Volume V of V

NMDC LIMITED
HYDERABAD
KUMARASWAMY IRON ORE PROJECT

BELLARY DIST - KARNATAKA
TENDER DOCUMENT
FOR
PACKAGE - II
DOWNHILL CONVEYOR SYSTEM
VOLUME V OF V
MECON LIMITED
BANGALORE
MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD REV. 0
JANUARY 2010
NMDC LIMITED
MECON
LIMITED

PACKAGE NO II
DOWN HILL CONVEYOR SYSTEM

CONTENTS
VOLUME I of V
Chapter
No
1.
2.
3.
4.
5.
6.
Description
Check list
Notice Inviting Tender (NIT)
Instructions to Tenderers (ITT)
General Conditions of Contract (GCC)
Special Conditions of Contract (SCC)
Erection Conditions Of Contract (ECC)
VOLUME II of V
1.
Preamble, Summary of Prices, Price for exemptions / variations

and Price Format
VOLUME III of V
Chapter
No
A
B
C
D
E
F
G
H
I
J
K
L
M
Description
Brief on the Project and Intent Of Tender
General technical conditions
General site information
Scope of work and battery limit
Performance guarantee and warranty
Surface preparation and painting
Quality assurance, inspection and testing
Construction, erection, testing and commissioning
Engineering services
Project management services
Site services
List of Tender Drawings
Part/1 - Documents/ drawings to be submitted along with the
tender
Part/2 Questionnaire and design data sheets to be filled and
submitted along with the tender
NMDC LIMITED
MECON
LIMITED

PACKAGE NO II
DOWN HILL CONVEYOR SYSTEM
Documents /drawings to be submitted by successful Tenderer
Spares, Special tools & Tackles
List of Preferred makes of equipment
Q1
Technical specification Mechanical
Q2
Technical specification Environmental
Enclosures: 1.
2.
3.
4.
Tender drawings as per the list under chapter-L

Specimen QAP format for Structural & Mechanical equipment
Specimen QAP format for Electrical equipment
Specimen Inspection call format
VOLUME IV of V
Chapter
No
Q3
Description
Technical specification Electrical
Q4
Technical specification Automation and Control
Q5
Technical specification Plant Communication System
VOLUME V of V
Chapter
No
Q6
Q7
Q8
Description
Technical specification Civil
Technical specification Structural
Technical specification Hydro Engineering
Q9
Technical specification Fire Detection and Suppression

System for Down Hill Conveyor
Q10
Technical specification General Layout, Roads and Fire
Fighting
Enclosures:- One Compact disc containing soft copy of the following:
1.
2.
3.
Soft copy of Questionnaire and design data sheet Chapter-M (Part-2 of 2)

Soil investigation report (for reference only)
Waste Dump Locations - Sketch dated 14.09.07
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 1 of 194
CHAPTER Q6
TECHNICAL SPECIFICATION CIVIL
CONTENTS
Section No.
Section - I
Section - II
Section - III
Section
Section
Section
Section
- IV
-V
VI
VII
Description
General & Scope of Work
Architectural & Civil Design
Parameters
Detail Specification for Civil
Construction Works
Norms of Cement Consumption
Dimensional Tolerances
Method of Measurement
Safety Code
MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD
2010, MECON Limited. All rights reserved.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 2 of 194
SECTION I : GENERAL & SCOPE OF WORK

1.0
GENERAL
1.1
The scope of this tender includes analysis, design, detailed

engineering, preparation of construction drawings, bar bending
schedules and submission of design calculations and
construction drawings for approval of the Owner/ Consultant,
supplying of all material, testing of all materials as per
specifications/ BIS codes and labour and construction of the
facilities as per the provisions of this specification,
commissioning and handing over all facilities to the client.
2.0
SCOPE OF WORK
2.1
The following / Buildings facilities are envisaged:

Sl.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Description
Remarks
RCC trestle foundations / foundation for See clause

No. 3.0
short post for Conveyor No: 718.
Given
Transfer
House
No:1
Column
foundations & with 200mm thick RCC below for
description
floors on steel beams.
of the
RCC trestle foundations / foundation for
facility /
short post for Conveyor No: 719.
Building.
RCC Storage Silo of 1000 t Capacity with
structural roof.
Tail/Drive house column foundations and
foundation for drive platform with RCC
floors.
Transfer
House
No:
2
Column
foundations & with 200mm thick RCC
Transfer
House
No:
2A
Column
Parking/Maintenance
station
for
traveling
trolley
(PS-1)
Column
foundations.
RCC Trestle foundations for Conveyor
No: 721.
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CHAPTER NO. Q6
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
VOLUME - V of V
Page 3 of 194
Down hill Conveyor No: 723 with RCC,

foundations, trestles with beam for
supporting steel gantry.
No: 727.
Parking/Maintenance
station
for
traveling
trolley
(PS-2)
Column
foundations.
Transfer
House
No:
3
Column
Transfer
House
No:
4
Column
Transfer
House
No:
5
Column
Transfer Station Column foundations &
with 200mm thick RCC floors on steel
beams.
Transfer
House
No:
6
Column
No: 727-1.
No: 727-2.
Sub-station at tail end of down hill
conveyor with Office room, VFD room,
Switchgear room, Pump house, Shift In
charge room, Control room, Cable cellar,
battery room, etc.
Sub-station near TH-5 with Office room,
VFD room, Switchgear room, Cable
cellar, battery room, etc.
Sub-station near TH-3 with VFD room
for Belt Feeder and other panels as per
requirement.
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CHAPTER NO. Q6
23.
24.
25.
26.
27.
2.2
VOLUME - V of V
Page 4 of 194
The following Service Roads including

culverts, road side drains, retaining
walls,
necessary
slope
protection
measures, etc.
a) Approach road to TH1, Silo area, Tail
/ drive house of Down Hill Conveyor, TH2, TH-2A, PS-1 and Electrical, control
cum office building from the approach
road proposed for Secondary Crushing
Plant.
b) Approach road to PS-2 and take-up
area of down hill conveyor
c) Approach road to belt lay down area
at two locations
d) Approach road to TH-3 from the
existing kachcha road.
e) Approach road to TH-4, TH-5, TH-6 &
electrical room near TH-5 from the roads
available already.
Belt
Lay
Down
Areas
(Area
of
300mx10m) At two places.
Micro leveling and area development
around Transfer House No: 1, 2, 2A, 3,
4, 5, 6, Tail
/ drive house, Silo,
Parking/Maintenance shed PS-1 & 2,
etc., including building aprons, storm
water drain, approach road, culverts,
retaining
walls,
necessary
slope
protection measures etc.
Parking Facility
Laying and fixing of MS / GI water pipe
line from the proposed fire water
reservoir / hill top reservoir to various
facilities proposed under package-II
including foundations and anchor blocks.
Based on
the conceptual drawings and the
basic design
parameters defined in
this tender, the tenderer shall
prepare
layouts, detailed architectural drawings, design
criteria, analysis and design calculations, civil shuttering and
reinforcement drawings, bar bending schedules. Approval of
the Consultant shall be taken at each of the stages before the
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Page 5 of 194
construction work is taken-up. Work shall be executed in

accordance with approved drawings, issued for construction.
2.3
The civil construction drawings, in AutoCAD, shall take care of

all the technological requirements. Any revision required for
the technological requirements shall be automatically
incorporated in the civil drawings and got approved again.
2.4
Design criteria, civil analysis and design, architectural

drawings and constructions drawings shall be got approved in
stages well in advance to match with the sequence of
execution.
2.5
Contractor shall submit ten sets of design calculations

documents and Drawings for approval of consultant.
2.6
Only latest revisions of the drawings shall be followed and

all old revisions shall be clearly marked SUPERCEDED and
kept separately or destroyed as directed by Consultant.
2.7
The tenderer shall acquaint himself of the site related data,

conduct additional investigation as may be essential and
required for efficient working of the facility as per sound
engineering practice, which will be deemed to be a part of the
scope even though not explicitly defined in the tender.
Tenderer is free to refer to site survey and soil investigation
data available with the Owner / Consultant which will be made
available to the tenderer on request. No claim shall be
entertained in case of deviations from the supplied data.
2.8
Along with the tender the tenderer will submit one set of
drawings showing the area he proposes in each of the area,
based on the concept
drawings and the architectural and
civil design parameters.
2.9
Provision for building drains, apron, sanitary & water supply

system, statutory requirements as per factories act will also
form a part of this tender.
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3.0
GENERAL DESCRIPTION OF BUILDINGS AND FACILITIES
3.1
Foundations for trestle supports for conveyors:

The foundations for structural trestle supports for all
conveyors shall be constructed in reinforced cement concrete
duly taking into account wind loads, earthquake load,
equipment loads, etc. The trestle foundations that are prone
to undermining and erosion of topsoil due to rainwater shall
be protected by appropriate methods like cut-off walls, catch
drains and stone pitching. Locating the trestle foundations in
the watercourses, rivulets and other water bodies shall be
avoided. In cases where the trestle foundations are to be
located on sloping hilly regions, the foundations shall be
placed on stable and firm soil stratum. The trestle foundations
shall be constructed on suitable and adequate capacity piles in
cases where such foundation system is to be adopted due to
engineering properties of existing soil. The down hill conveyor
No.723 shall be provided with RCC trestles up to a height of
12m (For trestle heights above 12m structural trestles shall be
considered.) with RCC foundations and RCC supporting beam
for the gallery.
3.2
Transfer Houses:
The transfer houses shall be in structural steel with CGI
sheeting and translucent cladding. The translucent sheeting
shall be about 15% of the roofing and side cladding area. The
foundations for the structural columns shall be in RCC. Floors
shall be of RCC. The floors of the transfer houses shall have
adequate slope to facilitate cleaning of accumulated muck
water washing. Granolithic floor of sufficient thickness
(min.200) with non-metallic floor hardener shall be provided.
3.3
RCC Storage Silo (1000t (effective storage) Capacity):

A RCC Silo of 1000 t capacity (effective storage) is proposed
for storing graded iron ore. The RCC silo shall be designed for
the dead load of iron ore material. Insert plates on the walls
and hopper bottom shall be provided for welding wear
resistant liners (for specification of liners refer relevant
chapters). Super structure of RCC silo shall be of structural
design. Mat foundation shall be provided for the RCC silo.
Foundations for belt feeders shall be designed and constructed
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considering the dynamic forces as per manufacturers load

data. Suitable opening shall be provided in the silo wall for
accommodating the belt feeder, approach to belt feeder
platform from the structural staircase, etc.
3.4
Open Excavation for single flight down hill conveyor:

The down hill conveyor shall be taken through open earthen
cuts whenever the ground level is higher than the conveyor
top level. The sides of the open cut surfaces shall be stable
and flat. The conveyor shall be supported on RCC pedestal and
on suitable foundation. Adequate surface storm water
drainage arrangement shall be provided on either side of
conveyor running through earth cuts. RCC box culvert of
adequate section shall be provided to drain off higher reaches
of the hill.
3.5
Office Building / Electrical Room / MCC Room / Control

Room:
These buildings shall be in RCC frame construction with
masonry infill walls. The carpet area of single/Double story
office shall be arrived based on technical requirements covered
in relevant chapters and as per relevant BIS norms. Plumbing
and sanitary fittings, bathroom, Indian and European type
water closets, septic tank and soaking pit shall be designed
and provided for 15 male members.
3.6
Service Road:
A service road of 10 m formation width, 1.5m shoulder on
either side and 4m WBM carriage way, with bitumen carpeting,
shall be designed for axle load of 10 t. The road shall be
designed as far as possible to run in cutting avoiding filling.
RCC retaining wall of adequate cross section shall be designed
in cases where road is required to pass over filling. The road
shall be designed for a gradient of 1 in 20. The road shall be
designed proving adequate turning radius at curves and
bends. Adequate super elevation and extra width shall be
provided at curves and bends for vehicular speed of 30 KMPH.
Overtaking sight distances, stopping sight distances, hairpin
bends and other geometric design elements shall be designed
and provided for as per relevant IRC codes of practice for
roads in Hilly Regions. Double rail (W-W section) Metal Crash
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barrier, Cat-eyes kilometer stones, informatory and warning

signs with suitable radium coating shall be provided at
appropriate locations as per IRC norms. Suitable drainage
facilities like roadside drains catch pits RCC box culverts shall
be provided.
3.7
Area Development:
The areas around Transfer Houses, Silo, tail/drive house,
office building/MCC / Control / Electrical Room shall be micro
leveled and suitable storm water drains to drain off rainwater
shall be designed and provided. RCC apron of 750mm wide
shall be provided around all buildings and facilities along with
building drain, which shall be connected to surface storm
water drain. The storm water drain / channel shall be
connected to a near by valley area for discharging storm
water.
3.8
Parking Facility:
Suitable vehicle parking facility for 2 no. of four-wheeler
vehicles and minimum of 10 no. of two-wheeler vehicles shall
be provided at all Transfer Houses, office building/MCC /
Electric / Control Room and RCC Silo areas. The parking shall
be designed in structural steel super structure with CGI
sheeting and RCC foundation. The parking area shall be
constructed in WBM construction of adequate thickness with
bitumen carpeting.
3.9
The tenderer shall consider the following finishes/ fixtures for

facilities covered under the scope:
I.
Schedule of finishes:
Sl.
No.
1.
AREA
DESCRIPTION OF FINISHES
Plastering and White / colour

wash
a) Inside
12mm thk. in CM (1:6)+ 2
coats OBD over priming coat.
b) Out side 15mm thk. in CM (1:6) +
cement based approved colour
wash over priming coat.
c) Ceiling
6mm thk. In CM (1:3) + 3

coats of white wash.
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NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q6
2.
Flooring and skirting

a) Hall and in-charge room
3.
II.
VOLUME - V of V
Page 9 of 194
20mm
thk.
Grey
Terrazo tiles and
skirting
cement
100mm
b) Toilet
i)
Floor
Ceramic
shade.
ii)
Dado
White glazed tile for 1500mm

high.
Polymeric
water
proofing
membrane over screed (75mm
ave. thk.)
Roof water proofing treatment.
tile
of
approved
Schedule of plumbing sanitary fitting / fixtures

Toilet:
a)
Closet: Indian type vitreous water closet of 580x440mm size

and approved colour. European type vitreous water closet of
580x440mm size and height of 400mm, and approved colour
including 15lit, PVC cistern etc.
b)
Urinal: White vitreous china urinal of size 430x260x350mm

including half round drain channel, 15lit, PVC cistern etc.,
c)
Wash basin: white vitreous chaina wash basin of size

630x450mm, including 600X600 mirror, a pair of 15mm C.P.
brass pillar taps, angle cock, bottle trap, soap container,
600mm Tower rail, etc.,
d)
Min. 1000 lit. Capacity HDPE overhead water tank with

32mm dia GI inlet and overflow pipes. 25mm dia GI outlet
pipes with distribution pipes of 20mm & 15mm GI pipes
including all accessories like 32mm,25mm gunmetal gate
valve with CI wheel.
e)
15mm CP brass
accessories.
bib
cock
&
stop
cock
including
all
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Schedule of Doors, Windows & Ventilators.

a) Door
D1 -
1000X2100 35 mm commercial ply flush door

including 100X75mm 2nd class teak wood door
frame, with 2 coats of enamel paint over a coat of
primer.
D2 -

including 100X75mm 2nd class teak wood
doorframe,
with
2
coats
of enamel paint over a coat of primer.
D3

including 100X75mm 2nd class teak wood
doorframe, with 2 coats of enamel paint over a
coat of primer.
b) Windows -
1500X1200 Glazed wooden window in 2nd class

teak wood including two coats of enamel painting
over coat of primer painting.
c) Ventilator -
600 X450 wooden ventilator in 2nd class teak

wood including glazed louvers and including two
coats of enamel painting over a coat of primer
painting.
d) Exhaust Fan -300 dia. Electric exhaust fan with all

fixtures.
necessary
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SECTION II : ARCHITECTURAL AND CIVIL DESIGN

PARAMETERS
1.0
GENERAL
1.1
This part of the specification defines the Architectural

requirements and design parameters for analysis and design of
the civil buildings/facilities.
2.0
ARCHITECTURAL DESIGN REQUIREMENTS
2.1
Architectural design shall be in accordance with the following

referenced publications:
a)
b)
c)
National Building code of India

State Government Factories Act.
Local Municipality or any other authoritys Byelaws as
applicable.
2.2
Spatial requirements:
2.2.1
Spatial requirements inside a building shall be based on the

activities to be performed in the building, equipment layout,
etc.
2.2.2
The objective of spatial arrangement is to satisfy functional

requirements and physical comfort and safety regulations as
well as aesthetics which has significant role in creating a
favourable working and living conditions.
2.2.3
However the following are the limiting sizes, dimensions for

various purposes, which are to be adhered to:
Minimum
size
habitable room
Minimum height
habitable room
of
of
any 9
sq.
m
with
minimum
dimension not less than 2.5m
any 3m, which may be reduced to
2.75m
for
air-conditioned
areas.
Maximum height of any 3. 6 m

habitable room
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Scale of accommodation 14 cum per occupant. Minimum

for Industrial work spaces
clear height of such workspaces
shall be 3.6m.
2.3
Day lighting and Natural ventilation
2.3.1
Established level of illumination shall be maintained for all

parts of the buildings by means of windows, skylights, etc.
Established level of ventilation in terms of air changes per
hour shall be maintained for all spaces. References shall be
made to National Building Code & Factories Act in this regard.
Natural ventilation shall be supplemented by mechanical or
electrical means of ventilation in all human occupied areas
2.4
Safety requirements
2.4.1
Safety from fire and like emergencies shall be taken into

account in building/shed design. Every building/ shed meant
for human occupancy shall be provided with fire exits sufficient
to permit safe escape of occupants in case of emergency.
2.4.2
The exits shall be in terms of doorway, corridors, passageways

to internal/ external staircase or to areas having access to
outside.
2.5
Building services
2.5.1
Water supply, distribution, drainage and sanitary services shall

be provided for all buildings/ sheds as essential services.
2.5.2
Areas of control room, spaces housing equipments, machinery,

panels, offices, etc., which require special conditioned
environment, shall be provided with forced ventilation/ air
conditioning.
2.6
Aesthetics
2.6.1
Apart from the fulfillment of functional & safety requirement,

aesthetic requirement of the building shall be given due
importance in the design. Elements like canopies, Overhangs,
Shades, Gutters, Door/window/ ventilator composition,
external wall location with respect to columns, colour scheme,
grooves in plaster, etc. shall be considered as contributory
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elements to aesthetics and these shall be designed judiciously.

2.7
Structural and construction elements
2.7.1
Type of structure and construction shall be as per technical

requirements. However the following may be followed as
guidelines:
Building
Transfer Houses
Trestle foundations
Down hill conveyor
Office building, Electric
room, MCC room.
Service Road
Type
of
structure
and
construction
RCC foundation, RCC floors on
structural beams. Structural Steel
super structure with
CGI /
Translucent Sheeting.
RCC.
Structural trestles for the structural
gallery.
RCC
framed
structure
with
masonry infill walls.
10 wide formation; 1.5m Shoulder;
4m WBM carriage way with bitumen
carpeting.
2.8
Terrace Levels
2.8.1
The terrace levels shall be fixed based on the topography of

the area and the filling/ cutting requirements as well as road
gradients. In general terrace levels shall be 300mm below the
road top level.
2.8.2
In areas of rock outcrops/ cutting the surface shall be so

chiselled so as to be aesthetically pleasing.
2.9
Finished floor levels
2.9.1
In general, finished floor levels of the building, sheds shall be

determined with respect to top of approach road or pavement.
Generally FFL shall be 600mm above terrace levels near the
building or as indicated in the drawings.
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2.10
Steps/ Ramps
2.10.1
Steps/ ramps shall be provided for access to the building/

sheds for pedestrian/ vehicular, equipment entry. Minimum
1000 mm wide platform shall be provided in between entrance
door and steps/ ramps. Following dimensions of steps/ ramps
shall be adhered to:
A
B
C
Tread
250 mm minimum
Riser
175 mm maximum
Slope of ramp
Not steeper than 1:6
Maximum number of steps in

D one flight
12 Nos.
2.11
Walls
2.11.1
Following shall be adhered to for wall material and thickness:

A
B
C
2.12
External & Load bearing

walls
Fire
wall
(around
transformers as specified)
Internal partition wall
230 mm brick masonry or

200 mm CC block masonry.
345mm brick masonry or
300mm CC block masonry
or 225mm RCC wall.
115mm brick masonry or
100 mm CC block masonry.
Note: 1.
115/100 mm thick Internal partition walls shall be

provided with 75 mm thick horizontal RCC bands
at every 5th course.
2.
Wherever conduits or pipes are required to be

concealed within partition wall, or boxes are to be
provided, the wall thickness shall be increased
suitably.
Doors: Doors shall be provided for access, security and safety

at all entry & exit of rooms, functional areas and buildings.
Sizes of the doors shall be determined on the basis of the
following schedule.
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B
C
D
E
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Page 15 of 194
Equipment, Panel area
Size
of
maximum
equipment
including
packing.
Other areas
Volume
of
movement
through the door.
Minimum entrance door size 1500 mm x 2100 mm (wall
opening size)
WC, Bath cubicle door(min) 750 mm x 2100 mm (wall
opening size)
Minimum size of other doors 1000 mm x 2100 mm (wall
opening size)
Note: 1.
Normally entrance doors shall be provided

covering full width of the entrance lobby. In that
case the door shall be of composite type
consisting of openable shutters & fixed portions.
2.
Rolling shutters shall be provided wherever area

requirement of openable shutters exceed 2500 x
2500 mm.
3.
Mechanically operated rolling shutters shall be

provided for all opening sizes.
2.13
Windows/ Ventilators
2.13.1
Windows/ Ventilators shall be provided in all areas for natural

lighting, ventilation and visibility at working level.
2.13.2
For the purposes of ventilation, total openable areas of the

windows/ ventilators shall be as per Factory act, subject to a
minimum of 15% of the floor area to be ventilated. However,
for non-process Control Room, security block, Gate Houses
and in office areas, etc. where visibility from inside is of prime
importance, increased window areas shall be provided. Areas
accommodating panels/ equipments shall be normally provided
with ventilators at high level for unobstructed distribution of
lighting.
2.13.3
Issue counters wherever required shall be provided with

separate sliding/ hinged shutters and peep holes in the glass
at appropriate height.
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2.13.4
For height more that 4000 mm additional window/

ventilators shall also be provided to ensure minimum
illumination & ventilation at every level of the building/ shed.
In case of walkway/ gangway, etc. windows/ ventilators at
working levels shall be provided in the same manner as at
working area.
2.13.5
Wherever due to limitation of external wall area or any other

reasons, stipulated area of Windows/ Ventilators cannot be
provided, suitable mechanical/ electrical devices shall be
provided.
2.13.6
Fly mesh shutters shall be provided for Pantry & Dining hall
Windows/ Ventilators.
2.14
Canopy/ Overhang
2.14.1
Canopy/ overhangs shall be provided at all entries and exist

for rain & sun protection, accentuation of entry/ exit and
movement from or to parked vehicle. Size of the overhang
shall be decided based on the aesthetics of the building/
shed subjected to minimum 1200 mm.
2.15
Shading devices shall be provided over all windows, openable

ventilators for rain & sun protection. These devices shall be
in form of horizontal projections, vertical projected fins or
combination of both as per building faade treatment.
Minimum projection shall be 600 mm. The top surface of the
shading devices shall be finished with cement plaster mixed
with water proofing compound (laid to slope) and shall be
provided with GI/PVC spouts. Roof projection shall be
provided wherever feasible for at least 750 mm.
2.16
Parapets shall be minimum 300 mm high for nonapproachable roof. In case of future expansion, GI/ MS
railing may be provided.
2.17
PVC Rain water pipes, spouts shall be provided for roof water
drainage. Number of rain water pipes shall be decided on the
basis of roof area., slope and rainfall intensity. Rain water
pipes shall be provided with bottom shoes and drain
channels leading to surface drains.
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2.18
Entrance lobby & corridors
2.18.1
Entrance lobby shall be provided as a common entrance for

such buildings/sheds accommodating separate or similar
functional spaces integrated together. Individual entries to
such functional spaces shall be from this lobby by means of
passages/ corridors. Apart from common entry lobby, separate
independent entries to these functional spaces shall be
provided if required.
2.18.2
Passages/ corridors shall be provided to integrate various

spaces. Width of the passages/ corridors shall be as per
following schedule:
A
B
C
Singly
loaded
corridor
Doubly
loaded
corridor
Stores, etc.
passage/ Minimum 1200 mm

passage/ Minimum 1800 mm
As
per
requirements
movement
2.19
Air lock lobby: Air lock lobby shall be provided for all entry and
exit of air-conditioned space. However air lock lobby may be
avoided in case of small air conditioned habitable spaces.
2.20
Emergency exits: Emergency exits shall be provided for all the

building/ sheds as per Factory acts. Emergency exits for
individual functional spaces such as console area, cable cellar,
switchgear rooms shall also be provided. Emergency exits shall
be located in such a manner that the escape route is direct,
unobstructed and without passing through any other function
areas to safe area. Corridor/ staircases shall be provided as
escape route to the emergency exits.
2.21
False ceiling: false ceiling shall be provided for the following

purposes wherever required.
A
B
C
To reduce the volume and hide ducting etc. for air

conditioned space.
To maintain acoustic level inside any space
To reduce habitable room, corridor, lobby, toilet heights
located in high ceiling building/ shed to minimum 3000 mm
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2.22
False Flooring/ cavity floor: False floor/ cavity floor shall be

provided
to
accommodate
under
floor
cabling
in
instrumentation console, rack, UPS room, etc.
2.23
Plinth protection: Plinth protection shall be provided to all

buildings/ sheds with minimum 1000 mm width and sloped
towards drain around the building.
3.0
ARCHITECTURAL FINISHES
3.1
All architectural finishes shall be as per specifications,

standards and approved list of vendors.
3.2
Colour scheme for all architectural items shall be as

approved by Consultant/ Owner.
3.3
All building elements i.e., floor wall, ceiling, roof, doors, &
windows, etc. shall be provided with architectural finishes as
shown in the building drawings. Wherever the finishes are
not mentioned, the following finishes shall be followed:
3.3.1
Floor finish
Sl.
No.
A
B
C
D
E
F
Note: 1.
Building/ room/ area

Control rooms, UPS room
etc.
Entrance, Conference rooms,
Office rooms, Corridors, etc.
Change
rooms,
Documentation rooms, etc.
Equipment rooms, service
rooms, pump houses, etc.
Stores
Toilets
Finish
False flooring
Marble
stone/
Vitrified
ceramic tile (mirror polish)
Terrazzo tiles.
Heavy
duty
cement
concrete flooring
Granolithic floors.
Antiskid ceramic tiles and
matching ceramic tile dado
(2.1m ht.)
Skirting shall be provided in all areas. Cement

plaster skirting shall be provided in areas having
cement concrete granolithic/ heavy-duty cement
concrete flooring. For other areas, skirting shall be
of same material as that of the floor. Skirting shall
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be of 125mm ht. Minimum for cement skirting and
terrazzo tiles and 100 mm for ceramic tiles.
2.
3.3.2
Panel dividers shall be provided in cement concrete

flooring.
Wall finishes & roof treatment.

