar members shall normally be poured in one

operation. In special circumstances, with the approval of the Consultant, these can be poured in horizontal layers, but it must be ensured that the under layer is not already hardened. Bleeding of under layer, if any, shall be effectively removed. Moulding, throating, drip course, etc. shall be poured as shown on the drawings or as desired by the Consultant.

12.2.6 Mass Concrete shall be poured in lifts not exceeding 1.0 m in height unless

otherwise indicated on drawings or as directed by the Consultant. Horizontal lift shall not be more than 150 cm in thickness, according to provision of IS:457.

12.2.7 No concrete shall be placed in wet weather or an a water covered surface.

Any concrete that has been washed by heavy rain shall be entirely removed, if there is any sign of cement and sand having been washed away from the concrete mixture. To guard against damage which may be caused by rain, the works shall be covered with tarpaulins immediately after the concrete has been placed and compacted before leaving the work unattended. Any water accumulating on the surface of the newly placed concrete shall be removed by approved means and no further concrete shall be placed thereon until such water is removed. To avoid flow of water over / around freshly placed concrete, suitable drains and sumps shall be provided.

12.2.8 Concrete, when deposited, shall have a temperature of not less than 5

degrees Centigrade and not more than 40 degree Centigrade. When depositing concrete in very hot weather, precautions shall be taken so that the temperature of wet concrete does not exceed 40 degrees Centigrade while placing. This shall be achieved by stacking aggregates under the shade and keeping them moist, using cold water, reducing the time between mixing by sprinkling water, starting curing before concrete dries out, etc. However, before mixing/placing concrete, when the above temperature conditions vary on either side, approval of the Consultant shall be obtained for the method of execution.

12.2.9 Concrete must be placed in its final position before it becomes too stiff to work. On no account water shall be added after the initial mixing. Concrete which has become stiff or has been contaminated with foreign materials and which has not been placed within half an hour of mixing water with cement shall be rejected.

12.2.10 For members involving vertical placing of concrete (eg. Columns, walls,

etc.), each lift shall be deposited in horizontal layer extending the full width between shutterings and of such depth that each layer can be easily and effectively vibrated and incorporated with the layer before by means of compaction.

12.2.11 Should any unforeseen occurrence results in a stoppage of concreting for

one hour or such other time as might allow the concrete, already placed, to begin to set before the next batches can be placed, the Contractor shall make at his own cost, suitable tongue, and groove construction joint, as approved by the Consultant. Any additional reinforcement required as directed by the Consultant shall also be provided by the Contractor at his own cost. Before placement of new batches of concrete over that construction joint, the surface preparation according to this specification stipulated earlier, shall be done by the Contractor at his own cost.

12.3 Work in Extreme Weather Conditions: 12.3.1 During hot weather (atmospheric temperature above 40 degree centigrade)

or cold weather (atmospheric temp at 5 degree centigrade and below) the concreting shall be done as per the procedures and precautions set out in lS:7861 (Parts I and II)

12.3.2 All concrete work performed in hot weather shall be in accordance with IS

:456, except as herein modified. Admixtures may be used only when approved by Consultant.

12.3.4 Adequate provision shall be made to lower concrete temperatures by cool ingredients, eliminating excessive mixing, preventing exposure of mixers and conveyers to direct sunlight and the use of reflective paint, on mixers etc., The temperature of the freshly placed concrete shall not be permitted to exceed 300 deg.C.

12.3.5 Aggregate shall be stock piled in shade and prevented from direct sun

rays. Spraying stock piles with water, use of cold water available and burying, insulation, shading and / or painting white the pipe lines and water storage tanks and conveyances.

12.3.6 In order to reduce loss of mixing water, the aggregates, wooden forms,

subgrade, adjacent concrete and other moisture absorbing surfaces, shall be well wetted prior to concreting placement and finishing shall be done as quickly as possible.

12.3.7 Extra precautions shall be taken for the protection and curing of concrete,

Consideration shall be given to continuous water curing and protection against high temperatures and drying hot wind for a period of at least 7 days after concrete has set and after which normal curing procedures may be resumed.

12.4 Placing concrete under water : 12.4.1 Under all ordinary conditions all foundations shall be completely de-watered

and concrete placed on the dry surface. However, when concrete placement under water is necessary, all work shall be executed in accordance with clause 14.2 of IS :456

13.0 COMPACTION 13.0.1 After the concrete has been placed, it shall be spaded and thoroughly

compacted by approved mechanical vibrators to a maximum subsidence without segregation and thoroughly worked around reinforcement or other embedded fixtures into the correct form and shape. Hand tamping in some cases may be allowed subject to the approval of the Consultant. Care must be taken to ensure that the inserts, fixtures, reinforcement and formwork are not displaced or disturbed during placing of concrete.

13.0.2 Vibrators shall penetrate both the layer poured and the under layer to

ensure good bond and homogeneity and to prevent the formation of cold joints. Immersion vibrators shall not be allowed to come in contact with steel reinforcement after start of initial set. Also, they shall not be allowed to come in contact with forms or finished surfaces.

13.0.4 Immersion vibrators shall have a ‘no load’ frequency, amplitude and

acceleration as per lS:2505 depending upon the size of the vibrator. Immersion vibrators shall be operated by experienced men. These vibrators shall be immersed not more than 450 mm apart and withdrawn when air

bubbles cease to come to the surface. Such vibrators shall in no case be used to push concrete inside the forms and vibrators shall be withdrawn slowly.

13.0.5 Whenever vibration has to be applied externally, the design of formwork

and the disposition of vibrators shall receive special consideration to ensure efficient compaction and to avoid surface blemishes. Surface vibrators and form attached vibrator shall not be permitted under normal conditions. Their use shall require written approval of the Consultant.

14.0 PROTECTION AND CURING OF CONCRETE 14.1 Protection: 14.1.1 Newly placed concrete shall be protected by approved means from rain, sun

and wind. Concrete placed below ground level, shall be protected from falling earth, during and after placing. Concrete placed in ground Containing any deleterious substances, shall be kept free from contact with such ground or with water draining from such ground, during placing of concrete and for a period of at least three days or as otherwise instructed by the Consultant.

14.1.2 The ground water around newly poured concrete shall be kept down to an

approved level by pumping or other approved means of drainage. Adequate steps shall be taken to prevent floatation or flooding. Steps, as approved by the Consultant, shall be taken to protect immature concrete from damage by debris, excessive loading, vibration, abrasion, mixing with earth or other deleterious materials, etc. that may impair the strength and durability of the concrete.

14.2. Curing: 14.2.1 As soon as the concrete has hardened sufficiently, it shall be kept in a

damp or wet condition by ponding or by covering with a layer of sacking, canvas, hessian or similar materials and kept continuously wet for at least seven days after final setting. This period may be extended, at the discretion of the Consultant, upto fourteen days. Curing of horizontal surfaces exposed to drying winds shall begin immediately after the concrete has hardened. Concrete slabs and floors shall be cured for the periods mentioned above by flooding with water of minimum 25 mm depth.

14.2.2 Quantity of water applied shall be such as to prevent erosion of freshly

placed concrete. 14.2.3 Approved curing compounds may be used in lieu of moist-curing with the

permission of the Consultant. However, such permission may be granted only in specific cases. Such compounds shall be applied to all exposed surfaces of the concrete, as soon as possible after the concrete has set. Curing compounds shall be liquid type while pigmented, conforming to U.S.

Bureau of Reclamation Specification. No curing compound shall be used on surface where future blending with concrete, water or acid proof membrane or painting is specified.

15.0 REPAIRING AND FINISHING OF CONCRETE SURFACES

15.1 Inspection and repair of concrete surfaces:

15.1.1 Immediately after the shuttering is removed, the surface of concrete shall be

inspected very carefully for all defects. Consultant who may permit patching of the defective areas or else reject the concrete unit either partially or entirely. Holes left by form bolts etc., shall be filled up and made good with mortar composed of one part of cement to one and half parts of sand passing through 2.36 mm IS sieve after removing any loose stones adhering to the concrete. Mortar filling shall be struck off flush at the face of the concrete. Concrete surface shall be finished as described under the particular item of work Superficial honey combed surfaces and rough patches shall be similarly made good immediately after removal of shuttering, in the presence of Consultant and superficiant water and air holes shall be filled in. The mortar shall be well worked into the surface with wooden float. Excess water shall be avoided. Unless instructed otherwise by Consultant , the surface of the exposed concrete placed against shuttering shall be rubbed down immediately on removal of shuttering to remove fine or other irregularities, care being taken to avoid damaging the surfaces. Surface irregularities shall be removed by grinding. If reinforcement is exposes or the honey combing occurs at vulnerable position e.g. ends of beams or columns, it may be necessary to cut out the member completely or in part and reconstruct. The decision of Consultant shall be final in this regard. Rejected concrete shall be removed and replaced by Contractor at no additional expense. If only patching is necessary, the defective concrete shall be cut out till solid concrete is reached (or to a minimum depth of 25 mm), the edges being cut perpendicular to the affected surface or with a small under cut if possible, anchors, tees or dowels shall be provided in slots whenever necessary to attach the new concrete securely in place. An area extending several centimetres beyond the edges and the surfaces of the prepared voids shall be saturated with water for 24 hours immediately before the patching material is placed. The area shall be repaired as follows:

a) Small size holes having surface dimensions about equal to the depth of

the hole, holes left after removal of form bolts, grout insert holes and slots cut for repair of cracks shall be repaired as follows :

b) The hole to be patched shall be roughened and thoroughly soaked with clean water until absorption stops.

c) A 5 mm thick layer of grout of equal parts of cement and sand shall be

well brushed into the surface to be patched followed immediately by the patching concrete which shall be well consolidated with a wooden float and left slightly proud of the surrounding surface. The concrete patch shall be built up in 10mm thick layers. After an hour or more, depending upon weather conditions, it shall be worked off flush with a wooden float and a smooth finish obtained by wiping with hessian. Steel trowel shall not be used for this purpose. The mix for patching shall be of the same materials and in the same proportions as that used in the concrete being repaired, although some reduction in the maximum size of the coarse aggregates may be necessary and the mix shall be kept as dry as possible.

d) Mortar filling by air pressure (guniting) shall be used for repair of areas

to large and / or too shallow for patching with mortar. Patched surfaces shall be given a final treatment to match the colour and texture of the surrounding concrete. White cement shall be substituted for ordinary cement, if so directed by Consultant , to match the shade of the patch with the original concrete.

15.1.2 Curing of Patched Work : The patched area shall be covered

immediately with an approved non-staining water saturated material such as gunny bags, which shall be kept continuously wet and protected against sun and wind for a period of 24 hours. Thereafter, the patched area shall be kept wet continuously by a fine spary of sprinkling water for not less than 10 days.

15.1.3 Approval by Consultant : All materials, procedures and operations used

in the repair of concrete and also the finished repair work shall be subject to the approval of Consultant. All fillings shall tightly bonded to the concrete and shall be sound, free from shrinkage cracks after the fillings have been cured and dried.

15.1.4 Use of bonding agent: The use of epoxy for bonding fresh concrete

used for repairs will be permitted upon written approval of Consultant. Bonding agents shall be applied in strict accordance with the instruction of the manufacturer.

15.2 Finish for formed and un-formed surfaces 15.2.1 The type of finish for formed concrete surfaces shall be as follows,

unless otherwise specified by the Consultant

a. For surfaces against which backfill or concrete is to be placed, no treatment is required except repair of defective areas.

b. For surfaces below grade, which will receive waterproofing treatment, the concrete shall be free of surface irregularities which would interfere with proper application of the water proofing materials which is specified for use.

15.2.2 The type of finish for un-formed concrete surfaces shall be as follows, unless otherwise specified by the Consultant

a. Unless specified, surfaces which will be exposed when the structure is

in service shall receive no special finish, except repair of damaged or defective concrete, removal of fins and abrupt irregularities, filling of holes left by form ties and rods and clean up of loose or adhering debris.

b. Surfaces which will be exposed to the weather and which would

normally be levelled, shall be sloped for drainage, Unless the drawing specify a horizontal surface or shows the slope required, the tops of marrow surfaces such as staircase treads, walls, curbs and parapets shall be stoped across the width approx. as 1 in 30. Broader surfaces such as walkways, roads, parking areas and platforms shall be sloped about 1 In 50. Surfaces that will be covered by backfill or concrete, sub floors to be covered with concrete topping, terrazzo or quarry tile and similar surfaces shall be smooth, screeded and levelled to produce even surfaces. Surface irregularities shall not exceed 6mm. Surfaces which will not be covered by backfill, concrete or tile topping such as outside decks, floors of galleries and sumps, parapets, gutters, sidewalks, floors and slabs shall be consolidated, screeded and floated.

c. Excess water and laitance shall be removed before final finishing.

Floating may be done with hand or power tools and started as soon as the screeded surface has attained a stiffness to permit finishing operations and these shall be the minimum required to produce a surface uniform in texture and free from screed marks or other imperfections. Joints and edges shall be tooled as called for on the drawings or as directed by Consultant.

15.3 Standard Finish for Exposed Concrete: 15.3.1 Exposed concrete shall mean any concrete other than floors or slabs

exposed to view upon completion of the job. Unless otherwise specified on the drawings, the standard finish for exposed concrete shall be of smooth finish.

15.3.2 A smooth finish shall be obtained with the use of forms having smooth and

even surfaces and edges. Panels and form linings shall be of uniform size and be as large as practicable and installed with closed joints. Upon removal of forms, the joint marks shall be smoothened off and all blemishes, projections etc. removed leaving the surfaces reasonably

smooth and unmarred. 15.4 Integral Cement Concrete Finish: 15.4.1 When specified on the drawings, an integral cement concrete finish of

specified thickness for floors and slabs shall be applied either monolithic or bonded, as specified in the drawings and as per IS :2571. The surface shall compacted and then floated with a wooden float or power floating machine. The surface shall be tested with a strainght edge and any high and low spots eliminated. Floating or trowelling of the finish shall be permitted only after all surface water has evaporated. Dry cement or a mixture of dry cement and sand shall not be sprinkled directly on the surface of the cement finish to absorb moisture or to stiffen the mix.

15.5 Rubbed Finish: 15.5.1 A rubbed finish shall be provided only on exposed concrete surfaces as

specified on the drawings. Upon removal of forms, all fins and other projections on the surfaces shall be carefully removed, off sets levelled and voids and / or damaged sections immediately saturated with water and repaired by filling with concrete or mortar of the same composition as was used in the surfaces. The surfaces shall then be thoroughly wetted and rubbed with carborundum or other abrasive. Cement mortar may be used in the rubbing, but the finished surfaces shall not be brush coated with either cement or grout after rubbing. The finished surfaces shall present a uniform and smooth appearance.

16.0 JOINTS IN CONCRETE 16.1 Joints including joint filler materials, water bars, resilient pads type vibration

damping material in and around the sides of concrete works, etc. shall be provided as shown in the drawings or as directed by the Consultant. Where necessary or/and specified, joints shall be made water tight by use of water stops.

16.1.0 Classification of joints: 16.1.1 From the point of view of utility the joints as provided may be classified as

below: a) Construction Joints: Construction joints are produced by placing fresh

concrete against surface of hardened concrete. Construction joints are generally, but not necessarily, vertical or horizontal. Treatment of construction joints shall be as per clause 6.05.00.

b) Contraction Joints: These are provided to eliminate tensile stresses

due to shrinkage and are commonly used where temperature

variations are small and where there is no likelihood of expansion, such as spaces below water and earth levels & unexposed to atmosphere. At contraction joints, the reinforcement is discontinued and bond is not allowed to develop between the joint faces, thereby introducing a structural discontinuity. A contraction joint also serves as a construction joint so far as break in the pouring of concrete is concerned.

c) Expansion Joints: These are provided either to completely eliminate

or to significantly reduce compressive stresses in concrete that would otherwise result from thermal expansion and might crush, buckle or crack, part of the structure. Expansion joints serve the purpose of contraction and also construction joints.

d) Control Joints: At places where cracking is inevitable, places of

weakness are introduced by the provision of control joints so that the cracking takes place along these joints instead of allowing it to develop in a haphazard manner.

e) Separation Joints: The places where the expansion of the structure is

not expected but they are required to be kept structurally separate so that stresses, vibrations, etc. are not transferred, a separation joint should be provided. Like expansion joint, a gaps is provided in separation joint also, but this is not expected to be used up by the expansion of members. In case, no gap is required, the separation joint can be obtained by using an approved alkathene sheet stuck on the surface against which concrete shall be placed.

f) Settlement Joints: Structures, which are likely to settle with respect to

the adjacent structures, shall be separated by a settlement joint so that the adverse effects of differential settlement are obviated. It is like an expansion joint but with a different sealing arrangement.

16.2 Joint Filler 16.2.1 Bitumen Board: The bitumen impregnated fibre board, a preformed

material shall be used as joint filler which shall fill space between the concrete surfaces at the joints. The minimum thickness of board shall be 12mm and the material shall conform to IS : 1838.

16.2.2 Expanded Polystyrene: The expanded polystyrene slab shall be of fire

retarding grade (type-2) conforming to IS: 4671. Density of material shall not be less than 25kg/cu.m.

16.2.3 Installation: The bitumen impregnated fibre board may be secured to

vertical concrete by nails in the first placed concrete. The joint filler shall be coated on both faces with coal-tar pitch conforming to lS:216 or bitumen of suitable grade conforming to IS:73 or lS:702.

16.3 Water Stops/ Water bars 16.3.1 Water stops shall be provided at the joints as a continuous diaphragm to

contain the filler material and/or to exclude passage of water or any other material into or out of the structure.

16.3.2 The Water stops shall be either metallic like Copper, or nonmetallic like

P.V.C. The material is to be procured from reputed manufacturers having proven records of satisfactory supply of Water Stops of similar make and shape for other jobs. Only PVC water stop shall be used, unless, otherwise, specifically approved by the Consultant.

16.3.3 Non-metallic Water Stop

a) These will be normally in P.V.C. and can be of shape having any

combination of the following features i) Plain

ii) Central Bulb

iii) Dumb-bell or flattened ends

iv) Ribbed and Corrugated Wings

v) V-shaped.

vi) Kicker type (Externally placed)

b) Water bars shall generally meet the stipulations of IS:12200. The minimum thickness of P.V.C. Water Stops shall be 6 mm and the minimum width 225 mm unless otherwise specified. The actual size and shape will be as shown on drawings and/or as directed by the Consultant. The material should be of good quality Polyvinyl Chloride, highly resistant to tearing, abrasion and corrosion as well as to chemicals likely to come in contact with during use. The performance requirements shall generally be as follows.