Sl. No.
Surface
Finish
A. Internal finishes of all buildings
1 Control room, Office room, Plastic emulsion paint over
Conference room, Labs, 12mm
thick
cement
entrance foyer, etc.
plaster.
2. Change
rooms, Acrylic washable distemper
documentation
rooms, over cement plaster
stores, Panel rooms, etc..
B. Exterior finishes
1 Admin buildings
Exterior emulsion paint.
2 All other buildings
Waterproof cement paint.
C. Roof treatment
1 Flat roofs
Polymeric water proofing
membrane over screed
(average 75mm th.)
2. Slopped roofs
Mangalore pattern tiles
over water proof cement
plastering.
4.0
ANALYSIS & DESIGN
4.1
Analysis and design of buildings/facilities shall be done as per

good engineering practices by experienced personnel. All data
required for checking of analysis and design shall be properly
documented and readily available. Cross-references to
relevant data and clauses of codes shall be explicitly
mentioned at every stage.
4.2
Design and construction of buildings, structures shall take into

account requirements of operation and maintenance of all
equipment and its users. All the design work shall be carried
out as per latest IS codal requirements. The buildings shall
have good architectural features.
4.3
The tenderer is free to use STAAD Pro software for the

purpose of analysis. However detailed working of design shall
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be submitted based on the results of analysis. The tenderer

shall be solely responsible for the analysis results and the
design not withstanding the approval accorded by the
Consultant. If in the opinion of the consultant the results are
not satisfactory, alternate method of analysis and design shall
be used with the approval of Consultant.
4.4
Preliminary soil investigation of different site indicates that

ordinary spread footing/raft will suffice for various structures.
However, the tenderer shall carryout his own soil investigation
and satisfy himself on the characteristics of soil and type of
foundation system to be provided. No claim shall be
entertained on account of ignorance of soil characteristics.
5.0
LOADS AND LOAD COMBINATIONS
5.1
General
5.1.1
All structures shall be designed for the most critical

combinations of different loads. The loads shall include, dead
loads, imposed loads, equipment loads, crane loads, slurry
piping (static & dynamic) and other piping loads, wind loads,
seismic loads, temperature loads, Blast loads, forces
developed due to differential settlement and any other loading
conditions which can occur during the design life of the facility.
All codes and standards referred are the latest editions/
revisions along with amendments if any.
5.2
Dead loads
5.2.1
Dead loads consist of the weights of the complete structure

with finishes, fixtures, partitions, wall panels and all
equipment of semi-permanent nature including tanks, bins,
partitions, roofing, piping, cable trays, bus ducts etc. The
content of tanks, silo, bins and hoppers etc. shall be measured
at full capacity for this purpose.
5.2.2
The piping loads, cable tray loads and the contents of the
tanks, bins and hoppers shall be listed separately so that they
can be excluded from dead load when dead loads are acting as
stabilising load for uplift.
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CHAPTER NO. Q6
5.2.3
VOLUME - V of V
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The following unit weights of materials shall be considered for

computing loads. Loads given in IS: 875 (part-I) shall be
made use of for the material not listed below.
Materials
Plain cement concrete
Reinforced cement concrete
Structural steel
Cement plaster
Floor Finish
Unit weight
2.40 t/cum
2.50 t/cum
7.85 t/cum
2.10 t/cum
2.40t/cum
:
:
:
:
:
5.3
Imposed loads
5.3.1
Imposed loads in different areas shall include live loads, dust

loads, minor equipment loads, cable trays, small pipe racks /
hangers, erection loads, operation/ maintenance loads, etc.
The loads considered shall not be less than that specified in
IS:875 (Part II). The loads listed hereunder are the minimum
loads for the areas involved. Special use areas shall be
investigated and loads revised upward as necessary. Floors
and supporting members which may be subjected to heavy
equipment live loads shall be designed on the basis of the
weight of equipment or specifically defined live loads,
whichever is greater.
5.3.2
The specific minimum floor live loads are listed below

Roofs:
A) Flat Roof
: 1.50 kN / sqm for roofs
B) Main control room/ electrical buildings

a)
b)
c)
d)
C)
Control room floor

MCC room
plant floors
Switch gear room
:
:
:
:
10
15
10
15
kN / sqm
kN / sqm
kN / sqm
KN / sqm
Other areas
i)
RCC floors
ii)
Toilet
: 5 KN/sqm for amenities

Building and general
floors
: 2 KN / sqm
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5.3.3
Culverts and allied structures including RCC pipes shall be

designed for Class AA loading and checked for Class A
loading as per IRC standards.
5.3.4
Covers for trenches & channels, which are not exposed to

vehicular traffic, shall be designed for live load of adjoining
area or 2 t / sqm whichever is higher. Where covers for
trenches and channels are likely to be exposed to vehicular
traffic, the requirements of code of practice for road bridges
shall be adhered to.
5.3.5
In addition to the live loads, a minimum of 0.50 kN / sqm shall

be considered as Hung loads for electrical, ventilation & air
conditioning. Load of 1.0 kN / sqm shall be considered as
Hung loads for piping unless otherwise mentioned.
5.3.6
Live load reduction shall be in accordance with the provisions

of IS:875 and IS:1893 in case of seismic analysis.
5.4
Earth pressure loads
5.4.1
Earth pressure for all underground structures shall be

calculated
using coefficients of earth pressure at rest,
coefficient of active or passive earth pressure (whichever is
applicable). However, for design of cold water basin of cooling
tower and under ground liquid storage tanks earth pressure at
rest shall be considered. Temperature stresses shall also be
considered for tanks subjected to the same like hot water
storage tank.
5.4.2
In addition to earth pressure and ground water pressure, etc.

a minimum surcharge load of 2.0 t/sqm shall also be
considered for the design of all underground structures
including channels, sumps, cable and pipe trenches, etc. to
take into account the vehicular traffic in the vicinity of the
structure.
5.5
Wind load
5.5.1
Wind load on structures shall be calculated as per provisions of

IS:875 (part 3). The wind shall be assumed to blow in any
direction and most unfavourable condition shall be considered
for design.
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5.5.2
In design of structures, wind force on equipment supported on

frame including all fixtures, piping, staircases, ladders,
handrails, etc. shall also be considered.
5.6
Seismic loads
5.6.1
Seismic analysis using response spectrum method as per

IS:1893 shall be done.
5.7
Equipment loads
5.7.1
Static and dynamic loads of major equipment shall be based

on the manufacturers data of the specified equipment and
shall be considered in design in addition to the live load.
5.7.2
The design for the supporting structure for vibrating screens,

chutes, and
hoppers shall be based on the load data (both
static and dynamic) supplied by the manufacturer.
The
supporting structure for all vibratory equipment shall be
properly isolated from building structures.
5.7.3
The design parameters like, natural frequency, operating

frequency of the equipment, load combinations, slenderness of
columns, deflections of beams etc., shall be considered in the
design as per the manufacturers recommendations.
5.7.4
In case of disagreement between codal and manufacturers

stipulations on the limiting values of various design
parameters, the tenderer shall follow the most stringent
provisions in the design.
5.7.5
The supporting structures for equipment shall be braced

adequately in both vertical and horizontal planes to achieve
rigidity.
5.7.6
Necessary platforms, staircases, walkways and sufficient room

around equipment shall be provided for smooth maintenance
operations. Necessary space around the vibrating screens
shall be provided for inspection purpose.
5.7.7
All equipment, tanks and piping design loading shall include

hydraulic test loading. Weight of equipment, ducts, tanks,
pipes, conduits, etc. supported by structure shall include
maximum possible loading conditions i.e. flooded conditions
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and associated impacts, test loading, anchorage and constraint

effects.
5.7.8
Blast loads
All structures shall be designed for resisting
IS:4991 and IS:6922.
Blast loads as per
5.8
Other loads
5.8.1
Stresses imparted to structures due to differential settlements,

variation of water table, erection and maintenance loads,
temperature variation, creep and shrinkage shall also be
considered in design of all structures.
5.9
Basic load cases
5.9.1
The following basic load cases shall be considered for the

analysis as a minimum:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
Dead load
Self weight of permanent equipment
Live load on floor/walkway
Live load on roof
Crane load with lift
Crane load without lift
Wind load
Seismic load
Load due to soil pressure
Load due to surcharge
Load due to hydrostatic pressure
Load due to temperature
Special loads
Blast loads
Erection loads
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
D
EL
L
LR
CR1
CR2
WL
SL
SP
SCL
HP
TL
SPL
BL
LE
5.10
Load combinations
5.10.1
The individual members of the frame shall be designed for

worst combination of forces such as bending moment, axial
force, shear force and torsion. Permissible stresses for
different load combinations shall be taken as per IS:875 (PartV) and other relevant IS code. Wind and seismic forces shall
not be considered to act simultaneously.
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5.10.2
Criticality of erection / maintenance loads shall also be

checked separately in combination with other simultaneously
occurring loads for possible design loading.
5.10.3
Load combinations for underground structures
5.10.3.1
Following loading conditions shall be considered in addition to

the loading from super structure for the design of sub
structure of channels, sumps, tanks, trenches and other under
ground structures.
5.10.3.2
Only liquid pressure from inside and no earth pressure and

ground water pressure and surcharge pressure from outside
(applicable only to the structures which are liable to be filled
with water or any other liquid).
5.10.3.3
Earth pressure, surcharge pressure and ground water pressure

from outside and no water pressure from inside.
5.10.3.4
Design shall also be checked for buoyancy due to ground

water during construction and operation stage. Minimum factor
of safety as per IS:3370 against buoyancy shall be ensured
considering empty condition ignoring superimposed loads.
6.0
REINFORCED
FOUNDATIONS
6.1
General
6.1.1
All structures, building foundations, machines / equipment

foundation, water retaining structures, trenches, pits, etc.
shall be designed as per latest relevant IS codes in general.
Construction in general shall follow provisions of IS:456
2000 and IS:3370 for normal and liquid retaining structures
respectively.
6.1.2
All designs of RCC structures shall be carried out by limit state

method as per IS:456 2000 unless use of working stress
method is specifically mentioned. Design strength of materials
and design loads shall be calculated using appropriate partial
safety factors over characteristic strength and characteristic
loads as per IS:456 - 2000
CONCRETE
STRUCTURES
AND
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6.1.3
For reinforcement detailing IS:5525, SP-34 and IS:13920 shall

be followed.
6.1.4
The walls shall be provided with reinforcement on both faces

for sections 150 mm or more, even if not required from design
consideration.
6.2
Foundations and Underground Structures
6.2.1
Type of foundation system, i.e. isolated, strip, or raft shall be

decided based on the loading arrangement, load intensity and
soil strata. Design of foundations at various levels shall be
dependent upon the soil bearing capacity at that level.
6.2.2
Foundation system adopted shall ensure that settlement /

relative settlement is as per provision of IS:1904 and other
Indian Standards. However, the settlement shall be restricted
to a lower value, if necessary as per the system requirement.
6.2.3
All foundations including machine / equipment foundations

shall be of RCC construction. All foundations shall be designed
in accordance with relevant parts of the latest revisions of
Indian standards IS:2974 and IS:456. Raft foundations shall
be designed as per IS:2950.
6.3
Liquid Retaining Structures
6.3.1
RCC liquid retaining structures like storage tanks, over head

water tank etc. shall be leakproof and designed as uncracked
section in accordance with IS:3370 (Part 1 to IV) by working
stress method.
6.3.2
All liquid retaining / storage structures shall be designed

assuming liquid upto the height of wall irrespective of
provision of any over flow arrangement. No pressure relieving
devices shall be permitted in underground structures.
6.3.3
In all liquid retaining structures, PVC water bar shall be

provided at each construction / expansion joint. The sequence
of construction shall also be specified on drawings showing
construction joints.
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6.4
Machine Foundations
6.4.1
The design of machine / equipment foundation shall be as per

IS:456 and IS:2974.
6.4.2
All machine / equipment foundations and structures subject to

vibrations shall be suitably proportioned so that amplitude and
frequency of the foundation / structures are within permissible
limits.
6.4.3
In all block foundations resting on soil, the mass of the RCC

block shall not be less than three times mass of the machine.
Dynamic analysis shall be carried out to calculate natural
frequencies in all modes including coupled modes and to
calculate vibration amplitudes. Frequency and amplitude
criteria as laid down by the relevant codes or machine
manufacturers shall be satisfied. Minimum reinforcement shall
be governed by IS:2974 and IS:456.
6.4.4
For the foundations supporting minor equipment weighing less

than one ton or if the mass of the rotating parts is less than
one hundredth of the mass of the foundation, no dynamic
analysis is necessary. However, if such minor equipment is to
be supported on building structures, floors, etc. suitable
vibration isolation shall be provided by means of springs,
neoprene pads, etc. and such vibration isolation system shall
be designed suitably.
6.4.5
Pumps, ID fans shall be supported on conventional framed /

block type RCC foundations.
6.4.6
All such foundations shall be separated from adjoining parts of

building and other foundations. Joints at floor / slab shall be
suitably sealed. All appendages to such foundations shall be
reinforced suitably to ensure integral action.
6.5
Increase in Stresses
6.5.1
Where stresses due to wind (or seismic) and temperature are

combined with those due to other loads, the allowable stresses
in concrete and reinforcement steel shall be as per relevant
Indian Standards in case of working stress design. However,
where the wind load is the predominant load on the structure,
no increase in permissible stresses is allowed in case of
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working stress design.

6.5.2
6.6
Bearing capacity of the soil shall be allowed to increase by

25% under wind load condition. Increase of bearing capacity
under seismic conditions shall be as per IS:1893.
Stability of Structures
6.6.1
Design shall be checked against buoyancy due to the ground

water during construction and maintenance stages for
structures like under ground storage tanks, pits, trenches, etc.
Minimum factor of safety of 1.2 against buoyancy shall be
ensured considering empty condition inside and ignoring the
superimposed loading. For purpose of calculating downward
load due to any overburden, only the mass located vertically
above the projected area of the base slab shall be taken in to
consideration.
6.6.2
All building sub-structures including pump houses / retaining

wall shall be checked for sliding and overturning stability
during both construction and operating conditions for various
combination of loads. Factor of safety for these cases shall be
taken as mentioned in IS:456 and other latest relevant IS
codes. However, following minimum factor of safety shall be
followed:
a)
b)
c)
Factor of safety against overturning due to wind,

seismic or other lateral load shall be 1.5 minimum
Factor of safety against sliding shall be 1.5 minimum
Factor of safety against uplift due to hydrostatic forces
shall be 1.2 and due to any other loads shall be 1.5.
6.6.3
In cases where dead load provides the restoring force, only

0.90 times characteristic dead load shall be considered.
Imposed loads shall not be considered as restoring force.
6.7
Minimum. Thickness of concrete structural elements
6.7.1
The following minimum thicknesses shall be followed:

a) Suspended floor / slab/ walkways / canopy slabs etc:200 mm
b) Ground floor slab (non-suspended)

: 150 mm
c) Water retaining slabs / walls, building walls
: 200 mm
d) Cable/pipe trenches/underground pits/launder walls
And base slab
: 125 mm
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e)
f)
g)
h)
i)
VOLUME - V of V
Page 29 of 194
All footings (including raft foundations)

Parapets
Sunshades at edge
Precast lauvers / fins
Precast trench cover slabs / floor slabs / louvers
:
:
:
:
:
400 mm
125 mm
75 mm
50 mm
75 mm
6.7.2
From fire resistance point of view minimum thickness of

reinforced concrete members shall be as per of IS:456 2000. Minimum fire rating of 2 hours shall be considered
where fire hazard is expected.
6.8
Minimum heights for pedestals of steel columns:
6.8.1
Top of RCC foundations (pedestals) shall normally be kept at a

lower level so that the column base plates together with
gussets and stiffeners remain below finished floor level (FFL)
unless specified otherwise.
Encasing of pedestals for steel
columns shall be done, wherever required, as per Clause No.
6.9.
Foundation levels for columns shall be decided to
accommodate underground services, pits, trenches, etc.
6.8.2
Stair and ladder pedestal shall be kept 200 mm above the

finished floor level.
6.8.3
Pedestals for steel columns for equipment structures:

a) Equipment in open area
: as required (300mm min)
b) Equipment in covered area
: as required (150mm min)
c) Structures and equipment

supplied
by
vendor
specified above.
: as
subject
per
to
vendors data
minimum
as
6.9
Minimum heights for encasement of steel columns
6.9.1
In case the top of pedestal is kept at a lower level so that the

column base plate together with gussets and stiffeners remain
below finished floor level (FFL) the column bases as well as the
column sections shall be encased in concrete, above FFL as per
following:
a) Open area
b) Covered area
: 300mm above paved level

: 150mm above FFL
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The size of encasement shall be equal to the size of RCC

pedestal.
6.10
Concrete mix
6.10.1
Cement used shall conform to the following standards:43 Grade Ordinary Portland Cement
IS: 8112-1989
6.10.2
In case the chemical nature of the soil warrants special cement

shall be used for structures below ground level
6.10.3
The proportions for nominal mix of concrete shall be as per

Table 9 of IS:456. Nominal mix in concrete shall be allowed for
grades up to M 10 only and all other grades of concrete shall
be with Design Mix concrete in accordance to IS:456 and
SP:23.
6.10.4
The concrete grade used for different structures shall be as

follows:
6.10.5
M5
Fill concrete
M7.5
Leveling course below foundations, trenches and

under ground structures.
M10
Foundation below concrete block wall, RR masonry

walls.
M15
Pavement around buildings including plinth

protection work, damp proof course below
concrete block work, Base plate encasement,
encasement of structural steel work, block area
paving, screed concrete, etc.
M25
Reinforced concrete work for foundations, framed

structure, under ground structure, Equipment
foundations, water retaining structure etc. as per
design requirement.
Minimum cement content, maximum water cement ratio, and

minimum grade of concrete shall be considered as per IS:456
for moderate exposure condition. Weigh batching plant shall
be mobilized for all types of RCC works.
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6.11
Reinforcement steel
6.11.1
Reinforcing bars for concrete shall be TMT bars with strength

requirements conforming to IS :1786-2008 of Grade Fe 415
manufactured by preferred manufactures.
6.12
Grouting
6.12.1
Non-shrink flowable grout shall be used for under pinning work

below base plate of columns. Non-shrink cum plasticiser
admixture shall be added in the grout. For grouting of base of
machine foundation high strength ready mixed non-shrink
flowable grout shall be used.
6.12.2
Crushing strength of the grout shall generally be one grade

higher than the base concrete. Minimum grade of grout shall
be M 30.
6.12.3
Nominal thickness of grouting shall be at least 50mm for

building columns and pedestals of major equipment. For
secondary posts, stair and ladder base,etc. grouting shall not
be less than 25mm thick.
6.13
Foundation bolts and insert plates
6.13.1
Minimum distance from the anchor bolt to edge of pedestal

shall be the maximum of the following:
6.13.2
Clear distance from the edge of base plate / base frames to the
outer edge of the pedestal shall be minimum 50mm.
6.13.3
Clear distance from the face of pocket to the outer edge of

pedestal shall be 75mm.
6.13.4
Clear distance from the edge of sleeve or anchor plate to the

edge of pedestal shall be 75mm.
6.13.5
Steel templates shall be used for placement of bolts in position

in all types of foundations. Foundation bolts and pockets shall
be pre-fabricated before placing them in position.
6.13.6
Anchor bolts shall be designed for working stress, in tension

and shear and for required embedded length in concrete.
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Shear and crushing strength of concrete shall also be checked.

Increase in allowable stress for loading including seismic and
wind loads shall not be permitted in design of anchor bolts.
6.13.7
Insert plates shall be designed/checked for shear and bending

moment. All lugs shall be checked for tension. Bond strength
of concrete shall also be checked. Lugs using steel bars shall
preferably be fillet welded to the plate to transfer full strength
of the lug.
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SECTION III: DETAIL SPECIFICATION FOR CIVIL

CONSTRUCTION WORKS
CONTENTS
Section
C-01
C-02
C-03
C-04
C-05
Title
Technical
Technical
Technical
Technical
Technical
works
Specification
Specification
Specification
Specification
Specification
for
for
for
for
for
site clearance and levelling

Excavation and backfilling
Anti - termite treatment
Soling and Hardcore
Plain & reinforced concrete and allied
C-06
Technical Specification for Masonry and Allied Works
C-07
Technical Specification for Plastering & pointing
C-08
Technical Specification for Flooring & Allied Works

Technical Specification for Steel Doors, Windows, Ventilators,
Louvers
Technical Specification for wood work, carpentry & joinery
C-09
C-10
C-11
C-12
C-13
C-14
C-15
C-16
C-17
C-18
Technical Specification for Rolling Steel Shutter & Grills

Technical Specification for Aluminum works
Technical Specification for Glass and Glazing
Technical Specification for Painting, White-Washing.
Distempering and other finishing work
Technical Specification for Drainage, Sanitation and Water
Supply
Technical Specification for Road & Pavements
Technical Specification for Supply and Laying of RCC pipes
Technical Specification for Water proofing treatment for flat
roof.
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C - 01: SITE CLEARANCE & LEVELLING

1.0
SITE CLEARING
1.1
This specification covers the requirements of site clearance

and site leveling.
1.2
The Tenderer shall inspect the site to determine the extent of

all items to be cleared and the cost of this work is deemed to
be included in the item allowed for site clearance.
1.3
No trees or bushes are to be cut without the prior approval of

the Department who shall have to be notified at least 48 hours
before starting this work. All trees and bushes cut shall
become the property of the Department and shall have to be
stacked in an orderly manner by the Tenderer and as directed
by the officers of the Department adjacent to the main road so
that they can be easily loaded on lorries by the Department
1.4
All boulders shall be stacked in neat piles on approved sites

and locations.
1.5
All combustible matter shall be disposed of as directed by the

Consultant
2.0
LEVELLING
2.1
The site shall be brought to a fairly good level for grid marking
pillars to be established. The formation level of the site shall
be a minimum of 150mm higher than the average existing
ground level, unless otherwise specified in the drawings.
2.2
Any special natural features such as small hillock, trees, etc.,

shall not be disturbed and shall form part of light landscaped
area.
2.3
The site development includes leveling and filling, outside the

boundary for approaches, construction of compound walls,
drains, and culverts at required locations
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C- 02 : EXCAVATION WORK AND BACKFILLING

1.0
SCOPE
1.1
This section of the specification covers the technical

requirements for excavation & filling
around structures,
buildings, pipes, foundations, trenches, pits, drains, channels,
cable ducts, underground facilities & similar works. It also
covers filling areas and plinths with selected materials,
conveyance and disposal of surplus spoils at the waste dumps
shown on the drawings and/or stacking them properly as
directed by the Engineer/Consultant.
1.2
The Tenderer shall be fully responsible for proper setting out

works, profiling in excavation, stacking, etc. taking adequate
safety measures etc. The Tenderer 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 Tenderer.
The Tenderer shall provide and install suitable safeguards
approved by the Consultant for this purpose.
1.4
Excavated material if permitted by Consultant shall be used for

filling/ backfilling. Unsuitable material/ excess material shall be
disposed off in layers not more than 150mm as directed by
Consultant at waste dump locations to be indicated during
execution.
2.0
GENERAL
2.1
The Tenderer 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 the Owner. The Tenderer has to provide at site all
the required survey instruments, along with qualified
surveyors, to the satisfaction of the Consultant so that the
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work can be carried out accurately and according to the

specification and drawings.
2.2
The Tenderer 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.
2.3
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.
2.4
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.
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: 3764
IS: 4081
1992
1986
IS: 4701
IS: 9759
1982
1981
Safety code for excavation work

Safety code for blasting and related drilling
operations
Code of practice for earth work on canals
Guide
lines
of
dewatering
during
construction
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IS: 10379
VOLUME - V of V
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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
at no extra cost to the owner.
4.3
All excavation for installation of underground facilities, such as

pipe lines, drain lines etc. shall be open cuts. For deep and
huge excavations and in other excavations, if required by the
Consultant, the Tenderer shall submit for Consultants
approval an Excavation Scheme showing the methodology to
be adopted for excavation.
4.4
When excavation requires bracing, sheeting or shoring etc. the

Tenderer shall submit drawings to the Consultant, showing
arrangements and details of proposed installation. The
Tenderer 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 Tenderer, irrespective of any approval of the Consultant.
4.5
The Tenderer 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
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until the excavation, placement of reinforcement, shuttering,

concreting, backfilling is completed. The Tenderer shall
remove all slush/muck from the excavated areas to keep the
work area dry. The Tenderer, if required, shall employ sludge
pumps, for this purpose.
4.6
The Tenderer shall remove all materials arising from

excavations from the vicinity of the work either for direct
filling, stacking for the subsequent filling or for ultimate
disposal at the waste dumps shown on the drawings and as
directed by the Owner/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
For the work of excavation in rock, Tenderer shall engage

specialized agency having experience of excavation in rock
involving wedging and blasting. The agency shall be approved
by Consultant and the Tenderer shall furnish details of relevant
experience in support while seeking approval for the agency.
All relevant approvals from the Licensing agency and
regulations shall be followed.
5.2
In case of over breaks 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 earlier.
5.3
Where blasting is prohibited for any reasons or it is

practicable in the opinion of the Consultant, then
excavation shall be carried out by chiseling, wedging or
other approved method. The decision of the Consultant in
regard shall be final binding on Tenderer.
6.0
EXCAVATION BELOW GROUND WATER TABLE
6.1
not
the
any
this
The Tenderer 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
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require dry condition in the area are completed.

7.0
FILLING
7.1
Materials
7.1.1
Materials to be used for filling purpose shall be approved

earth, 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.
7.1.2
If excavated materials are to be used for filling, then the

Tenderer 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
laying in stockyard for a long period of time.
7.1.3
In case the materials have to be brought from pits/quarries, it

shall be the Tenderers 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 Tenderer shall pay any fees, royalties etc. that
may have to be paid for utilization of borrow areas.
7.2
Filling Procedure
7.2.1
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
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ground shall be dressed and consolidated by ramming and

light rolling.
7.2.2
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.
7.2.3
All space between foundation (concrete or masonry) and the

sides of 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 1.50
meters of building walls, piers for operation. The methods of
compaction shall be subjected to approval of Consultant under
any circumstances.
7.2.4
Fill adjacent to pipes shall be free of stones, concrete etc. and

shall be hand placed and compacted uniformly on both sides of
the pipes 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.
7.2.5
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
20mm, of the specified level.
7.2.6
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
200mm thick graded stones shall be laid in loose layers of
200mm, then the interstices filled with properly graded fine
materials consisting of selected earth brought from borrow
areas. Each layer shall be watered and compacted to the
specified density before the next layer is laid. However, no
cushion shall be required where filling is over non-rocky
surface.
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7.2.7
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.
7.2.8
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.
7.3
Compaction
7.3.1
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 dried by aeration to a moisture content of
3-5% above the Optimum Moisture Content to be determined
by the Tenderer. Each layer shall be watered, rammed and
compacted to the density as specified Consultant.
7.3.2
For compacting each sand layer, water shall be sprayed and

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.
7.3.3
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.
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7.3.4
The degree of compaction of compacted fill in place will be

subject to tests by the Consultant as the work progresses, and
the Tenderer 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 Tenderer. Compaction
procedure shall be amended as necessary to obtain
satisfactory results.
7.3.5
When semi-compacted fill is specified by the Consultant, the

Tenderer 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.
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C- 03 : ANTI - TERMITE TREATMENT

1.0
GENERAL
1.1
Pre-constructional antitermite treatment shall be provided to

all buildings with a chemical barrier against the sub-terrain
termites.
1.2
Anti-termite treatment being a specialized job, should be got

executed through specialized agencies only. The specialized
agency should be preferably a member of the Indian Pest
Control Association.
1.3
The scope of pre-constructional anti-termite treatment covers

the soil treatment with approved chemicals in water emulsion
in foundation trenches for columns, plinth beams, pile caps,
brick walls, service trenches, lift pits, steps, ramps etc., in top
surfaces of plinth filling, at junction of walls and floor, in
expansion joints etc., in stages as detailed in this
specifications and drawings, unless otherwise specified, the
anti-termite treatment will be carried out as per IS : 6313
(Part-II)-2001 and or as per direction of the Consultant.
2.0
CHEMICAL TO BE USED
2.1
The following chemical in water emulsion, after approval from

the Consultant, shall be used uniformly over the area to be
treated.
CHLROPYROPHOS
2.2
The Tenderer should produce voucher (s) for the chemical

purchased and should get verified the sealed container(s) of
the specified chemical from the Consultant before preparing
the emulsion / use for the treatment.
3.0
GUARANTEE
3.1
The Tenderer has to furnish the guarantee for 10 (ten) years

from the date of completion of work, stating that in case of
reappearance of termites within the building area due to
defective materials or workmanship or due to any other
reasons, the Tenderer will carry out the necessary post
constructional treatment to keep the entire area free from
termite, once again, without any extra cost to the Department
during the guarantee period.
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C 04 : 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 / hardcore
under foundations, hand packed, complete as per 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 consultant before
incorporation in the work.
2.2
Preparation of Surface & lying:
2.2.1
The bed on which rubble soling is to be laid shall be cleared of

all loose materials, leveled, watered and compacted and got
approved by the Consultant before laying rubble soling. Cable
or pipe trenches if shown in the drawing and as required by
the Consultant 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
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
Tenderer 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
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approved by the Consultant 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
Tenderer while laying and compacting the rubble soling to see
that concrete surfaces in contact with soling are not damaged.
3.0
HARDCORE FOR FOUNDATIONS
3.1
Where specifically mentioned in the drawings, on specific

recommendation of soil expert, hardcore layer shall be
provided as a preparatory surface to receive blinding
concrete/ leveling course.
3.2
Hardcore layer shall comprise of well-graded broken stones

80mm nominal size with the following gradation:
IS Sieve designation
80 mm
63 mm
40 mm
20 mm
10 mm
% passing
100
85-100
0-30
0-5
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.
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C- 05 : 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 Tenderer 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
CODES AND STANDARDS
2.1
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.
2.2
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 Tenderer.
2.3
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.
2.4
The following are the

IS : 73
1992
IS : 216
1961
IS : 269
1989
IS : 280
1978
various relevant Indian Standards:

Specification for paving bitumen
Specification for coal tar pitch
Specification for 33 grade Ordinary
Portland cement
Specification for mild steel wire for
general Engineering purposes
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IS : 383
1970
IS : 432 (Parts I)
1982
IS : 432(Parts II)
1982
IS: 455
IS: 456
1989
2000
IS: 516
1959
IS : 650
1991
IS: 702
IS: 800
1988
1984
IS: 816
1969
IS: 1161
1998
IS: 1322
1993
IS: 1363 (Part 1)
2002
IS: 1363 (Part 2)
2002
IS: 1363 (Part 3)
2002
IS : 1609
1991
IS : 1786
2008
Specification for coarse and fine

aggregates from natural sources for
concrete
Specification for mild steel medium
tensile steel bars and hard drawn
steel wire for concrete reinforcement
Mild steel & medium tensile bars
Specification for mild steel medium
tensile steel bars and hard drawn
steel wire for concrete reinforcement
- Hard drawn steel wire
Specification for Portland slag cement
Code of practice for plain and
reinforced concrete
Method of test for strength of
concrete
Specification for standard sand for
testing of cement
Specification for industrial bitumen
Code
of
practice
for
general
construction in steel
Code of practice for use of metal arc
welding for general construction in
mild steel
Specification for steel tubes for
structural purpose
Specification for bitumen felts for
waterproofing and damp proofing
Hexagon head bolts, screws and nuts
of product grade C Hexagon head
bolts (size range M 5 to M 64)
of product grade C Hexagon head
screws (size range M 5 to M 64)
of product grade C Hexagon nuts
(size range M5 to M 64)
Code of practice for laying damp
proofing treatment using bitumen
felts.
Specification
for
high
strength
deformed steel bars and wires for
concrete reinforcement.
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IS: 1834
1984
IS: 2016
IS: 2074
1967
1992
IS : 2386 (Part 1)
1963
IS : 2386 (Part 2)
1963
IS : 2386 (Part 3)
1963
IS : 2386 (Part 4)
1963
IS : 2386 (Part 5)
1963
IS : 2386 (Part 6)
1963
IS : 2386 (Part 7)
1963
IS : 2386 (Part 8)
1963
IS : 2502
1963
IS : 2571
1970
IS : 2645
2003
IS : 2751
1979
IS : 3037
1986
IS : 3150
1982
IS : 3370 (Part I)
1965
Specification for hot applied sealing

compound for joints in concrete
Plain washers
Specification for ready mix paint, air
drying, red oxide zinc chrome
Methods of test of aggregates for
concrete Particle size & shape
concrete Estimation of deleterious
material and organic impurities
concrete Specific gravity, Density,
voids, absorption and bulking
concrete Mechanical properties
concrete Soundness
concrete Measuring mortar making
properties of fine aggregates
concrete Alkali aggregate reactivity
concrete Petrographic examination
Code of practice for bending and
fixing
of
bars
for
concrete
reinforcement.
Code of practice for laying in-situ
cement-concrete flooring.
Specification for Integral cement
water proofing compounds for cement
mortar and concrete
Code of practice for welding of mild
steel plain and deformed bars for
reinforced concrete construction.
Specification for bitumen mastic for
use in water proofing of roofs
Specification
for
hexagonal
wire
netting for general purposes.
Code
of
practice
for
concrete
structures for the storage of liquids
General requirements
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IS : 3370 (Part II)
1965
IS : 3384
1986
IS : 3414
1968
IS : 3550
1965
IS : 4130
1991
IS : 4326
1993
IS : 5525
1969
IS : 5624
IS : 7861 (Parts I)
1993
1975
IS: 8112
1989
IS : 10262
1982
SP : 23
SP : 24
SP : 34
1982
1983
1987
Code
of
practice
for
concrete
structures for the storage of liquidsReinforced concrete structures
Specification for bitumen primer for
use in waterproofing & damp proofing.
Code of practice for design and
installation of joints in buildings.
Methods of test for routine control for
water used in Industry.
Safety
Code
for
demolition
of
buildings.
Code of practice for earthquake
resistant design and construction of
buildings.
Recommendations for detailing of
reinforcement in reinforced concrete
work.
Specification for foundation bolts.
Code of practice for extreme weather
concreting Recommended practice
for hot weather concreting
Specification for 43 Grade Ordinary
Portland Cement
Recommended guidelines for concrete
mix design.
Handbook of concrete mixes.
Explanatory Handbook on IS: 456
Handbook on concrete reinforcement
and detailing.
3.0
MATERIALS
3.1
General
3.1.1
All the materials used in the manufacture of concrete shall be

in accordance with these specifications, Storage and Handling
of Common Building Materials, which shall be deemed to form
a part of this specification.
3.1.2
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. The Tenderer
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shall arrange such an inspection and the Consultant s approval

shall be obtained prior to starting the work.
3.2
Aggregates
3.2.1
Aggregate shall consist of natural sand, crushed stone/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 IS:383
3.2.2
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.
3.3
Cement
3.3.1
The cement generally used shall be the Ordinary Portland

cement 43 grade. However, any special type of cement such
as High strength cement or sulphate resisting cement may be
used under specific circumstances with prior approval from
consultant.
3.3.2
The Tenderer 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 Tenderer
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
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such that there is no dead storage. Not more than 12 bags

shall be stacked in any tier. The storage arrangement shall be
got approved by the Consultant. Consignments of cement shall
be stored as received and shall be consumed in the order of
their delivery.
3.4
Reinforcement
3.4.1
Steel reinforcement bars for concrete shall be corrosion

resistant TMT bars with strength requirements conforming to
Grade Fe-415 of IS: 1786 manufactured by preferred
manufactures.
3.4.2
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.
3.5
Water
3.5.1
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.
3.6
Admixtures
3.6.1
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
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manufacturer. Calcium chloride as accelerating admixture is

not permitted to be used other than in mass concrete works.
The Tenderer shall produce latest test results carried out at
approved Government Test Houses for the approval of the
Consultant, before use.
3.7
EMBEDDED PARTS
3.7.1
Steel for light structural work and for preparation of inserts

and embedments shall conform to IS:2062.
3.7.2
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.
3.7.3
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)
3.7.4
Plain washers shall conform to IS: 2016 and spring washers

shall conform to IS: 3063.
3.7.5
Steel pipe sleeves shall conform to Medium class of IS: 1161.
4.0
CONCRETE MIX, WORKABILITY & DURABILITY
4.1
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 only by designing the mix. Design mix concrete
shall be designated as M20, M25, etc.
4.2
Workability
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.
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b) 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.
4.3
Durability of concrete:
a) Durability requirement 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.
b) Stipulations of minimum cement content and limiting water
cement ratio should be considered during design of mix.
5.0
PREPARATORY WORKS
5.1
Earth surface on which direct placement of concrete is to be

placed shall be rammed and consolidated 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. 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. In
case the drawings indicate hardcore below the blinding
concrete, the same shall be provided as per relevant
specifications.
5.2
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 of 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
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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. The final resulting surface shall be a
pitted surface, from which all dirt, unsound concrete, laitance
and glazed mortar have been removed.
5.3
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.
6.0
FORMWORK AND STAGING
6.1
Formwork shall compose of steel, best quality wood or nonabsorbent 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,
wormholes, warps or other surface defects and shall have
smooth finish.
6.2
The Tenderer 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 meters
span unless otherwise shown on the drawings. For cantilever,
camber at free end shall be 1 in 100.
6.3
The Tenderer shall begin the removal of formwork only after

approval of the Consultant. 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
6.3.1
Tolerances is a specified permissible variation from lines,

grade or dimensions given in drawings. Unless otherwise
specified, the following tolerances will be permitted.
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Tolerances for R.C. Buildings
Variation from the plumb
In the line and surfaces of
5 mm per 2.5 m,
columns, piers, walls and in
but not more than
buttresses
25 mm
For exposed corner columns and other conspicuous lines
In any bay or 5 m. maximum
(+/-) 5 mm
In 10 m. or more
(+/-) 8 mm.
Variation from the level or from the grades indicated on
the drawings
In slab soffits, ceilings,
beam soffist and in arises.
In 2.5 m
(+/-) 5 mm.
(+/-) 8 mm
In 10 m. or more
(+/-)15mm
For exposed lintels, sills, parapets, horizontal grooves
and other conspicuous lines
(+/-)15mm
In 10 m. or more
(+/-)10mm
Variation of the linear building lines from established
position in plan and related position of columns, walls
and partitions
In any bay 5 m. maximum
(+/-) 10 mm
In 10 m. or more
(+/-) 20 mm.
Variations in the sizes and
(+/-) 5 mm
locations of sleeves, openings in
walls and floors except in the
case of and for anchor bolts
Variation in cross-sectional
(+)10mm / (-)5
dimensions of columns and
mm
beams and in the thickness of
slabs and walls
Footings
variation in dimensions in plan
(+) 50 mm / (-) 5
mm
Misplacement of concentricity
2% of footing within
the direction of
misplacement but
not more than 50
mm.
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Reduction in thickness
Variation in steps
In a flight of stairs
Rise
Tread
In consecutive steps
Rise
Tread
(-) 5% of specified
thickness subject to
maximum of 50
mm.
(+/-) 3.0 mm
(+/-) 5.0 mm
(+/-) 1.5 mm
(+/-) 3 mm
Tolerance in other Concrete Structure

All structures
1
Variation of the constructed linear out line from
established position in plan
In 5 m
(+/-) 10 mm.
In 10 m. or more
(+/-) 15 mm.
2
Variation of dimensions to individual structure features
from established positions in plan
In 20m. or more
(+/-) 25 mm.
In buried constructions
(+/-) 150 mm
3
Variation from plumb, from specifies batter or from
cured surfaces of all structures
In 2.5 m
(+/-) 10 mm.
In 5.0 m
(+/-) 15 mm.
In 10.0 m. or more :
(+/-) 25 mm
(+/-) Twice the
above limits.
4
Variation from level or grade indicated on drawings in
slabs, beams, soffits, horizontal grooves and visible
arises
In 2.5 m
(+/-) 5 mm.
In 7.5 m. or more
(+/-) 10 mm
(+/-) Twice the
above limits
5
Variation in cross-sectional
(+) 10mm./(-) 5
dimensions of columns, beams,
mm.
buttresses, piers and similar
members
6
Variation in the thickness of
(+) 10 mm./(-) 5
slabs, walls, arch sections and
mm
similar members
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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.
7.0
REINFORCEMENT PLACEMENT
7.1
All reinforcement for concrete works shall be provided as per

approved drawings. The Tenderer 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.
7.2
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.
7.3
Unless shown otherwise on the drawings, minimum clear

concrete cover for reinforcement (exclusive of plaster or other
finishes) shall be as specified in Cl. 26.4 of IS:456
7.4
Special requirements in corrosive atmosphere: Unless special

protective coatings are used, the appropriate measures for
structures exposed to sever conditions shall be followed.
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8.0
EMBEDDED PARTS
8.1
Embedded steel parts shall be supplied, fabricated and erected

by the Tenderer 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. Embeded parts shall not be
welded to the reinforcement.
9.0
MIXING OF CONCRETE
9.1
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 Tenderers 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.
9.2
BATCHING OF CONCRETE
9.2.1
Aggregates and 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.
Water may be measured either by weight or by volume.
9.2.2
Any solid admixture, to be added, shall be measured by

weight, but liquid or semi-liquid admixture may be measured
by weight or volume.
10.0
TRANSPORTATION OF CONCRETE
10.1
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
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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.
10.2
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 Tenderer.
11.0
CONCRETE PLACING
11.1
Before the concrete is actually placed in position, the inside of

the formwork 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.
11.2
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 Tenderer for this purpose and to be submitted along with
the Tenderers bills.
11.3
Slabs, beams and similar members shall 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.
11.4
No concrete shall be placed in wet weather or on water

covered surface. Any concrete that has been washed by
heavy rain shall be entirely removed, if there is any sign of
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cement and sand having been washed away from the concrete
mixture.
11.5
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.
11.6
During hot weather (atmospheric temperature above 40

degree centigrade) the concreting shall be done as per the
procedures and precautions set out in lS:7861 (Parts I and II)
11.7
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
12.0
COMPACTION
12.1
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
PROTECTION AND CURING OF CONCRETE
13.1
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.
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13.2
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.
13.3
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.
14.0
JOINTS IN CONCRETE
14.1
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 watertight by use of
water stops.
14.2
Construction Joints: Location and treatment of construction

joints shall be as approved by Consultant
14.3
Contraction Joints provided to eliminate tensile stresses due to

shrinkage where temperature variations are small and where
there is no likelihood of expansion, such as spaces below
water and earth levels and not exposed 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.
14.4
Expansion Joints provided either to completely eliminate or to

significantly reduce compressive stresses in concrete that
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would otherwise result by thermal expansion which might

crush, buckle or crack, part of the structure. Expansion joints
serve the purpose of contraction and also construction joints.
Bitumen impregnated fiber board 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. Expanded polystyrene
slab when used shall be of fire retarding grade (type-2)
conforming to IS:4671. Density of material shall not be less
than 25kg/cum.
14.5
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. The Water stops shall be 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.
14.6
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.
14.7
Polysulphide sealant 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 manufacturers guidelines.
14.8
Metal cover strips shall be made of aluminium as shown on

drawings. The minimum thickness of aluminium strips shall be
3 mm. Aluminium alloy strip shall be corrosion resistant grade
31000 as per IS:737.
15.0
CEMENT ADDITIVES/ADMIXTURES IN CONCRETE
15.1
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
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15.2
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.
16.0
GROUTING
16.1
Ready mixed non-shrink cementitious grout for 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%
16.2
Grouting of pockets/holes in concrete: shall be done using

cement-sand grout or cement, sand and aggregate grout
depending upon the size of the pockets/holes in the concrete.
This mix shall generally be used for grout thickness above 40
mm for dry pack application. Normally the grade of such
concrete/mortar shall not be less than the grade of parent
concrete. In filling the holes of foundation bolts and expanding
admixture of approved type shall be used as per
manufacturers specification..
16.3
Surface to be grouted shall be thoroughly roughened and

cleaned of all foreign matter and laitance. The block outs, 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.
17.0
PRECAST CONCRETE ELEMENTS
17.1
Precast concrete elements such as fencing posts, copings, sills,

shelves, trench/ pit cover slabs, louvers, etc., shall be at least
of mix M-20. Concrete for Precast concrete shall comply with
IS:456.
17.2
Precast concrete elements shall be cast in forms or moulds.

The forms / mould shall be of fiberglass 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.
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17.3
Elements shall be cast on suitable bed or platform with firm

foundation. 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.
17.4
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.
17.5
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
stored 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
18.0
SAMPLING, TESTING AND QUALITY ASSURANCE
18.1
Samples from fresh concrete shall be taken in accordance with

IS:1199 and tested as per IS:516. Normally only compressive
test shall be performed, but the Consultant may require other
tests to be performed in accordance with lS-516. For Trial
Mixes & mix design, at least four trial mixes shall be made
with minimum 6 test cubes for each mix. For works tests 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, the Consultant may at
his discretion reduce the frequency of sampling. All sampling
and testing shall be done in the presence of the Consultant.
18.2
To control the consistency of concrete from every mixing,

slump tests and compaction factor tests in accordance with lS1199 shall be carried out by the Tenderer as directed by the
Consultant. Slumps corresponding to the test specimens shall
be recorded for reference.
18.3
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
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remaining portion of the structure.

18.4
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
Tenderers expense.
18.5
Unacceptable concrete work shall be dismantled by the

Tenderer 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 Tenderer, to the satisfaction of the
Consultant, at no extra cost.
18.6
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.
18.7
If directed by Consultant, Ultrasonic tests and core tests on

structures to ascertain the quality and grade of concreting
shall be carried out. Tenderer shall arrange for the specialised
agency for conducting the test at his own cost. The Tenderer
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 Tenderer 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.
18.8
Consultant , if he so desires, may order for tests to be carried

out on cement, sand, coarse aggregate, water etc., in
accordance with the relevant Indian Standards.
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19.0
APPLICATION OF LIVE LOAD
19.1
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.
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C- 06 : MASONRY AND ALLIED WORKS

1.0
SCOPE
This section of the specification covers providing, constructing
of masonry and allied works including DPC and plinth
protection.
2.0
GENERAL REQUIREMENTS
2.1
All workmanship shall be in accordance with the latest

standards and best possible practice. Masonry work shall be
true to line & level as shown on drawings. All such masonry
shall be tightly built against structural members and bonded
with dowels, anchors, inserts, etc. as shown on the drawings.
2.2
The Tenderer shall carryout all works for setting out the
building lines, locating the co-ordinates and establishing the
reduced levels (RLs) on the basis of reference grid lines and
bench mark, which shall be furnished by the Owner, at one or
more locations.
2.3
Any approval, instructions permission, checking, review, etc.

whatsoever by the Consultant shall not relieve the Tenderer of
his responsibility and obligation regarding adequacy,
correctness,
completeness,
safety,
strength,
quality,
workmanship, etc.
3.0
CODES AND STANDARDS
3.1
All applicable standards, acts and codes of practice referred to

shall 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
Tenderer.
3.2

Standards, Codes etc.) referred to in clause 3.3 the former
shall prevail.
3.3
Some of the applicable Indian standards, Codes, etc. are

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IS: 1077
1992
IS: 2116
1980
IS: 2185 (Part 1)
2005
IS: 2212
IS: 2250
1991
1981
IS: 2386 (Part 1)
1963
IS: 2386 (Part 2)
1963
IS: 2691
1988
IS: 3495 (Part 1)
1992
IS: 3495 (Part 2)
1992
IS: 3495 (Part 3)
1992
IS: 3495 (Part 4)
1992
IS: 4031 (Part 5)
1998
IS: 4031 (Part 7)
1998
IS: 4130
1991
IS: 4326
1993
Specification for Common burnt clay

bricks
Specification for sand for masonry
mortars
Concrete Masonry Units Specification Part 1 Hollow and Solid
Concrete Blocks
Code of practice for brick work
Code of practice for preparation and
use of masonry mortar
Methods of test for aggregate for
concrete Particle size & shape
Methods of test for aggregate for
concrete Estimation of deleterious
materials and organic impurities
Specification for burnt clay facing
work
Method of tests for burnt clay
building bricks Determination of
compressive strength
water absorption
efflorescence
warpage
Methods of physical tests for
hydraulic cements - Determination of
initial and final setting time
Methods of physical tests for
hydraulic cements - Determination of
compressive strength of masonry
cement
Safety code during demolition of
buildings
Code of practice for earth quake
resistant design and construction of
buildings
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SP: 20
1991
SP: 25
1984
Hand book on masonry design &

construction
Handbook on causes and prevention
of cracks in buildings
4.0
STONE MASONRY
4.1
Random rubble masonry: The rubble shall be of the best

quality trap / granite / ballast stones obtained from the
approved quarry. The sample of the stone, to be used shall be
got approved from the Consultant. All stones shall, generally
be freshly quarried and shall be sound, dense, hard, free from
segregation, cracks, weathered portions and other structural
defects or imperfections, tending to off set soundness and
strength. The percentage of water absorption shall generally
not exceed 5% by weight. All stones shall be wetted before
use. Stones shall be neatly worked to requisite sections and
forms and shall have fully dressed beds and joints. At least
50% of the stones shall be 0.015 cum. in content when
reckoned individually. The length of stones for stone masonry
shall not exceed three times the height and the breadth or
base shall not be greater than three fourth the thickness of
wall, or not less than 15 cm. The height of stone may be upto
30 cm. Stones shall be laid on the natural beds and shall run
sufficiently inside the wall thickness. No hollow space shall be
left out and inter spaces of stones being filled with mortar and
stone chips, driven hard and not with mortar only.
4.2
All mortar to be used shall be of proportion (1:5). Cement,

sand and water to be used shall conform to their relevant
specifications as described under cement concrete.
The
masonry shall be laid to plumb, lines levels, curves, shapes as
shown in drawings. All required holes for passage of water or
pipes are to be embedded during construction as specified.
4.3
All stones shall be wetted before laying in masonry. Concrete

surfaces of columns, beams, lintels, chajjas etc. coming in
contact with masonry shall be properly chipped, washed and
wetted before start of masonry work. The concrete surface
coming in contact of masonry shall be given a thick coat of
cement slurry as the masonry work progress in height. Clean
chips and sprawls carefully selected to fit in the space shall be
wedged into the mortar joints and beds wherever necessary to
avoid thick beds or joints or mortar. However, proper shaping
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and dressing of stones shall be done prior to their laying in

masonry and hammering shall not be resorted to often after
the stones are laid in position. The bond stones shall be used
in every square meter area of masonry wall and shall extend
from front to back to thin walls having width of 600 mm. and
shall overlap by at least 150 mm. in walls having thickness
more than 600 mm. when laid from both sides. When the
work has to be started on the old or the one completed a long
while ago or in the previous working seasons. Care shall be
taken to roughen and clean old surface satisfactorily without
disturbing the masonry before laying the new masonry. It
shall be wetted before laying the bedding mortar.
4.4
When practicable, the whole masonry in any structure shall be

carried out upto a uniform level throughout. But when breaks
are unavoidable in carrying the work continuously in uniform
level, sufficiently long steps shall be left. All junction of walls
shall be formed at the time when walls are being built. Cross
walls should be carefully bonded into the main walls. All
masonry built in cement mortar shall be kept continuously wet
for 14 days from the date of laying. Should the mortar perish
i.e. becomes dry, white or powder through neglect of watering
and if the masonry shows hollow joints or non adherence of
mortar to the stones or if the work does not conform to
drawings and specifications, the work shall be pulled down and
rebuilt by the Tenderer at his own cost and risk. All masonry
shall be thoroughly cleaned and washed down on completion
and all stains, adhering mortar removed from the surface and
raking of joints carried out as the scaffolding is being lowered
and removed. Holes left in masonry for supporting scaffolding
shall be filled and made good before pointing / plastering.
4.5
Coursed rubble masonry : The face of the stones shall be

square / rectangular in shape and shall be so dressed alround
that those can be set on proper bases and shall render uniform
joints. The stones may have bushing on the face but shall not
project more than 40 mm. the external faces shall be laid in
courses of about 200 mm. height or as specified and the
internal face shall be finished with rubble backing.
5.0
PRECAST CEMENT CONCRETE SOLID BLOCK MASONRY :
5.1
Precast cement concrete solid blocks shall be of best quality

locally available / manufactured at site and should be
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approved by the Consultant before incorporation in the work.