Sp. Gr. 1.3 to 1.4 Shore Hardness 60A to 80A Tensile Strength 110 kgf/cm2 mm Maximum safe continuous Temperature 70°C Ultimate Elongation Not less than 300% Tear Resistance 45 kgf/cm2 mm Stiffness in flexure 25kgf/cm2 mm Accelerated extraction

Tensile strength 110 kgf/cm2 Ultimate elongation 250%

Water absorption in7 days 5% (max) Effect of Alkali (7 days)

Weight increase 0.25% max. Weight decrease 0.10% max

Hardness change n 5 Effect of Alkali (28 days)

Weight increase 0.40% max. Weight decrease 0.30% max

Dimension change ± 1 % 16.3.4 Installation a) Water stops shall not have any longitudinal joints and shall be procured and

installed in largest practicable lengths having a minimum number of transverse joints. The jointing procedure shall be as per the manufacturer’s recommendations and shall be reviewed and approved by the Consultant. Suitable field splicing kit including heater shall be used for this purpose. The edges shall be neatly crimped and bent to ensure proper bond with the concrete.

b) As Non-metallic Water Stops can be easily handled in very large lengths

unlike metal strips, transverse joints will be allowed only under unavoidable circumstances and with the specific approval of the Consultant. The method of forming these joints, laps, etc. shall be as specified by the Manufacturer and/ or approved by the Consultant, taking particular care to match the centre and the edges accurately.

c) Particular care shall be taken for the correct positioning of the waterstops to

prevent any faulty installation which may result in joint leakage. Adequate provisions shall be made to support the water stops during progress of work and to ensure their proper embedment in the concrete. The symmetrical halves of the water stops shall be equally divided between the concrete pours adjacent to the joints.

d) Maximum density and imperviousness of the concrete shall be ensured by

thoroughly working in the vicinity of joints. However, particular care should be exercised in use of vibrators in the proximity of joints to avoid dislodging of the water stops.

e) Splices: Splices in the continuity of intersections of runs of water stops shall

be jointed as per manufacturer’s stipulations depending on the type of waterstops used. In case of a cross section, overlapping must not be done but, instead factory made cross joint should be used. It is essential that the material is not damaged during the splicing operation and that the continuity of the entire water stops across the section be maintained.

f) Inspection: All waterstops installations shall be subject to inspection and

approval by the Consultant, before concreting operations, encasing waterstops, are performed.

16.4 Sealing Compound

16.4.1 Bitumen Sealing Compound The bitumen sealing compound shall be from approved manufacturer and shall conform to the requirements of lS:1834. For joints in concrete lining on canals/reservoirs, sealing compound conforming to lS:5256 shall be used.

16.4.2 Polysulphlde Sealing Compound:

This shall be two-part polysulphide sealant and shall be from approved manufacturer, conforming to lS:12118. Materials shall consist of polysulphide polymer and a curing agent. Gun grade material shall be used unless otherwise specified. The application of the sealant shall be strictly followed as per manufacturer’s guidelines.

16.4.3 Installation: When directed, the gap in joints shall be thoroughly cleaned

and sealing compound laid as per manufacturer’s specification and approved drawings. Primer shall be applied wherever required. For reservoir & canal lining, procedure as stipulated under clause 9.0 of lS:5256 shall be followed.

16.5 Metal Cover Strips 16.5.1 Metal cover strips shall be made from aluminium or mild steel sections as

shown on drawings. The minimum thickness of aluminium strips shall be 3 mm and that of mild steel 6 mm. Aluminium alloy strip shall be corrosion resistant grade 31000 as per IS:737. Mild steel shall conform to lS:2062.

16.5.2 Installation: The metal Cover strips shall be pinned (using stainless steel) at

one end and slotted at the other end. Exposed surface of mild steel shall be painted with two coats of approved anti-corrosive paint (as per lS:2074) and/or bituminous paint. Welding of Aluminimum shall be in accordance with IS: 2812.

17.0 CEMENT ADDITIVES/ADMIXTURES IN CONCRETE 17.0.1 The admixtures shall conform to IS:9103 and shall be of proven make and

from a reputed manufacturer. In addition, for plasticizer-cum-water proofing compound, materials shall meet the permeability requirements as per lS:2645. Similarly for plasticizer-cum retarder admixture material shall satisfy the setting time requirements of retarder and other properties of plasticizer as per IS:9103

17.0.2 Admixture may be used in concrete only with the approval of Consultant based upon evidence that, with the passage of time neither the compressive strength nor its durability reduced. When admixtures are used, the designed concrete mix shall be done with the admixture. Admixtures shall be used as per manufacturers instructions and in the manner and with the control specified by Consultant-.

17.0.3 Calcium Chloride : Calcium chloride shall not be used for accelerating set of the cement for any concrete containing reinforcement or embedded steel parts. When calcium chloride is permitted to be used, such as in mass concrete works, it shall be dissolved in water and added to the mixing water in an amount not to exceed 1.5 percent of the weight of cement in each batch of concrete.

17.0.4 Admixtures in concrete for promoting workability, improving strength,

entraining air or for similar purposes may be used only after the written permission from the Consultant, is obtained. Addition of admixtures shall not reduce the specified strength or durability of concrete in any case.

17.0.5 The Contractor shall furnish all labour and equipment to place and mix

water proofing cement additive and cement plasticiser in concrete of any grade and cement mortar. Thereafter, he shall carry out the work as specified earlier in relevant clauses of this specification for concrete and hence complete the work as indicated on the drawing and as per the specification listed hereunder.

17.1 Classification of admixtures: 17.1.1 Admixture can be classified as under: a) Air Entraining Agents : Where specified and approved by Consultant

, neutralized vinsol resin or any other approved air entraining agent may be used to produce the specified amount of air in the concrete mix and these agents shall conform to the requirements of ASTM standard 6.260. Air entraining admixtures for concrete. The recommended total air content of the concrete is 4% (+/-) 1%. The method of measuring air content shall be as per IS : 1199.

b) Retarding Admixtures : Where specified and approved by

Consultant , retarding agents shall be added to the concrete mix in quantities specified by Consultant.

c) Water Reducing Admixtures : Where specified and approved by

Consultant, water reducing lignosulfonate mixture shall be added in quantities specified by Consultant. The admixtures shall be added in the form of solution.

d) Water Proofing Agents : Where specified and approved by

Consultant , chloride and sulphate free water proofing agents shall be added in quantities specified by Consultant. Water proof cement additive shall conform to lS:2645 and shall be of proven make and from a reputed manufacturer

e) Other Admixtures : Consultant may at his discretion, instruct

contractor to use any other admixture in the concrete.

17.2 Admixtures/water proofing additive shall be used at the rate specified by the manufacturer or as indicated on the drawings and shall be mixed with water, as required by the Consultant.

18.0 GROUTING 18.0.1 One of the following types of grouts shall be used unless specifically

mentioned in the drawings:

a) Ready mixed non-shrink cementitious grout. b) Cement-Sand Grout : The proportion of cement to sand shall generally be

1:2, unless otherwise specified. c) Cement Aggregate Grout : The approximate proportions of Cement, sand

and coarse aggregate shall be 1:1.25:2, with a maximum size of aggregate as 10 mm. This mix shall generally be used for grout thickness above 40 mm for dry pack application.

18.0.2 Grouting under base plates and foundation pockets shall be done as

indicated in the drawings, or as directed by Consultant. The contact area between the grout and base plate shall not be less than 80%

Grouting the pockets/holes in concrete: Depending upon the size of the

pockets/holes in the concrete, the mix of grout shall be either of concrete or of cement sand mortars. Normally the grade of such concrete/mortar shall be M-20 unless specified otherwise. In filling the holes of foundation bolts and expanding admixture of approved type shall be used as per manufacturer’s specification.

18.0.3 Anchor bolts, anchor bolt holes and bottom of equipment and column base

plates shall be cleaned of all oil, grease, dirt and loose material. The use of hot, strong, caustic solution for this purpose will be permitted.

18.0.4 Prior to grouting, the hardened concrete surfaces to be grouted, shall be

saturated with water. Water in anchor bolt holes shall be removed before grouting is started.

18.1.0 Mixing 18.1.1 Depending upon the ease of placement and method of application, there

shall be following three grout consistencies.

a) Fluid Mix: This grout mix shall be suitable for application with low pressure grouting equipment or self low pressure grouting equipment or self flowing and suitable for grouting of pockets/blockouts, etc.

b) Plastic Mix: This grout mix shall be suitable for application with trowel or

rod.

c) Stiff Mix: This grout mix shall be suitable for dry-pack application. The

consistency should allow pressurising into firm hard ball without cracking. 18.1.2 The proportions of grout shall be such as to produce a flowable mixture

consistent with minimum water content and shrinkage. The grout proportions shall be limited as follows:

Consistency

Grout thickness Mix. proportions W/C Ratio (Max)

Fluid mix Under 25mm One part portland cement to one part sand.

0.6

Plastic 25mm and over but less than 50mm

One part portland cement to 2 parts of sand.

0.5

Stiff mix. 50mm and over One part portland cement to 3 parts of sand

0.4

18.1.3 Plasticiser may be added to increase workability, wherever required with

the approval of Consultant.

18.1.3 Sand for general grouting purposes, shall be graded within the following limits:

Passing IS sieve 2.36 mm 95 to 100% Passing IS sieve 1.18mm 65 to 95% Passing IS sieve 300 micron above 10 to 30% Passing IS sieve 150 micron above 3 to 10%

i) Sand for fluid grouts shall have the fine material passing the 300 and

150 micron sieves at the upper limits specified above. ii) Sand for stiff grouts, shall meet the usual grading specifications and

concrete. 18.2 Placing 18.2.1 Surface to be grouted shall be thoroughly roughened and cleaned of all

foreign matter and laitance. The blockouts, bolt holes etc. which have to be grouted, shall be cleaned thoroughly by use of compressed air just prior to taking up the grouting operation.

18.2.2 Grout shall then be prepared by mixing this admixture with water as per

manufactuerer’s recommendations. Any grout which has been mixed for a period longer than half an hour shall not be used on the work.

18.2.3 Grouting through holes in base plate shall be by pressure grouting.

Immediately after preparation, grout shall be poured into the blockouts, through the holes provided for, this purpose in the base plate, by using special equipment for pressure grouting. It shall be ensured by rodding and by tapping of bolts that the blockout is completely filled without leaving any voids. The pouring shall cease as soon as each hole is filled

and any excess grout found on the surface of the concrete foundation shall be completely removed and the surface dried.

18.2.4 Grouting, once commenced, shall be done continuously. Grout shall be

worked from one end to the other (to prevent air entrapment) and until the grout oozes out through the grout holes provided in the base plates. Grouting, shall be done quickly and continuously to prevent segregation, bleeding and breakdown of initial set

18.2.5 In case of stiff mix, the space between the top surface of foundation

concrete and the underside of the base plate shall be dry packed by firmly pressing or ramming into place against fixed supports.

18.2.6 When it is clear that the entire base has been properly filled, the grout

outside the base plate shall be lightly rammed to ensure compaction below the edges. Shims provided for the alignment of base plates shall be removed not less than 7 days after the grouting has been executed. The resulting cavities shall be made good with the same grade of grout as has been used for grouting under the rest of the base plate.

18.3 Curing: 18.3.1 The work shall be cured for a period of at least 7 days commencing 24

hours after the completion of the grouting. The curing shall be done by covering the surface with wet gunny bags and flooding.

19.0 PRECAST CONCRETE ELEMENTS 19.0.1 Precast concrete elements such as columns, fencing posts, door and

window frames, lintels, chajjas, copings, sills, shelves, cover slabs, louvers etc., shall be of grade of mix as specified in the drawings. Concrete for Precast concrete shall comply with IS : 456.

19.0.2 Precast concrete elements shall be cast in forms or moulds. The forms

/ mould shall be of fiber glass or of steel sections for better finish. Provision shall be made in the forms and moulds to accommodate fixing devices such as nibs, clips, hooks, bolts and forming of notches and holes.

19.0.3 Elements shall be cast on suitable bed or platform with firm foundation

and free from wind. The contractor may precast the units on a cement or steel platform which shall be adequately oiled provided the surface finish is of the same standard as obtained in the forms. Each unit shall be cast in one operation. Contractor shall be responsible for the accuracy of the level or shape of the bed or platform

19.0.5 Precast elements shall have a dense surface finish showing no coarse

aggregate and shall have no cracks, crevices or other defects that would interfere with the proper placing of the units. All angles of the precast units with the exception of the angles resulting from the splayed

or chamfered faces shall be true right angles. The arises shall be clean and sharp except those specified or shown to be rounded. The wearing surface shall be true to the lines. On being fractured, the interior of the units should present a clean homogenous appearance.

19.1 Marking, Curing & Lifting:

. 19.1.1 If so required, Pre-cast units shall be clearly marked with identification name, the top of member and its location and orientation in the structure. The reinforced side of the units shall be distinctly marked

19.1.1 After having been cast in the mould or form the concrete shall be

adequately protected during setting in the first stages of hardening from shocks and from harmful effects of frost, sunshine, drying winds and cold.

19.1.2 All precast work shall be cured for at least 7 days after casting and

during that period each units shall be kept constantly watered or preferably by completely immersed in water if the size of unit so permits.

19.1.3 No precast unit shall be lifted until the concrete reaches a strength of at

least twice the stress to which the concrete may be subjected at the time of lifting. The precast articles shall be matured for 28 days before erection or being built in so that the concrete shall have sufficient strength to prevent damage to units when first handled

19.1.4 Precast units shall be stored, transported and placed in position in such

a manner that they will not be overstressed or damaged. The lifting and removal of precast units shall be undertaken without causing shocks, vibration or under bending stresses to or in the units. Before lifting and removal takes place, contractor shall satisfy Consultant or his representative that the methods he proposes to adopt for these operations will not over stress or otherwise affect seriously the strength of the precast units.

20.0 SAMPLING, TESTING AND QUALITY ASSURANCE

20.1 General 20.1.1 Concrete cubes for works tests shall be cured under laboratory

conditions, except when in the opinion of the Consultant, extreme weather conditions prevail at which time, these may require curing under job conditions.

20.1.2 For the purposes of statistical analysis, any substandard cube result,

which in the opinion of the Consultant, is due to improper sampling, moulding or testing shall be discarded and a dummy result shall be

substituted. The value of a dummy result shall be equivalent to the average value of the cubes from the same grade of concrete tested immediately before and after the discarded result. The number of such substandard cubes shall not exceed 5%.

20.1.3 If the ‘strength’ of the laboratory controlled cubes, for any portion of the

concrete work, falls below the compressive strength specified, the Consultant shall have the right to order a change in the proportions or the water content for the remaining portion of the structure.

20.1.4 If the ‘strength’ of the works cured test cubes falls below the specified

strength, the Consultant shall have the right to require provisions for temperature and moisture control during the period of curing as necessary to secure the required strength, and may require retests in accordance with the ‘standard method of securing, preparing and testing specimens from hardened concrete for compressive and flexural strengths, or load tests to be made on the portion of the building so affected. All such tests shall be made at the Contractor’s expense.

20.1.5 Unacceptable concrete work shall be dismantled by the Contractor and

replaced by fresh work, meeting the specification requirements. In the course of dismantling, if any damage is done to the embedded items or adjacent structures, the same shall be made good, by the Contractor, to the satisfaction of the Consultant, at no extra cost.

20.1.6 Only as a very special case and that too in non-critical areas, the

Consultant may accept concrete work which is marginally unacceptable as per the criteria laid down in lS:456. For such accepted work, payment shall be made at a reduced rate prorata to the concrete cube strength obtained, against that stipulated.

20.1.7 If directed by Consultant, Ultrasonic tests on structures to ascertain the

quality and grade of concreting shall be carried out. Contractor shall arrange for the specialised agency for conducting the test at his cost. The Contractor shall provide all the necessary facilities and arrangement for conducting the test at site in terms of access, scaffolding etc. In case of any defects, the Contractor shall rectify the same as directed by the Consultant. Rebound hammer test shall be carried out for ascertaining the quality of concrete work, as directed by the Consultant.

20.1.8 Test shall be conducted for the water tightness of the liquid retaining

structures as per lS:3370 and IS:6494. The details and sequence of tests shall be as given hereunder:

a) All arrangements, including supply of water for testing purposes,

shall be kept ready when the tank is nearing completion. b) Water supply to the tank shall be in stages of 300 to 450 mm height

in order to check the water tightness of the tank at full water level

and location of leakage of various levels. c) The permissible drop in level in 24 hours shall be 6 mm in case of

covered reservoir/tank and 12 mm in the case of open reservoir-tank. If the structure does not satisfy the conditions of test and the daily drop in water level is decreasing the period of test may be extended for further seven days and if specified limit is then reached, the structure may be considered satisfactory.

d) The leakage points shall be marked and separately treated after

dewatering e) The underground structures /water retaining structures shall be

retested for water tightness after rectification. For basement type structures like basin, neutralising pit, etc. the Contractor shall examine the water tightness against ingress of sub-soil water.

20.1.9 Optional Tests :

a) EIC , if he so desires, may order for tests to the carried out on cement, sand, coarse aggregate, water etc., in accordance with the relevant Indian Standards.

b) Tests on cement will be carried out by department and shall include

(I) fineness test, (ii) test for normal consistency, (iii) test for setting time, (iv) test for soundness (v) test for compressive strength, (vi) test for heat of hydration (by experiment and by calculations) in accordance with IS :269.

c) Tests on sand shall included (i) sieve test, (ii) test for organic

impurities, (iii) decantation test for determining clay and silt content, (iv) specific gravity test, (v) test for unit weight and bulkage factor, (vi) test for sieve analysis and fineness modulus.

d) Tests on coarse aggregate shall include (i) sieve analysis, (ii)

specific gravity and unit weight of dry, loose and rodded aggregate, (iii) soundness and alkali aggregate reactivity, (iv) petrographic examination, (v) deleterious materials and organic impurities, (vi) test for aggregate crushing value.

20.2 Sampling of Concrete 20.2.1 Samples from fresh concrete shall be taken according to lS:1199 and

tested as per IS:516. 20.2.2 Normally only compressive test shall be performed but the Consultant

may require other tests to be performed in accordance with lS:516.

20.2.3 Trial Mixes & mix design: At least four trial mixes shall be made with minimum 6 test cubes for each mix.

20.2.4 Works Tests:

a) The minimum. frequency of sampling of concrete of each grade shall

be according to clause 15.2.2 of lS:456. However, after getting continuous satisfactory results and in the case of voluminous concrete works, the Consultant, may at his discretion reduce the frequency of sampling as follows.

b) For each grade of concrete, and for each 8 hours (shift) of work or

part thereof, at least one sample consisting of six specimens shall be taken from each 150 cum. of concrete or part thereof, 3 specimens shall be tested at 7 days and remaining 3 shall be tested at 28 days. However, in all cases, the 28 days compressive strength shall alone be the criterion for acceptance or rejection.

c) To control the consistency of concrete from every mixing, slump

tests and compaction factor tests in accordance with lS:1199 shall be carried out by the Contractor every two hours or as directed by the Consultant. Slumps corresponding to the test specimens shall be recorded for reference.

d) The strength of sample shall be the average of the strength of three

specimens. The individual variation should not be more than ± 15% of the average.

20.3 Acceptance Criteria 20.3.1 The acceptance criteria of concrete shall be in accordance with clause

no.16 of IS-456. However, in exceptional circumstances, the Consultant may. at his discretion, accept a concrete of lower strength than that specified at reduced rates.

20.3.2 In case of doubt regarding the grade of concrete used or results of cube

strength are observed to be lower than the designed strength as per specifications at 28 days, compressive strength test of concrete based on core test, ultrasonic test and / or load test shall be carried out by the digital ultrasonic concrete tester by an approved agency as directed by the Consultant all at the cost of the contractor

Core Test: a) The points from which cores are to be taken and the number of

cores required, shall be at the discretion of the Consultant and shall be representative of the whole of concrete concerned. In no case, however, shall fewer than three cores be tested. Cores shall be prepared and tested as described in IS : 516-1959.

b) Concrete in the member represented by a core test shall be considered acceptable if the average equivalent cube strength of the cores is equal to at least 85% of the cube strength of the grade of concrete specified for the corresponding age and no individual core has a strength less than 75%.

c) In case the core test results do no satisfy the requirements as above

or where such tests have not been done, load test may be resorted to.

20.3.3 Other non-destructive test such as ultrasonic sound methods may be

adopted, in which case the acceptance criteria shall be agreed upon between the Consultant and the contractor and the test shall be done under expert guidance.

20.3.4 Load Test: If in the opinion of the Consultant, the safety of the structure,

or any part of the structure is in doubt and the results of other tests are not encouraging, the Consultant may directload lest to be conducted before ordering its removal and reconstruction, in accordance with the provision of clause no.17.60 of IS:456-2000.

20.3.5 Load Tests on Parts of Structure :

a) Load tests should be carried out as soon as possible after expiry of 28 days from the time of placing of concrete.

b) The structure should be subjected to a load equal to full dead load of

the structure plus 1.25 times the imposed load for a period of 24 hours and then the imposed load shall be removed. Dead load includes weight of the structural members plus weight of finishes and walls of partitions, if any, as considered in the design.

c) The deflection due to imposed load only shall be recorded. If within

24 hours of removal of the imposed load, the structure does not recover at least 75% of the deflection under super imposed load, the test may be repeated after a lapse of 72 hours. If the recovery is less than 80% the structure shall be deemed to be unacceptable.

d) If the maximum deflection in mm shown during 24 hours under load is less than 40 L/D, where L is the effective span in M and D the overall depth of the section in mm, it is not necessary for recovery to be measured and the recovery provision as above will not apply.

20.3.06 In case these tests do not satisfy the requirements, the consultant will

be at liberty to reject the concrete, and the contractor, at his own cost, has to dismantle and redo the same or carry out such remedial measures as approved by the consultant.

20.4 Testing to Underground Structures/ inspection chambers etc : 20.4.1 The above will be tested after the completion according to the

procedure laid down here :

a) The middle compartment shall be filled first to its full height and the

leakage if any shall be checked on its outer surfaces and if found, the same shall be examined carefully and defects rectified / grouted if necessary. The drop in level of surface of water shall also be recorded for 48 hours. If this drop in level exceeds 20 mm and shows any leakage in the said walls, necessary steps shall be taken in consultation with the Consultant.

b) After this compartment is tested to the satisfaction of the Consultant

, all water from middle compartment shall be pumped into side compartment to the full height and checked for water leakages from the outer surfaces of the tank as well as inner surface of the middle compartment. The drop in level of surface of water shall also be checked as stated above and defects rectified.

c) The external surface of the chamber shall then be plastered and

cured as per the specifications and back filling shall be taken up thereafter. The water from the compartments shall then be pumped out and the inner surface of the tank in all compartments then be checked and defects rectified.

d) After satisfactory completion of checks, internal plaster shall be

taken up as specified in the specifications.

e) The contractor shall be responsible for carrying out the complete

test, rectifying the leakages if any. The cost of providing all equipments, labour for carrying out tests shall be borned by the contractor. The rates quoted for concreting items for constructing under ground structures/chambers shall be inclusive of testing for water tightness as per above specifications. The contractor shall make his own arrangement for filling the tank.

21.0 Application of Live Load The designated live load shall be allowed on any structure only after 28

days, after proper curing is carried out on the last concrete poured in structure.

SUPPLYING & LAYING RCC PIPES 1.1 SCOPE

This specification covers the supply and laying of R.C.C. Hume pipes as may be required. The entire work shall be carried out as per latest edition of Indian Standards IS: 783 and IS: 458.

1.2 SUPPLY OF PIPES

The contractor shall supply the R.C.C. Hume pipes of various diameters along with complete fittings required for carrying out the work. R.C.C. Hume Pipes should conform to class NP3 of IS: 458 as may by required and should be in good condition. The Contractor must furnish, on being demanded by the Engineer, manufacturer’s certificates and/or test certificates from recognised authorities.

1.3 ALIGNMENT, LEVELS AND GRADE

The work shall be carried out in conformance to the alignment, levels and grades specified In the drawings. The layout and levels shall be made by him at his own cost from one reference grid and bench mark given by the Engineer. He shall give all help in instruments, materials and men to the Engineer for checking the detailed layout and levels as and when required. Making of reference layout and level pillars along the pipeline route and maintaining them upto completion of the work shall be the responsibility of the Contractor, at his own cost.

1.4 LAYING OF PIPES

1.4.1 General The laying of R.C.C. Pipes shall conform to IS: 783-1985.

1.4.2 Conditions for laying The conditions for laying of pipes to suit the conditions at site and/or as per drawings and instruction of the Engineer shall be as classified below:

1.4.3 Culvert Condition

In this condition the pipe is laid under embankment and may project wholly or partly above the original ground surface.

1.4.4 Trench Condition In this condition the pipe is laid in a trench excavated for the purpose. The trench shall be refilled with thoroughly tamped earth after laying and jointing of pipes in approved manner.

1.4.5 Open Condition In this condition the pipe is laid such that it projects wholly or partly

above original ground surface, there being no super imposed overburden on the pipe.

1.5 Bedding and Supports 1.5.1 Culvert Condition

In this condition the pipes shall be laid generally as per sector B9 to B16 of Appendix-B, of IS:783-1985.

1.5.2 Trench Condition

In this condition the pipes shall be laid generally as per Section B1 to B8 of Appendix - B of IS: 783-1985.

1.5.3 Concrete Cradle Bedding

If specified in the drawing or so instructed by the Engineer, the pipes shall be laid on Concrete cradles, conforming to section B1 of Appendix-B of IS: 783-1985 in case of trench condition and conforming to section B5 of Appendix - B of IS:783-1985 in case of culvert condition.

1.5.4 Open Condition

In Open conditions the pipe laid shall be supported over rigid pedestals constructed at intervals not greater than the length of one individual piece of pipe, as per drawings and instruction of the Engineer. In no case shall the joint between to pieces of pipe shall lie at the centre of span between the supports. The pedestals shall be of reinforced concrete with a properly shaped out top to receive one third perimeter of the pipe.

1.5.5 Jointing of Pipes

Joints shall be flexible type as per IS: 783-1985. Rubber ring, with material conforming to type - 1A of IS: 5382-1967 shall be placed on the spigot with special shape and the spigot is forced into the socket previously laid. This compresses the rubber ring as it rolls into the annular space formed between the two surfaces of the spigot and socket.

1.6 Hydrostatic Testing of Pipes The pipeline as laid shall be subjected to hydrostatic test as per clause

15.5 of IS:783-1985.

METHOD OF MEASUREMENT 1.0 GENERAL 1.1 The method of measurement of the various items of work shall be in

accordance with IS : 1200 (Part 1 to 28) – 1971 to 1993 / SP-27 .unless otherwise mentioned in this part or in the schedule of items or in preamble or in the specification.

1.2 If there is any contradiction in meaning between any portion of this part and

that of IS : 1200 (Part 1 to 28) – 1971 to 1993, the stipulation of this part shall prevail.

1.3 The descriptions and explanations given herein have as much forces as

though they are incorporated into the description of the items themselves in the schedule of items.

1.4 In case of dispute between the method of measurements mentioned here and

the respective bill of quantities, the method of measurement mentioned in the bill of quantities shall prevail.

2.0 EARTH WORK & FILLING 2.1.0 General 2.1.1 Each dimension upto 25 m shall be measured to nearest 0.01 m and to

nearest 0.1 m for dimensions over 25 m. Areas shall be worked out to the nearest 0.01 m2 and cubical contents to the nearest 0.01 m3.

2.1.2 Shoring and strutting shall not be measured separately unless otherwise

specified. 2.1.3 Dewatering for earth work and sand filling work shall not be measured

separately unless otherwise specified. 2.1.4 For classification of soils, relevant clauses of Technical specification

(workmanship and other requirements) is to be followed.

Requirements for particular works Site levelling For site levelling levels shall be taken jointly before start & after completion of work and the quantity computed based on the levels. Measurements shall be made only for excavation and no separate measurement for filling shall be made except where earth, borrowed from elsewhere for site levelling work, will be measured separately only for that borrowed portion of earth.

In cases where it is not possible or convenient to take measurements from excavated cuts or borrow pits, excavation shall be worked out from filling based on the levels to be taken before and after completion of works. Deduction of 10 percent will be made for voids, however for consolidated fills done through heavy mechanical means, the deduction for voids shall be 5% in place of 10%. In exceptional cases where the quantity is measured on the lorry measurement, loose stacks, boxes or any other similar method with the approval of the Consultant the deduction for voids shall be 20 percent from the actual quantity. Excavation Before commencing excavation of foundations for buildings and structures, the initial ground levels shall be jointly recorded. The depth of excavation and the calculation of lift shall be based on this. Normally the initial ground level shall be considered as the level of the site as handed over to the Contractor. In case excavation is planned and approved to be taken up subsequent to terracing, the terrace level shall be treated as initial ground level. Excavation of foundations, trenches, basements, pits, etc., shall be measured to the dimensions shown in the excavation plan, if any, or of the lowest concrete or masonry course, as the case may be and the actual depth. Working space and slopes shall not be measured. Excavation of rock shall be measured from stacks of excavated rock with a deduction of 50 per cent for voids or measured in the solid based on levels. In case of following works, no measurement will be recorded for the excavation beyond drawing/specification. In work which will be covered externally with damp proof covering. In work which requires formwork. In work which requires workmen to operate from the outside and for guniting and post tensioned concrete, ground beams etc. However, if there is a specific provision otherwise in the item/ specification/ preamble, for authorised working, it shall be measured accordingly. This working space may be 60 cm measured from the face of the structure at lowest level, unless otherwise mentioned. Surface dressing Trimming of natural ground, excavated surface and filled up area to remove vegetation and/or small in equalities not exceeding 15 cm deep shall be described as surface dressing and measured in square metres unless otherwise specified in the schedule of items/preamble.

Lead The distance for removal shall be measured over the shortest practicable route and not necessarily the route actually taken. The description of the item shall include loading and unloading. For the purpose of the measurement of the lead, the area excavated shall be divided in suitable block and for each block the distance from the centre of the block to the centre of the placed earth pertaining to this block shall be taken as lead. Back filling/filling In foundations, trenches, basements, pits, etc. and in other like areas, the measurements shall be the theoretical volume of the filling computed from drawings i.e. the volume measured under excavation minus the volume occupied by the structure and part filling if any, done otherwise. In filling under floors the measurements shall be the theoretical volume as per drawings after deducting the part filling if any, done otherwise. In embankments, the work shall commence only after recording jointly the initial ground levels and the measurements shall be made on the basis of finished cross section and initial ground levels. Where controlled compaction by mechanical compaction is done, 5% deduction for voids shall be made. In case controlled compaction by mechanical means is not done then deduction for voids shall be 10%. Filling/back filling shall not be measured separately for items of excavation, where filling/back filling is a part of the composite item and as such is included in excavation item itself. CONCRETE (PLAIN & REINFORCED) 3.1 Concrete 3.1.1 Dimensions shall be measured to nearest 0.01 m except for the thickness of

slab, which will be to nearest 0.005 m. Areas shall be worked out to nearest 0.01 m2 and cubic contents to nearest 0.01 m3.

3.1.2 The concrete shall be measured as per drawings except in the cases of

approved variations which will be measured separately. No deductions shall be made for the following:

• Ends of dissimilar materials such as beams, rafters, purlins, etc., upto 500 sqcm in cress section.

• Openings upto 0.1 sqm in area (In calculating area of an opening, the thickness of any separate lintel or sill shall be included in the height. No extra labour for forming such opening or voids shall be measured).

• Volume occupied by reinforcement or other embedments such as anchors,

inserts, conduits or volume occupied by pipes, sheathing, etc., not exceeding 100 sqcm each in cross sectional area or as specified.

• Small voids not exceeding 40 sqcm each in cross section.

• Moulds, drip moulding, chamfer, splay, beds, grooves and rebates upto 10 cm

in width or 15 cm in girth. Columns shall be measured from top of column base to underside of first floor slab and from top of floor to underside of floor slab thereafter. Beams shall be measured from face to face of columns and will include haunches. Depth of beam shall be measured form bottom of slab and in case of inverted beams from top of slab. Chajjas and other cantilevers shall be measured from face of projection. Where vertical fins are combined with chajja, the later shall be measured clear between fins. In case chajja is not combined with lintel, beam or slab, it shall be measured inclusive of bearing. Reinforcement 4.1 Norms for steel consumption The requirement of mild and high strength deformed bars for various works like reinforcement, guard bars, fan hooks, etc. shall be calculated as mentioned below:

• As per drawing including

1. Authorised laps, bends, standard hooks and deviations etc. 2. Spacer bars, chairs, hangers, supports, spacer blocks, dowels etc. are

to be considered for wastage only and not to be measured for payment purpose.

• Quantity upto 0.5% of (i) above towards unaccounted wastages, plus

• Quantity upto 3% of (i) above towards cut pieces, which shall be pieces below

2m length. These cut pieces shall not be taken back even though steel has been issued by the client/owner.

4.2 Reinforcements shall be measured in lengths to the nearest 0.01 m for various

diameters of bar and converted into weight in tonnes to the nearest kg on the basis of standard weights as per IS: 1786 – 1986. No allowance shall be made in the weight for rolling margin.

• Authorised laps, standard hooks, bends shall be measured. • Spacer bars, chairs, hangers, supports, spacer blocks and unauthorised laps

etc. shall not be measured unless otherwise specified. • Dowels neither shown on the drawings nor instructed by the Consultant but

required for construction facilities and/or sequence, shall not be measured for payment.

• Modification of already embedded reinforcement, if required due to faulty

fabrication or placement, shall not be measured for payment. • The measurements of reinforcements (including authorised laps, hooks, bends

shall be taken only from Bar bending lists or from the drawings except in the cases of approved variations which will be measured as per 4.2.2).

• Hoop iron shall be fully described and measured in running metres unless

otherwise specified in the schedule of item. • Wire netting and fabric reinforcement shall be described (including meshes

and wire/ strands) and measured in square metre, unless otherwise specified in the schedule of item. Auhtorised laps shall be measured. Racking of circular cutting and waste shall be included in the description of item.)

• Binding wire for the reinforcement shall not be measured separately and shall

be included in the item of reinforcement. 5.0 Admixture 5.1 Admixture will be measured separately as specified or on the basis of the

requirement as approved by the Consultant. 6.0 Formwork 6.1 Each dimension shall be measured to the nearest 0.01 m and area to the

nearest 0.01 sq.m. 6.2 Formwork shall be measured as the actual surface in contact with concrete

and paid in sq.m. unless included in the rate for concrete in specific item of work.

6.3 All the measurements shall be computed from the drawings except in the

cases of approved variations which will be measured separately. 6.4 Formwork shall not be measured separately for precast concrete work,

grouting and damp proof course which shall be included in the concrete rates.

6.5 No measurement for formwork in construction joints shall be made. 6.6 Openings upto 0.1 sqm shall be neglected, as if non-existant, for the purpose

of formwork measurement. 6.7 No extra measurement or payment shall be made for making the form work

water proof or for supports, scaffolding, staging, centering, approaches, etc. 6.8 No measurement shall be taken for the formwork in pockets, openings,

chambers, chases, etc., in concrete if the cross sectional area is less than or equal to 0.1 sq.m. in each case. If the cross section area of any opening exceeds 0.1 sq.m. the actual area of the formwork shall be measured for payment.

7.0 Embedded Parts 7.1 These shall be measured on the basis of standard theoretical weight of the

complete insert according to the drawing/direction. 7.2 Embedded steel, which are the integral parts of the embedment according to

drawing and are required for anchoring the embedded parts in concrete shall be measured on the basis of the theoretical standard weight. In case of anchor bolts the theoretical weights of the nuts, lock nuts, check nuts and washers shall be added in the measurement for payment.

7.3 All bye-works such as jigs, fixtures, templates and other arrangements which

are not integral parts of the embedded parts, but necessary to secure those (embedded parts) in position shall not be measured for payment.

7.4 Anti-corrosive paint over the exposed surfaces and protection of the anchor

bolts with grease etc., shall not be measured for payment. 7.5 Modification works necessary to rectify the mistake of already placed

embedded parts shall not be measured. 8.0 Grouting 8.1 Grouting shall be measured in volume except in the cases of grouting by

special cement compound or epoxy compound which will be measured by number.

8.2 Measurement shall be computed from the drawings except in the cases of

approved variations which shall be measured separately and subsequently added to or deducted from.

8.3 Necessary formwork shall not be measured for payment.

9.0 MASONRY 9.1 Dimensions shall be measured to nearest 0.01 m, areas to nearest 0.01

sqm and cubic contents to nearest 0.01 cum 9.2 No deduction shall me made for:

• Ends of dissimilar materials such as joints, beams, posts, girders, trusses, lintels, purlins, etc., upto 0.1sqm in section.

• Openings upto 0.1 sqm. In area. • Wall plates, be plates, bearing of slab, etc., thickness not exceeding 10

cm and bearing not exceeding over full thickness of wall. • Cement concrete blocks for hold fasts and the like. • Iron fixtures such as pipes, etc., upto 300 mm in diameter and hold fasts

for doors and windows.

9.3 Dressed stonework such as in sills, cornices, column caps, copings, etc., shall be measured as the smallest rectangular block from which the finished stone can be worked.

9.4 Honey comb openings shall not be deducted from the area of honeycomb

brickwork. 9.5 Brickwork of full brick width or more shall be measured in cum while of

thickness half brick or less shall be measured in sqmt unless otherwise specified.