The ingredient and cement concrete used shall confirm to
relevant I.S. as stipulated in specification for cement concrete
works herein before.
5.2
Minimum crushing strength of the solid blocks shall be 50 kg /

Sqcm. at 28 days. The size of the blocks shall be as per
IS:2185(Part-1) and the proportion used in making the blocks
shall be so as to achieve a minimum compressive strength of
50 kg / Sqcm. The blocks shall be cured well at least for 14
days. The cement mortar for concrete blocks masonry shall be
(1:5) and joints shall not be more than 20 mm. thick. The type
of the bond to be adopted will be decided by the Consultant
but vertical joints shall be staggered
6.0
DAMP PROOF COURSE (DPC)
6.1
Damp proof course shall be 50 mm thick (unless specified

otherwise) consisting of cement concrete in the proportion (1:
1: 3) (1 cement, 1 sand, 3 stone chips 10 mm down) with
admixture of a water proofing compound as approved by the
Consultant. The percentage of admixture shall be as per
manufacturers specification.
6.2
The surface of the brick work/ stone masonry work shall be

leveled and prepared before laying the cement concrete.
Edges of DPC shall be straight and even. The side shuttering
shall consist of wooden forms and shall be strongly and
properly fixed so that it does not get disturbed during
compaction and mortar does not leak through.
6.3
The concrete mix shall be of workable consistency and dense.

When the side shuttering is removed the surface should come
smooth without any honeycombing. The top surface shall be
double chequered and cured by ponding for at least 7 days.
Cement concrete shall be allowed to dry for 24 hours after
curing and hot bitumen of grade 85/25 Conforming to IS: 702
at the rate of 1.7 kg/sqm. shall be applied over the dried
surface of cement concrete properly cleaned with brush and
finally with a cloth soaked in kerosene oil. The bitumen shall
be applied uniformly so that no blank spaces are left
anywhere.
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7.0
PLINTH PROTECTION
7.1
Plinths of all buildings shall be protected with 1000 mm wide

plinth protection consisting of 50 mm thick PCC M20 grade
with 12 mm maximum size aggregate over 200 mm thick
stone soling using 40 mm nominal size, rammed consolidated
& grouted with fine sand. Plinth protection shall be laid with a
minimum outward slope of 1:50.
7.2
For the purpose of stone filling, the ground shall be dressed

consolidated by ramming or by light rolling & 12 mm thick
cushion of sand be laid. Over this, 75 mm thick layer of stone
aggregate, with stone size not more than 40 mm, shall be
spread uniformly. This shall be then compacted by light roller
(by 1/2 ton roller & 4 to 5 passes) or any other means as
approved by Consultant. After compacting, sand shall be
uniformly spread & water shall be sprayed over it to ensure
that the voids are filled with sand. Water shall be spread in
such a manner that bulking in sand does not take place.
7.3
This process shall be repeated till the filling reaches the

desired level. When it reaches the finished level, surface shall
be flooded with water for 24 hours, allowed to dry & then
rammed & consolidated to avoid any settlement at a later
stage.
8.0
SAMPLING TESTING AND QUALITY CONTROL
8.1
The Tenderer 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 Engineering practice to the directions
of the Consultant. Tests shall be done in the field and at a
laboratory, approved by the Consultant and the Tenderer 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 minor operations.
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8.2
Material/work found unsuitable for acceptance, shall be

removed and replaced by the Tenderer. The works shall be
redone as per specification requirements and to the
8.3
All masonry shall be built true and plumb within the tolerances
prescribed as below. Care shall be taken to keep the perpends
properly aligned.
a) Deviation in verticality in total height of any wall of a
building more than one storey in height shall not exceed
+/- 12.5 mm.
b) Deviation from vertical within a storey shall not exceed +/6 mm per 3 m height.
c) Deviation from the position shown on the plan of any
brickwork more than one storey in height shall not exceed
12.5 mm.
d) Relative displacement between load bearing walls in
adjacent storeys intended to be in vertical alignment shall
not exceed 6 mm.
e) Deviation of bed joint from horizontal in any length upto 12
m shall not exceed 6mm, and in any length over 12m it
shall not exceed 12.5 mm total.
f) Deviation from the specified thickness of bed-joints, crossjoints or perpends shall not exceed 3 mm.
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C- 07: PLASTERING & POINTING

1.0
SCOPE
1 .1
This specification covers the plastering work on brick or

concrete faces of specified thickness with architectural features
wherever necessary. For application of Cement and Cement
lime - plaster finishing. IS: 1661-1972 Code of practice for
application of cement and lime plaster finishes shall be
applicable.
2.0
MIX
2.1
Mortar for plastering in the proportion as specified on

drawings/ specification, shall be mixed in a dry state and then
wetted and mixed thoroughly to obtain the required
consistency. The mortar shall be mixed in an approved manner
including machine mixing if desired by the Consultant and in
batches so that the mortar is consumed within half an hour of
mixing. Any mortar for plaster which is partially set shall be
rejected and removed from site.
2.2
The mix for plastering shall be as follows:

Main
walls
(CC block
masonry)
Outside Plaster First layer (base coat) of 12 mm
thick
(1:6), (1 Cement, 6 Fine
sand and second layer (finish
coat) of 6 mm thick (1 : 4) (1
Cement, 4 Fine sand)
Inside Plaster 12 mm thick (1 : 6), (1 Cement,
6 Fine sand)
Partition walls (To be used 12 mm thick (1: 4), (1Cement, 4
only for inside Fine sand)
walls)
Concrete Ceiling Plaster
6 mm thick (1 : 4), (1Cement,
4 Fine sand)
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3.0
APPLICATION
3.1
Before application of plaster, surface is to be prepared

conforming to IS:1661 latest revision.
3.2
In all plaster work, mortar shall be applied with somewhat

more than that the required thickness and well pressed into
the joint and in the surface and rubbed and levelled with a flat
wooden rule to give required thickness.
3.3
Plaster, when more than 12 mm thick, shall be applied in two

coats, base coat followed by the finishing coat. Thickness of
base coat shall be just sufficient to fill up all unevenness in the
surface; no single coat, however, shall exceed 12 mm in
thickness. The undercoat shall be thicker than the upper coat.
The overall thickness of the plaster shall not be less than the
minimum thickness shown in the drawings or as specified. The
undercoat shall be allowed to dry and shrink before applying
the second coat of plaster.
3.4
Cement mortar for plastering work shall be used within 30

minutes after adding water to cement and should be kept
agitated at intervals of 10 minutes.
3.5
The undercoat shall be scratched or roughened before it is

fully hardened to form a mechanical key. The method of
application shall be thrown on rather than applied by trowel.
The finished surface shall be true to line and plumb and the
Tenderer shall without any extra cost to Owner make up any
irregularity in the masonry/ concrete work with plaster. The
mortar shall adhere to the surface intimately when set and
there should be no hollow sound when struck. All vertical
edges of pillars, doorjambs etc. shall be chamfered or rounded
off as directed by the Consultant. All corner must be finished
to their true angles or rounded. Any plastering that is
damaged shall be repaired and left in good condition at the
completion of the job without any extra cost to Owner.
3.6
All external plaster shall be done with approved water proofing

compound. The external plaster shall be at least 20mm thick.
3.7
Cement Pointing shall be done on exposed masonry. Exposed

faces shall be cement rule pointed with (1:3) CM. The mortar
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shall be raked out of the joints to a depth of 12 mm. The dust

shall be brushed out of the joints and the wall well wetted.
The pointing shall be kept wet for 7 days. During this period it
shall be suitably protected from all damages.
3.8
Lime punning: For plastered surface, where an even smooth

surface is specified, lime punning with 5 parts of shell lime
properly slaked, sieved and aged, mixed with 1 part clean,
washed, sieved, fine sand by volume shall be done. The
thickness of lime punning shall not be less than 2 mm and not
more than 3 mm. The plastered surface shall be saturated with
water before application of the lime punning. The lime punning
shall be applied by skilled workmen and given a smooth and
even finish.
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C- 08 : FLOORING & ALLIED WORKS

1.0
SCOPE
1.1
This specification covers furnishing, installation, finishing,

curing, testing, protection, maintenance till handing over
various types of floor finishes and allied items of work as listed
below:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Integral finish to concrete base

In situ Terrazzo finish
Metallic hardener like Ironite finishes
IPS Flooring
Terrazzo Tiled finish
Glazed tile finish
Vitrified ceramic tiles finish
Acid resistant tile finish
PVC tile finish
False flooring
2.0
GENERAL
2.1
Base: The base to receive the finish either formed concrete

sub-base or floor slab covered under other relevant
specifications.
2.2
Only workers specially experienced in particular items of

finishing work shall be engaged; where such workers are not
readily
available,
with
the
Consultants
permission,
experienced supervisors recommended by the manufacturer
shall be engaged. In particular case where the Consultant so
desire, the Tenderer shall get the finishing items installed by
the manufacturer.
2.3
The surface to be treated shall be thoroughly examined by the

Tenderer. Any rectification necessary shall be brought to the
notice of the Consultant and his approval shall be obtained
regarding method and extent of such rectification work. For all
types of flooring, skirting, dado and similar works, the base to
receive the finish shall be adequately roughened by chipping,
raking out joints and cleaning thoroughly all dirt, grease etc.,
with water and hard brush and detergent if required, unless
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otherwise directed by the manufacturer of any special finishing

treatment, the base shall be thoroughly soaked with water and
all excess water mopped up. The surface shall be done dry
where adhesive are used for fixing the finishes. Prior to
commencement of actual finishing the approval of the
Consultant shall be taken as to the acceptability of the surface.
3.0
CODES AND STANDARDS
3.1

Tenderer.
3.2

shall prevail.
3.3

IS: 1237
1980
IS: 1443
1972
IS: 2114
1984
IS: 2571
1970
IS: 5318
1969
IS: 4441
1980
IS: 4457
1982
IS: 13753
1993
IS: 13753
1993
Specification for Cement concrete

flooring tiles
Code of practice for laying and
finishing of cement concrete flooring
tiles.
Code of practice for laying in situ
terrazzo floor
Code of practice for laying-in-situ
concrete flooring
Laying of flexible sheet and tile
flooring
Code of practice for use of silica type
chemical resistant mortar
Specification for Ceramic unglazed
vitreous acid resistant tiles.
Specification for dust pressed ceramic
tiles with water absorption of E> 10%
Group (B III)
tiles with water absorption of 6% <E<
10% Group (B II b)
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IS : 13753
1993
IS : 13753
1993

tiles with water absorption of 3% <E<
6% Group (B II a)
tiles with low water absorption of E<
3% Group (B I)
4.0
MATERIALS
4.1
Materials required for individual finishing items are specified

under respective items. In general, all such materials shall be
as per relevant IS Codes where available. In all cases these
materials shall be of the best quality available indigenously
unless specified otherwise.
4.2
The materials for finishing items must be procured from wellreputed specified manufacturers and on the basis of samples
approved by the Consultant. The materials shall be ordered,
procured and stored well in advance to avoid compulsion to
use substandard items to maintain the construction schedule.
5.0
INTEGRAL FINISHING TO CONCRETE BASE
5.1
While the surface of the concrete laid as per specification for

cast-in situ concrete and allied works has been fully
compacted and levelled but the concrete is still green, thick
slurry made with neat cement shall be applied evenly and
worked in with iron floats. When the slurry starts to set, it
shall be pressed with iron floats, to have a firm compact
smooth surface without any trowel mark or undulations. This
finish shall be as thin as possible by using 2.2 Kg of cement
per sqm. of area. The surface shall be kept in shade for 24
hours and then cured for at least 7 days continuously by
flooding with water. The surface shall not be subjected to any
load or abrasion till 21 days after laying. As desired by the
Consultant, the surface, while still green shall be indented by
pressing strings. The markings shall be of even depth, in
straight lines and the panels shall be of uniform and
symmetrical patterns.
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6.0
IN-SITU TERRAZZO FINISH
6.1
It shall consist of an underbed and a topping laid over an

already laid and mature concrete base.
6.2
Unless otherwise specified the total thickness of the finish shall

be minimum 40mm for horizontal and 20 mm for vertical
surface of which the topping shall be not less than 12 mm and
10mm respectively. While the topping shall be of uniform
thickness the thickness of underbed may vary, to provide
necessary slopes. The vertical surface shall project out 6 mm
from the adjacent plaster or other finishes. Necessary cutting
into the surface receiving the finish shall be done to
accommodate the specified thickness.
6.2.1
All junctions of vertical with horizontal shall be rounded neatly

to uniform radius of 25 mm.
6.3
MIX
6.3.1
Underbed : the underbed for floors and similar horizontal

surface shall consist of a mix of 1 part cement, 2 part sand
and 4 parts stone chips by volume. For vertical surfaces the
mix shall consist of 1 part cement to 3 parts of coarse sand by
volume. The stone chips shall be 12.5mm down well graded.
Just sufficient water shall be added to give a workable
consistency.
6.3.2
Topping : The mix for the topping shall be composed of

cement, colour pigment, marble powder and marble chips.
Proportions of the ingredients shall be such as to produce the
terrazzo of colour, texture and pattern approved by the
Consultant. The cement shall be grey, to which pigment shall
be added to achieve the desired colour. 3 parts of this mixture
to 1 part marble powder by weight shall be added and
thoroughly mixed dry. To 1 part of this mix, 1.5 parts of
marble chips by volume shall be added and thoroughly mixed
dry again. The pigment added shall conform to the relevant
Indian Standard specification and must be stable and nonfading. It must be very finely ground. The marble powder
shall be from white marble and shall be finer than I S Sieve
No. 30. the size of marble chips may be between 3 mm to 20
mm. Sufficient quantity to cover each visible area shall be
prepared in one lot to ensure uniform colour. Sufficient water
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to make it just workable shall be added, to a quantity of mix

that can be used up immediately before it starts to set.
6.4
LAYING
6.4.1
The underbed shall be laid in panels. The panels shall not be

more than 5 sq.m. in area of which no side shall be more than
2.5 m long. For exposed locations the maximum area of a
panel shall be 2.0 sq.m. The panels shall be laid in alternate
bays or chequered board pattern. No panels shall be in contact
with another already laid until the latter has contracted to the
full extent.
6.4.2
Dividing strips made of aluminium/glass shall be used for

forming the panels. The strips shall exactly match the total
depth of underbed plus topping.
6.4.3
After laying, the underbed shall be levelled compacted and

brought to proper grade with a screed or float. The topping
shall be laid after about 24 hours while the underbed is still
somewhat green but firm enough to receive the topping. A
slurry of the mixture of cement and pigment already made
shall be spread evenly and brushed in just before laying the
topping. The topping shall be rolled for horizontal areas and
thrown and pressed for verical areas to extract all superfluous
cement water and to achieve a compact dense mass fully
bonded with the underbed. The surface of the topping shall be
trowelled over, pressed and brought to a smooth dense
surface showing a minimum 75% area covered by marble
chips in an even pattern of distribution.
6.5
Curing: The surface after laying shall be left for about 12 to 18

hours and then cured by allowing water to stand on the
surface or by covering with wet sack for four days.
Grinding and Polishing
6.6
6.6.1
When the surface has sufficiently hardened it shall be watered,

and ground evenly with rapid cutting coarse grade (No. 60)
grit blocks, till the marble chips are exposed and the surface is
smooth. Then the surface shall be thoroughly washed and
cleaned. A grout, with already prepared mixture of cement and
pigment shall be applied to fill up all pinholes.
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6.6.2
This surface shall be cured for 7 days by keeping it moist and

then ground with fine grit block (No. 120). It shall again be
cleaned with water, the slurry applied again to fill up pinhole
that might have appeared and allowed to be cured again for 5
days. Finally the surface is ground third time with very fine grit
blocks (No. 320) to get smooth surface without any pinhole.
The grinding shall be done by a suitable machine. Where
grinding machine cannot be used hand grinding may be
allowed when the first rubbing shall be with carborundum
stone of coarse grade (No. 60), second rubbing with medium
grade (No. 80) and final rubbing and polished with fine grade
(No. 120). The surface shall be cleaned with water, dried and
4 covered with oil free clean sawdust. The final polishing shall
be postponed until just before handing over, if desired by the
Consultant.
6.6.3
Just before handing over, the surface shall be dusted with

Oxalic acid at the rate of 0.33 gm per sq. m., water sprinkled
on it and finished by buffing with felt or hessain bobs. The
floor be cleaned with soft moist rag and dried.
7.0
METALLIC HARDENER FINISH
7.1
It shall consist of an underbed and a topping (incorporating

iron particles) laid over an already laid and matured concrete
base.
7.2
Thickness
7.2.1
Unless otherwise specified the total thickness of the finish shall

be minimum 25mm for horizontal surface of which topping
shall not be less than 12 mm. While topping shall be of
uniform thickness, the underbed may vary in thickness to
provide necessary slope. The vertical surface shall project 6
mm from adjacent plaster or other finishes. Necessary cutting
into the surface receiving the finish shall be done to
accommodate the specified thickness.
7.3
Material
7.3.1
The hardening compound shall be uniformly graded iron

particles, free from non-ferrous metal impurities, oil, grease,
sand, soluble alkaline compounds or other injurious materials.
When desired by the Consultant, actual samples shall be
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tested.
7.4
Mix
7.4.1
The underbed for floor and similar horizontal surfaces and for
vertical surface shall be as per clause 6.03.01 of this section.
7.4.2
Proportion of metallic hardener shall be as specified or as

indicated by the manufacturer. However, in absence of any
such direction 1 part metallic hardener shall be mixed dry with
4 parts cement, by weight. To this mixture 6 mm nominal size
stone chips shall be added in proportion of 1 part cement
mixed with hardener to 2 parts of stone chips by volume and
uniformly mixed. Minimum quantity of water shall be added to
make it workable.
7.5
Laying
7.5.1
The concrete floor shall be laid in panels of 1m x 1m or as

directed by the Consultant. Alternate panels shall be laid on
one day followed by the other group of alternate panels the
next day. The edges of the panels shall be supported either by
wooden strips or flat angle iron pieces fixed in position
properly. The concrete floor shall be laid upto the required
grade. The forms if any shall remain sufficiently projecting to
take the finish. The surface shall be roughened by wire brush
as soon as possible.
7.5.2
The junction of floor and walls, floors and dado or skirting shall
be rounded off as directed.
7.5.3
Wooden strips or flat iron pieces shall be removed from their

places before the succeeding alternate layers are laid. The
finish shall be laid while the concrete underbed is still very
green within about 3 hours of laying of the later. The finish
shall be of uniform thickness and even dense surface without
trowel marks, pinhole etc. The top layer shall be pressed firmly
and worked vigorously and quickly to secure full bond with the
concrete base. Just when the initial set starts the surface shall
be finished and smoothened with steel trowel. The finish floor
shall be cured for 7 days by keeping it wet.
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8.0
IPS FLOORING (Concrete Floor finish with floating Coat of

Neat Cement)
8.1
It shall consist of an underbed and topping laid on an already

laid and mature concrete base.
8.2
Thickness
8.2.1
It shall have thickness of 40 mm for horizontal and 20 mm for

vertical surfaces unless otherwise specified. All junctions
between vertical and horizontal work shall be rounded neatly
to a uniform radius of 25 mm.
8.3
Underbed Mix
8.3.1
The underbed for floor and similar horizontal surfaces consists

of a mix of 1 part cement, 2 parts sand and 4 parts stone
chips by volume. For vertical surfaces the mix shall consist of
1 part cement to 3 parts sand by volume. The sand shall be
coarse. The stone chips shall be 12.5 mm down well graded.
Only sufficient water to be added to give a workable
consistency.
8.4
Topping Mix
8.4.1
The topping shall be floating coat of neat cement using not

less than 2.2 kg of cement per sq. m. area.
8.5
Laying
8.5.1
The IPS flooring including the underbed shall be laid in

alternate bays or in chequered board pattern. No panel shall
be cast in contact with another already laid till the contraction
of the latter has already taken place. The maximum area of
each panel shall be 5 m x 5m. A cement grout shall be applied
and worked in to the surface to receive the finish, the
underbed then laid, compacted and levelled to proper grade
with a screed or float. The requisite slope as shown in the
drawings or directed by the Consultant shall also be provided
in under bed only maintaining a minimum thickness of 25 mm
at the edges. The topping shall be applied evenly on the
underbed while it is not fully set but firm enough and rolled
and pressed to get full bond. The topping shall be trowelled to
a dense finish to the satisfaction of the Consultant. After the
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surface is sufficiently set, the finished floor shall be kept moist

for 7 days for curing.
9.0
TERRAZZO TILE FINISH
9.1
These shall include terrazzo tiles finish over already laid and
mature base of concrete or masonry by means of underbed
cement : sand (1:4) mortar.
9.2
Thickness
9.2.1
The total thickness including the underbed shall be minimum

40 mm for floors and 32 mm for walls unless otherwise
specified. The skirting, dado and similar vertical surfaces shall
project out 6 mm uniformly from the adjacent plaster or other
wall finishes. The necessary cuttings into the surface receiving
tiled finish, to accommodate the specified thickness shall be
done.
9.3
Terrazzo Tiles
9.3.1
The tiles shall, unless specifically permitted in special cases, be

machine made, under quality control in a shop. The tiles shall
be pressed hydraulically to a minimum of 140 kg. per sq. cm.
Each tile shall bear on its back permanent and legible trade
mark of the manufacturer. All angles of the tiles shall be right
angles, all edges sharp and true, colour and texture of the
wearing face uniform throughout. Tolerance on length, breadth
and thickness of tiles shall be as specified in lS-1237 latest
edition. Wearing faces of the tile shall be plane, free from
pinholes and other blemishes.
9.3.2
The tiles shall be composed of a backing and topping. The

topping measured as per IS:1237 (latest edition) shall be of
uniform thickness not less than 8 mm. The total thickness
including the topping shall be as specified but not less than 20
mm in any case. The backing shall be composed of 1 part
ordinary grey cement 2 parts of sand and 3 parts of stone
chips by weight mixed with water.
9.3.3
The shade and texture of topping shall be as approved by

consultant. The tiles shall be cured at the shop for at least 14
days before delivery to the site. First grinding shall be given to
the tiles at the shop before delivery. Tiles shall be packed
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properly to prevent damage during transit and storage. The

tiles must be stored carefully to prevent staining by damp,
rust, oil and grease, or other chemicals. Tiles made in each
batch shall be kept and used separately so that colour of each
area of the floor may remain uniform. The manufacturer shall
supply alongwith the tiles the grout mix containing cement and
pigment in exact proportions as used in topping of tiles. The
container for the grout mix shall be suitably marked to relate it
to the particular type and batch of tiles
9.4
Mix : Underbed
9.4.1
The underbed for floor and similar horizontal surfaces shall be

1 part cement 2 parts coarse sand 4 parts stone chips by
volume (12.5 mm nominal size), mixed with sufficient water.
For skirting and dado and all vertical surface it shall be 12 mm
thick and composed of 1 part cement and 3 parts coarse sand
by volume.
9.5
LAYING
9.5.1
The underbed mortar shall be evenly spread and brought to

proper grade and consolidated to a smooth surface. The
surface shall be roughened for better bond. Before the
underbed had time to set and while it is still fairly moist but
firm, cement shall be hand dusted over it or a cement slurry
applied and the tiles shall immediately be placed upon and
firmly pressed by wooden mallet on to the underbed until it
achieves the desired level. The tiles shall be kept soaked for
about 10 minutes just before laying. The joints between tiles
shall be as close as possible and not more than 1.5 mm wide.
Special care shall be taken to check the level of the surface
and the lines of the joints frequently so that they are perfect.
When tiles are required to be cut to match the dimensions,
these shall be sawn and edges rubbed smooth. The location of
cut tiles shall be planned in advance and approval of the
Consultant shall be taken.
9.5.2
At the junction of horizontal surface with vertical surface the.

tiles on the former shall enter at least 12 mm under the latter.
After fixing, the floor shall be kept moist and allowed to
mature undisturbed for 7 days. Heavy traffic shall not be
allowed. If desired dividing strips as specified under Clause
6.4. may be used for dividing the work into suitable panels.
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9.6
Grinding and Polishing
9.6.1
Procedure shall be same as Clause 6.6.2. Only grinding shall

not commence earlier than 14 days after laying of tiles.
10.0
GLAZED TILE FINISH
10.1
This finish shall be composed of glazed earthware tiles of

approved make and quality, with an underbed laid over a
concrete or masonry base.
10.2
Thickness
10.2.1
The total thickness shall be minimum 20 mm including the

underbed.
10.2.2
The tile finish on vertical surface shall project out 6 mm

uniformly from the adjacent plaster or other wall finishes. The
necessary cutting into surface receiving the finish, to
accommodate the specified thickness shall be done.
10.3
Tiles - Glazed
10.3.1
The tiles shall be of earthware, covered with glaze, white or

coloured, plain or with designs, of 150 mm x 150 mm nominal
sizes and 5 mm thick unless otherwise specified.. The
tolerance shall be + 1.5 mm for length and breadth and + 0.5
mm for thickness. Specials like internal and external angle
beads, covers, cornices, corner pieces etc. shall match. The
top surface of the tiles shall be glazed with a gloss or matt
unfading stable finish as desired by the Consultant. The tiles
shall be true in shape and size. The colour shall be uniform
and fractured section shall be fine grained in textures, dense
and homogenous. The tiles shall be strong. and free from
flaws like cracks, chips craze, spacks, crawlings etc. and other
imperfections. The edges and the underside of the tiles shall
be completely free from glaze and the underside shall have
ribs or indentations for better anchorage with the fixing
mortar. The coloured tiles, when supplied shall preferably
come from one batch to avoid difference in colour.
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10.4
Mix - Underbed
10.4.1
The mix for the under bed shall consist of 1 part cement and 3
parts coarse sand by weight mixed with sufficient water or any
other mix if specified.
10.5
Laying: Laying shall be as per Clause 9.5
10.6
Finishing
10.6.1
The joints shall be cleaned and flush pointed with white

cement and cured for 7 days by keeping it wet. The surface
shall be cleaned with soap or suitable detergent, washed fully
and wiped with soft cloth to prevent scratching before handing
over.
11.0
PVC TILE FINISH (Rubberised)
11.1
This shall include various types of tiles manufactured from

rubber, set with an adhesive on a concrete or masonry base.
An underbed may be required to obtain a satisfactory surface
and grade.
11.2
Thickness
11.2.1
The thickness of the tiles shall be 3mm unless otherwise

specified. The thickness including underbed shall be 40 mm for
floors and 25 mm for walls, unless otherwise specified.
11.3
Tiles
11.3.1
Unless otherwise required the tiles shall be square and of

approved dimensions. The tolerance in dimensions shall be +/1.5 mm.
11.3.2
The face of the tiles shall be free from porosity, blisters,

cracks, embedded foreign matter or other physical defects
which affect appearance or serviceability. All edges shall be cut
true and square. The colour shall be non-fading and uniform in
appearance, insoluble in water and resistant to alkalis,
cleaning agents and all usual floor polishes.
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11.4
Finishing
11.4.1
If any adhesive marks are present on the surface a soft cloth

soaked in solvent shall be used to wipe them off. The surface
shall be cleaned with soft soap, dried and polished or sealed
with an approved type of polish or sealant just before handling
over.
12.0
VITRIFIED CERAMIC TILE FINISH

The vitrified ceramic tiles shall be polished & of approved
shade and of size 300 x 300 mm, 400 x 400 mm, 600 x 600
mm with minimum thickness 7.0 mm and shall be compact
and homogenous throughout its cross-section. These shall be
made of finest white clay, quartz, feldspars and calcined metal
oxides pressed to minimum 450 kg/cm2 and shall be fully
sintered at a temperature of around 1200 C. Technical
specifications shall be as per international standards ISO13006/EN176 and following properties shall be maintained:
Sl.
No.
Property
1
2
3
4
5
6
7
8
Deviation in length
Deviation in thickness
Straightness of sides
Rectangularity
Surface Flatness
Water absorption
MOHS Hardness
Flexural strength
9
10
11
12
13.0
13.1
International
Standard ISO-136
/ EN176
+ 0.6%
+ 5.0%
+ 0.5%
+ 0.6%
+ 0.5%
<0.5%
>6
>27N/mm2
Abrasion resistance
Skid resistance
Breaking strength
Density
<204 mm3
>0.4
1113 N
>2
Method of
Testing
EN98
EN98
EN98
EN98
EN98
EN99
EN101
EN100
EN12
ASTM C-1028
ASTM C-648
DIN S-1082
ACID RESISTANT TILE FINISH

This finish shall be composed of ceramic unglazed vitreous tiles
of approved make and quality, with an underbed laid over a
concrete or masonry base. The tiles are laid with chemical
resistant mortars.
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13.2
Thickness
13.2.1
The total thickness shall be minimum 25 mm including the

underbed.
13.2.2
The tile finish on vertical surface shall project out 12 mm

uniformly from the adjacent plaster or other wall finishes. The
necessary cutting into surface receiving the finish, to
accommodate the specified thickness shall be done.
13.3
Tiles Ceramic unglazed vitreous acid resistant shall generally

conform to IS:4457.
13.3.1
The tiles shall be of vitreous ware and shall be free from

deleterious substances. The acid resistant shall be determined
in accordance with appendix F of IS:4457. The size of tile
shall be 150 mm x 150 mm or 200 mm x 200 mm nominal
sizes and 12 mm thick unless otherwise specified.. The
tolerance shall be +/- 2.5 % for length, breadth and thickness.
Specials like internal and external angle beads, covers,
cornices, corner pieces etc. shall match. The tiles shall be true
in shape and size. The colour shall be uniform and fractured
section shall be fine grained in textures, dense and
homogenous. The tiles shall be strong. and free from flaws like
cracks, chips craze, spacks, crawlings etc. and other
imperfections. The edges and the underside of the tiles shall
be completely free from glaze and the underside shall have
ribs or indentations for better anchorage with the fixing
mortar. The coloured tiles, when supplied shall preferably
come from one batch to avoid difference in colour.
13.4
Mix Underbed & Mortar
13.4.1
The mix for the under bed and joint filling mortar shall be also
of chemical resistant type conforming to IS: 4441.
Laying:
The laying shall be done by approved specialist
agency as per recommendation of manufacturer.
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14.0
MODULAR ACCESS FLOORING (FALSE FLOORING)
14.1
Access flooring wherever required to be provided shall be in

modular grid pattern with grid spacing of approximately
600mm. The flooring shall be supported on ordinary cement
concrete floor/slab with integral smooth finish as specified
elsewhere.
14.2
The flooring shall be of heavy-duty type suitable to take up live

load of at least 500 kg/sqm or as may be required for the
equipment being supplied. The panel shall have antistatic
finish of approved shade. The flooring system shall be supplied
and erected by approved agency.
15.0
ACCEPTANCE CRITERIA
The finish shall be checked specially for
a) Level, slope, plumb as the case may be
b) Pattern, and symmetry
c) Alignment of joints, dividing strips etc.
d) Colour, texture
e) Surface finish
f) Thickness of joints
g) Details of edges, junction etc
h) Performance
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C-09: STEEL DOORS, WINDOWS, VENTILATORS & LOUVERS

1.0
SCOPE
The work in general shall consist of supplying, erecting and
installing of all metal doors, windows, ventilators, louvers,
glazed partitions etc. as stipulated here or elsewhere in these
specifications with all materials complete including labour and
equipment.
2.0
GENERAL
2.1
The Tenderer shall submit 3 copies of shop drawing covering

all types of work under this specification before manufacture.
The drawing shall show all dimensions, details of construction,
installation, relating to adjoining and related work etc
3.0
CODES AND STANDARDS
3.1

Tenderer.
3.2

shall prevail.
3.3

IS: 1038
1983
IS: 1081
1960
IS: 1361
1978
IS: 1477 (Part

1)
IS: 1477 (Part
2)
2000
2000
Specifications for Steel doors, windows

and ventilators
Code of practice for fixing and glazing
of metal (steel and aluminium) doors,
windows & ventilators
Specifications for Steel windows for
industrial building
Code of practice for painting ferrous
metals in buildings - Pretreatment
Code of practice for painting ferrous
metals in buildings - Painting
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IS: 2074
1992
IS: 3564
1996
IS: 4351
IS: 7452
2003
1990
Specifications for ready mixed paint, air

drying, red oxide zinc chrome, priming
Specifications for hydraulically
regulated door closers
Specifications for Steel door frames
Specifications for Hot rolled steel
sections for doors, windows and
ventilators
4.0
MATERIALS
4.1
Steel sections used for fabrication of doors, windows, etc. shall

be standard rolled steel section specified in IS:1038, lS-1361
and IS:4351 or as specified in drawing. The Mild Steel sheets
for frames, shutters, louvre blades etc. shall be of approved
quality and of gauge mentioned in this specification. Hardware
and fixtures of the best quality from approved manufacturers
shall only be used. The Tenderer shall specifically state the
particular manufacturers materials he proposes to use. All
hardware and fixtures shall be able to withstand repeated use.
Door closers shall conform to IS:3564 and shall be suitable for
doors weighing 61-80 kg unless otherwise stated. Each closer
shall be guaranteed against manufacturing defect for one year
and any defect found within this period shall be rectified or the
closer replaced free of charge. Concealed door closes shall be
either floor mounted or transom mounted, suitable for
installation with metal doors. It shall conform to the
performance requirements and endurance test stated in
IS:3564 - Appendix A.
4.2
The Tenderer shall submit samples of each type of hardware to

the Consultant. The approved samples shall be retained by the
Consultant for comparison with bulk supply. The mastic for
caulking shall be of best quality from a manufacturer approved
by the Consultant.
5.0
FABRICATION
5.1
Door Frames
5.1.1
Frames shall be reinforced for door closers. They shall be

mortised, reinforced, drilled and tapped for hinges, lock and
bolt strikes. Flush butt-welding to form a solid fused joint, so
that all frames are square and flat shall be used with sections
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cut to required length and mitered. Rubber door silencers shall

be furnished for the striking jamb. Loose T masonry anchors
shall be provided. Frames shall finish flush with floor and
adjustable floor anchors shall be supplied. Frames shall be
brought to site with floor ties/weather bars installed in place.
5.2
Double Plate Flush Door Shutters
5.2.1
Door shutters shall be 45 mm thick, completely flush design

and shall comprise of two sheets of 18G steel sheets, rigidly
connected and reinforced inside with continuous vertical 20G
stiffeners, spot welded in position at not more than 150 mm
on centres. Both edges of doors shall be joined and reinforced
to full height by steel channels placed immediately inside and
welded to the door faces. Top and bottom of doors shall be
reinforced horizontally by steel channels running full width of
door. Doors shall not have more than 2.5 mm clearance at
jambs and head, shall have proper level on lock stiles and rails
to operate without binding, and shall be reinforced at corners
to prevent sagging or twisting. Pairs or double doors shall
have meeting stile edges beveled or rebated.
5.2.2
Doors shall be mortised, reinforced, drilled and tapped in shop

for hinges, locks and bolts. They shall also be reinforced for
closer, push-plates and other surface hardware where
necessary. Any drilling and tapping required for surface
hardware shall be done at site. Wherever required, provision
shall be made for fixing glazing, vision panels, louvers etc.
Glazing mouldings shall be of 18G mild steel or extruded
aluminum sections with profiles shown in drawings and
suitable for fixing 6 mm glass. Louver blades shall be V or Z
shaped and made out of 16G sheets.
5.3
Sliding Doors
5.3.1
Sliding doors shall be either single or double plate construction

as required and made out of 18 Gauge steel sheets with
adequate stiffeners. The Tenderer shall specify the weight of
the door in his shop drawing and submit the manufacturers
catalogue of the sliding gear he proposes to use. Where shown
on the drawings the Tenderer shall make provisions for
openings in the door for monorail beams. Door shall close
positively to exclude rain water from seeping in. Sliding doors
shall withstand specified wind loads without buckling or
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jamming. The door shall slide freely under all ambient

conditions.
5.4
Steel Windows, Sashes, Ventilators etc.
5.4.1
These shall conform in all respects to IS:1038, lS-7452 and lS1361 and are as shown on drawings. The details as called for
in the above codes shall be applicable for coupling mullions,
transom, weather bars, pivot arrangements for ventilators etc.
5.4.2
Windows: Window shutters shall be hung on projecting hinges.

One leaf of the hinges shall be welded into a slot in the outer
frame and the other leaf of the hinges riveted to the opening
shutters. Hinges may be of the friction type in which case the
window shall not be fitted with peg stay. In case of nonfriction projecting hinges, a brass or bronze three holes peg
stays 300mm. Long with pegs and brackets, welded or riveted
to the frame shall also be provided. Handles shall be of brass
or bronze, and shall be mounted on a mild steel handle plate
welded to the shutter in such a way that it should be fixed
after the shutter is glazed. The handles shall have a two point
nose which shall engage with brass, bronze or aluminium alloy
as specified, striking plate, on the fixed frame so that it can
hold the shutters in a slightly openable as well in a fast
position.
5.4.3
Top hung ventilators: These shall be fixed with plain hinges,

riveted to the fixed frames or welded to it after cutting a slot
in it. A peg stay 300mm long of brass or bronze with three
holes, as in case of windows shall be provided. The locking
bracket shall either be fitted to the fixed frame or to the
ventilators.
5.4.4
Centre Hung Ventilators: These shall be hung on two pairs of

brass of lead / tin/ bronze cup pivots, riveted to the inner and
outer frame of the ventilator to permit these to swing through
an angle of approximately 85 deg. The opening portion of the
ventilators shall be so balanced that it remains open at any
desired angle under normal weather condition.
5.4.5
A bronze or brass spring catch shall be provided at the top

centre of the ventilator. A brass cord pulley wheel in a mild
steel or malleable iron brackets, shall be fitted with screws or
welded at the sill and a cord eye shall be fixed to inner frame
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CHAPTER NO. Q6
VOLUME - V of V
Page 96 of 194
of ventilators to facilitate opening of ventilators.

5.5
All welds shall be flush butt welded to form a solid fused joint
so that all frames are square and flat.
5.6
Where composite unit openings are shown on drawings, the

individual window units shall be jointed together with requisite
transoms and mullions. All windows shall be inside glazed,
fixed with metal glazing beads. All windows, ventilators,
sashes shall be fixed with handles, peg stays etc. of approved
make and best quality.
5.7
Pressed Steel Louvers
5.7.1
The louver blade shall be Z shaped and made out of 18G

sheets in EZ7 steel frames. The frames shall be of ISMC 100.
5.8
Fabrication drawings shall be submitted by the Tenderer which

shall also include weights of the materials used and got
approved from the Consultant.
6.0
SHOP COAT OF PAINT
6.1
Unless otherwise specified in Sub-section, the shop paint for

steel doors, windows, ventilators, louvers etc. shall be best
quality Zinc Chromate primer paint from approved
manufacturer conforming to lS-274. All surface shall be
thoroughly cleaned of rust, grease, loose mill scales and
foreign matter as per lS-1477 Part-I, and given one coat of
shop paint. Portions like mullions, transom etc. which will be
inaccessible after assembly of units shall be given an extra
coat of paint before assembly.
6.2
All steel doors, windows, etc. shall have one shop coat and
one site coat of Zinc chromate paint (Primer) conforming to
IS:2074 with a pigment to be specified by the Consultant and
two coats of synthetic enamel paint of approved quality and
conforming to relevant l.S. Code, unless specified otherwise in
these specifications. Wherever required, all steel doors,
windows, etc. shall be hot dip galvanized to give a coating
weight of 460 gms to 610 gms per sq.m. One coat zinc
chromate primer coat shall then be applied as shop paint.
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PACKAGE NO - II
CHAPTER NO. Q6
7.0
VOLUME - V of V
Page 97 of 194
HANDLING AND STORAGE

All metal doors, windows, etc. shall be packed and crated
properly before dispatch, to ensure that there will be no
damage to the fabricated materials. Loading into wagons and
trucks shall be done with all care to ensure safe arrival of
materials at site in undamaged condition. All metal doors,
windows etc. shall be stored under cover in a way to prevent
damage or distortion.
8.0
ASSEMBLY AND ERECTION
8.1
In general, the fixing of metal doors, windows ventilators,

louvers, etc. shall conform to IS:1081. The Tenderer shall
assemble and install all steel doors, windows, sashes, fixed
metal louvers, etc. including transoms and mullions for
composite units in respective places keeping proper lines and
levels, and in approved workmanlike manner, to give trouble
free and leak-proof installation. If required by the Consultant,
the installation shall have to be carried out under the
supervision of the manufacturers staff. The Tenderer shall
take every precaution against damage of the components
during installation. Necessary holes chases etc. required for
fixing shall be made by the Tenderer and made good again as
per original, after installation.
8.2
After installation of metal doors, windows, etc. all abrasions to

shop-coat of paint shall be retouched and made good with the
same quality of paint used in shop-coat.
8.3
All coupling mullions, transoms, frames. etc. in contact with

unpainted steel and other members, shall be well embedded in
mastic. The Tenderer shall bring to the site the mastic cement
in original sealed containers of manufacturer and shall apply it
as per the instructions.
8.4
Door shutters, partitions, hardware fixtures etc. shall be

fixed only after major equipments have been installed in
rooms. Wherever required, nylon cords of approved quality
shall be supplied along with pivoted sashes and shall be of

adequate length to terminate one meter from the floor. Loose
ends of cords shall end in metal or plastic pull as approved by
the Consultant.
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PACKAGE NO - II
CHAPTER NO. Q6
9.0
ACCEPTANCE CRITERIA
9.1
For Fabricated Items

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
9.2
VOLUME - V of V
Page 98 of 194
Overall dimension shall be within + 1.5 mm of the size

Mullions, transoms etc. shall be in one length and
permissible deviations from straightness shall be limited
to (+)1.5 mm from the axis of the member.
Door and window shutters shall operate without
jamming. The clearance at head and jamb for door
shutters shall not exceed 1.5 mm. For double leaf doors,
the gap at the meeting of stiles shall not be more than
1.5mm.
Door leaves shall be undercut wherever required.
Doors, windows, frames etc. shall be on a true plane,
free from warp or buckle.
All welds shall be dressed flush on exposed and contact
surfaces.
Correctness of location and smoothness of operations of
all shop installed hardware and fixtures.
Provision for hardware and fixtures to be installed at
site.
Glazing clips, fixing devices etc. shall be supplied in
adequate numbers
Shop coats shall be properly applied.
Glazing beads shall be cut with mitered corners.
For Installed Items

a)
b)
c)
d)
e)
f)
g)
Installations shall be at correct location, elevation and in

general, on a true vertical plane.
Fixing details shall be strictly as shown on drawings.
Assembly of composite units shall be strictly as per the
drawings with mastic caulking at transoms and mullions,
gaskets, weather strips etc. complete.
All frames on external walls shall be mastic caulked to
prevent leakage through joint between frames and
masonry.
All openable sections shall operate smoothly without
jamming.
Locks, fasteners etc. shall engage positively. Key shall
be non-interchangeable.
Cutting to concrete or masonry shall be made good and
all abrasions to shop paint shall be touched up with
paint of same quality as shop paint.
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CHAPTER NO. Q6
VOLUME - V of V
Page 99 of 194
C-10: WOODEN WORK, CARPENTRY & JOINERY

1.0
SCOPE
This shall include supply, fitting and fixing of timber frames to
doors and windows with M.S. Holdfasts, panelled or flush
doors, windows, shutters, etc. as shown in drawings, including
a prime coat of approved paint/varnish or fixing of plastic
laminate where called for. This shall also include the supply
and fixing of all hardware and fixtures.
2.0
CODES AND STANDARDS
2.1

Tenderer.
2.2

Standards, Codes etc.) referred to in clause 2.3. the former
shall prevail.
2.3

IS: 204 (Part 1)
1991
IS: 204 (Part 2)
1992
IS: 205
1992
IS: 206
IS: 207
1992
1964
IS: 208
IS: 281
1996
1991
IS: 287
1993
Specification for Tower bolts- ferrous

metals ;
Specification for Tower bolts- Non
ferrous metals
Specification for Non-ferreus metal butt
hinges
Specification for Tee and strap binges
Specification for Gate and shutter hooks
and eyes
Specification for Door handles
Specification for Mild steel sliding door
bolts for use with padlocks.
Recommendation
for
maximum
permissible moisture contents of timber
used for different purposes.
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VOLUME - V of V
Page 100 of 194
IS: 303
1989
IS:
IS:
IS:
IS:
362
363
364
401
1991
1993
1993
2001
IS: 451
1999
IS: 452
1973
IS: 453
1993
IS: 723
1972
IS: 729
1979
IS: 848
1974
IS: 851
1978
IS: 852
1994
IS: 1019
IS: 1141
IS: 1200
XIV)
IS: 1200
XXI)
1974
1993
(Pt. 1984
(Pt. 1973
IS: 1328
1996
IS: 1341
IS: 1378
1992
1987
IS:
IS:
IS:
IS:
1977
1990
1980
1996
1658
1659
1823
1868
Specification for Plywood for general

purpose
Specification for Parliament hinges
Specification for Hasps and staples
Fanlight catch
Code of practice for preservation of
timber
Technical supply condition for wood
screws
Specification for Door springs, rat-tail
type
Specification for Double acting spring
hinges
Specification for Steel counter sunk
head wire nails
Specification for Drawer locks, cup
board locks, and box locks
Specification for Synthetic resin
adhesives for plywood (Phenolic &
Aminoplastic)
Specification
for
Synthetic
resin
adhesive for construction work (non
structural ) in wood
Specifications for animal glue for
general wood working purposes.
Specification for Rim latches
Code of practice for seasoning of timber
Method of measurement of Building and
Civil Engineering works - Glazing
Method of measurement of Building and
Civil Engineering works- Wood work
and joinery
Specification for Veneered decorative
plywood
Specification for Steel Butt hinges
Specification
for
Oxidized
copper
finishes
Specification for Fiber hard board
Specification for Block boards
Specification for Floor door stoppers
Specification for Anodic coating on
Aluminium
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VOLUME - V of V
Page 101 of 194
IS: 1911
1967
IS: 2191 (Part 1)
1983
IS : 2191 (Part 2)
1983
IS: 2202 (Part 1)
1999
IS: 2202 (Part -2
1983
IS: 2209
1976
IS: 2380 (parts 1 1977

to 21)
IS: 2380 (Part
22)
1981
IS: 2380 (Part

23)
1981
IS: 2681
1993
IS: 2835
1987
IS: 3087
1985
IS: 3097
1980
IS: 3400-(Pt.II)
1980
IS: 3400-(Pt.IV)
1987
IS: 3400-(Pt.IX)
1978
Schedule of unit weights of building

materials
Specification for wooden flush door
shutters (cellular & hollow core type)
plywood face panels
shutters (cellular & hollow core type) Particle board face panels and hard
board
shuters (solid core type) plywood face
panels
shuters (solid core type) Particle
board face panels and hard board
Specification for Mortise locks (vertical
type)
Method of test for wood particle board
and
boards
from
lignocellulosic
materials
and
boards
from
lignocellulosic
materials Determination of surface
gulability
and
boards
from
lignocellulosic
materials Vibration test for particle
boards
Non ferrous metal sliding door bolts
(aldrops) for use with pad locks
Flat transparent sheet glass (3rd
Revision).
Specification for wood particle board
(medium density) for general
engineering purpose
Specification for Veneered particle
boards (1st Revision)
Method of test for vulcanized rubbers Hardness
Method of test for vulcanized rubbers Accelerated aging
Method of test for vulcanized rubbers Relative density
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VOLUME - V of V
Page 102 of 194
IS: 3564
1986
IS: 3618
1966
IS: 3813
1967
IS: 3818
1992
IS: 3847
1992
IS: 4020 (Part 1 1998
to 16)
IS: 4021
1995
IS: 4827
1983
IS: 4948
2002
IS: 4992
1975
IS: 5187
IS: 5523
1972
1983
IS: 5930
1970
IS: 6318
1971
IS: 6607
1972
IS: 6760
1972
IS: 7196
IS: 7197
1974
1974
IS: 7534
1985
Specification
for
Door
closers
(Hydraulically regulated)
Phosphate treatment of iron and steel
for protection against corrosion
Specification for C hooks for use with
swivels
Specification for Continuous (Piano)
hinges
Specification for Mortise night latches
Methods of tests for wooden flush
Doors (Type tests)
Specification for Timber door, window
and ventilator frames
Electroplated coating of nickel and
chromium on copper and copper alloys
Specification for Welded steel wire
fabric for general use.
Specification for Door Handles for
mortise locks (vertical type)
Specification for Flush bolts
Method of testing anodic coating on
aluminium & its alloys.
Specification for Mortise latch (vertical
types)
Specification for Plastic window stays &
fasteners
Specification for Rebated mortise locks
(vertical type)
Specification for Slotted countersunk
head wood screws
Specification for Hold fasts
Specification for Double action floor
springs (without oil check) for heavy
doors
Specification for sliding locking bolts for
use with padlocks
3.0
MATERIALS
3.1
Timber
3.1.1
Unless otherwise specified, all timber shall be best quality well