9.6 Reinforcement for reinforced brick work shall be measured separately,

unless otherwise specified and no deduction for reinforcement shall be made from brickwork.

10.0 PLASTERING & POINTING 10.1 All plastering and pointing shall be measured in sq.m. unless otherwise

described. Dimensions shall be measured to nearest 0.01 m and areas to 0.1 sq.m..

10.2 The methods of measurement including the deductions for openings etc.

shall be according to the relevant part of IS: 1200 (Part 1 to 28) 10.3 White washing, Colour washing, Painting and other finishes. The method of measurement shall be according to the relevant part of IS 1200 (Part 13 & 15).

IX. SAFETY REQUIREMNTS FOR CONSTRUCTION WORKS 1.0 GENERAL 1.1 This specification deals with the subject matter of safety and protection to be observed in the Road and bridge Construction. This shall be followed along with all related statutory requirements/obligation including Governmental byelaws, codes, ordinance of local or central authorities related to the construction work. 1.2 In case of complicated work like deep excavation, intricate shuttering and formwork, excavation in loose soil and below water table, stacking of excavated earth etc., work plan with necessary drawings and documents have to be prepared by the Contractor and got approved by the Consultant. 1.3 Necessary reference shall be made to the following Indian Standard Codes on safety requirements for various type of work : 2.0 INDIAN STANDARD 4130 – 1991 Demolition of Buildings 3764 – 1992 Excavation Work 4014 – (P-II) – 1967 Scaffolding, Steel Tubular 3696 – (P-I & P-II) Scaffolds and Ladders 1987 to 1991 4138 – 1977 Working in Compressed Air 7293 – 1974 Working with Construction Machinery 8989 – 1978 Erection of Concrete Framed Structures 5916 – 1970 Safety code for construction involving use of hot bituminous materials 3.0 EXCAVATIONS 3.1 No excavation or earth work below the foundation level of an adjoining building shall be taken up unless adequate steps are taken to prevent damage to the existing structure or fall of any part. 3.2 Every accessible part of an excavation, pit or opening in the ground into which there is a danger of persons falling shall be suitably fenced with a barrier upto a height of one metre suitably placed from the edge of the excavation as far as practicable.

3.3 No material or load shall be placed or stacked near the edge of the excavation or opening in the ground. The excavated material shall not be placed within 1.5 m of the trench or half of the depth of the trench whichever is more. 3.4 Cutting shall be done from top to bottom. No undercutting of sides of excavation shall be allowed. 3.5 Materials shall not be dumped against existing walls or partition to a height that may endanger the stability of the walls. 3.6 While withdrawing piled materials like loose earth, crushed stone, sand, etc. from the stock piles, no over hanging shall be allowed to be formed in the existing dump. 3.7 No material on any of the sites of work shall be so stacked or placed as to cause danger or inconvenience to any person or public or any other agency at work. 4.0 SCAFFOLDING, LADDERS & SHUTTERING 4.1 For all work that cannot be done from the ground level or from part of any permanent structure or from other available means of support, soundly constructed scaffoldings of adequate strength shall be used as a safe means of access to places of work. 4.2 All scaffolding shall be securely supported or suspended and wherever necessary be properly braced to ensure stability. 4.3 All working platform and stages from which workers are liable to fall shall be of adequate width depending on the type of work done and closely boarded and planked. 4.4 Every ladder shall be securely fixed at top and bottom. A ladder more than 5 m long shall have a prop. 4.5 No portable single ladder shall be over 8 m in length. 4.6 Unfinished scaffolding which is under construction shall be prominently marked as unsafe and any access points shall be closed. 4.7 Shuttering The above remarks shall be applicable for this also. Shuttering, particularly for slabs, should be treated as a scaffold. Unfinished shuttering should be marked as dangerous similarly the finished form work should be adequately supported, care being taken to avoid trap door effects. 5.0 SAFETY APPLIANCE

5.1 Those engaged in white washing and mixing or stacking of cement bags or any materials which is injurious to the eyes, shall be provided with protective goggles. 5.2 The Contractor shall not employ men below the age of 18 and women on the work of painting with products containing lead in any form. Whenever men above the age of 18 are employed on the work of lead painting the following precautions shall be taken : 5.3 All necessary personnel safety equipment such as safety helmets, safety boots, safety belts, leather gloves for welders, clear glass safety goggles etc., as considered adequate by the Consultant have to be kept available for the use of persons employed at the site of work and maintained in condition suitable for immediate use and Contractor shall take steps to ensure proper use of equipment by the workers. 5.4 Sign boards 1 x 1.5 m in size with the following wording shall be erected at the access to these areas. “CONSTRUCTION AREA, HELMET REQUIRED BEYOND THIS POINT”. Arrangement for rendering prompt and adequate first aid to the injured persons shall be maintained at every work site under the guidance of a medical officer-in-charge of the project. Depending upon the magnitude of the work the availability of an ambulance at a very short notice (a telephone call) shall be ensured. First-aid arrangements commensurate with the degree of hazard and with the number of workers employed shall be maintained in a readily accessible place throughout the working hours. At least one experienced first-air attendant with his distinguishing badge shall be available on each shift to take care of injured persons. Arrangements shall be made for calling the medical officer, when such a need may arise. It is recommended that foreman/assistant foreman/supervisor/permanent workmen who are normally present at each working phase in each shift are given adequate training on first-aid methods to avoid employment of a separate attendant. 6.0 MISCELLANEOUS 6.1 The Contractor shall provide necessary fencing and lights to protect the public from accident. 6.2 To ensure effective enforcement of the rules and regulations relating to safety precautions, the arrangements made by the Contractor shall be open to inspection by the Consultant and Owner. 6.3 All sources of ignition shall be prohibited in areas where flammable liquids are stored, handled and processed. Suitable warning and ‘NO SMOKING’ signs shall be posted in all such places. Receptacles containing flammable liquids shall be stacked in such a manner as to permit free passage of air between them. 6.4 All combustible materials shall be continuously removed from such areas where flammable liquids are stored, handled and processed. All spills of flammable

liquids shall be cleared up immediately. Containers of flammable liquids shall be tightly capped. 7.0 REPORTING OF ACCIDENT 7.1 All accidents, major or minor must be reported immediately. The Contractor, will provide first aid to the injured person immediately and the injured person shall report to the first aid station along with the ‘INJURED ON WORK’ form duly filled in quintuplicate and submit to the Medical Officer of the First Aid Station”. 7.2 Serious Injury 7.2 In case of serious injury, the following procedure shall be adopted by the Contractor: Provide First Aid at his own First Aid Station. Take the injured person to the Hospital along with the “INJURED ON WORK” form duly filled in. Reporting the accident to the Owner/Consultant by the Contractor. 7.3 Fatal Accident Fatal accident must be reported immediately to the Consultant/Owner as well as to the Police. 8.0 PENALTY Failure to observe the Safety Rules will make the Contractor liable to penalty by way of suspension of work, fine and termination of contract.

CHAPTER- III


&

SCOPE OF WORK

FOR

PILING JOB

1.0 PURPOSE This document defines the scope of works for RCC bored cast-in- situ piles and its specific requirements including pile foundation system for the proposed installation of Highmast Towers at Paradeep Terminal, Orissa. 2.0 CODES, STANDARDS & SPECIFICATION a. IS: 2911 (All Parts) b. Specification for materials for Reinforcement concrete piles c. Specification for construction and installation for bored cast in situ piles d. Specification for testing of concrete piles 3.0 SCOPE 3.1 General Providing RC bored cast in situ piles and R.C. pile caps as per design carried out by the bidder, vetted by reputed engineering institute like IIT, Kharagpur or any other reputed Engineering Institutes/ Consultant duly approved by HPCL and submitting to HPCL for review before commencement of piling work. All jobs to be completed within the specified time period mentioned in the tender. Supply of all materials is also included in contractor’s scope. The scope in general consists of designing the RCC pile foundation basis the soil investigation report/ recommendation, which shall be provided to the successful bidder. The party has to carry out the design of the pile foundation basis the soil report after the award of the contract and get the design vetted by reputed engineering institute like IIT, Kharagpur or any other reputed Engineering Institutes/ Consultant duly approved by HPCL within the quoted rates. For the purpose facilitating the bidders to provide their techno commercial offer the diameter of piles have been assumed ranging from 500 mm dia to 800 mm dia and depth of termination approximately 15 meters The quantities mentioned in the schedule of rates are approximate and actual payment shall be made basis the actual executed quantities based on the approved design. The testing of piles shall also be carried out by the contractor in line with IS 2911– (Part IV) and relevant specifications of this tender document within the quoted rates. No extra payment shall be made to the Bidders on this account. However the contractor is expected to quote for this tender based on the information provided herein and other sections of this tender document including the Schedule of Quantities. The work involves but not limited to the following:

(i) Design & Construction of Pile foundation for High mast towers (ii) Conducting Routine Load tests on designated working piles namely

Vertical, Lateral & Pullout load tests.

3.2 Minimum Requirement of Piling Equipment Sufficient no of hydraulic self propelled or manual rotary piling rig complete with casing Adaptor and Casing Oscillator to complete the entire job as per the time schedule provided in this tender document.. The Contractor shall mobilize sufficient spares; cutting tools (e.g. flat teeth bits, round shank bits, holders, etc) to avoid any stoppage of work.

3.3 Surveying and Staking It is the express responsibility of the contractor to bring to site all surveying instruments necessary for the marking out, fixation of levels, etc. and conduct these survey operations himself with utmost accuracy. The contractor shall put-up stable bench marks etc. as necessary for the work. HPCL will be present when this work is being carried out and will inspect all these operations with the Contractor’s assistance. The contractor shall be entirely responsible for accurate setting out of the work and he shall at his own expense make good any defects arising from errors in line and levels. 3.4. Dewatering Dewatering of accumulated water in all locations on job site from whatever source or cause until the virtual completion of the entire work shall be done by the contractor at his own expense and shall not be separately paid for. The rates quoted by the contractor shall be deemed to be inclusive of this. 3.5 Tenderer’s shall submit the following information as part of their technical bid: i) Numbers of the piling rig proposed to be deployed. ii) Full Technical details of piling rigs and accessories in the form of catalogues, data sheets, etc. iii) Piling procedure, piling programme and accessories to be mobilized by the contractor at no extra cost to the client. 3.6 The contractor shall use only Ready mixed concrete for the proposed piling and pile caps works. Contractor shall indicate the resources available in this regards including number of batching plants to be mobilized considering the time frame and nature of works. As a specific requirement, only Portland puzzolana cement conforming to IS 1489 shall be used for all concrete works. All rebars shall be Corrosion resistant steel (Tiscon CRS/SAIL-HCR- /RINL-HSCR) and shall conform to IS 1786 grade Fe 500 for mechanical properties. 3.7 The work involves but not limited to the following: a) Construction of straight shaft RCC bored cast-in-situ piles of approved diameter and depth of termination (basis approved design carried out by the bidder based on soil investigation report to be handed over the bidder after award of work order) and approximate number of piles

b) Carrying out routine load tests as specified on randomly selected job piles selected by Engineer-in-Charge and as per codal provisions. 4.0 AVAILABLE INFORMATION 4.1 The proposed pile top need to be terminated at 600mm above Pile cut off level. The same will be chipped off at the time of commencement of pile cap job to progress the job further. The soil profile and design requirements shall dictate length of temporary casing pipe required for construction purposes which shall be immediately withdrawn after casting of the pile Free boring, if any will not be considered for measurement & payment. 5.0 REQUIREMENTS All work shall be carried out in accordance with the specifications enclosed herewith and contractor shall ensure minimum requirements as laid down hereunder: 5.1 Termination of Piles Piles shall be terminated with a minimum embedment of 2.40m inside the soft /disintegrated strata having SPTN Value more than 100 or as per soil investigation report or as per design requirements. After encountering the soft /disintegrated medium dense layer, the beginning of the layer shall be established by conducting SPT. In case SPT is observed more than 100, the pile shall be terminated with an embedment of minimum 2.4m inside the strata. For confirmation of the similar strata two more SPT shall be conducted thereafter with an interval of 1.0m, conducting of SPT shall be done at least one in five (1 in 5) pile location. In case medium hard or hard strata encountered before minimum embedment depth in the above specified strata the pile shall be terminated in this layer with a minimum embedment of 500mm in medium hard strata or 200mm in hard strata. Piling in soft / disintegrated strata shall be done preferably with chisel as per discretion of Engineer-in-Charge and in the case of medium hard / hard rock strata pile boring shall be proceed with chisel of weight 2.5t or more. The level of encountering the particular strata and termination depth in all cases shall be certified by Engineer-in-Charge and shall be binding on the tenderer. 5.2 Safe Load Carrying Capacity For Vertical Compression/Lateral/Uplift The tenderer shall guarantee minimum safe load of 1.5 times the design capacity for the piles provided. The safe load may be increased by 25% in the case of wind and seismic. 5.3 MATERIALS Materials shall conform to specifications for materials for Reinforcement concrete pile which is enclosed elsewhere in this tender document and forming a part of the tender. 5.3.1 CONCRETE The concrete shall have a minimum strength of 30 N/sq. mm at 28 days. The cement for concrete shall be Portland puzzolana cement having minimum cement content not to be less than 400 kg/cum and a max water cement ratio of 0.45. The cement

content shall be governed by Design mix or soil characteristics, which ever is higher. The allowable slump shall be as per relevant latest revision of IS codes (IS 2911 Part 1/Sec 2). The Engineer-in-charge may allow marginal adjustment in water/cement ratio to obtain concrete of good workability. The other concrete specifications shall be as per relevant clauses of “Design, Construction & Installation of Bored cast-in-situ piles forming part of this tender. 5.3.2 REINFORCEMENT Reinforcement shall conform to IS: 1786 (latest version) grade Fe-500 for mechanical properties and shall be Corrosion resistant steel and it shall be either “TISCON CRS” from TISCO or HSCR-M from Vizag Steel or HCR-M from SAIL only. The reinforcement in the pile shall consist of the following: a) Longitudinal/Ties/Spacer bar Reinforcement Reinforcement provided shall be as per approved design with respect to diameter, numbers and should run through the entire length of the pile. d) Cover Clear cover to reinforcement shall be as per approved design (min 75mm). 5.4 INSTALLATION 5.4.1 Installation of piles shall be carried out in accordance with the pile lay out drawings as prepared/vetted/approved which are prepared by the contractor at the time of execution of work. 5.4.2 Cut-off level of the piles shall correspond to those given in the working drawings. 5.4.3 To ensure dense and sound concrete upto cut-off level, concreting shall extend minimum 600 mm above cut-off level. However, no extra payment shall be made for this and quoted rates shall be inclusive of this. 5.4.4 In case the reinforcement cage is made up of more than one segment, the same shall be assembled by welding only, before lowering, as per IS: 456-2000 by providing necessary laps. 5.4.5 The vertical reinforcement shall project 50 times its diameter above the cut-off level. 5.4.6 Pile shall be constructed by using temporary casing upto minimum 1.5m to 3.0m inside the stiff to very stiff clay exists below very soft / marine clay as per site conditions or design requirements. Adequate bentonite mud shall be used as full depth temporary casing not been used during the boring below temporary casing. Concrete shall be placed by tremie. All precautions for obtaining clean and sound pile shaft shall be strictly observed. 5.4.7 For Tremie concreted piles, a sample of drilling fluid shall be taken from the base of the borehole by means of an approved sampling device in the first few piles and at suitable interval of piles thereafter. Concreting shall not proceed if density of fluid exceeds 1250 kg/cu.m. The sand content in the fluid shall not exceed 7 percent.

5.5 MEASUREMENT OF PILES 5.5.1 The piles shall be measured and paid for the actual pile length from pile tip to the cut off level, as per the approved working drawings submitted by the contractor based on the approved design or as indicated by the Engineer-in-Charge. No extra payment shall be made for empty boring, if any. 5.5.2 Payment for routine load tests which shows unsatisfactory results shall not be made. 5.5.3 Piles showing unsatisfactory results shall be treated as defective piles. Defective piles shall be removed or left in place and replaced by additional piles as directed by engineer-in-Charge at no additional cost to the owner. 5.5.4 Reaction piles, if required for the purpose of conducting load tests on piles shall not be paid extra. Quoted rate for tests shall be inclusive of this. However, for routine lateral and uplift tests, if required, job piles may be used as reaction piles. 5.5.5 The quoted rate for bored cast in situ piles shall be exclusive of reinforcement conforming to IS 1786 – Fe 500 corrosion resistant bars of TISCON – CRS, HSCR-M from Vizag steel or HCR-M from SAIL. However, measurement/payment for reinforcement used shall be made through a separate item available in the schedule of rates. 5.6 PILE TESTING 5.6.1 Initial Load Test : DELETED 5.6.2 Routine Load Test Routine load tests shall be carried out up to one and half times the design load. The piles for the test shall be randomly selected by the Engineer-in-Charge 5.6.3 Pile Load Test Details i) For pile load tests, the test set up shall be as per IS 2911 Part IV and specifications for testing of concrete piles. ii) All testing shall be done by Direct method of loading in successive increments as per the relevant clauses of IS: 2911 Part IV & Standard Specifications for testing concrete piles forming a part of this tender iii) Each stage of loading shall be maintained till the rate of movement is less than 0.2 mm per hour. Test shall be carried out at the cut-off level. 5.6.4 Maximum test loads shall be as follows: i) Initial pile load tests: Deleted ii) Routine vertical load test: Load corresponding to 12 mm settlement or one and half times the safe load whichever occurs earlier. 5.6.5 Number of Tests Required The number of tests required shall be as per relevant clause of IS 2911 Part IV. 5.6.6 Payment for testing of Piles

No additional payment shall be made for testing of piles. The rates quoted in the schedule of rates shall deem to be inclusive of the pile testing required to be carried out under clause 5.6. NOTE: Kentledge load shall be at least 25% higher than the maximum test loads. 5.6.5 Criteria for Assessment of Safe Loads 5.6.5.1 Safe vertical load on single pile shall be the least of the following: i) Two thirds of the final load at which the total settlement attains a value of 12 mm. ii) 50% of the final load at which the total settlement equals to 10% of the piles dia. iii) Safe lateral load on single pile shall be least on the following: iv) 50% of the final load at which the total lateral displacement equals to 12 mm. v) Final load corresponding to the total displacement of 5 mm. 5.6.5.2 A full record of pile load test results shall be submitted in triplicate to the Engineer-in-Charge immediately on completion of each test. The record shall also include the plots of load-settlement (for various stages of loads) characteristics of pile and also the interpretation of the pile load test curve as per criteria for safe loads mentioned in the specifications for testing concrete piles forming a part of this tender. Any special observations shall be duly explained by the contractor.