seasoned Grade I teakwood free from large or loose knots,
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Page 103 of 194
cracks or other defects. Where specified, timber shall be

treated with approved wood preservative before use. Before
starting the carpenters work, the Tenderer shall have the
rough timber approved by the Consultant. Size of doors and
windows frame shall be 100 x 60mm.
3.2
Laminated Plastic Sheets
3.2.1
All laminated plastic sheets shall be minimum 1.50 mm thick

and shall be Formica, Decolam or approved equivalent make.
The colour, pattern, finish and texture shall be approved by
the Consultant and the bulk supply procured in sheet sizes
which will ensure the least number of joints in one surface.
3.3
Flush doors
3.3.1
Flush door shall be solid core doors with commercial or

decorative faces and hardwood edges. It shall have 3 layer flat
pressed teak wood particle board (Commercial veneer) bonded
with BWP type phenol formaldehyde conforming to lS-848 and
total thickness shall be 35 mm. The board core shall conform
to lS-3087 Type-1. The door shall be given 35 x 12 mm teak
wood beading all around as per drawings and as directed by
the Consultant.
3.4
Fittings and Fixtures
3.4.1
Fixtures and fittings for doors, windows, furniture etc. shall be

as shown on drawing and as directed by the Consultant. These
shall be of heavy type, best quality and from approved
manufacturer.
4.0
JOINERY
4.1
General
4.1.1
The work shall be done by skilled carpenters as per details

shown on drawings or as instructed by the
Consultant.
Framing timber and other work shall be closed fitting with
proper wood joinery, accurately set to required lines or levels
and rigidly secured in place.
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CHAPTER NO. Q6
VOLUME - V of V
Page 104 of 194
4.1.2
The surface of frames etc. which will come in contact with

masonry after fixing, shall be given two coats of approved
paint before fixing. Mastic caulking shall be done after fixing
external door and window frames. Special care shall be taken
to match the grain of timber of plywood which will be
subsequently polished. Screwing or nailing will not be
permitted to the edge of plywood or chipboard sheets.
4.1.3
Fixing of frames and partitions shall generally be with 40 mm

x 5 mm x 400 mm long M.S. Hold fasts at bifurcated end and
grouted with (1:2:4) cement concrete, The gap between
masonry and external door and window frame shall be caulked
with mastic. M.S. grills or guard bars shall be provided to
windows where called for in the specification. M.S. Hold fasts
shall conform to IS: 7196-1974 without any burns or dents
and shall be fixed to wooden frames with 10mm dia bolt & nut.
4.2
Finish
4.2.1
All carpentry work after finishing shall be sand papered

smooth, A primer coat of paint shall be given after inspection
by the Consultant to all surfaces other than those which shall
be subsequently polished or covered with laminated plastic
sheet.
4.3
Surface Treatment
4.3.1
When shown on drawings, decorative ply or laminated plastic

sheets shall be bonded under pressure to the surface to be
finished. The adhesive used shall be of a approved brand and
brought to site in sealed containers. The rate of application
and the length of time for which the pressure is to be applied
shall be as per the manufacturers instructions. The edge of
sheets shall be protected by teak lipping or beveled as shown
on drawings.
4.4
Preservative
4.4.1
Where required as per the drawings or by the Consultant,

timber shall be treated with specified preservative strictly in
accordance with the manufacturers instructions and to the
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Page 105 of 194
5.0.
FITTINGS AND FIXTURES
5.1
The work covered under these specifications consist of

supplying different types of fittings and fixtures required for
teak wood door shutters etc., complete in strict accordance
with these specifications and drawings/samples approved.
5.2
All fittings and fixtures shall be of heavy quality brass, powder

coated aluminium (of approved colour), iron oxidised (M.S) or
as specified. These shall be well made, reasonably smooth
and free from sharp edges, corners, flaws and other defects.
Screws holes shall be counter sunk to suit the heads of the
specified screws. All hinges pins shall be of steel for brass
hinges and aluminium alloy NR-6 or steel pins for aluminium
hinges with nylon washers or as specified. All riveted heads
pertaining to hinge pins shall be well-formed. Screws supplied
for fittings shall be of the same metal and finish as the fittings.
However brass cadmium plated / chromium plated screws
shall be supplied with aluminum fittings. Samples of each
fixture / fitting shall be furnished by the Tenderer for the
approval of the Consultant and got approved from him before
placing bulk order for purchase. The fittings and fixtures to be
incorporated in the work shall be strictly according to the
approved sample. Fittings shall be fixed in proper position as
shown in the drawing and as directed by the Consultant.
These shall be truly vertical or horizontal as the case may be.
Screws shall be driven home with a screw driver and not
hammered in. Recess shall be cut to the exact size and depth
of fittings and fixtures shall be done in a workman like manner
and any damages (one either to fittings and fixtures or the
shutter frames etc.) Should be rectified by the Tenderer at his
own cost.
5.3
BUTT HINGES
5.3.1
Brass and aluminum hinges shall be manufactured from the

extruded sections and shall be free from cracks and other
defects. M.S. butt hinges shall be cranked and manufactured
from M.S. Sheets. All butt hinges conform to latest I.S.
specifications. The size of butt hinges shall be taken as the
length of the hinge. Width of the hinge shall be measured
from the centre line of hinge pin to end of flange.
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CHAPTER NO. Q6
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Page 106 of 194
5.4
PARLIAMENTARY HINGES
5.4.1
These shall be manufactured from cast brass or aluminum or

M.S. and shall be free from cracks and other defects. The size
of the parliamentary hinges shall be taken as the width
between open flanges, while the depth shall be as specified.
5.5
PIANO HINGES :
5.5.1
These shall conform to I.S. specifications and shall be either

brass oxidised, powder coated aluminium (of approved
colour), iron oxidised (M.S.) or as specified. Piano hinges shall
be fixed in the entire length of the cupboard shutters in a
single piece. No joints are allowed.
5.6
TOWER BOLTS
5.6.1
The tower bolts shall be of the following types :

a) M.S. semi barrel tower bolt with MS sheet pressed barrel
and G.I. bolt or with M.S. barrel and M.S. sheet bolt.
b) Oxidised brass barrel tower bolt with brass sheet barrel and
rolled or drawn brass bolt.
c) Powder coated aluminium (of approved colour) tower bolt
with barrel and bolt of extruded sections of aluminum alloy.
5.6.2
In case of M.S. tower bolt plates and straps after assembly

shall be firmly revetted or spot welded properly.
5.6.3
The knobs of brass tower bolts shall be cast and the bolt fixed
into the knob firmly as per I.S. specifications. The tower bolt
shall be finished to correct shape and pattern so as to have a
smooth action. Wherever specified, aluminum barrel tower
bolts shall be manufactured from extruded sections of barrel
and bolts.
5.6.4
Knobs shall be properly screwed to the bolt and riveted at the

back. The size of the tower bolt shall be taken as the length of
barrel without top socker.
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CHAPTER NO. Q6
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Page 107 of 194
5.7
FLUSH BOLTS
5.7.1
These shall be cast brass and shall be finished chromium

plated / oxidised, as specified. The size of the flush bolt shall
be taken as the length of the flush plate without top socket.
5.8
ALDROPS
5.8.1
These shall be oxidised brass or powder coated aluminium (of

approved colour), iron oxidised or as specified and shall be
capable of smooth sliding action and shall be as per IS:26811964. Brass sliding door bolt (aldrop) shall be made from
rolled brass. The hasp shall be of cast brass and screwed to
the bolt in a workman like manner. Alternatively the hasp and
the bolt may be in one piece. Bolts shall be finished to shape
and threaded with worth standard and provided with round
brass washers and nuts of square or hexagonal shape. All
components shall be smooth and polished.
The leading
dimensions of aldrop shall be as per the length of the bolt and
specified diameter.
5.9
DOOR HANDLES BOW / PLATE HANDLES
5.9.1
These shall be of cast brass of specified size, shape and

pattern as approved by the Consultant. Brass handles shall be
finished bright, chromium plated or oxidised as specified.
Aluminum or iron oxidised (M.S) handles shall be of specified
size, shape and pattern. The size of the handle is taken as the
inside grip of the handle. In case of iron oxidised handles, the
same shall be manufactured from M.S. sheet pressed into oval
section as per I.S.
5.10
MORTISE LOCK
5.10.1
Mortise lock with latches and a pair of level handles shall be 6

levers, with zinc alloy pressure die cast / brass or as specified
body of approved quality, and shall be right or left handed as
specified. The pair of handles shall be either brass chromium
plated or powder coated aluminium (of approved colour) of
approved shape and pattern or as specified. It shall be of the
best Indian make of approved quality. The size of the lock
shall be determined by its length. The lock for single leaf door
shall have plain face and that for double leaf door a rebated
face. Level handles with springs shall be mounted on plates
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5.11
VOLUME - V of V
Page 108 of 194
and shall be of approved quality, powder coated aluminium (of

approved colour) or as specified.
HYDRAULIC DOOR CLOSER
5.11.1
Hydraulic door closer shall be of approved quality and make.

The operation of the Hydraulic door closer shall be very
smooth.
5.11.2
This should be of H.D.-66 for external / main doors and

elegant 63 for all internal doors. The overall height should
not be more than 170 mm. for H.D.-66 and 160 mm. for
elegant-63. Base shall be 110 x 60 mm. for H.D.-66 and 100 x
55 mm. for elegant 63. weighing not less than 4.5 kg. For
H.D. 66 and 4 kg. for elegant 63. Speed of the Hydraulic
door closer shall be adjustable and latch closing also shall be
adjustable type. Suspension and lubrication of door closer
shall be in perfect line and level.
5.12
The Tenderer shall provide for all the incidentals required for
fixing these fixtures and fittings such as cadmium plated
screws etc. Fittings and fixtures shall be fixed securely in a
workman like manner all as directed by the Consultant. Any of
the fixture damaged during the fixing shall be removed and
new one fixed in their place and the surface of joinery made
good where affected, at his own expense. Mortise plates shall
be used over holes where the bolts enter in the wood work.
Metal sockets shall be provided to all bolts where the shoot
enter brick, stone, concrete etc. The incidental fixtures like
mortise plates, metal sockets, screws etc. shall not be paid for
separately
6.0
ACCEPTANCE CRITERIA
6.1
Door and Window Frames
6.1.1
All frames shall be square and flat at the time of delivery and
shall be checked for dimensions and corner angles. After fixing
they shall be in a true vertical plane. All external door and
window frames shall be caulked with mastic.
6.2
Door and Window Shutters
6.2.1
These shall be of proper size, shape and design and free of

warps. When fixed to frames these shall operate smoothly
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without jamming and all latching or locking devices shall

engage properly without under pressure.
6.3
Door and Window fittings
6.3.1
One set of all approved door and window fittings shall be

submitted to the Consultant for reference and comparison with
the fittings being provided.
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Page 110 of 194
C-11: ROLLING SHUTTERS & GRILLS

1.0
SCOPE
1.1
This specification covers the design, supply of materials,

fabrication, delivery and erection of Rolling Shutters/Grills with
motor drives and/or manual operation including all accessories
as hereinafter specified. All electrical work shall be in
accordance with the latest Indian Electricity Rules.
2.0
CODES AND STANDARDS
2.1

Tenderer.
2.2

shall prevail.
2.3

IS : 6248
1979
IS : 10451
1983
3.0
FABRICATION
3.1
Components
Specification for metal rolling shutters

and rolling grills
Steel sliding shutters
a) Slats for rolling shutters shall be made from tested bright

cold rolled, annealed M.S. strips, not less than 0.9 mm thick
for shutters upto 3.5 M wide and not less than 1.24 mm
thick for shutters 3.5 M wide and above, machine rolled at
75 mm rolling centres, interlocking with each other. The
profile will be such as to prevent excessive deflection under
specified wind load.
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Page 111 of 194
b) Rolling grill shall be constructed out of 8 mm dia rods at 35

mm on centres running horizontally flexibly connected with
vertical links spaced not more than 200 mm centres.
Alternatively, rolling grills shall be made from perforated
slats of approved design reinforced with 6 mm dia. rods.
c) End locks shall be heavy type M.C.I./C.I. and shall be
provided at each end of alternate slats.
d) Bottom bars shall be finished with two angles not less than
6 mm thick for external shutters. When shown on drawings
a flexible weather strip shall be applied to make tight
contact with the floor.
e) Guides shall be of such depth as to retain the shutter under
a wind pressure of 200 kg/sq.m. The minimum thickness of
guide to be 12 G.
f) Shafts shall be of steel pipe of sufficient size to carry the
torsional load with a maximum deflection of 1/360th of
span. Grease packed ball bearings or bushings shall be
provided for smooth trouble free operation.
g) Hoods shall be formed of not less than 20 gauge steel,
suitably reinforced to prevent sag.
h) Locks shall be slide bolt and hasp, or cylinder lock operable
from one or both sides. Provision for securing hand chain
with padlock, provisions for removable handle for hand
cranks etc. shall be made as desired by the Consultant.
i) Power unit shall be suitable for 3 phase, 50 cycle, 400 volts
A.C. Power supply and shall be either floor or wall mounted
unit. The motor shall be of sufficient capacity to move the
unit. The motor shutter shall move in either direction at
speed of 0.3 metres per second. In addition to the gear
motor each standard power unit shall include a magnetic
brake, a reversing starter with built-in overload protection,
a geared limit switch and one push button station located
inside the building unless otherwise stated. It is desirable
that the bottom bar of motor operated doors shall be
provided with a sensitive edge, electrically connected to
stop the travel of the door on meeting an obstruction.
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CHAPTER NO. Q6
VOLUME - V of V
Page 112 of 194
j) Operating chains shall be of tested quality, heavily

galvanized and with all ends rounded to assure smooth
operation and hand protection.
k) Reduction gears shall be of high strength grey cast iron,
machine mounted from machine cut patterns.
3.2
Manually Operated Shutters/Grills
3.2.1
Manually operated shutters shall be easily operable by one

person. The speed of operation shall be about 0.3 metres per
second. In general, manually operated shutters shall be push
pull type of opening upto 9 sq. metre in area. Larger shutters
shall be either chain and gear operated or crank and gear
operated. The crank handle shall be removable. All shutters
shall be lockable from one or both sides as desired by the
Consultant.
3.3
Power Operated Shutter/Grill
3.3.1
These shall be operable from a push

conveniently located besides the door or
drawings. One emergency hand chain/crank
also be provided for use in case of failure
system.
4.0
FIXING
4.1
Brackets shall be fixed on the lintel/beam or under the

lintel/beam as specified in item with rawlplugs and screws,
bolts, washers etc. The shaft along with the spring shall then
be fixed on the brackets. The guide channels shall be fixed to
the wall through the plates welded to the guides. These plates
and brackets shall be fixed by means of steel screws, bolts and
rawlplugs drilled into the wall. The plates and screws, bolts
shall be concealed in plaster to make their locations invisible.
Fixing shall be done accurately in a workman like manner that
the operation of the shutter is easy and smooth. All grout
holes and damages on the wall while fixing of shutters shall be
made good by the Tenderer at no extra cost to the Owner.
The Tenderer shall ensure smooth and easy working of
shutters.
button station
as shown on
operation shall
of the electric
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CHAPTER NO. Q6
VOLUME - V of V
Page 113 of 194
5.0
PAINTING
5.1
All the members of the rolling shutter shall be thoroughly

cleaned off dust, scales, rust etc. and shall be given approved
priming coat of red oxide paint before fixing the shutter in
position and then shall be painted with two coats of
flat/synthetic enamel paint of approved quality and shade.
6.0
ACCEPTANCE CRITERIA
6.1
Field Inspection
After installing the shutters, the Tenderer shall test the
performance of the shutter in the presence of the Consultant.
The doors shall be smoothly operable under all ambient
conditions. All control and locking devices shall give fault-free
performance.
6.2
Guarantee
The Tenderer shall give one years
successful operation of the shutters.
guarantee
for
the
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PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 114 of 194
C-12: ALUMINIUM WORKS
1.0
SCOPE
1.1
The work in general shall consist of fabrication, supplying,

erecting and installing of all aluminium doors, windows,
ventilators, louvers, glazed partitions etc. as stipulated here or
elsewhere in these specifications with all materials complete
including labour and equipment.
2.0
GENERAL
2.1
The Tenderer shall submit 3 copies of shop drawing covering

all types of work under this specification before manufacture.
The drawing shall show all dimensions, member designations,
details of construction, installation, relating to adjoining and
related work etc The work shall be carried out as per approved
shop drawings, relevant detailed approved shop drawings.
2.2
The Tenderer shall submit 3 copies of shops drawings covering

all type/details of work and generally shown in architectural
drawings and envisaged under these specifications before
manufacture. The drawings shall show all dimensions, details
of constructions, installation of fixtures and relation to
adjoining and related works. No fabrication work shall be
undertaken prior to obtaining approval of the shop drawings
from the Consultant. The Tenderer shall intimate at the time
of tendering the type of sections he proposes to use on the
works.
3.0
CODES AND STANDARDS
3.1

Tenderer.
3.2

shall prevail.
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CHAPTER NO. Q6
VOLUME - V of V
Page 115 of 194

IS: 733
1983
IS: 1081
1960
IS: 1868
1996
Specifications for wrought aluminium

and aluminium alloy bars, rods,
sections (for general engineering
purposes)
of metal (steel and aluminium) doors,
windows & ventilators
Specifications for anodic coatings on
aluminium and its alloys
4.0
MATERIALS
4.1
Aluminium alloy for extruded sections for the above work shall
correspond to I.S-733 (extruded sections shall conform to IS
Designation HE 9 WP. Hollow sections shall conform to IS
Designation HV9-WP), shall be powder coated (of approved
colour) before incorporating in the work. The Door, Window,
Ventilator, glazing framework, beadings, hinges, pegstays,
stiles, mullions, beadings, transoms and handles etc., shall be
of powder coated aluminium (of approved colour) section as
shown in detailed approved drawings. All aluminum sections
shall be from approved reputed manufacturer.
4.2
The Tenderers can also propose nearest alternative sections

they manufacture/posses without changing the elevation,
structural stability and functional requirement. Consultant
reserves the right to accept the alternative section or
otherwise.
The sections shall be structurally suitable to
withstand all the loads, the members have to sustain.
4.3
Counter sunk screws, nuts, bolts, washers, rivets and other

miscellaneous fastenings devices shall be of approved brass
cadmium plated or stainless steel as specified in the approved
drawing. Each door leaf shall be prepared to receive glazed
panel of required thickness.
4.4
Glazing shall be done with neoprene dry set glazing gasket (of
best quality and approved make) with snap in beveled
powder coated (of approved colour) matt finish aluminium
metal glazing stops inside and outside.
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CHAPTER NO. Q6
VOLUME - V of V
Page 116 of 194
5.0
FABRICATION
5.1
Doors
5.1.1
The frames shall be manufactured square and flat, the corners

of the frame being fabricated to true right angle. All the fixed,
sliding and opening frames shall be constructed of sections
which have been to length, mitred, welded and mechanically
fixed at the corners.
5.1.2
Where hollow sections are used with welded joints, argon-arc

welding or flash butt welding shall be employed (Gas welding
or brazing not to be done). In case welded joints are used,
anodizing shall be done after fabrication as a whole. All
welding shall be on unexposed sides in order to prevent pitting
/ discoloration of other surface imperfections after fixing etc.
5.1.3
Necessary allowance shall be made while manufacturing the

aluminium door entrances, wall spans and glazing for receiving
plaster. Field fabrication of frames shall be done only if
permitted by Consultant.
5.1.4
A thick layer of clear transparent lacquer based on

methacrylates or cellulose butyrate shall be applied on the
finished sections of the aluminium work by the Tenderer to
protect the surfaces from wet cement, lime, dirt, dust etc
during the construction activities. The size for door, window or
ventilator frames shall not vary by more than (+/-) 1.5 mm.
5.1.5
All aluminium surfaces in contact with masonry or concrete

shall be given a thick coat of bitmastic paint. After fabrication,
aluminium sections shall be protected from construction
hazards that may damage their appearance or finish. All
exposed surfaces of aluminum door entrance shall be
protected by masking tape during transshipment and erection
5.2
Windows, Ventilators and Glazings
5.2.1
The frames shall be manufactured square and flat.

The
corners of the frames shall be fabricated to true right angles.
All the fixed, sliding, openable frames shall be constructed
from sections which have been cut to length, mitred and
mechanically jointed or welded at the corners.
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PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 117 of 194
5.2.2
Where hollow sections are used with welded joints, argon arc
welding or flash butt welding shall be employed (Gas welding
or brazing not to be done). Sub-dividing bars of units shall be
tennoned and rivetted into the frames. In case welded joints
are used, all welding shall be on unexposed sides in order to
prevent pitting, discoloration and other surface imperfections
after finishing.
5.2.3
The dimensions shown in the drawing are overall heights and

widths to the outside of frames of aluminium windows. The
side-hung shutters shall have projected friction type hinges of
aluminium alloy. Concealed projected hinges having structural
stability and of good quality will also be considered only after
the inspection of the sample submitted by the Tenderer
5.2.4
The necessary pegstays, handles, window fasteners etc shall

be of aluminium. The handle shall be mounted on a handle
plate rivetted to the opening frame. The pegstays shall be
300 mm. long or as required, complete with peg and locking
bracket and shall have holes for keeping the shutter open in
three different positions. Field fabrication of frames shall be
done only if permitted by Consultant.
5.2.5
The complete fabricated assembly shall be powder coated

of approved colour and satin finish with minimum film
thickness of 0.015 mm for the entire surface. A thick layer of
clear transparent lacquer based on methacrylate or cellulose
butyrate shall be applied on the finished sections of the
aluminium windows etc. by the supplier to protect the surfaces
from wet cement, lime, dirt, dust etc during the installation.
The lacqure coating shall be removed after installation is
complete, if approved by the Consultant and all sections of the
windows shall be protected by PVC film covering
6.0
HARDWARE
6.1
All sections and hardware shall have anodic film and cover a
minimum thickness of 0.015 mm
6.2
All doors shall have off-set pivots, double action (180 degree
minimum swing) floor springs with oil check boxes of approved
manufacture. All doors shall have 4 lever concealed brass
body mortise lock without handles as per manufactures
design, with concealed flush C.P. brass tower bolts provided at
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CHAPTER NO. Q6
VOLUME - V of V
Page 118 of 194
suitable locations. All doors shall have push plates of design

shown in the approved drawing as described in the schedule of
quantities. All entrances shall be without thresholds.
6.3
All cutouts, recess, mortising or milling and operations

required for fixing the hardware shall be accurately made
reinforced with pacing plate as required to ensure adequate
strength of the connection.
6.4
All the hardware accessories shall be of best-approved type

and of powder coated (of approved colour) finish same as of
rate frames and other sections. Each lock shall be supplied
with two stainless steel keys and each key shall be with
number stamped thereon according to the number on doors so
installed.
6.5
All hardware shall be free from defects which may affect the
appearance and serviceability. All hardware shall be fixed
after obtaining the prior approval of the Consultant.
6.6
Approved samples of hardware shall be kept in the custody of

the Consultant. Working and moving parts of lock sets shall
be accurately fitted to smooth, close bearings and shall be free
from rattle.
6.7
The floor springs shall be of heavy-duty type and should allow

door operation smoothly.
6.8
The tenderer shall furnish a guarantee for all finishing and

quality of hardware items covered under this section and
which shall remain free from defects of any kind, either
materials and / or workmanship for a period of one year
(unless otherwise specified) from the date of completion /
handling over of work.
6.9
The Tenderer shall repair or replace any and all defective work
and damage caused, at any time or times during that period
within 3 days from the written notice. This shall be done
without any extra cost to the Owner.
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PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 119 of 194
7.0
FIXING
7.1
The frames shall be accurately fixed in the flooring/brick

masonry or R.C.C works. The fixing of the frame shall be done
with cadmium plated brass counter sunk screws driven on to
the teak wood, rough ground, or fixed to the wall with
holdfasts as directed by the Consultant, and as shown in
approved drawings.
7.2
All aluminum works shall be fixed in position as per relevant

Indian Standard Specifications and code of practice for fixing
and glazing of aluminum work. Joints between metal and
masonry shall be neatly painted with matching cement and
excess materials shall be removed.
7.3
Fixing of aluminum door entrances, hardware etc shall be done

in best workmanship like manner true to line, level, plane,
plumb etc and all as directed by the Consultant. Breaking of
floor for providing floor springs and restoration of the floor
finishes to the original specification and finishes and minor
additions and alternations to the openings shall be deemed to
have been included in the quoted rates.
7.4
All aluminum windows shall be fixed in position as per IS:

1081. All joints between metal and masonry / rough ground
wooden frame shall be fully caulked with mastic or
polysulphide compound in order to ensure watertight joints.
Joints shall be neatly painted with matching cement and
excess materials shall be removed. Hardware shall be fixed in
workman like manner all as directed by the Consultant.
8.0
HANDLING AND STORAGE
8.1
All aluminum doors, windows, etc. shall be packed and crated

properly before dispatch, to ensure that there will be no
damage to the fabricated materials. Loading into wagons and
trucks shall be done with all care to ensure safe arrival of
materials at site in undamaged condition. All Doors, Windows
etc. shall be stored under cover in a way to prevent damage or
distortion.
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CHAPTER NO. Q6
9.0
ACCEPTANCE CRITERIA
9.1
For Fabricated Items
VOLUME - V of V
Page 120 of 194
a) Overall dimension shall be within + 1.5 mm of the size

b) Mullions, transoms etc. shall be in one length and
permissible deviations from straightness shall be limited to
1.5 mm from the axis of the member.
c) Door and window shutters shall operate without jamming.
The clearance at head and jamb for Door shutters shall not
exceed 1.5mm. For double leaf Doors, the gap at the
meeting of stiles shall not be more than 1.5mm.
d) Door leaves shall be undercut wherever required.
e) Doors, Windows, frames etc. shall be on a true plane, free
from warp or buckle.
f) All welds shall be dressed flush on exposed and contact
surfaces.
g) Correctness of location and smoothness of operations of all
shop installed hardware and fixtures.
h) Provision to be made for hardware and fixtures to be
installed at site.
i) Glazing clips, fixing devices etc. shall be supplied in
adequate
numbers
j) Shop coats shall be properly applied.
k) Glazing beads shall be cut with mitred corners.
9.2
For Installed Items

a) Installations shall be at correct location, elevation in
general, on a true vertical plane.
b) Fixing details shall be strictly as shown on drawings.
c) Assembly of composite units shall be strictly as per the
drawings with mastic caulking at transoms and mullions,
gaskets, weather strips etc. complete.
d) All frames on external walls shall be mastic caulked to
prevent leakage through joints between frames and
masonry.
e) All openable sections shall operate smoothly without
jamming.
f) Locks, fasteners etc. shall engage positively. Key shall be
non-interchangeable.
g) Cutting to concrete or masonry shall be made good and all
abrasions to shop paint shall be touched up with paint of
same quality as shop paint.
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CHAPTER NO. Q6
VOLUME - V of V
Page 121 of 194
C- 13 : GLASS & GLAZING
1.0
SCOPE
1.1
The work in general shall consist of supplying and fixing all

glass and glazing including all clips, putty, mastic cement etc.
wherever required as shown on drawings.
2.0
CODES AND STANDARDS
2.1

shall be the latest editions, including all applicable official
Tenderer.
2.2

shall prevail.
2.3

IS : 419
IS : 1081
1967
1960
IS
IS
IS
IS
1987
1988
1994
2000
:
:
:
:
2835
3548
5437
14900
Putty for use on window frames

metal (steel & aluminum) Doors,
Windows and Ventilators
Flat transparent sheet glass
Code of practice for glazing in building
Figured rolled and wired glass
Specification for transparent float glass
3.0
MATERIALS
3.1
The Tenderer shall supply and install all glass and glazing as
required for various Doors, Windows, Sashes, Ventilators, and
fixed louvers, miscellaneous glazing and partitions, unless
otherwise stated, from approved manufacture having uniform
refractive index and free from flaws, specks and bubbles. The
glass shall be brought to site in the original packing from the
manufacturer and cut to size at site. The cut edges shall be
straight and free from chips, spall or any other damages.
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CHAPTER NO. Q6
VOLUME - V of V
Page 122 of 194
3.2
The glass shall be plain float glass from approved

manufacture, as specified and it shall be free from bubbles,
flaws specs, waves, air holes, distortion, scratches or other
defects. The glasses in bulk quantities shall be brought to site
in Makers original packings and Makers guarantee shall be
produced if called for by the Consultant. The glass shall be of
required thickness as mentioned in the items of schedule of
quantities and / or drawing or as directed by the Consultant.
The Tenderer shall submit the sample of the glass which he
proposes to use on the work and only such approved quality of
glass shall be used in the works. The glass brought to site
shall be protected against damages.
Wherever frosted
(obscure) glass is mentioned in the item of schedule of
quantities and / or shown in drawings, the glass shall be of
sand blown pattern and shall also be got approved by the
Consultant.
3.3
After the inspection is over and permitted by the Consultant,

glass panes shall be cleaned off any labels paints smears and
spots and shall be washed from both the sides and all glazing
left clear, perfect and free from rattling. The Tenderer shall
provide all the scaffolding tools and plants for fixing the glass
panes at his own cost.
3.4
Glare reducing (tinted) or heat absorbing glass shall be

Calores of Hindustan Pilkington or approved equivalent and
special care shall be taken to grind smooth and round off the
edges before fixing.
3.5
Clear glass shall be flat drawn and shall be at minimum 4 mm

thick for panel area upto 0.5sq.m., Conforming to lS-2835.
Sheet glass for doors shall be minimum 6.3 mm thick.
3.6
Wired glass shall be 6 mm thick rolled glass with centrally

embedded 24 G wire mesh of Georgian type. This may be of
clear or coloured glass, as required by Consultant and shall
conform to lS-5437.
3.7
Obscure glass shall have a cast surface on one side.
3.8
Coloured and figured glass shall be as per approved sample.
3.9
In general, the putty shall conform to lS-419 and be of best

quality from approved manufacturer. it shall be brought to site
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CHAPTER NO. Q6
VOLUME - V of V
Page 123 of 194
in the manufacturers original packing. Quick setting putty

shall be used for windows and sashes except when glare
reducing glass is used where it shall be of non-setting type.
3.10
Neoprene gaskets with snap-fit glazing shall be fixed as per

manufacturers instruction and shall fit firmly against the glass
to give a leak proof Installation.
4.0
FIXING
4.1
The glass shall be cut to the required sizes of panels where it is

to be fitted and it shall be so cut that it fits properly in the
frames without rattling. Pre-measurement of each panel prior
to the cutting of glass is essential.
4.2
The beading shall then be fixed to glass panes and screwed at

close intervals not more than 10 cm. from each corner and the
intermediate not more than 20 cm. apart. When glass panes
are fixed with wooden beadings having mitred joints or
aluminium beading, thin layer of glazier putty shall be applied
covering the area in contact between the glass and sashbars
and beadings. In case of louvers, all the exposed edges of the
glass shall be ground properly
4.3
All glazing clips, bolts, nuts, putty, mastic cement, etc. as

required shall be supplied by the Tenderer.
4.4
All glass shall be thoroughly cleaned before placing in

positions. Each glass pane shall be held in place by special
glazing clips of approved type. As specified in relevant l.S.
Codes, four glazing clips shall be provided per glass pane,
except for large panes where six or more clips shall be used as
per Consultants instructions. All holes that may be necessary
for holding the clips, glazing beads and all other attachments
shall be drilled by the Tenderer.
4.5
Glass pane shall be set without springing, and shall be bedded

in putty and back putted, except where mouldings or gaskets
are specified. Putty, mastic cement etc. shall be smoothly
finished to a true even line. Obscure and figured glass shall be
set with smooth. side out.
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CHAPTER NO. Q6
VOLUME - V of V
Page 124 of 194
4.6
After completion of glazing work, the Tenderer shall remove all

dirt, stains, putty etc. clean the glass panes and leave the
work in perfectly acceptable condition. All broken, cracked or
damaged glass shall be replaced by new ones
4.7
The beading shall be of teak wood of superior quality timber in

case of teak wood doors and windows of required sizes
mentioned in the items of schedule of quantities as shown in
drawing. In case of steel doors and windows the beading shall
be powder coated aluminium (of approved colour) beading of
channel section as per size mentioned in the item and / or
shown in the drawing. The junction of the beadings shall be
mitre jointed.
5.0
ACCEPTANCE CRITERIA
a) All installations shall be free from cracked, broken or
damaged glass. Edges of large panes of thicker glass and
heat absorbing glass shall be inspected carefully for
chipped, cracked or unground edges.
b) Glazing shall be carefully done to avoid direct contact with
metal frames.
c) All glass shall be embedded in mastic or fixed by neoprene
gaskets to give a leak-proof installation.
d) At completion, the panes shall be free from dirt, stains,
excess putty etc. and to complete satisfaction of the
Consultant.
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PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 125 of 194
C-14: PAINTING, WHITE WASHING, DISTEMPERING AND

OTHER FINISHING WORKS
1.0
SCOPE
1.1
This Specification covers painting, white washing. polishing,

distempering etc. of both interior and exterior surfaces of
masonry, concrete, plaster, plaster of Paris, structural and
other miscellaneous steel items, rain water down comer, floor
and roof drains, waste and service water pipes, and other
ferrous and non-ferrous metal items as indicated elsewhere in
these specifications or as directed by the Consultant.
1.2
If surface to be finished cannot be put in suitable condition for

painting by customary preparatory methods, the Tenderer
shall notify the Consultant in writing or assume responsibility
for the same and
rectify unsatisfactory finishing. Before
commencing painting, the Tenderer shall obtain the approval
of the Consultant in writing regarding the scheduling of work
to minimise damage, disfiguration or staining by other trades.
He shall also undertake normal precautions to prevent
damage, disfiguration or staining to work of other trades or
other installations.
2.0
CODES AND STANDARDS
2.1

Tenderer.
2.2

shall prevail.
2.3

IS: 75-1973
Linseed oil, raw and refined
IS: 77-1976
Linseed oil, boiled, for paints
IS:102-1962
Ready mixed paint, brushing, red, lead,
nonsetting, priming
IS:103-1962
Ready mixed paint, brushing, white lead, for
priming and general purposes
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VOLUME - V of V
Page 126 of 194
IS:104-1979
Specification
for
ready
mixed
paint,
brushing, zinc chrome, priming
IS:133-1993
Enamel, interior (a) under coating (b)
finishing colour as required
IS:137-1965
Ready mixed paint, brushing, matt or eggshell flat, finsihing, interior, to Indian
Standard Colour, as required
IS:158-1981
Ready mixed paint, brushing, bituminous,
black lead free acid alkali, water and heat
resisting for general purposes.
IS:168-1993
Ready mixed paint, air drying for general
purpose.
IS:217-1988
Cut back bitumen
IS:218-1983
Creosote and anthracene oil for use as wood
preservatives
IS:290-1961
Coal tar black paint
IS:337-1975
Varnish, finishing interior
IS:338-1952
Varnish, under coating exterior, natural
resin
IS:339-1952
Varnish, under coating, exterior, synthetic
resin
IS:340-1978
Varnish, mixing
IS:341-1973
Black Japan, type A, B, & C
IS:345-1952
Wood filler, Transparent, liquid
IS:347-1975
Varnish, shellac for general purpose
IS:348-1968
French polish
IS:419-1967
Putty for use on window frames
IS:427-1965
Distemper, dry, colour as required
IS:428-1969
Distemper, oil emulsion colour as required
IS:524-1983
Specification for Varnish, Finishing, Exterior,
Air-drying
IS:525-1968
Varnish, finishing, exterior and general
purposes
IS:533-1973
Gum spirit of turpentine (oil of turpentine)
IS:712-1984
Specification for building limes
IS:1477(I and Code of Practice for painting of ferrous
II)
metals in building
IS:2095-1982 Gypsum plaster boards.
IS:2096-1992 Asbestos cement flat sheets.
IS:2339-1963 Aluminium paint for general purposes, in
dual container
IS:2395
(I Code of Practice for painting concrete,
and II)
masonry and plaster surface
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q6
IS:2547-1976
IS:2932-1994
IS:2933-1975
IS:5410-1992
IS:5411-(Pt.I)-1974
IS:6278-1971
IS : 13467
BS : 5493
VOLUME - V of V
Page 127 of 194
Gypsum building plaster
Enamel synthetic, exterior (a)
Under
coating (b) Finishing.
Enamel, Exterior (a) Under coating (b)
Finishing
Cement paint, colour as required
Plastic emulsion paint for interior use
Code of practice for white washing & colour
washing
Specification for chlorinated rubber for
paints
Code of practice for protective coating of
Iron & Steel structure against corrosion
3.0
MATERIALS
3.1
Materials shall be of highest-grade products of well-known

approved manufacturer and shall be delivered to the site in
original sealed containers, bearing brand name, manufactures
name and colour shade, with label intact and seals unbroken.
All materials shall be subject to inspection & approval by the
Consultant. It is desired that materials of one manufacturer
only shall be used as far as possible and paint of one shade be
obtained from the same manufacturing batch.
3.2
All paint shall be subjected to analysis from random samples

taken at site from painters bucket, if so desired by the
Consultant.
3.3
All prime coats shall be compatible to the material of the

surface to be finished as well as to the finishing coats to be
applied. All unspecified materials such as shellac, turpentine or
linseed oil shall be of the highest quality available and shall
conform to the reputed recognised manufacturers and shall be
approved by the Consultant.
3.4
All colour shall be as per painting schedule and tinting and

matching shall be done to the satisfaction of the Consultant. In
such cases, where samples are required, they shall be
executed in advance with the specified materials for the
approval of the Consultant.
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4.0
WHITE WASHING
4.1
Shall be done from pure shell lime or fat lime, or a mixture of

both as instructed by the Consultant, and shall conform to
IS:712. Samples of lime shall be submitted to the Consultant
for approval, and lime as per approved sample shall be
brought to site in unslaked condition. After slaking, it shall be
allowed to remain in a tank of water for two days, and then
stirred up with a pole, until it attains the consistency of thin
cream. 100 grams of gum to 6 litres of white wash water and
a little quantity of indigo or synthetic ultramarine blue shall be
added to the lime.
5.0
WATERPROOF CEMENT PAINT
5.1
Shall be made from best quality white cement and lime

resistant colours with accelerators, waterproofing agents and
fungicides. The paint shall conform to IS:5410.
6.0
ACRYLIC EMULSION PAINT
6.1
Shall be water based acrylic copolymer emulsion with rutile

titanium dioxide and other selected pigments and fungicide. It
shall exhibit excellent adhesion to plaster and surface and
shall resist deterioration by alkali salts. The paint film shall
allow the moisture in wall to escape without peeling or
blistering. The paint, after it is dried, shall be able to withstand
washing with mild soap and water without any deterioration in
colour, or without flaking, blistering or peeling.
7.0
SYNTHETIC ENAMEL PAINT
7.1
Shall be made from synthetic resin and drying oil with rutile
titanium dioxide and other selected pigments to give a
smooth, hard, durable and glossy finish to all exterior and
interior surfaces. White and pastel shades shall resist
yellowing and darkening with aging. The paint shall conform to
IS: 2932 and IS: 2933.
8.0
DRY DISTEMPER
8.1
Dry distemper of required colour conforming to IS: 427 and of

approved brand and manufacturer shall be used. The primer
where used shall be cement primer or distemper primer. The
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Page 129 of 194
shade shall be got approved from the Consultant. Dry

distemper as required shall be stirred slowly and in clean
water using 0.6 litre of water per kg of distemper or as
specified by the manufacturer. Distemper shall not be mixed in
larger quantity than is actually required for one-day work.
Warm water shall preferably be used. The treatment shall
consist of a priming coat of whiting followed by the application
of two or more coats of distemper till the surface shows an
even colour.
9.0
OIL BOUND DISTEMPER
9.1
Oil bound distemper (IS: 428-1969) of approved brand and

manufacturer shall be used. Any unevenness in surface shall
be made good by applying putty. The patched surface shall be
allowed to dry thoroughly before the coat of distemper is
applied. One coat of distemper properly diluted with thinner as
specified by the manufacturer applied with brushes in
horizontal strokes followed immediately by vertical ones
together will constitute one coat. Two or more coats of
distemper as found necessary shall be applied to obtain even
shade.
10.0
COLOUR WASH
10.1
It shall be done with mineral colours, not affected by lime

added to white wash. No colour wash shall be done until a
sample of the colour wash to the required tint or shade has
been approved by the Consultant. The colour shall be of even
tint or shade over the whole surface. If it is blotchy or
otherwise badly applied, it shall be redone by the Tenderer at
no extra cost to Owner.
11.0
CHLORINATED RUBBER BASED PAINT
11.1
Chlorinated rubber is the product obtained from the reaction of

chlorine with rubber. The product contains average chlorine
content of about 65%.
11.2
Chlorinated rubber shall be formulated with resins (for

adhesion and gloss), plasticizers (for flexibility and
toughness), pigments (for colour), stabilizers and solvents (for
fluidity). This shall meet the general requirements of IS:13467
& BS:5493.
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CHAPTER NO. Q6
VOLUME - V of V
Page 130 of 194
12.0
STORAGE
12.1
The Tenderer shall arrange for safe and proper storage of all
materials and tools. Paints shall be kept covered at all times
and mixing shall be done in suitable containers. All necessary
precautions shall be taken by the Tenderer to prevent fire.
13.0
PREPARATION OF SURFACE
13.1
Before starting the work the Tenderer shall obtain the approval
of the Consultant regarding the soundness and readiness of
the surface to be painted on.
13.2
Masonry, Concrete and Plastered Surfaces shall be free from

all oil, grease, efflorescence, mildew, loose paint or other
foreign and loose materials. Masonry cracks shall be cleaned
out and patch filled with mortar similar to the original surface
and uniformly textured. Where this type of resurfacing may
lead to the finishing paint being different in shade from the
original surfaces, the resurfaced area shall be treated with
minimum one coat of cement primer which should be
continued to the surrounding area for a distance of minimum
100 mm.
13.3
Surface with mildew, efflorescence shall be treated as -below.

a) Mildew: All mildewed surfaces shall be treated with an
approved fungicide such as ammonical wash consisting of 7
gm of copper carbonate dissolved in 80 ml.liquid ammonia
and diluted to 1 litre with water or 2.5 per cent magnesium
silico-fluoride solution and allowed to dry thoroughly before
paint is applied.
b) Efflorescence: All efflorescence shall be removed by
scrubbing the affected surfaces with a solution of muriatic

acid in water (1 : 6 to 1 : 8) and washed fully with clear
water and allowed to dry thoroughly.
13.4
Metal Surfaces
13.4.1
All metal surfaces shall be absolutely clean, dry and free from
wax, grease or dried soap films. All steel and iron surfaces in
addition shall be free from rust. All galvanized iron surfaces
shall be pre-treated with a compatible primer according to the
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manufacturers direction. Any abrasion in shop coat shall be

touched up with the same quality of paint as the original coat.
14.0
APPLICATION
14.1
The method of application shall be as recommended by the

manufacturer in case of selection of special shades and colour
(not available in standard shades) the Tenderer shall mix
different shades and prepare test panels of minimum size 1
metre square as per instruction of the Consultant and obtain
his approval prior to application of finishing paints.
14.2
Proper tools and implements shall be used. Scaffoldings if used

shall be independent of the surface to be painted to avoid
shade differences of the freshly repaired anchor holes. Painting
shall be done by skilled labourers in a workman like manner.
All materials shall be evenly applied, so as to be free of sags,
runs, crawls or other defects. All coats shall be of proper
consistency. In case of application by brush, no brush marks
shall be visible. The brushes shall be clean and in good
condition before application of paint.
14.3
All priming undercoats for painting shall be applied by brush

only and rollers, spray equipments etc. shall not be used.
14.4
No work shall be done under conditions that are unsuitable for

production of good results. No painting shall be done when
plastering is in progress or is drying. Application of paint which
seals of surface to moisture shall be done after the moisture
on and under the surface has dried out.
14.5
All coats shall be thoroughly dry before being sand papered or

before the succeeding coat is applied. Coats of painting as
specified are intended to cover surfaces perfectly.
14.6
In case the surface is not covered properly by applying the

specified number of coats, further coats shall be applied by the
Tenderer when so directed by the Consultant, without any
extra cost to Owner. All primers and undercoats shall be tinted
to approximate the colour of the finishing coats. Finished coats
shall be of exact colour and shade and as per approved
samples and finish shall be uniform in colour and texture. All
parts of mouldings and ornaments shall be left clean and true
to finish.
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CHAPTER NO. Q6
VOLUME - V of V
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14.7
White Washing: The surface where white washing is to be

applied shall be cleaned of all loose materials and dirt. All
holes and irregularities of the surface shall be filled up with
lime putty and shall be allowed to dry up before application of
the lime solution. One coat of white wash shall consists of one
stroke from top downwards, another from bottom upwards
over the first stroke and another from left to right before the
previous one dries up. Second coat shall be applied after the
first dries up completely and similarly the third coat shall be
applied and in case the Consultant feels that one or more
coats is required the Tenderer shall do so without any extra
cost to the Owner. No brush marks shall show on the finished
surface. The inner plastered surfaces of walls shall be given
three or more coats of white washings.
14.8
Waterproof Cement Paint: Surface to be coated with cement

paint shall be washed and brushed down. As soon as the
moisture has disappeared, the surface shall be given one coat
of paint. Care shall be taken so that the paint does not dry out
too rapidly. After 4 to 6 hours, the water shall be sprinkled
over the surface to assist curing and prevent cracking. After
the first coat has dried (24 to 48 hours) the second coat shall
be applied. In a similar manner the finished surface shall be
kept moist by occasional sprinkling with water for seven days
after painting.
14.9
Acrylic Enamel Paint: Lime gauged cement plastered surfaces

shall not be painted for at least one month after plastering. A
sample patch shall be painted to check alkali reaction if so
desired by the Consultant. Painting shall be strictly as per
manufacturers specification. Minimum two coats shall be
applied.
14.10
Synthetic Enamel Paint: Shall be applied on properly primed

surface. Subsequent coats shall not be applied till the previous
coat is dry. The previous coat shall be lightly sand papered for
better adhesion of subsequent coats. Minimum two coats shall
be applied.
14.11
Dry Distemper: The treatment shall consists of a priming coat

of whiting followed by the application of two or more coats of
distemper till the surface shows an even colour as per
manufacturers instruction. The entire surface shall be coated
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with the mixture uniformly, with proper distemper, in

horizontal strokes followed immediately by vertical ones, which
together shall constitute one coat. Subsequent coats shall be
applied only if the previous coat has dried.
14.12
Oil Bound Distemper: Any unevenness in the surface shall be

made good by applying putty. The patched surface shall be
allowed to dry thoroughly before coat of distemper is applied.
One coat of distemper properly diluted with thinner as
specified by the manufacturer shall be applied with brushes in
horizontal strokes followed immediately by vertical ones, which
together will constitute one coat. Two or more coats of
distemper, as found necessary shall be applied to obtain even
shades.
14.13
Colour Washing: For new work, the priming coat shall be of

white wash with lime or with whiting. Two or more coat shall
than be applied on the entire surface till it represents a
smooth and uniform finish. The finished dry surface shall not
be powdery and shall not readily come off on hand when
rubbed. Indigo (neel) shall however, not to be added.
15.0
PAINTING OF IRON & STEEL WORKS
15.1
Paint to be used for various items of work shall be of best

quality and shall be obtained ready mixed in sealed containers
from approved manufacturer. The Tenderer shall obtain the
Consultants approval for the make and colour of the paint he
proposes to use.
15.2
All surfaces shall be thoroughly cleaned of all dirt, loose

particles and rust, and approved prior to application of paint.
Workmanship shall conform to lS-1477 (Part - I & II).
15.3
Specific number of coats shall be applied and at least 24 hours

shall elapse between the applications of successive coats. No
painting shall be carried out on exterior work in wet weather
or on surfaces which are not entirely dry.
16.0
CHEMICAL RESISTANT PAINT
16.1
For chemical resistant paint stipulation of BS: 5493 shall also

be followed.
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CHAPTER NO. Q6
17.0
VOLUME - V of V
Page 134 of 194
PROTECTION
17.1
Furniture and other movable objects, equipments, fittings and

accessories shall be moved, protected and replaced upon
completion of the painting work. All stationary items of
equipments shall be well covered so that no paint can fall on
them. All protection shall be as per instruction of the
Consultant.
18.0
CLEANING UP
18.1
The Tenderer shall, upon completion of painting etc. remove

all marks and make good the surface, where paint has been
spilled, splashed or splattered, including all equipments,
fixtures, glass, furniture, fittings etc. to the satisfaction of the
Consultant.
19.0
ACCEPTANCE CRITERIA
a) All painted surfaces shall be uniform and pleasing in
appearance.
b) The colour, texture etc. shall match exactly with approved
samples.
c) All stains, splashes and splatters of paints shall be removed
from surrounding surfaces.
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CHAPTER NO. Q6
VOLUME - V of V
Page 135 of 194
C-15: DRAINAGE, SANITATION AND WATER SUPPLY

1.0
SCOPE
This section covers the design, layout and construction of
drains for the entire plant area for foul water, surface water
and sewage together with all fittings and fixtures and inclusive
of ancillary works, such as connections, manholes and
inspection chambers used within the building and from the
building to the connection to Owners main sewer line
manholes stipulated here or elsewhere in these specifications.
The scope is also inclusive of design, supply, erection of all the
tanks, pipes, fittings etc. required for the water supply to be
taken from the terminal point to the respective buildings.
2.0
INSTALLATION
2.1
Surface Drainage
The Tenderer shall construct the entire drainage scheme as
per the drawings. Necessary slopes shall be provided in
longitudinal drain.
2.2
General
All pipelines, locations of fittings and fixture etc. shall be as
per approved drawings or as directed by the Consultant.
Correctness of lines, plumb, orientation, symmetry and levels
shall be strictly ensured. All items shall be fully secured
against movement in any direction and so located as to allow
maintenance where desired by the Consultant.
All pipelines and fittings fixtures shall be installed leak proof.
When the works under scope of this specification connect with
others the connections shall be such as to prevent any
splashing or emission of foul odour and gases.
a)
Polyethylene water Tank
Tanks shall meet the requirements of IS:12701. Virgin HDPE

granules of approved grade, suitable for drinking water shall
be used for making the tank. Carbon black shall be added with
the granules. Tanks shall be single piece, seamless
construction, moulded by rotational moulding. Shape of tank
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shall be cylindrical - vertical type with corrugation along the

length and bottom of the tank. Tank shall have closed top
provided with lid. However, for storage inside, the rectangular
loft tank of approved colour shall be provided. Tank shall be
provided with all fittings for inlet, overflow, outlet pipes and
ball valves including mosquito proof coupling. Tank shall be
leak proof. Tank shall be installed with proper support and
anchorage for installation and it shall be carried out according
to the recommendation of clause No. 13 of IS:12701-1989.
2.3
Rainwater Down Comers