5.6.5.3 Replacement of Rejected Piles

Piles/boring/casing that are defective or exceed the tolerances specified above shall be left in place or pulled out as directed by Engineer In Charge without adversely affecting the performance of the adjacent piles. In case the piles/casing cannot be removed they shall be cut out as directed by Engineer In Charge. Voids resulting from rejected borings or extraction of the piles or casings shall be filled with gravel or sand unless other piles are installed in such voids at the cost of contractor . 6.0. General Pumping and bailing out of water, shoring, strutting, etc., if found necessary for successful and speedy operation of work shall be carried out by the contractor and cost of such works shall be included in his rates. No extra claims whatsoever on all subsidiary works pertaining to pilling work will be entertained.

All the excavated materials including debris, Loose earth, muck etc shall be carted away and disposed off by the contractor out of the premises to any suitable place as per local statutory authorities.

The Contractor shall provide all the equipments, tools and plants required for the work and rates shall include the cost of bringing the equipment etc, to site, proper maintenance and removal of the same after completion of work.

Control of Piling Installation shall be as per the relevant IS Code (IS 2911 (part 1 section2).

Piles that are defective shall be left in places as judged by Engineer In Charge and additional piles shall be driven to replace them at no extra cost.

Adequate length of bars to be left over the cut-off level of the pile to develop anchorage in the pile caps and also dowels to be kept of adequate lengths.

Sample of the hard strata shall be taken appropriately marked and preserved by the contractor and finally handed over to HPCL. The level on the container should specify the date of piling, pile marked and depth of strata from which the sample has been obtained.

Rig register and weekly report as per the format, approved by HPCL shall be submitted to In-charge of the project.

During the period of establishing mix- design at site, nominal mix 1:1:2 for piling work only can be followed but the cement consumption for entire volume of piling work under reference will be reconciled based on approved design mix. For the purpose of measurements and payments, the length of pile shall be measured from the tip of the pile to the bottom of the pile cap. The 8 cm. length of the pile projecting into the cap shall not be measured for the payment and also shall not be deducted from the quantity of Pile cap concrete.

Reinforcement placed in the pile shall be paid for separately for the actual quantity of reinforcement placed in the pile exclusive of couplings, welded joints, spacer bars and binding wire as stipulated in the relevant specifications for reinforcements.

All piles shall be concreted to a level 600 mm above the specified pile cut off elevation which shall be 7.5 cm. above the bottom of the Pile cap. For piles cast by tremie method, in bentonite established bore holes, this level of concreting above pile cut of level shall not less than 600mm.

Before casting the pile cap, this excess concrete shall be cut off up to pile cut off elevation. In case sound concrete is not met with at such elevation the piles shall be cut to such elevation where sound concrete is met.

Piles shall be cut off at level and true to elevation shown or specified on the Drawings. Care shall be taken not to damage the reinforcement or the concrete below cut off elevation during such stripping operations. Where stripping to be done to a level lower than the specified cut off elevation to obtain dense and sound concrete, the Piling Contractor shall built up the pile up to cut off elevation at his own cost.

Upon completion of the piling work, all casing equipments, construction tools, protective covering and debris resulting from the piling operations shall be removed from the works site with the permission of the HPCL.

A minimum length of 2-3 metres of temporary casing shall be provided for each bored piles unless otherwise specifically desired. Additional length of temporary casing shall be used depending on the condition of the strata, ground water level etc.

7.0 Recording of Data Daily site records shall be maintained by the Contractor for the installation of piles against each Rig and shall contain the number and dimension of the pile, depth bored ( including depth in soft / hard rock ), time taken for boring, concreting and empty boring ( cut-off level) , chiseling and where the pile is wet or dry. Sample bore log in the initial stage or when major variation occur should be shown. When drilling mud is used, amount of bentonite needed for stabilization of bore, specific gravity of the fresh supply and contaminated mud in the bore hole before concreting shall be checked and recorded regularly. Concrete volume actually cast per pile against required volume and actual cement consumption. Detail of any obstruction encountered, its nature, depth and obstruction time. Any deviation from the designated location alignment or load capacity of any pile shall be noted. Typical data sheet in triplicate for facility of recording piling data to be prepared by the Contractor before starting of actual piling operation at site and information to be recorded against each pile in the data sheet shall be signed by the contractor and countersigned by HPCL. One copy of the data sheet shall be retained by the Contractor and the other two copies to be submitted to HPCL for records & future reference. At least six photographs are to be taken by the party depicting progress of the job in every week and a set of same to be separately submitted for review and record to HPCL.

STANDARD SPECIFICATION

FOR MATERIALS FOR

REINFORCED CONCRETE

PILES

CONTENTS

1. GENERAL

2. MATERIALS FOR CONCRETE

3. ADMIXTURES

4. REINFORCEMENT

1.0 GENERAL 1.1 Scope:

1.1.1 This specification establishes the material specification of reinforced cement concrete to be used in pile foundation. Any special requirements as shown or noted on the drawings shall govern over the provisions of these specifications. 1.1.2 For specific work requirements concerning design and construction or otherwise modifying or supplementing the provision of this specification, refer to the specific requirements. In case of conflict between specific requirements and provision of this specification, former shall govern. 1.2 Definitions:

1.2.1 Reference to Indian Standard Codes shall always mean reference to the latest issue of the relevant standards including all its amendments up to date. 1.3 Codes:

All design and construction shall be performed in accordance with the Indian Standard Code of Practice for Plain and Reinforced Concrete I S: 456 & IS: 2911 2.0 MATERIALS FOR CONCRETE All materials which may be used in the Plain or Reinforced Cement Concrete work shall be of Standard quality conforming to IS or equivalent and shall have IS certification mark as far as possible unless otherwise approved by the Engineer-in-Charge. The contractor shall get all materials approved by Engineer-in-Charge prior to its procurement and before actual use. The Engineer-in-Charge shall have the right to determine whether all or any of the materials offered or delivered for use in the works are acceptable. Any material brought to site and not conforming to specification and instruction of Engineer-in-Charge shall be rejected and the contractor shall have to remove the same immediately from site at his own expense. 2.1 Cement 2.1.1 General The cement used shall be Portland Puzzolona cement conforming to IS: 1489 latest version and the make of the same shall be approved by HPCL. 2.1.2 Tests after Delivery Each consignment of cement may, after delivery on the site at the discretion of the Engineer-in-Charge, be subjected to any or all of tests and analysis required by the relevant Indian Standard Specifications. Facilities for testing shall be provided by contractor at his own cost.

2.1.3 Storage on the Site The cement shall be stored in a suitable weather-tight building and in such a manner as to permit easy access for proper inspection to prevent deterioration due to moisture and to minimize warehouse deterioration. Cement of different type and brands shall be kept in separate storage. All accepted cement stored on the site shall be arranged in batches, and used in the same order as received from the manufacturer. The contractor shall maintain a cement register, in which all entries shall be completed day to day showing the quantities received, date of receipt, source of dispatch, type of cement, etc. and also the daily cement consumption on site. The register shall be accessible to the Engineer-in- Charge for his verification. 2.1.4 Rejection of Cement The Engineer-in-Charge may reject any cement as a result of any tests thereof, notwithstanding the manufacturer’s certificate. He may also reject cement which has deteriorated owing to inadequate protection from moisture or due to intrusion of foreign matter or other causes. Any cement which is considered defective by the Engineer-in-Charge shall not be promptly removed from the site of the work by the contractor at his own expense. 2.2 Aggregates for Concrete: 2.2.1 General Coarse and fine aggregates for concrete shall conform in all respect to IS: 383, “Specification for Coarse and Fine Aggregates from Natural Sources for Concrete”. Aggregates shall be obtained from a source known to produce those satisfactory for concrete. Aggregates shall consist of naturally occurring sand and granite/basalt trap stone, crushed or uncrushed, or a combination thereof. They shall be chemically inert, hard, strong, dense, durable, clean and free from veins, adherent coatings and shall be of limited porosity. Flaky and elongated pieces shall not be used. The source of aggregates shall be approved by the Engineer-in-Charge and shall not be changed during the course of the job without his approval. Rejected aggregates shall be removed from the work site by the contractor at his own expense. 2.2.2 Deleterious Materials Aggregates shall not contain any harmful materials such as iron pyrites, coal, mica, shale or similar laminated materials, clay, alkali, soft fragments, sea shells, organic impurities etc. in such quantities as to affect the strength or durability of the concrete. In addition to the above, for reinforced concrete, any material which might cause corrosion of the reinforcement and aggregates which are chemically reactive with the alkalis of cement shall not be used. The maximum quantities of deleterious materials in the aggregates, as determined in accordance with IS: 2386 (Part-II) “Methods of Test for Aggregates for Concrete”, shall not exceed the limits given in Table-I of IS: 383. The sum of the percentages of all deleterious materials shall not exceed five. Deleterious materials also include material passing 75 micron IS sieve. 2.2.3 Coarse Aggregates Coarse aggregate is aggregate most of which is retained on 4.75 mm IS sieve. These may be obtained from crushed or uncrushed granite/basalt trap stone as per Cl. 2.3.1 and may be supplied as single sized or graded aggregates given in Table-II of IS:

383. The Engineer-in-Charge may allow all-in-Aggregate to be used provided they satisfy the requirements of clause 4.4 and T able-IV of IS 383. 2.2.4 Fine Aggregates Fine aggregate is aggregate most of which passes 4.75 mm IS Sieve but not more than 10% pass through 150 microns IS Sieve. These shall comply with the requirements of grading zones I, II and III and given in Table-III of IS: 383. Fine aggregate conforming to grading zone IV shall not be normally used in reinforced concrete unless tests have been made by the contractor to ascertain the suitability of the proposed mix proportion and approved by the Engineer-in-Charge. Fine aggregate shall consist of natural sand resulting from natural disintegration of rock and which has been deposited by streams or glacial agencies, or crushed stone sand or crushed gravel sand. 2.2.5 Sampling and Testing In case of doubt the Engineer-in-Charge may require the contractor to carry out tests, at the contractor’s expense in accordance with – IS: 516 – Method of Tests for Strengths of Concrete; and IS: 2386- Method of Tests for Aggregates for Concrete. 2.2.6 Storage of Aggregates The contractor shall at all times maintain at the site of work such quantities of aggregate as are considered by the Engineer-in-Charge to be sufficient to ensure continuity of work. Each type and grade of aggregate shall be stored separately on hard firm ground having sufficient slope to provide adequate drainage to rain water. Any aggregate delivered to site in a wet condition or becoming wet at site due to rain shall be kept in storage for at least 24 hrs. to obtain adequate drainage, before it is used for concreting, or the water content of mix must be suitably adjusted as directed by Engineer-in-Charge. 2.3 Water Water used for concrete shall be clear and free from injurious amounts of Oil, Acid Alkali, Organic matters or other harmful substances in such amount that may impair the strength or durability of structure. Potable water shall generally be considered satisfactory for mixing and curing concrete. The Engineer-in-Charge may require the contractor to prove at latter’s expense, that the concrete mixed with water proposed to be used should not have a compressive strength, lower than 90% of the strength of concrete mixed with distilled water. The Engineer-in-Charge may require the contractor to get the water tested from an approved laboratory at his own expenses and in case the water contains any sugar or an excess of acid, alkali, any injurious salts, etc. the Engineer-in-Charge may refuse to permit its use. 3.0 Admixtures 3.1 Admixtures such as CICO grade I or KIM (KRYTON make) or equivalent may be used in concrete only with the approval of Engineer-in-Charge. 4.0 Reinforcement 4.1 Corrosion resistant Steel reinforcement

4.1.1 The reinforcement shall confirm to IS: 1786, Fe-500 grade. The reinforcement shall be Corrosion resistant steel and it shall be either “TISCON CRS” from TISCO or HSCR-M from Vizag Steel or HCR from SAIL-M normally be mild steel in the form of round bars, conforming to IS: 432-Grade 1 unless specified otherwise. 4.1.2 Hard-Drawn Steel wire Fabric When specified in the drawings, hard drawn steel wire fabric shall be used conforming to IS: 1566, It shall be of approved type and of the weights and dimensions shown in the drawings. 4.2 Welding: 4.2.1 Field welding of reinforcing bars will not be permitted without the written consent of the Engineer-in-Charge. Where welding is permitted it must be at staggered locations. Tests shall be made to provide that the joints are of the full strength of bars connected. Welding of reinforcement shall be done in accordance with the recommendation of IS: 2751. 4.3 Storage: 4.3.1. The steel reinforcement shall be stored in such a way as to avoid distortion and to prevent deterioration and corrosion. 4.4 Other Specifications 4.4.1 General construction details and workmanship relative to reinforcement including bar bonds, lap splices and installation shall be in accordance with I S:2502- Code of Practice for Bonding and Fixing of Bars for concrete reinforcement, as well as the detailing of reinforcement given in I S:456. 4.4.2 Hot bending of bars shall not be allowed. 4.4.3 The number of sizes, shape and position of all the reinforcement shall, unless otherwise directed or authorized by the Engineer-in-Charge, be strictly in accordance with the drawings. The reinforcement shall be adequately secured and held in position by metal chairs and spacers. Ties of inter-sections shall be made with 16 SWG soft black annealed binding wire. 4.4.4 The contractor must obtain the approval of the Engineer-in-Charge for the reinforcement placed, before any concrete is placed in the forms. The reinforcement of this time shall be free from loose rust or scale or other coating that will destroy or reduce bond. 4.7.5 Concrete spacer blocks of the same strength as parent concrete shall be used to ensure correct cover to the reinforcement. This clear cover shall be as shown on the drawings or as per instructions of the Engineer-in-Charge. 4.7.6 All the reinforcing bars shall be so tied as to form a rigid cage to prevent displacement before or during concreting.

STANDARD SPECIFICATION

FOR

CONSTRUCTION AND

INSTALLATION OF

RCC BORED

CAST-IN-SITU PILES

CONTENTS 1. SCOPE 2. CODES 3. MATERIALS 4. DESIGN CONSIDERATIONS 5. EQUIPMENTS AND ACCESSORIES 6. PILE INSTALLATION 7. DEFECTIVE PILES 8. RECORDING OF DATA

1.0 SCOPE 1.1 This standard specification covers the construction and installation of load bearing reinforced concrete bored cast-in-situ piles. 1.2 For specific work requirements concerning construction or otherwise modifying or supplementing the provisions of this specification, reference may be made to ‘Specific Requirements’. In case of any conflict between requirements set forth in ‘Specific Requirement’ and the provisions of this specification, the ‘Specific Requirements’ shall govern. 2 CODES 2.1 IS: 2911 (Part I /Sec.2) – Indian Standard Code of Practice for Design and Construction of pile foundations for Bored Cast-in-Situ Piles shall be referred to in conjunction with these specifications during the entire design, construction and installation work. 2.2 Reference to any code shall always mean reference to the latest revised edition of the code including all its amendments up to date, unless otherwise specified. In the event of any conflict between the requirements of this specification and those of the referred codes, the former shall govern. 3 MATERIALS 3.1 All materials, viz. cement, steel, aggregates, water, etc. which are to be used in the construction work, shall conform to Standard Specification for construction and installation of RCC bored cast-in-situ piles. 3.2 Concrete 3.2.1 Methods of the manufacture of cement concrete shall in general, be in accordance with IS: 2911 (Part I /Sec.2) and as per following clauses: 3.2.2 The grade of concrete shall be M-30 with a minimum cement content of 400 kg/cum and a max water cement ratio of 0.45. The cement content shall be governed by Design mix or soil characteristics, which ever is higher. 3.2.3 Slump of Concrete Slump of concrete shall range between 100 to 180 mm depending on the manner of concreting. The table below gives the general guidance. PILI NG SLUMP (In MM) TYPICAL CONDITIONS OF USE Min. Max. A 100 180 Pouring into water-free unlined bore having

widely spaced reinforcement. Where reinforcement is not spaced widely enough, cut-off level of pile is within the casting and diameter of pile less than or

equal to 600mm, higher order of slump within this range may be used.

B 150 180 Where concrete is to be placed under water

or drilling mud by tremie or by placer 4 DESIGN CONSIDERATIONS 4.1 Structural Design: The piles shall have necessary structural strength to transmit the load imposed on it, to soil. Relevant part of IS: 2911 (Part I/ Sec.2) and specific requirements shall be considered to apply for assessing the structural capacity of piles. 4.2 Reinforcement: 4.2.1 The minimum longitudinal reinforcement shall be 0.4% of the cross sectional area of the pile. 4.2.2 Clear cover to the main reinforcement shall be 50 mm. This shall be increased to 75 mm in case of aggressive soils and ground water conditions. 4.2.3 The vertical reinforcement shall project 50 times its diameter above the cut-off level. 4.2.4 The minimum clear distance between the two adjacent main reinforcement bars should normally be 100 mm for the full depth of cage. The bars shall be so placed as not to impede the placing of concrete. 4.2.5 The lateral ties in the reinforcing cage shall be preferably spaced not closer than 150 mm centre to centre. 4.2.6 The minimum diameter of the lateral ties shall be 6 mm. 5 EQUIPMENT AND ACCESSORIES 5.1 The equipment and accessories for installation of bored case-in-situ piles shall be selected giving due consideration to the subsoil conditions and the method of installation, etc. These shall of standard type and shall have the approval of the Engineer-in-Charge. 5.2 The capacity of the rig shall be adequate so as to reach the desired depth. 5.3 Provision shall be kept for chiselling within the borehole in case of any underground obstruction/hard strata. However, chiselling shall be carried out only with the approval of Engineer-in-Charge. 5.4 In case pile is required to be socketted in medium or good quality rock strata, the equipment mobilized shall have adequate capability to do so up to the required socket length. For the purpose of classification of rock for the determination of length of socketting, pilot drill holes shall be carried out in the areas to be piled.

5.5 Pilot drill hole shall be of Nx or Bx size as per specific requirements. Rock drilling shall be carried out using double tube core barrel. Drilling and storing of rock cores shall conform to relevant IS codes. Rock quality shall be classified as under depending upon the RQD. RQD (%) ROCK QUALITY <25 Poor 25 to 75 Medium >75 Good 6 PILING INSTALLATION 6.1 Control of Alignment 6.1.1 The piles shall be installed as accurately as possible as per the designs and drawings. The permissible positional deviations shall be governed by IS: 2911 (Part I /Sec.2). In case of piles deviating beyond such permissible limits, the piles shall be replaced or supplemented by additional piles, as directed by Engineer-in-Charge. 6.2 Boring 6.2.1 The boring shall be done by one of the following methods: (a) Direct mud circulation (b) Reverse mud circulation (c) Bailer bentonite The actual method of construction to be followed shall be as per specific requirements. 6.2.2 In very soft soil a permanent liner shall be installed to ensure stability of borehole. A liner shall be used to protect the green concrete where a high hydrostatic pressure exists in the subsoil or where an underground flow of water exists and which is likely to damage the concrete on withdrawal of casing. 6.2.3 Use of temporary liner only in lieu of bentonite to stabilize sides of boreholes shall not be permitted. 6.2.4 Properties of bentonite used and quality control shall be as per IS: 2911 (Part I /Sec.2). 6.3 Concreting of Piles 6.3.1 Reinforcement 6.3.1.1 The reinforcements shall be made into cages sufficiently rigid to withstand handling without damage. In case the reinforcement cage is made up more than one segment, the same shall be assembled by providing necessary laps preferably by welding. 6.3.1.2 Stirrups to the main bars shall be tack welded.

6.3.1.3 Care shall be taken to ensure that the reinforcement bars do not come closer while the cage is lowered down the hole. 6.3.1.4 Proper cover and central placement of the reinforcement shall be ensured by use of suitable concrete spacers or rollers, case specifically for the purpose. 6.3.2 Concreting 6.3.2.1 Concreting shall not be commenced until the Engineer-in-Charge satisfies himself that at final borehole depth the soil is not weaker than that taken as the basis for pile design. If necessary, SPT or similar test shall be conducted to ensure the above. 6.3.2.2 Borehole bottom shall be thoroughly cleaned to make it free from sludge or any foreign matter before lowering the reinforcement cage. The full length of reinforcement cage shall be in position before start of concreting. 6.3.2.3 Concreting shall be done by tremie method. The operation of tremie concreting shall be governed by IS: 2911 (Part I / Sec.2). 6.3.2.4 The concrete placing shall not proceed if specific gravity of fluid near about the bottom of borehole exceeds 1.2. Determination of the specific gravity of the drilling mud from the base of the borehole shall be carried out by taking samples of fluid by suitable slurry sampler approved by the Engineer-in-Charge, in first few piles and at a suitable interval of piles thereafter and the results recorded. Control of consistency of drilling mud shall be carried out throughout boring as well as concreting operations. 6.3.2.5 Care shall be exercised to preserve correct cover and alignment of reinforcement and avoid any damage to it throughout the complete operation of placing the concrete. 6.3.2.6 The top of the pile shall be brought up above the cut off level minimum by 0.75 m so as to permit removal of all laitance and weak concrete before capping and to ensure good and sound concrete at the cut off level for proper embedment into the pile cap. Any defective concrete in the head of the completed piles shall be cut-away and made good with new concrete. 7 DEFECTIVE PILES 7.1 Defective piles shall be removed or left in place, as judged convenient by the Engineer-in-Charge, without affecting the performance of adjacent piles of capping above and additional piles shall be provided to replace them. 8 RECORDING OF DATA 8.1 A competent supervisor shall be present to record the necessary information during the installation of piles. The data to be recorded shall include: a) The dimensions of the piles, including the reinforcement detail and the mark of the pile. b) The boring method employed.

c) The type of soil in which pile is terminated. d) The depth bored. e) The depth of water table. f) When drilling mud is used, the specific gravity of the fresh supply and contaminated mud in the borehole before concreting is taken up, in case of first few piles and subsequently at suitable interval of piles. g) The time taken for concreting. h) The cut-off level/working level, and i) The consumption of cement. j) Any other important observations. 8.2 Typical data sheets of recording piling data shall be as given in Appendix-D of IS: 2911 (Part I/ Sec.2). 8.3 Any deviation from the designed location, alignment or load carrying capacity of any pile shall be noted and promptly reported to the Engineer-in-Charge.

STANDARD

SPECIFICATION

FOR

TESTING OF

CONCRETE PILES

CONTENTS

1. GENERAL 2. VERTICAL LOADING TEST 3. LATERAL LOADING TEST 4. PULL OUT CAPACITY OF PILES 5. COMBINED VERTICAL AND LATERAL LOADING TEST 6. SPECIAL TYPE OF LOADING

APPENDIX 1 – PILE LOAD TEST RECORD

1.0 GENERAL 1.1 Scope: 1.1.1 This Specification covers the requirement and methods of testing of a single pile for evaluating its safe capacity in: a) Vertical Loading (Compression) b) Lateral Loading c) Pull Out d) Combined Vertical and Lateral Loading e) Special type of loading such as vibratory loadings 1.1.2 These specifications shall be applicable for all types of piles in general excepting sheet piles. 1.1.3 For specific work requirements or otherwise modifying or supplementing the provision of this specification, refer to specific requirement. In case of conflict between requirements set forth in the specific requirements and the provisions of this specification, the specific requirements shall govern. 1.2 Definitions: 1.2.1 Reference to Indian Standard Codes shall always mean reference to the latest issue of the relevant standards, including all the amendments up to date. 1.3 Codes: 1.3.1 All testing shall be performed in accordance with the following codes and the provision of these specifications IS: 2911-(Part IV) – Code of Practice for design and construction of pile foundations – Load Test on Piles. 1.4 Requirements:

1.4.1 The load test shall be required to provide data regarding the load deformation characteristics of the pile up to failure or otherwise specified and the safe design capacity. 1.4.2 Full details of the equipment proposed to be used and the test set up shall be submitted to the Engineer-in-Charge with detailed sketches for approval. Approval of the Engineer-in-Charge shall also be obtained after the test set up is complete, prior to commencement of loading. 1.4.3 All measuring devices shall be tested for satisfactory performance and accuracy at an approved institution and a certificate to that effect obtained and submitted to the Engineer-in-Charge prior to use.

1.4.4 The test pile shall be constructed using same equipment and technique as for the job piles. 1.4.5 A minimum time period of one week shall be allowed between the time of installation and testing in case of a precast pile and not less than four weeks from the time of casting in case of a cast-in-situ pile. 1.4.6 Records A full record giving all details of the test in the proforma shown in Appendix-I shall be submitted in triplicate to the Engineer-in-Charge immediately on completion of each test. The record shall also include the plot of load time settlement characteristics of piles. 2.0 VERTICAL LOADING TESTS 2.1 Equipment and Test Set -up 2.1.1 Test Pile 2.1.1.1 The test pile shall be decided by the Engineer-in-Charge. It may be one of the working piles or a separate test pile. 2.1.1.2 The head of the test pile shall be brought to the proper level and provided with a pile cap with a level and plane surface and with adequate space for proper seating of a jack and dial gauges. 2.1.1.3 Test pile surface shall be prepared for testing purposes on the expiry of one week after casting the pile. 2.1.2 Loading Systems 2.1.2.1 Loading shall be applied by the reaction method consisting of an hydraulic jack centrally against a loaded platform. Supports of the platforms shall be adequately designed. Special anchor piles or any other suitable type of anchorage systems may be used. However, use of the uplift capacity of neighbouring piles for providing the reaction shall normally not be permitted. 2.1.2.2 The loading system shall be adequate to ensure that the test can be carried up to the specified limit. The reaction to be made available for the test shall be at least 25% greater than the maximum jacking force required. 2.1.3 Measuring System 2.1.3.1 Loading on Piles The load applied on the pile shall be recorded on a calibrated pressure gauge mounted on the jack. 2.1.3.2 Settlement of Pile

a) Settlement of the pile shall be recorded by dial gauges suspended from datum bars. Four dial gauges of 0.01 mm sensitivity shall be positioned on four corners around the pile. b) The datum bars shall have rigid supports preferably of concrete pillars or steel sections, embedded well into the ground. The supports shall be located more than three times the pile diameter, subject to a minimum of 1.5 m, clear away from the pile face and also sufficiently away from the supports of the loaded platform to avoid any disturbance on these accounts. Movements near the supports of the datum bar shall be avoided while the test is in progress. 2.2 Method of Conducting Test The test shall be carried out by the direct method of loading in successive increments or by the cyclic loading method as specified and as described by the Engineer-in-Charge. 2.2.1 Direct Method of Loading in Successive Increments The test shall be carried out as per the procedure outlined : a) The load shall be applied to the pile top in increments of about of fifth of the rated capacity of the pile or as specified. Settlement readings shall be taken before and after the application of each new load increment and at 2, 4, 8, 15, 30, 60 minutes and at every two hours until application of the next load increment. b) Each stage of loading shall be maintained till the rate of movement of the pile top is not more than 0.2 mm per hour or until two hours have elapsed, whichever is later. c) Further loading shall then be continued as in (a) above till one of the following occurs:

i) Yield of soil-pile system occur causing progressive settlement of the pile exceeding a value of one tenth of the pile diameter. ii) The loading on the pile top equals twice the rated capacity or as specified in the case of a separate test pile and 1.5 times the rated capacity of the pile in case of a working pile.

d) Where yielding of the soil does not occur, the full test load shall be maintained on the pile head for 24 hours or more if necessary and settlement readings shall be taken at 6 hours interval during the period. e) Unloading shall be carried out in the same steps as loading. A minimum of half hour shall be allowed to elapse between two successive stages of load decrement. The final rebound shall be recorded 6 hours after the entire test load has been removed. f) If so directed by the Engineer-in-Charge, loading and unloading cycles shall be carried out for all load stages within the assumed working load.

g) Assessment of Safe Load The safe capacity of the pile shall be the least of the following values

i) Load corresponding to settlement specified in specific requirements which is based on the nature and type of structure. ii) 50 percent of the final load at which the total displacement equals 10 percent of the pile diameter in case of uniform diameter piles and 7.5 percent of bulb diameter in case of under-reamed piles.

2.2.2 Cyclic Loading Test The test shall be carried out as per procedure outlined by IS: 2911-(Part-IV) and as described below: a) The load shall be applied to the pile top in increments of about one fifth the estimated safe capacity of the pile or as specified. Settlement readings shall be taken before and after the application of each new load increment at 2, 4, 8, 15, 30, 60 minutes and at every two hours until application of the next load increment. b) Alternate loading and unloading shall be carried out at each stage and the total and net settlements recorded as specified. If so directed by the Engineer-in-Charge, more than one cycle of loading and unloading shall be carried out at any or all of the stages. c) Each stage of loading or unloading shall be maintained till the rate of movement of the pile top is not more than 0.2 mm per hour provided that the minimum period if two hours for loading and one hour for unloading. T he following load stages shall however be maintained for longer periods as given below:

i) At load of 1.5 time assumed safe capacity (for routine test only) – 24 hours. ii) At load of twice assumed safe capacity (for initial test only) – 24 hrs.

The loading shall be continued till one of the following occurs:

i) Yield of the soil pile system occur causing progressive settlement exceeding one tenth of the pile diameter. ii) The loading on the pile top equals twice the estimated safe load in case of a separate test pile and 1.5 times the rated capacity of the pile in case of a working pile.

d) Assessment of Safe Load The safe capacity of the pile shall be the least of the following:

i) Load corresponding to settlement specified in specific requirements which is based on the nature and type of structure. ii) Half of the final load at which the total settlement equals one tenth of the pile diameter.

3.0 LATERAL LOADING TEST 3.1 Equipment and Test Set -up 3.1.1 Test Pile

The test pile shall be decided by the Engineer-in-Charge. It may be one of the working piles or a separate test pile. The test pile shall be cut off at the proper level and provided with a cap with vertical plane sides having an adequate area for proper seating of the jack and dial gauges. 3.1.2 Loading System, 3.1.2.1 Loading shall be applied by an hydraulic jack of adequate capacity, abutting the pile horizontally and reacting against the suitable system. The reaction may be provided by the wall of the excavated pit when the test is being conducted below ground level or by a neighbouring pile in which case thrust pieces shall be inserted on either end of the jack to make up the gap. 3.1.3 Measuring System 3.1.3.1 Lateral load applied on the pile shall be measured by a calibrated pressure gauge mounted on the jack, having a least count of 500 kg. 3.1.3.2 Deflection of the pile head shall be measured by dial gauges, fixed to datum bars and having a least count of 0.01 mm. The datum bars shall be provided with rigid supports as described in Clause 2.1.3.2 (b) above. 3.2 Method of Conducting Tests The test shall be carried out in accordance with the provisions of I S: 2911-(Part-IV) and as detailed below: 3.2.1 Loading shall be applied in increments of 500 kgs or as specified. 3.2.2 Each stage shall be maintained for a period till the rate of movement of the pile head is not more 0.2 mm/hr or 1 hr whichever is greater. 3.2.3 Loading shall be continued till one of the following occurs: a) Deflection of the pile head exceeds 12 mm. b) The applied load on the pile is twice the assumed lateral load capacity of the pile in case of a separate test pile and 1.5 times the rated capacity in the case of a working pile. 3.2.4 Assessment of Safe Load The safe load shall be the smaller of the following:

i) Half of the final load for which the total deflection is 12 mm. ii) Load corresponding to 5 mm total deflection.

Note: The deflection is at the cut off level of the pile. 4.0 PULLOUT CAPACITY OF PILES 4.1 Equipment and Test Set up 4.1.1 Test Pile

4.1.1.1 The test pile shall be decided by the Engineer-in-Charge. The test shall be conducted on separate pile installed specifically for this purpose. 4.1.1.2 The test pile shall be built up to the proper length and the head provided with suitable arrangements for anchoring the load applying system. 4.1.2 Loading System 4.1.2.1 Load shall be applied using an approved reaction system. Uplift force on the pile may be applied directly to the test pile or through a level system. T he reaction may be provided by neighboring piles or blocks may be constructed for the purpose. A hydraulic jack shall be used for load application. 4.1.3 Measuring System 4.1.3.1 Load applied by jack shall be measured by a calibrated pressure gauge with a least count of 1000 kgs. 4.1.3.2 Movement of the pile shall be measured by dial gauges, fixed to datum bar and having a least count of 0.01 mm. A minimum of two dial gauges, placed diametrically opposite shall be used. Datum bars shall be provided with rigid supports as described in 2.1.3.2 (b) above. 4.2 Method of Conducting Test The test shall be conducted as outlined below: 4.2.1 Loading shall be applied to the pile top in increments of one fifth the rated capacity of pile. 4.2.2 Each stage shall be maintained for a period till the rate of movement of the pile head is not more than 0.2 mm/hr or one hour, whichever is greater. 4.2.3 Loading shall be continued till one of the following occurs:

a) Yield of soil pile system occurs causing progressive movement of he pile exceeding 12 mm. b) The loading on the pile top equals twice the estimated safe load or as specified.

4.3 Assessment of Safe Load The safe capacity of the pile shall be the least of the following: a) Two-thirds of load at which the total displacement is 12 mm or the load corresponding to a specified permissible uplift, and b) Half of the load at which the load displacement curve shows a clear break (downward trend).

5.0 COMBINED VERTICAL AND LATERAL LOADING 5.1 Equipment and Test set -up 5.1.1 The equipment and test set up shall be same as described in Clause 3. In addition, a platform shall be constructed on the pile top, and loaded to 1.0 times the pile capacity in vertical loading. The pile shall be first subjected to the full vertical load. The lateral load shall commence after all settlements due to the vertical load have ceased and while the full vertical load is in position. 5.1.2 The loading system, measuring system and recording of the results shall be the same as described in clause-3. 5.2 Method of Conducting Test and Assessment of Safe Load This shall be in accordance with the provision of clause 3.2 above. 6.0 SPECIAL TYPE OF LOADING This shall include evaluating the pile response to vibratory loads, both horizontal and vertical in nature. The test set up and method of conducting the test shall be covered under specific requirements.

APPENDIX – 1

PILE LOAD TEST RECORD

Vertical / Lateral / Pull Out Test

Pile No…………………… Date of ……………… WT of Hammer …………………….. Type……………………… Driving……………….. AVR. Drop of Hammer……………. Diameter (cm)……………. Casting……………….. Total No. of Blows………………….. Length below Commence of Test Sum of Temporary Compression in cms G.L. (M)………………… ………………………… ………………………………………. Location………………… Completion of Test…… Ground level ………………………… Date Time Total

time (hr)

Load on (T)

Load off (T)

Total Load (T)

Settlement (Deflection) Gauge (mm)

AVR. Settlement (Deflection) (mm)

Rebound (mm)

Remarks

I II Total Net

APPROVED MAKES LIST OF RECOMMENDED MAKES/ MANUFACTURERS/ 1.00.00 GENERAL 1.01.00 The makes and manufacturers shall be preferably from the following list. In case the same is not available in the market or incase of a change in trade name, equivalent makes/ re-designated manufacturer shall be used with the approval of Consultant. For Items which have been missed in the current list, vendor shall seek details from owner during execution. 1.02.00 In case of items not covered in the list, the material shall be best available in the market and each item should have BIS certification mark.

Sl.No

Description

Manufacturers

1

CEMENT – OPC/PPC

ACC,

GUJARAT AMBUJA

RAJASHREE,

ZUARI,

ULTRA TECH CEMENT

LAFARGE

2

REINFORCEMENT STEEL

HCR TMT STEEL SAIL,TATA STEEL, RINL

��

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1.0 GENERAL 1.1 Special Conditions of Contract (SCC) shall be read in conjunction with the

General Conditions of Contract (GCC) also referred to as General Terms & Conditions of Works Contract, Schedule of Quantities, specifications of work, drawings and any other document forming part of this Contract wherever the context so requires.

1.2 Notwithstanding the sub-division of the document into these separate

sections and volumes, every part of each shall be deemed to be supplementary of every other part and shall be read with and into the Contract so far as it may be practicable to do so.

1.3 Where any portion of the GCC is repugnant to or at variance with any

provisions of the Special Conditions of Contract, then unless a different intention appears, the provision(s) of the Special Conditions of Contract shall be deemed to override the provision(s) of GCC only to the extent that such repugnancy or variations in the Special Conditions of Contract are not possible of being reconciled with the provisions of GCC.

1.4 Wherever it is stated in this Bidding Document that such and such a

supply is to be affected or such and such a work is to be carried out, it shall be understood that the same shall be affected and /or carried out by the Contractor at his own cost, unless a different intention is specifically and expressly stated herein or otherwise explicit from the context. Contract Price shall be deemed to have included such cost.

1.5 The materials, design & workmanship shall satisfy the applicable relevant

Indian Standards, the job specifications contained herein & codes referred to. Where the job specifications stipulate requirements in addition to those contained in the standard codes and specifications, these additional requirements shall also be satisfied. In the absence of any Standard / Specifications / Codes of practice for detailed specifications covering any part of the work covered in this bidding document, the instructions / directions of Engineer-in-Charge will be binding upon the Contractor.

1.6 In case of contradiction between relevant Indian standards, GCC, Special

Conditions of Contract, Specifications, Drawings and Schedule of Rates, the following shall prevail in order of precedence.

i) Detailed Purchase Order along with Statement of Agreed Variations, if

any, and its enclosures . ii) Fax of Intent (FOI)/Letter of Intent(LOI)

iii) Schedule of Quantities AND Technical specifications iv) Special Conditions of Contract v) Drawings/data sheets/job procedures vi) Instructions to Bidders vii) General Conditions of Contract viii) Relevant Indian Standards.

1.7 SAFETY, FIRE FIGHTING AND SPECIFIC REQUIREMENTS OF

HPCL 1.7.1 Contractor shall provide adequate number of standard lengths of IS Stamped

Fire hoses, IS Stamped DCP Fire extinguishers, fire buckets with sand and nozzles. These items can be taken back by the Contractor after completion of work. Sand shall also be maintained dry by the Contractor with fresh supply, whenever required. Work permit may not be issued by HPCL in the absence of above items.

1.7.2 Safety Helmets shall be provided to all the employees of Contractor including

that of his labour contractors. 1.7.3 Safety Belts and Harnesses shall be provided by the Contractor in adequate

number for the workers working at heights. 1.7.4 Proper earthing shall be provided for all equipments and generators. 2.0 THE WORK 2.1 Scope of Work & Scope of Supply

2.1.1 The scope of work and Scope of Supply covered in this

Contract will be as described in Scope of work provided in the Instructions to bidders, Schedule of Quantities, Technical Specifications, Drawings, etc.

2.2 Time Schedule The Completion period for this job shall be 4 (FOUR) Months from the date of

LOI. 2.2.1 Time is the essence of this Contract. The period of completion given

includes the time required for mobilization as well as testing, rectifications, if any, retesting, demobilization and completion in all respects to the satisfaction of the Engineer-in-Charge.

2.2.2 A joint program of execution of work will be prepared by the Engineer-in-Charge and Contractor. This program will take into account the time of completion period of the Contract.

2.2.3 Monthly execution program will be drawn up by the Engineer-in-Charge

jointly with the Contractor based on availability of materials, work fronts and the joint program of execution as referred to above. The Contractor shall scrupulously adhere to the Targets / Program by deploying adequate personnel, Construction Equipment, Tools and Tackles and also by Timely Supply of required materials coming within his scope of supply as per Contract. In all matters concerning the extent of target set out in the monthly program and the degree of achievement, the decision of the Engineer-in-Charge will be final and binding upon the Contractor.

2.2.4 Contractor shall give every day category-wise labour and equipment

deployment report along with the progress of work done on previous day in the proforma prescribed by the Engineer-in-Charge.

2.3 Measurement of Works 2.3.1 Mode of measurement will be as specified in Specifications or SOR. 2.4 Payment Terms 2.4.1 Payment will be released within 15 days of submission of duly certified

Running Account Bills at Disbursement section at Mumbai after deduction of WCST(Works Contract Sales Tax) or VAT whichever is applicable, IT(Income Tax) and any other statutory deduction as applicable from time to time, Any MRR(Materials Received Report- An internal document forwarded by HPCL Site –in-Charge/ Engineer to Disbursement Section along with Contractor’s Bill and duly certified measurement sheets for release of payment) Deductions, LD, etc. In case of Final Bill, Payment will be released within 45 days of submission of duly certified Final Bill along with all requisite documents, drawings, etc. Payment break up for various items covered in SOR/PRICED BID is as indicated as Appendix 1 to SCC. No further alteration is permitted in approved payment break up.

2.5 Temporary Works 2.5.1 All temporary works, enabling works, including dewatering of surface

and subsoil water, preparation and maintenance of temporary drains at the work site, preparation and maintenance of approaches to working areas, adequate lighting, wherever required, for execution of the work, shall be the responsibility of the Contractor and all costs towards the same shall be deemed to have been included in the quoted prices.

2.6 Quality Assurance 2.6.1 Detailed quality assurance programme to be followed for the execution

of Contract under various divisions of works will be mutually discussed and agreed to.

2.6.2 The Contractor shall establish, document and maintain an effective quality

assurance system as outlined in the specifications and various codes and standards.

2.6.4 The Owner/Consultant or their representative shall reserve the right to

inspect/witness, review any or all stages of work at shop/site as deemed necessary for quality assurance and / or timely completion of the work.

2.6.4 In case Contractor fails to follow the instructions of Engineer-in-Charge with respect to above clauses, next payment due to him shall not be released unless and until he complies with the instructions to the full satisfaction of Engineer-in-Charge

2.7 Leads 2.7.1 For the various works, in case of contradiction, leads mentioned in the

Schedule of Quantities shall prevail over those indicated in the Technical specifications.

3.0 ROYALTY, INCOME TAX, SERVICE TAX AND PRICES 3.1 Royalty 3.1.1 All royalties etc., as may be required for any Borrow Areas, including

right of way etc., to be arranged by Contractor shall be deemed to have been included in the quoted prices.

3.1.2 Contractor’s quoted rates should include the royalty on different

applicable items as per the prevailing State Government rates. In case, Owner is able to obtain the exemption of royalty from the State Government the Contractor shall pass on the same to Owner for all the items involving royalty. Any increase in prevailing rate of royalty shall be borne by the Contractor at no extra cost to the Owner.

3.2 Income Tax 3.2.1 Income Tax at the prevailing rate as applicable from time to time shall be deducted

from Contractor’s Bills as per Income Tax Act and quoted rates shall be inclusive of this. Owner will issue the TDS (Tax Deduction at Source) Certificate.

3.3 Firm Prices 3.3.1 The contract price shall remain firm and fixed till the completion of work

in all respects and no escalation in prices on any account shall be admissible to the Contractor except for statutory variations as per General Terms and Conditions (GTC).

4 PROVIDENT FUND,LABOUR, LABOUR LAWS AND SITE

REQUIREMENTS 4.1 Provident Fund 4.1.1 The Contractor shall strictly comply with the provisions of Employees

Provident Fund Act and register himself with Regional Provident Fund Commissioner (RPFC) before commencing work. The Contractor shall deposit Employees and Employers contributions to the RPFC every month. The Contractor shall furnish along with each Running bill, the challan / receipt for the payment made to the RPFC for the preceding month. The Contractor shall furnish the code number allotted by the RPFC Authority to the Engineer-in-Charge before commencing the work.

4.1.2 In case the RPFC challan / receipt, as above, is not furnished, Owner

shall deduct 16% (sixteen percent) of the payable amount from Contractor’s running bill and retain the same as a deposit. Such retained amounts shall be refunded to Contractor on production of RPFC Challan / receipt for the period covered by the related running bill.

4.2 Labour License 4.2.1 Before starting of work, Contractor shall obtain a license from concerned

authorities under the Contract Labour (Abolition and Regulation) Act 1970, and furnish copy of the same to Owner.

4.3 Labour Relations 4.3.1 In case of labour unrest/labour dispute arising out of non-implementation

of any law, the responsibility shall solely lie with the Contractor and they shall remove/resolve the same satisfactorily at his cost and risk.

4.3.2 The Contractor shall at all times take all reasonable precautions to

prevent any unlawful, riotous or disorderly conduct by or amongst his staff and labour and to preserve peace and protection of persons and property in the neighbourhoods of the Works against such conduct.

4.4 Employment of Local Labour 4.4.1 The Contractor shall ensure that local labour skilled and / or unskilled, to

the extent available shall be employed in this work. In case of non – availability of suitable labour in any category out of the above persons, labour from outside may be employed.

4.4.2 The Contractor shall not recruit personnel of any category from among

those who are already employed by other agencies working at site but shall make maximum use of local labour available.

4.5 Site Cleaning 4.5.1 The Contractor shall clean and keep clean the work site from time to

time to the satisfaction of the Engineer-in-Charge for easy access to work site and to ensure safe passage, movement and working.

4.5.2 The Contractor shall dispose off the unserviceable materials, debris etc.,

to the earmarked area within the premises or any other location outside the premises as decided by the Engineer-in-Charge. No extra payment shall be paid on this account.

4.5.3 Review/Approval of Drawings, Design and other documents submitted by

Contractor 4.5.3.1 HPCL/consultant will normally require and utilize a maximum time frame of

seven (07) working days from the date of Receipt for Review/Approval of Drawings, Design and other documents submitted by Contractor. Upon Review of the submitted documents, HPCL may give their comments and ask for redesign/ resubmission after necessary rectifications/ modifications and the time frame of 7 working days will be applicable for same.

4.6 Protection of Existing Facilities 4.6.1 Contractor shall obtain all clearance (work permit) from the Owner, as may

be required from time to time, prior to start of work. Work without permit shall not be carried out within the existing premises.

4.6.2 Contractor shall obtain plans and full details of all existing and planned

facilities/services/utilities from the Owner and shall follow these plans closely at all times during the performance of work. Contractor shall be responsible for location and protection of all facilities/utilities and structures at his own cost.

4.6.3 Despite all precautions, should any damage to any structure / utility etc. occur,

the Contractor shall contact the Owner / authority concerned and

Contractor shall forthwith carry out repair at his expenses under the direction and to the satisfaction of Engineer-in-Charge and the Owner/concerned authority.

4.6.4 Contractor shall take all precautions to ensure that no damage is caused

to the existing facilities etc., during construction. Existing structures/facilities/utilities damaged / disturbed during construction shall be repaired and restored to their original condition by Contractor after completion of construction to the complete satisfaction of Owner.

4.7 Work Front 4.7.1 The work involved under this Contract may include such works as have

to be taken up and completed after other agencies have completed their jobs. The Contractor will be required and bound to take up as and when the fronts are available for the same and no claim of any sort whatsoever shall be admissible to the Contractor on this account. Only extension of time limit shall be admissible, if the availabilities of work fronts to the Contractor are delayed due to any reason not attributable to the Contractor and the same is clearly recorded.

4.8 Site Facilities 4.8.1 The Contractor shall arrange for the following facilities at site, for

workmen deployed/engaged by him / his sub-contractor, at his own cost:

i) Arrangement for First Aid. ii) Arrangement for clean & potable drinking water. iii) A crèche where 10 or more women workers are having children below

the age of 6 years. iv) Any other facility/utility as may be required under the Contract as per

the existing legislation/regulations. 4.9 Contractor’s Site Office and Stores 4.9.1 Owner shall provide land only for contractor’s site office and stores and

fabrication yard, if any at site. However, same shall be dismantled prior to submission of Final Bill.

4.9.2 The Contractor shall remove all temporary buildings / facilities etc., before

leaving the site after completion of works in all respect.

4.10 Construction Power and Water

4.10.1 Owner shall not provide power and the Contractor shall be exclusively responsible to make his own arrangements for supply of power, without any extra cost to the Owner.

4.10.2 Water required for the works shall be arranged by the Contractor. The

contractor has to make all necessary arrangement for drawing water including making temporary storage, pumping etc.

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The permissible wastage (wastage defined as bars having less than 3 mt. Length) shall be of 3% of theoretical consumption. Recovery for less consumption as per theoretical consumption will be recovered at Rs.50,000/- per MT. All scrap (scrap defined as pieces of steel bars measuring less than 3 mt. in length) shall be the property of the contractor. The wastage quantity shall not be considered to be included within the theoretical quantity and no extra shall be payable on account of wastage.

4.11 Construction 4.11.1 Rules and Regulations 4.11.2 Contractor shall observe in addition to Codes specified in respective

specification, all national and local laws, ordinances, rules and regulations and requirements pertaining to the work and shall be responsible for extra costs arising from violations of the same.

5.0 Procedures 5.1 Various procedures and method statements to be adopted by Contractor

during the construction as required as per the respective specifications shall be submitted to Engineer-in-Charge in due time for approval.

5.2 Security 5.2.1 As the premises will be protected area, entry into the area shall be

restricted and may be governed by issue of photo gate passes. The Contractor shall arrange to obtain through the Engineer-in-Charge, well in advance, all necessary entry permits/gate passes for his staffs and labourers and entry and exit of his men and materials shall be subject to vigorous checking by the security staff. The Contractor shall not be eligible for any claim or extension of time whatsoever on this account.

5.2.2 It shall be the responsibility of the contractor to safeguard all his

materials/owned from theft, damage etc. For this purpose the contractor shall be allowed to keep his own security inside HPCL premises

5.3 Drawings and Documents 5.3.1 Drawings accompanying the Bidding Document are indicative of scope of

work and issued for bidding purpose only. Purpose of these drawings is to enable the bidder to make an offer in line with the requirements of the owner.

5.3.2 The contractor as per ‘scope of work’ shall carry out preparation of

detailed and working drawings. Detailed construction layout drawings as needed shall be prepared by contractor and got reviewed/approved by Engineer-in-Charge/Architect before taking up the work.

5.4 Rounding off 5.4.1 All payments to and recoveries from the Contractor shall be rounded off to

the nearest rupee. Wherever the amount to be paid / recovered consists of a fraction of a rupee (paise), the amount shall be rounded off to the next higher rupee if the fraction consists of 50 (fifty) paise or more and if the faction of a rupee is less than 50 (fifty) paise, the same shall be ignored.

5.5 Contractor’s Billing System 5.5.1 HPCL will provide an approved format for Measurement sheets, Bill Summary

and Bill Abstract. Contractor has to ensure that these data are updated for each subsequent RA and Final Bill.

5.5.1 HPCL will utilize these data for processing and verification of the

Contractor’s bill. 5.6 Site Organization 5.6.1 The Contractor shall without prejudice to his overall responsibility to

execute and complete the works as per specifications and time schedule progressively deploy adequate qualified and experienced personnel together with skilled / unskilled manpower and augment the same as decided by Engineer-in-Charge depending on the exigencies of work to suit the construction schedule without any additional cost to Owner.

5.6.2 The Contractor shall provide all necessary superintendence during the

execution of the Works and as long thereafter as the Engineer-in-Charge may consider necessary for the proper fulfilling of the Contractor’s obligations under the Contract Such superintendence shall be given by sufficient persons having adequate knowledge of the operations to be carried out (including the methods and techniques required, the hazards likely to be encountered and methods of preventing accidents) for the satisfactory and safe execution of the Work. The workmen deployed by the Contractor should also possess the necessary license etc., if required under the existing laws, rules and regulations.

5.7 Additional / Extra Works

Owner reserves the right to execute any additional works / extra works, during the execution of work, either by themselves or by appointing any other agency, even though such works are incidental to and necessary for the completion of works awarded to the Contractor.

5.8 Responsibility of Contractor

5.8.1 It shall be the responsibility of the contractor to obtain the approval for

any revision and/or modifications decided by the contractor from the Owner / Engineer-in-Charge before implementation. Also such revisions and / or modifications if accepted / approved by the Owner / Engineer-in-Charge shall be carried out at no extra cost to the owner. Any change required during functional requirements or for efficient running of system, keeping the basic parameters unchanged and which has not been indicated by the contractor in the data / drawings furnished along with the offer shall be carried out by the contractor at no extra cost to the owner.

5.8.2 All expenses towards mobilization at site and demobilization including

bringing in equipment, work force, materials, dismantling the equipment,

clearing the site etc. shall be deemed to be included in the prices quoted and no separate payments on account of such expenses shall be entertained.

5.8.3 It shall be entirely the contractor’s responsibility to provide, operate and

maintain all necessary construction equipment, steel scaffoldings and safety gadgets, cranes and other lifting tackles, tools and appliances to perform the work in a workman like and efficient manner and complete all the jobs as per time schedule.

5.8.4 Preparing approaches and working area for the movement of his men and

machinery. 5.8.5 The procurement and supply in sequences and at the appropriate time of

all materials, and consumables shall be entirely the contractor’s responsibility and his rates for execution of work will be inclusive of supply of all these items.

5.9 Coordination with other agencies 5.9.1 Contractor shall be responsible for proper coordination with other

agencies operating at the site of work so that work may be carried out concurrently, without any hindrance to others. The Engineer – in – Charge shall resolve disputes, if any, in this regard, and his decision shall be final and binding on the Contractor.

5.10 Underground and overhead structures 5.10.1 The Contractor will familiarize himself with and obtain information and

details from the Owner in respect of all existing structures, and utilities existing at the job site before commencing work. The Contractor shall execute the work in such a manner that the said structures, utilities, etc. are not disturbed or damaged, and shall indemnify and keep indemnified the Owner from and against any destruction thereof or damages thereto.

5.11 Documents required with final bill 5.11.1 Statement of final bills – issue of No Claim/ No Due Certificate 5.11.2 The Contractor shall furnish a No-Claim/No-Due declaration indicating that

there are no balance dues to his sub-vendor/sub-contractors/labour contractors along with the Final Bill.

5.12 Working hours

5.12.1 Depending upon the requirement, time schedule / drawing/ programme and the target set to complete the job in time, the works may also have to continue beyond normal working hours/night hours / holidays or during such periods with out causing any inconvenience to the neighbours/others with due permission from EIC, for which no extra claim shall be entertained. However for all such working contractor’s responsible representative shall be available at site to receive the work permit to be issued by HPCL. With out responsible representative of the contractor, no work shall be allowed inside the premises.

6.0 TESTS, INSPECTION AND COMPLETION 6.1 Tests and Inspection 6.1.1 The Contractor shall carry out the various tests as enumerated in the

technical specifications of this Bidding Document and technical documents that will be furnished to him during the performance of the work at no extra cost to the Owner.

6.1.2 All the tests either on the field or at outside laboratories concerning the

execution of the work and supply of materials by the Contractor shall be carried out by Contractor at his cost.

6.1.3 The work is subject to inspection at all times by the Engineer-in-Charge.

The Contractor shall carry out all instructions given during inspection and shall ensure that the work is being carried out according to the technical specifications of this bidding document, the technical documents that will be furnished to him during performance of work and the relevant codes of practice.

6.1.4 Compressed air for carrying out works ,if required shall be arranged by

the Contractor at his own cost. 6.1.5 For material supplied by Owner, Contractor shall carry out the tests, if

required by the Engineer-in-Charge, and the cost of such tests shall be reimbursed by the Owner at actual to the Contractor on production of documentary evidence.

6.1.6 All results of inspection and tests will be recorded in the inspection

reports, proforma of which will be approved by the Engineer-in-Charge. These reports shall form part of the completion documents. Any work not conforming to execution drawings, specifications or codes shall be rejected and the Contractor shall carry out the rectifications at his own cost.

6.2 Final Inspection

After completion of all tests as per specification the whole work w ill be

subject to a final inspection to ensure that job has been completed as per requirement. If any defect is noticed, the Contractor will be notified by the Engineer-in-Charge and he shall make good the defects with utmost speed. If however, the Contractor fails to attend to these defects within a reasonable time (time period shall be fixed by the Engineer-in-Charge) then Engineer-in-Charge may have defects rectified at Contractor’s cost.

6.3 Inspection of Supply Items 6.3.1 All inspection and tests on bought out items shall be made as required by

specifications forming part of this contract. Various stages of inspection and testing shall be identified after receipt of Quality Assurance Programme from the contractor / manufacturer.

6.3.2 Inspection calls shall be given for association of Owner , as per mutually

agreed programme in prescribed proforma , giving details of equipment and attaching relevant test certificates and internal inspection report of the contractor. All drawings, general arrangement and other contract drawings, specifications, catalogues etc. pertaining to equipment offered for inspection shall be got approved by Owner and copies shall be made available to Owner before hand for undertaking inspection.

6.3.3 The contractor shall ensure full and free access to the inspection engineer of

Owner at the contractor’s or their sub-contractor’s premises at any time during contract period to facilitate him to carry out inspection and testing assignments.

6.3.4 The contractor / sub – contractor shall provide all instruments, tools,

necessary testing and other inspection facilities to inspection engineer of Owner free of cost for carrying out inspection.

6.3.5 Where facilities for testing do not exist in the contractor’s / sub-contractor’s

laboratories, samples and test pieces shall be drawn by the contractor / sub-contractor in presence of Inspection Engineer of Owner and duly sealed by the later and sent for tests in Government approved test house or any other testing laboratories approved by the Inspection Engineer at the contractor’s cost.

6.3.6 The contractor shall comply with the instructions of the Inspection

Engineer fully and with promptitude.

6.3.7 The contractor shall ensure that the equipment / assemblies / component of the plant and equipment required to be inspected are not assembled or dispatched before inspection.

6.3.8 The contractor shall not offer equipment for inspection in painted

conditions unless otherwise agreed in writing with the Owner . 6.3.9 The contractor shall ensure that the parts once rejected by the inspection

engineer are not used in the manufacture of the plant and equipment. Where parts rejected by the inspection engineer have been rectified or altered, such parts shall be segregated for separate inspection and approval, before being used in the work.

6.3.10 On satisfactory completion of final inspection and testing, all accepted

part of the work and equipment shall be stamped suitably and inspection certificate shall be stamped suitably and inspection certificate shall be issued in requisite copies for all accepted items. For stage inspection and for rejected items, only inspection memo shall be issued indicating therein the details of observations and remarks.

6.3.11 All inspections and tests shall be made as required by the specifications

forming part of this contract. Contractor shall advise HPCL in writing at least fifteen days in advance of the date of final inspection / tests. Manufacturers inspection or testing certificate for equipment and materials supplied may be considered for acceptance, at the discretion of Engineer-in-Charge. All costs towards testing etc. shall be borne by the contractor within their quoted rates.

6.4 Documentation 6.4.1 Completion Documents

The following documents shall also be submitted by the Contractor in triplicate as part of completion documents :

a) Test certificate for materials supplied by the Contractor. b) Certified records of field tests on materials / equipment, as applicable. c) Material appropriation statement as required. d) Six sets of drawings showing therein the as built conditions of the

work duly approved by the Engineer-in-Charge along with one set of reproducible on polyester film (drawings prepared by Contractor) along with soft form of the same.

e) Other documents as mentioned in Technical Specification.

6.4.2 “AS BUILT” Drawings

Upon completion of work, the Contractor shall complete all drawings to “As built” status (including all vendor / Sub – vendor’s drawings for bought out items) and provide the Owner, the following :

a. One complete set of all original tracings / reproducible along with the soft form of the same.

b. Six complete sets of prints. 7.0 OTHERS 7.1 Dispute Settlement between Govt. Dept. / PSU & PSE 7.1.1 In the event of any disputes or differences between the Contractor and

the Owner, if the Contractor is a Government department, a Government company or an undertaking in the public sector, then such disputes or differences shall be resolved amicably by mutual consultation or through the good offices or empowered agencies of the Government. If such resolution is not possible, then the unresolved disputes or differences shall be referred to arbitration of an arbitrator to be nominated by the Secretary. Department of legal affairs (Law Secretary) in terms of the Office Memorandum No. 55 / 1 / 75 – CF dated 19th December 1975 issued by the Cabinet Secretariat (Dept. of Cabinet Affairs) as modified from time to time. The Arbitration Conciliation Act 1996 shall not be applicable to the arbitrator under this clause. The award of the arbitrator shall be binding upon parties to the dispute, provided, however any party aggrieved by such award may make a further reference for setting aside or revision of the award to Law Secretary whose decision shall bind the parties finally and conclusively.

7.2 Project Scheduling and Monitoring 7.2.1 The following schedules / documents / reports shall be prepared and

submitted by the CONTRACTOR for review / approval at various stages of the contract.

7.2.3 After placement of Purchase Order Upon placement of Purchase Order, Contractor has to furnish a detailed bar chart within 15 days of issue of FOI/LOI.

7.2.4 Project Review Meetings 7.2.4.1 The CONTRACTOR shall present the programme and status at various

review meetings as required.

Monthly Review Meeting Level of Participation: Senior Officers of Owner & Contractor.

Agenda a)Progress Status/ statistics. . b) Completion Outlook c) Major hold ups / slippages. d) Assistance required. e) Critical issues. f) Client query / approval. Venue : Site 7.2.5 Progress Reports

I) Monthly Progress Report This report shall be submitted in three copies on a monthly basis within Ten calendar days from cut-off date as agreed upon, covering overall scenario of the work. The report shall include but not be limited to the following :

a) Brief introduction of the work. b) Activities executed / achievements during the month. c) Scheduled vs actual percentage progress and progress curves for

sub-ordering, manufacturing / delivery, sub-contracting, construction activities and overall quantum wise status of purchase orders against scheduled.

d) Areas of concern / problems / hold ups, impact and action plans. e) Resource deployment status. f) Annexure giving status summary for Material Requisitions and

deliveries, sub-contracting and construction

Distribution: OWNER Two copies & One at Site. II) Daily Report:

Daily report in duplicate as out lined in 2.2.4 of SCC and any other additional information/data/guideline/job procedure sought by Engineer-in-Charge shall be submitted without fail to HPCL at site by contractor.

7.3 General Environment Requirement

The contractor has to ensure efficient use of natural resources like water, fuel oil and lubricants. The contractor should ensure proper awareness to workers to maintain a green and clean environment inside / outside the building premises. The contractor must collect and dispose of all the waste and scrap materials at the designated place only as directed by Engineer – in – Charge.

7.4 DEFECT LIABILITY PERIOD/Warranty Period

As per clause No. 5n of GTC.

7.5 Form C/D etc will not be issued by M/s HPCL

APPENDIX -1 TO SCC ��

��( ��)( �*�� 1.1 The basis and terms of payment without prejudice to any other mode of

recovery available to Owner, shall be as given below :

1.2 The Contractor shall be paid monthly running account bills at stages of completion of individual item / work, based on the joint measurement, in the following manner after deductions of necessary dues payable by Contractor to the Owner such as Retention money, Taxes, Duties etc. in accordance with various provisions made elsewhere in this document.

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�Following payment shall be made to the contractor against the running bills subject to the rate awarded to him and the clause regarding retention money as per general terms and conditions.

. 1. Piling/ Pile Cap 80% on completion

20% on completion and acceptance of all jobs as per schedule of Quantities/ Rates against submission of Performance Bank Guarantee for an equivalent amount valid for a period of two (2) years from date of completion of job along with guarantee (in the form of indemnity bond) for additional eight years period. In case, the settlement of pile foundations are more than the limit (in ten years period) as mentioned in the relevant IS Codes, Party has to rectify the same at their cost and risk, failure to do so will result in invoking the bank guarantee. 2. ALL SUPPLY ITEMS

80% against Supply 15% against commissioning 5% after completion and acceptance by HPCL as per SOQ

3. ALL OTHER ITEMS

95% progressively till completion of the concerned job 5% after completion and acceptance by HPCL as per SOQ ��NOTES : �� &/�� 9:� (4�@�A� ��9�((��1� 4�(46�@� (:�� <�� 9/� ��4�7� �6/�� 4/� 9��6� 6�@� 4:��

��9��4�@��<��>B��(�@6?��</?��

2. Partial bill will be processed only after submission of duly certified copy of proof of payment towards royalty. 3. Final bill will be processed only after submission of “No objection certificate” from relevant statutory authorities towards payment of royalty.

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SAFETY , HEALTH & ENVIRONMENT POLICY

SPECIFICATION FOR SAFETY HEALTH AND ENVIRONMENT (SHE) MANAGEMENT

&�*��*�� ________________________________________________________________________ CLAUSE NO. TITLE ________________________________________________________________________ 1.0 SCOPE 2.0 REFERENCES 3.0 REQUIREMENT OF SAFETY, HEALTH AND

ENVIRONMENT (SHE)

3.1 MANAGEMENT RESPONSIBILITY

3.2 HOUSE KEEPING

3.3 SAFETY, HEALTH & ENVIRONMENT

4.0 DETAILS OF SHE MANAGEMENT SYSTEM

BY CONTRACTOR

4.1 ON AWARD OF CONTRACT

4.2 DURING JOB EXECUTION

1.0 SCOPE

This specification establishes the Safety Health and Environment (SHE) management requirement to be complied with by the Contractors during construction.

Requirements stipulated in this specification shall supplement the requirements of SHE Management given in relevant Act (s) / legislations. General Conditions of Contract (GCC), Special Conditions of Contract (SCC) and Job Specifications. Where different documents stipulate different requirements, the most stringent shall be adopted.

2.0 REFERENCES

This document should be read in conjunction with following:

- General Conditions of Contract (GCC) - Special Conditions of Contract (SCC) - Job Specifications

3.0 REQUIREMENTS OF SAFETY HEALTH & ENVIRONMENT (SHE) MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS

3.1 MANAGEMENT RESPONSIBILITY

3.1.1 The Contractor should have a documented SHE policy to cover commitment of their organization to ensure health, safety and environment aspects in their line of operations.

3.1.2 The SHE management system of the Contractor shall cover the SHE requirements including but not limited to what is specified under Para 1.0 and para 2.0 above.

3.1.3 Contractor shall be fully responsible for planning and implementing SHE requirements. Contractor as a minimum requirement shall designate / deploy the following to co-ordinate the above :

No. of workers deployed

Up to 250 - Designate one safety supervisor

Above 250 & up to 500 - Deploy one qualified and experienced safety Engineer / officer

Above 500 - One additional safety (for every 500 or less) engineer/officer as above.

Contractor shall indemnify & hold harmless Owner / HPCL & either representatives free from any and all liabilities arising out of non – fulfillments of SHE requirements.

3.1.4 The Contractor shall ensure that the Safety, Health and Environment (SHE) requirements are clearly understood & faithfully implemented at all levels at site.

3.1.5 The Contractor shall promote and develop consciousness for Safety , Health and Environment among all personnel working for the Contractor. Regular awareness, program site meetings shall be arranged on SHE activities to cover hazards involved in various operations during construction.

3.1.6 Arrange suitable first aid measures such as First Aid Box, trained personnel to give First Aid, Stand by Ambulance or Vehicle and install fire protection measures such as : adequate number of steel buckets with sand and adequate fire extinguishers to the satisfaction of HPCL/Owner.

3.1.7 The Contractor shall evolve a comprehensive planned and documented system for implementation and monitoring of the SHE requirements. This shall be submitted to HPCL/Owner for approval. The monitoring for implementation shall be done by regular inspections and compliance to the observations thereof. The Contractor shall get similar SHE requirements implemented at his sub-contractor(s) work site/office. However, compliance of SHE requirements shall be the sole responsibility of the Contractor. Any review / approval by HPCL/Owner shall not absolve contractor of his responsibility / liability in relation to all HSE requirements.

3.1.8 Non-Conformance on SHE by Contractor (including his Sub-contractors) as brought out during review/audit by HPCL/Owner representatives shall be resolved forthwith by Contractor. Compliance report shall be provided to HPCL/Owner.

3.1.9 The Contractor shall ensure participation of his Resident Engineer / Site-in-Charge in the Safety Committee / SHE Committees meetings arranged by HPCL/Owner. The compliance of any observations shall be arranged urgently. He shall assist HPCL/Owner to achieve the targets set by them on SHE during the project implementation.

3.1.10 The Contractor shall adhere consistently to all provisions of SHE requirements. In case of non-compliance or continuous failure in implementation of any of SHE provisions; HPCL/Owner may impose stoppage of work without any Cost & Time implication to Owner and/or impose a suitable penalty for non-compliance with a

notice of suitable period, up to a cumulative limit of 1.0% (one percent) of Contract Value with a maximum limit of Rs. 10 lakhs. This penalty shall be in addition to all other penalties specified else where in the contract. The decision of imposing stoppage work, its extent & monitory penalty shall rest with HPCL/Owner & binding on the Contractor.

3.1.11 All fatal accidents and other personnel accidents shall be investigated by a team of Contractor’s senior personnel for root cause & recommend corrective and preventive actions. Findings shall be documented and suitable actions taken to avoid recurrences shall be communicated to HPCL/Owner. Owner / HPCL shall have the liberty to independently investigate such occurrences and Contractor shall extend all necessary help and co-operation in this regard.

3.2 HOUSE KEEPING

3.2.1 Contractor shall ensure that a high degree of house keeping is maintained and shall ensure inter alia the followings wherever applicable:

a. All surplus earth and debris are removed/disposed off from the working areas to identified location(s).

b. Unused/Surplus Cables, Steel items and steel scrap lying scattered at different places within the working areas are removed to identified location(s).

c. All wooden scrap, empty wooden cable drums and other combustible packing materials, shall be removed from work place to identified location(s).

d. Roads shall be kept clear and materials like: pipes, steel, sand boulders, concrete, chips and bricks etc. shall not be allowed on the roads to obstruct free movement of men & machineries.

e. Fabricated steel structural, pipes & piping materials shall be stacked properly for erection.

f. Water logging on roads shall not be allowed.

g. No parking of trucks / trolleys, cranes and trailers etc. shall be allowed on roads which may obstruct the traffic movement.

h. Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working areas.

i. Trucks carrying sand, earth and pulverised materials etc. shall be covered while moving within the premises.

j Only properly designed steel scaffolding materials to be used for working at heights more than 3.0M . Double scaffolding using wooden ballis may be allowed for working at height less than 3.0M

3.3 SAFETY, HEALTH AND ENVIRONMENT

3.3.1 The Contractor shall provide safe means of access to any working place including provisions of suitable and sufficient scaffolding at various stages during all operations of the work for the safety of his workmen, and, HPCL/Owner. Contractor shall ensure deployment of appropriate equipment and appliances for adequate safety and health of the workmen and protection of surrounding areas.

3.3.2 The Contractor shall ensure that all their staff and workers including their sub-contractor(s) shall wear Safety Helmet and Safety shoes. Contractor shall also ensure use of safety belt, protective goggles, gloves etc. by the personnel as per job requirements. All these gadgets shall conform to relevant IS specifications or equivalent.

3.3.3 Contractor shall ensure that a proper Safety Net System shall be used at appropriate locations. The safety net shall be located not more than 30 feet (9.0 metres) below the working surface at site to arrest or to reduce the consequences of a possible fall of persons working at different heights.

3.3.4 Contractor shall ensure that flash back arrester shall be used while using Gas Cylinders at site. Cylinders shall be mounted on trolleys.

3.3.5 The Contractor shall assign to his workmen, tasks commensurate with their qualification, experience and state of health for driving of vehicles, handling and erection of materials and equipments. All lifting equipments shall be tested certified for its capacity before use. Adequate and suitable lighting at every work place and approach there to, shall be provided by the Contractor before starting the actual operations at night.

3.3.6 Hazardous and/or toxic materials such as solvent coating, or thinners shall be stored in appropriate containers.

3.3.7 All hazardous materials shall be labelled with the name of the materials, the hazards associated with its use and necessary precautions to be taken.

3.3.8 Contractor shall ensure that during the performance of the work, all hazards to be health of personnel, have been identified, assessed and eliminated.

3.3.9 Chemical spills shall be contained & cleaned up immediately to prevent further contamination.

3.3.10 All personnel exposed to physical agents such as ionizing radiation, ultraviolet rays or similar other physical agents shall be provided with adequate shielding or protection commensurate with the type of exposure involved.

3.3.11 Where contact or exposure of hazardous materials could exceed limits or could otherwise have harmful affects, appropriate personal protective equipments such as gloves, goggles, aprons, chemical resistant clothing and respirator shall be used.

- A Crèche where 10 or more female workers are having children below the age of 6 years.

- Reasonable Canteen facilities are made available at appropriate location depending upon site conditions.

3.3.13 Suitable facilities for toilet, drinking water, proper lighting shall be provided at site and labour camps, commensurate with applicable Laws / Legislation.

3.3.14 Contractor shall ensure storage and utilization methodology of materials that are not detrimental to the environment. Where required Contractor shall ensure that only the environment friendly materials are selected.

3.3.15 All persons deployed at site shall be knowledgeable of and comply with the environmental laws, rules & regulations relating to the hazardous

materials substances and wastes. Contractor shall not dump, release or otherwise discharge or dispose off any such materials without the express authorization of HPCL/Owner.

4.0 DETAILS OF SHE MANAGEMENT SYSTEM BY CONTRACTOR

4.1 On Award of Contract

The Contractor shall prior to start of work submit his Safety Health and Environment Manual or procedure and SHE Plans for approval by HPCL/Owner. The Contractor shall participate in the pre-start meeting with HPCL/Owner to finalise SHE Plans including the following :

- Job procedure to be followed by Contractor for activities covering. Handling of equipment, Scaffolding, Electric Installation, describing the risks involved, actions to be taken and methodology for monitoring each activity.

- HPCL/Owner review / audit requirement.

- Organization structure along with responsibility and authority records / reports etc. on SHE activities.

4.2 During job execution

4.2.1 Implement approved Safety Health, and Environment management procedure including but not limited to as brought out under para 3.0. Contractor shall also ensure to:

- arrange workmen compensation insurance, registration under ESI Act, third party liability insurance etc., as applicable.

- arrange all HSE permits before start of activities (as applicable) like hot work, confined space, work at heights, storage of chemical / explosive materials and its use and implement all precautions mentioned therein.

- submit timely the completed checklist on SHE activities, Monthly SHE report, accident reports, investigation reports etc. as per HPCL/Owner requirements. Compliance of instructions on SHE shall be done by Contractor and informed urgently to HPCL/Owner.

- ensure that Resident Engineer / Site-in-Charge of the Contractor shall attend all the Safety Committee / SHE meetings arranged by HPCL/Owner. Only in case of his absence from site that a second senior most person shall be nominated by him in advance and communicated to HPCL/Owner.

- display at site office and work locations caution boards, list of hospitals, emergency services available.

- provide posters, banners for safe working to promote safety consciousness.

- carryout audits / inspection at sub contractor works as per approved SHE document and submit the reports for HPCL/Owner review.

- assist in SHE audits by HPCL/Owner, and submit compliance report.

- generate & submit HSE records / report as per SHE Plan.

- appraise HPCL/Owner on SHE activities at site.

Date post:	15-Feb-2018
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