Rainwater down comers shall be of PVC pipes of 6 kg/sqcm
pressure class. Rainwater down comers shall run along and be
secured to wall, column etc. Where desired by the Consultant
these may have to be installed in chases cut in the structure.
All pipes shall be well secured and supported by adequately
strong circumferential clamps.. The clamps shall be moulded
plastics, split ring type or perforated strap iron type as
approved by the Consultant. Suitable spacer shall be provided
against the vertical surfaces to which the pipe is fixed. All
bends and junctions shall be supplied with water tight
cleanouts. All horizontal pipes shall have a minimum fall of 1
in 100.
2.4
Soil and Drainage Pipes
2.4.1
Gradients
The minimum gradients of soil and drainage pipe line shall be
as follows:
100
150
230
300
2.4.2
mm
mm
mm
mm
nominal
nominal
nominal
nominal
dia
dia
dia
dia
1
1
1
1
in
in
in
in
35
65
120
200
Relation with Water Supply Pipeline

Under no circumstances, unless specifically cleared by the
Consultant in special cases, drainage and soil pipes shall be
allowed to come close to water supply pipelines.
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2.4.3
VOLUME - V of V
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Laying
Each separate pipe shall be individually set for line, level,
plumb etc. Where lengths of sewer or drain pipes are laid in
trench, properly painted sight-rails shall be fixed across the
trench at a height, equal to length of the boning rod to be
used, above the required invert level of the drain or sewer at
the point, where the sight is fixed. More sight rails shall be
required at manholes, changes of gradient and intermediate
positions if the distance of sighting is too far, which shall not
be more than 15.0 m apart. The excavation shall be boned in
at least once in every 1.8 m. The foot of the boning rod shall
be set on a block of wood of the exact thickness of the wall of
the pipe. Each pipe shall be separately and accurately boned
between sight rails.
2.4.4
For water pipelines, meticulous care shall be taken to avoid

chances of airlock and water hammer. The layout of pipe work
shall be such that there is no possibility of backflow towards
the source of supply from any cistern appliances whether by
siphonage or otherwise. Where desired by the Consultant,
pipes shall be concealed in masonry or concrete of the
structure. Chases, openings, conduits as necessary shall be
cut or left in the masonry or concrete. Clamps and fittings
shall be as per the standard practice and approved by the
Consultant.
2.4.5
Support and Protection to Pipelines

All drainage and sewer pipes shall be laid with spigot leading
uphill. Preferably the pipes shall rest on solid and even
foundations for the full length of the barrel. However, the pipe
manufacturers instructions as approved by the Consultant
shall be followed in the matter of support and jointing. Cast
Iron pipes and concrete pipes may be supported on suitable
concrete or brick support, where specified. The supports shall
be unyielding and strong enough. At least one support shall be
located close to each joint. Spacing of intermediate supports
shall be as desired by Consultant. Pipes shall be secured to the
supports by approved means.
Anchoring of pipes where necessary shall be achieved by
suitable concrete encasing designed for the expected thrust.
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2.4.6
VOLUME - V of V
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Entry Into Structures

For entry of the pipelines into any building or structures,
suitable conduits under the structures, or sleeves shall be
used. The conduits and sleeves shall be such as to allow easy
repair and replacement of the pipes. When openings or chases
are required to be made in the structure for entry of pipelines,
locations and sizes shall be marked and checked by the
Consultant. After laying of the pipeline the openings and
chases shall be mended.
2.4.7
Ducts
Where solid, waste and ventilating pipes are accommodated in
ducts, access to cleaning eyes shall be provided. Connection to
drain shall be through a gully trap with sealed cover to guard
against ingress of sewer gas, vermin or backflow.
2.4.8
Traps and Ventilating Pipes

Pipes for carrying of the waste from water closets and waste
water and overflow water from baths, wash basins, sinks to
drains shall be trapped immediately beneath such fixtures.
Traps shall have minimum water seal of 50 mm and shall be
ventilated whenever such ventilation is necessary to maintain
water seal of the trap. Ventilating pipes shall be carried up
vertically from the drain to a height of at least 600 mm above
the outer covering of the roof of the building or as shown on
drawings. All vertical ventilating, anti-siphonage and similar
pipe shall be covered on top with a cowl. The cowl shall be
made of C.I.
2.4.9
Manholes and Inspection Chambers

The maximum distance between manholes shall be 30 metres
unless specially permitted otherwise. In addition, at every
change of alignment, gradient or diameter there shall be a
manhole or inspection chamber. The distance between
manhole or inspection chamber and gully chamber shall not
exceed 6 metres unless desired otherwise. Manhole shall be
constructed so as to be watertight under test. The benching at
the sides shall be carried out in such a manner as to prevent
lodgment for any splashing in case of accidental flashing of the
chamber. The channel or drain at the bottom of chamber shall
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be plastered with (1:2) cement sand mortar and finished

smooth to the grade. The channels and drains shall be shaped
and laid to provide smooth flow.
Connection to existing sewer lines shall be through a manhole.
Manholes shall be provided with C.I. standard covers. The
covers shall be close fitting so as to prevent gases from
coming out.
2.4.10
Jointing
Jointing of laid pipes shall be so planned as to avoid
completely any movement or strain to the joints already
made. If any joint is suspected to be damaged it shall be
opened out and redone.
All joints between pipes, pipe fittings and manholes shall be
gastight when above ground and watertight when
underground. Method of jointing shall be as per instruction of
the pipe and fittings manufacturer and as approved by the
Consultant. However in the absence of any instruction
available from the manufacturer, methods as detailed
hereunder shall be used.
a)
Cast Iron Pipes

Socket and spigot pipes shall be joined by cast lead
joints. The spigot shall be centered in the socket of the
next pipe by tightly caulking in sufficient turns of tarred
gasket or hemp yarn to have unfilled half the depth of
socket. When the gasket or hemp yarn has been
caulked tightly, a jointing ring shall be placed round the
barrel and tightened against the face of the socket to
prevent airlock. Molten lead shall then be poured in to
fill the remainder of the socket and caulked with
suitable tools right round the joint to make up for
shrinkage of the molten metal on cooling and shall be
finished 3 mm behind the socket face.
In special cases if flanged joints are accepted by the
Consultant, the joints shall be made leak proof by
inserting approved type of rubber or other gasket not
less than 1.5 mm thick. The bolts shall be secured in
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stages to avoid uneven strain. Damaged gasket shall be

replaced.
b)
G.I. Pipes
Threads shall be cut with sharp tools, and before
jointing, all scales shall be removed from pipes by
suitable means. The screw threads of the pipe shall be
cleaned out and the joints made by screwing the fittings
after treating the threads with approved pipe jointing
compound. Once a joint has been screwed up it shall
not be backed off unless the threads are re-cleaned and
new compound applied.
c)
Glazed Stoneware Pipes

Tarred gasket or hemp yarn soaked in thick cement
slurry shall first be placed round the spigot of each pipe
and the spigot
2.5
Installation
All plumbing fittings and fixtures shall be installed in most
workmen like manner by skilled workers. Those shall be
prefect in level, plumb, plane, locations and symmetry. All
items shall be securely anchored to wall and floors. All cuttings
in walls and floors shall be made good by the Tenderer.
3.0
TESTING AND ACCEPTANCE
3.1
All pipes, fittings and fixtures shall be inspected, before

delivery at the site to see whether they conform to accepted
standards. The frequency of testing and sampling as given
Table - I of this Section. The pipes shall again be inspected on
site before laying by sounding to disclose cracks. All defective
items shall be clearly marked and forthwith removed from the
site.
3.2
Testing of Pipelines for Drainage & Sanitation

Comprehensive test of all pipelines shall be made by
simulating conditions of use. The method of actual tests shall
be decided by the Consultant. All test date shall be recorded
and submitted to the Consultant for review and Instruction.
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The Consultants discretion regarding tolerance shall be final.

General guidance for the test are given below :a)
Smoke Test
All soil pipes, waste pipes, vent pipes & all other pipes
when above ground shall be approved gas tight by a
smoke test conducted under a pressure of 25 mm of
water and maintained for 15 minutes after all trap seals
have been filled with water. The smoke is produced by
burning oily waste or tar paper of similar material in the
combustion chamber of a smoke machine. Chemical
smoke is not allowed.
b)
3.3
For Straightness
i)
It shall be checked by inserting at the high end of

the sewer or drain a smooth ball of a diameter
1.3 mm less than the pipe bore. In the absence of
obstruction, such as yarn or mortar projecting
through the joints, the ball will roll down the
invert of the pipe and emerge at the lower end;
and
ii)
By means of mirror at one end of the line and

lamp at the other end. If the pipeline is straight,
the full circle of light may be observed. The
mirror will also indicate obstruction in the barrel if
the pipeline is not straight.
Testing of Water Mains after Laying

After laying and jointing, the main shall be slowly and carefully
charged with water, so that all air is expelled from the main,
by providing 25 mm inlet with a stop-cock, allowed to stand
full of water for a few days if time permits, and then tested
under pressure. The test pressure shall be 5 Kg/sqcm. or
double the maximum working pressure, whichever is greater.
The pressure shall be applied by means of a manually
operated test pump, or in the case of long mains or mains of a
large diameter by a power driven test pump provided that the
pump is not left unattended. In either case due precaution
shall be taken to ensure that the required test pressure is not
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exceeded. Pressure gauges shall be accurate and shall

preferably have been recalibrated before the test. The pump
having been stopped, the test pressure shall maintain itself
without measurable loss for at least five minutes. The end of
the mains shall be closed by fitting a watertight expanding
plug and plug shall be secured by struts to resist end thrust of
the water pressure in the mains.
3.4
Testing of Service Pipes and Fittings

The service pipes shall be slowly and carefully charged with
water allowing all air to escape avoiding all shock or water
hammer.
3.5
Fixture etc.
All fixtures and fittings shall be connected by Water tight
joints. No dripping shall be accepted.
4.0
DESIGN & CONSTRUCTION OF SEPTIC TANK & SOAK PIT
4.1
Design & Construction of septic tank & soak pit for sewage
disposal shall be as per IS:2470 part I & II.
5.0
IS CODES
Some of the applicable Indian Standards, Codes are referred
to here below:
Latest editions shall always be referred.
IS: 1172
IS: 1239
IS: 3486
IS: 3589
IS: 1537
IS: 1742
Basic requirements for water supply, drainage

and sanitation.
(Part I & II) Mild Steel Tubes and Mild Steel
Tubulars and other wrought Steel Pipe fittings.
Cast Iron Spigot and Socket drain pipes
Electrically welded steel pipe for water, gas and
sewage (200mm to 2000 mm nominal diameter).
Vertically cast iron pressure pipe for water, gas
and sewage.
Code of practice for building drainage.
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PACKAGE NO - II
CHAPTER NO. Q6
IS: 5329
VOLUME - V of V
Page 143 of 194
Code of practice for sanitary pipe work above
ground for building
IS: 1538
Cast iron fittings for pressure pipes for water, gas

and sewage.
IS: 1230
Cast iron rainwater pipes and fittings.
IS: 1729
Sand cast iron spigot and socket soil, waste and
ventilating pipes, fittings and accessories.
IS: 1626
Asbestos cement building pipes, gutters.
IS: 2065
Code of practice for water supply in building.
IS: 1726
Cast iron manhole covers and frames intended for
use in drainage works.
IS: 5961
Cast iron gratings for drainage purposes. IS:
5219 (Part - I) P and S traps, cast copper alloy
traps
IS: 771
Glazed fire dry sanitary appliances
IS: 772
General requirements of enameled cast iron
sanitary appliances
IS: 774
Flushing cistern for water closets and urinals
(Valve less Siphonic type)
IS: 775
Cast iron brackets and supports for wash basin
and sinks.
IS: 2548
Plastic water closet seats and covers.
IS: 2527
Code of practice for fixing - rainwater gutters and
downpipes for roof drainage.
IS: 1068
Chromium plating
IS: 1073
Ball valves including floats for water supply
purpose.
IS 2470:Part 1: 1985 Code of practice for installation of septic
tanks: Part I design, criteria and construction
IS 2470:Part 2: 1985 Code of practice for installation of septic
tanks: Part II Secondary treatment and disposal
of septic tank effluent
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CHAPTER NO. Q6
VOLUME - V of V
Page 144 of 194
C-16: ROAD AND PAVEMENTS

1.0
SCOPE OF WORK
1.1
The work contemplated under these specifications refers to

earth work in excavation, forming embankments, soling, WBM.
Bituminous Macadam. Wearing course/sealing coat etc. for
Road and pavement works.
2.0
EARTH WORK IN EXCAVATION
2.1
The specifications for Excavation work & Back filling under

section - III, specified in C-02 shall be generally followed.
2.2
Forming embankment :
2.2.1
The work shall include preliminaries of clearing site, setting

out and preparing the ground and there after forming
embankment for the roads, paths etc. With approved material
available form excavations under this contract (excavation
paid separately under respective items) or elsewhere,
spreading in layers, watering and compacting to the required
density and lines, curves, grades, chambered cross section
and dimensions shown in the plan or as directed by the
Consultant. When the embankment is to be laid on hill sides or
slopes, the existing slopes are to be ploughed deeply. If the
cross slopes are steeper than 1 in 3, steps with reverse slope
shall be cut into the slopes to give proper hold and seating to
the bank as directed by the Consultant. The top 15cm of soil
shall be scarified and watered if directed and compacted to the
same density as specified for the embankment before any
material is laid for the embankment work.
2.2.2
Only the approved excavated earth shall be placed in the

embankments in successive horizontal layers not exceeding
200mm, extending to the full width of the embankment
including the slopes at the level of the particular layer and 30
cm, more on both sides to allow compaction of the full
specified section. The extra loose stuff at the edges shall be
trimmed later after completion of the bank work without extra
cost leaving the correct section fully compacted.
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2.2.3
Keeping the width of the bank initially less and widening it

later by dumping loose earth on the slopes shall not be
permitted as the additional width and slopes will remain loose
and uncompacted. Similar procedure to extend the
embankment by dumping the material longitudinally shall also
not be allowed. Each layer of the embankment shall be
watered, levelled and compacted as specified here-in-after,
before the succeeding layers are placed. The surface of the
embankment shall at all times during construction, be
maintained in such a manner so as to prevent ponding. Water
to be used shall be free from all harmful elements which may
cause efflorescence etc. and approved by the Consultant.
2.2.4
If the material for embankment contains moisture less than

the optimum moisture, water shall be added in the 100mm,
layers of the embankment to bring moisture uniformly upto
requirement. If the excavated material contain more than
required moisture, it shall be allowed to dry until the moisture
is reduced to required extent. If due to the wetness, the
moisture content of the soil cannot be reduced to the
appropriate amount by exposure, embankment work shall be
suspended till suitable conditions prevail at no extra
claim/compensation.
2.2.5
When loose layer is levelled manually or mechanically and

moistened or dried to a uniform moisture content suitable for
maximum compaction, it shall be compacted by 8 to 10 tonne
power roller or sheep foot rollers or heavy hauling or dozing
equipment to give the specified 95% of the proctor density, if
on testing, the density is found to be less than 95% of the
proctor density, the Tenderer shall do additional compaction
necessary to get the specified density after adding water if
required. If the density cannot be improved by such
reasonable efforts, the work may be accepted as substandard
work by the Consultant. If consultant thinks it is not harmful
for the purpose and paid for at a reduce rate. Test shall be
made to determine the maximum density of the material to be
used by the proctor method before starting the work. Density
test shall be carried out for the embankment work during the
progress of the work. One set of three core samples for every
1000 sqm. (about 1000 sq.yd.) area of each layer of
embankment work shall be taken and tested. The average
density shall not be less than 95% of the proctor density,
obtained in the laboratory.
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VOLUME - V of V
Page 146 of 194
2.2.6
Arrangement for obtaining the samples and transporting the

same to laboratory, shall be made by the Tenderer at his own
cost.
2.2.7
Embankment not accessible to rollers, such as those adjoining

bridges, culverts and other works shall be carried out
independently of the main embankments and shall have the
layers placed in 150 mm to 200 mm height and each layer
shall to moistened and thoroughly compacted with mechanical
or manual tamper. Before placing the next layer, the surface
of the under layer shall be moistened and scarified so as to
provide a satisfactory bond with the next layer.
2.2.8
The embankment shall be finished and dressed smooth and

even, in conformity with the alignment, levels and cross
section, and dimensions shown on the drawing. On curves,
section shall be provided with super elevation and increased
width, is shown on the plans as directed by the Consultant.
2.2.9
Joining of old and new embankment shall be done by stepping

in an overall slope of about 1 to 5.
2.2.10
The Tenderer shall be responsible for maintaining the

embankment work in satisfactory conditions at his own cost till
finally accepted including making good any damage.
3.0
SUB GRADE
3.1
Preparation of Sub-grade: The surface of the formation for a

width of sub-base which shall be as per drg. shall first be cut
to a depth equal to the combine depth of sub-base and surface
courses below the proposed finished level (due allowance
being made for consolidation). It shall then be cleaned of all
foreign substances. Any ruts or soft yielding patches that
appear due to improper drainage conditions, traffic hauling or
from any other cause, shall be corrected and the sub-grade
dressed off parallel to finished profile.
3.2
Consolidation: The sub grade shall be consolidated with a

power road roller of 8 to 12 tonnes. The roller shall run over
the sub grade till the soil is evenly and densely consolidated
and behaves as an elastic mass (the roller shall pass a
minimum of 5 runs on the sub grade). All undulations in the
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VOLUME - V of V
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surface that develop due to rolling shall be made good with

fresh material or quarry spoils as the case may be and the sub
grade is rerolled.
3.3
Surface Regularity: The finished surface shall be uniform and

conform to the lines, grades and typical cross sections shown
in the drawings. When tested with the template and straight
edge, the variation shall be within the tolerances specified in
the Table below:
Permissible tolerances of surface regularity
Longitudinal profile
Cross profile
Maximum permissible undulation Maximum permissible variation
when measured with a 3 metre
from specified profile when
straight edge
measured with a cambertemplate
24 mm
15 mm
3.4
Where the surface irregularity of the sub-grade falls outside

the specified tolerances, the Tenderer shall be liable to rectify
these with fresh material or quarry spoils as the case may be,
and the sub grade rerolled to the satisfaction of the
Consultant.
4.0
SUB-BASES/BASE
4.1
Water Bound Macadam Sub-base/Base with stone aggregate :

Stone aggregate of size graded-I & II shall be used. This
consists of clean crushed coarse aggregate mechanically
interlocked by rolling using power road roller of 8 to 10 t and
voids thereof filled with screening and binding material with
the assistance of water, laid on a prepared sub grade/ sub
base.
4.1.1
Quantities of Materials: Quantities of coarse aggregate,

screening and binding material required to be stacked for
100mm approximate compacted thickness of WBM sub-base
course for 10 sqm. Shall be as per table given below:
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PACKAGE NO - II
CHAPTER NO. Q6
Coarse
Classifi- Compa
cation cted
thickn
ess
Gradi100
ng-1
mm
VOLUME - V of V
Page 148 of 194
Aggregate
Size
Netrange quantities
90m
to
45m
4.1.2
1.21 Cum.
to
1.43Cum
Stone screenings
Grading/Classifi Quantiti
cation and size
-es
Binding
Material
Type A
13.2mm
0.08
Cum
to 0.10
Cum
0.27Cum
to
0.3Cum
Quantities of Materials: Quantities of coarse aggregate,

screening and binding material required to be stacked for
75mm approximate compacted thickness of WBM Base course
for 10 sqm. Shall be as per table given below:
Classi
ficatio
n
Gradi
ng-2
Coarse Aggregate
Comp Size
Netacted range
Quantities
thickn
ess
75
63mm
0.91 Cum.
to
mm
to
1.07Cum
45mm
Stone screenings
Grading/Classifi Quantit
cation and size
ies
Binding
Material
Type A 13.2mm 0.12Cum

to
0.15Cu
m
0.06
Cum
to 0.09
Cum
NOTE : Net Quantity = Loose quantity measured in stack

minus 7.5%
4.1.3
Stone screenings to fill the voids in the coarse aggregates shall

generally consist of the same material as the coarse
aggregate. Screenings shall conform to the table given below:
Size of Screenings
IS Sieve
Designation
13.2 mm
13.2 mm
11.2 mm
5.6 mm
180 micron
% by Weight
Passing
IS Sieve
100
95-100
15-35
0-10
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4.1.4
VOLUME - V of V
Page 149 of 194
Coarse Aggregate
Coarse Aggregates shall conform to the
requirement as set forth in the following table
Size of
Aggregate
Grade I (45
mm to 90 mm)
Grade II (45
mm to 63 mm)
grading
IS Sieve
Designation
(IS:460)
125 mm
90 mm
63 mm
45 mm
22.4 mm
% by Weight
Passing
IS Sieve
100
90-100
25-60
0-15
0-5
90 mm
63 mm
53 mm
45 mm
22.4 mm
100
90-100
25-75
0-15
0-5
4.1.5
Preparation of foundation: In the case of an existing

unsurfaced road, where new materials is to be laid, the surface
shall be scarified and reshaped to the required grade,
chambered shape as necessary. Weak places shall be
strengthened, corrugations removed and depressions and
potholes made good with suitable materials, before spreading
the aggregate for WBM.
4.1.6
Spreading Aggregate: The coarse aggregate shall be spread

uniformly and evenly upon the prepared base in required
quantities with a twisting motion to avoid segregation. In no
case shall these be dumped in heaps directly on the area
where these are to be laid nor shall their hauling over a partly
completed base be permitted. The aggregates shall be spread
uniformly to proper profile by using templates placed across
the road, six metres part. Where specified, approved
mechanical devices may be used to spread the aggregates
uniformly. The levels along the longitudinal direction upon
which the metal shall be laid, shall be first obtained at site to
the satisfaction of Consultant and these shall be adhered to.
4.1.7
The surface of the aggregate spread shall be carefully trued up

and all high spots by removing or adding aggregate as may be
required.
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4.1.8
The WBM sub-base/base shall be normally constructed in

layers of 100/75 mm compacted thickness. No segregation of
large or fine particles shall be allowed and the coarse
aggregate, as spread shall be of uniform gradation with no
pockets of fine material.
4.1.9
The coarse aggregate shall normally not be spread in lengths

exceeding three days average work ahead of the rolling and
blending of the proceeding section.
4.2
Rolling
4.2.1
Immediately following the spreading of the coarse aggregate,

it shall be compacted to the full width by rolling with either a
three-wheel power roller of 8 to 10t capacity or an equivalent
vibratory roller. Initially, light rolling is to be done which shall
be discontinued when the aggregate is partially compacted
with sufficient void space in them to permit application of
screenings.
4.2.2
The rolling shall begin from the edges with the roller running
forward
and
backward
and
adding
the
screenings
simultaneously until the edges have been firmly compacted.
The roller shall then progress gradually from the edges to the
centre paralled to the centre line of the road and overlapping
uniformly each preceding rear wheel track by one half width
and shall continue until the entire area of the course has been
rolled by the rear wheel. Rolling shall continue until the road
metal is thoroughly keyed with no creeping of metal ahead of
the roller. Only slight sprinkling of water may be done during
rolling, if required. On super cleaved curves, the rolling shall
proceed from the lower edge and progress gradually
continuing towards the upper edge of the pavement.
4.2.3
Rolling shall not be done when the sub-grade is soft or yielding

or when the rolling causes a wave like motion in the sub-base
of sub-grade. When rolling develops irregularities that exceed
12mm when tested with a three metre straight edge, the
irregular surface shall be loosened and then aggregate added
to or removed from it as required and the area rolled until it
gives a uniform surface conforming to the desired crosssection and grade. The surface shall also be checked
transversely by template for chambered any irregularities
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corrected in the manner descried above. In no case shall the

use of screenings to made up depressions be permitted.
4.3
Application of screening
4.3.1
After the coarse aggregate has been lightly rolled to the

required true surface, screening shall be applied gradually over
the surface to completely fill the interstices. Dry rolling shall
be continued while the screening are being spread so that the
jarring effect of the roller causes them to settle into the voids
of the coarse aggregates. The screening shall not be dumped
in piles on the coarse aggregate but shall be spread uniformly
in successive thin layers either by the spreading motion of the
hand shovels or a mechanical spreader.
4.3.2
The screening shall be applied at a slow rate (in three or more

applications) so as to ensure filling of all voids. Rolling and
brooming shall continue with the spreading of the screenings.
Either mechanical brooms or hand brooms or both may be
used. In no case shall the screening be applied, so fast and
thick as to form cakes, ridges on the surface making the filling
of voids difficult, or to prevent the direct bearing of the roller
on the coarse aggregates. The spreading, rolling and brooming
of screening shall be performed on sections which can be
completed within one days operation and shall continue until
no more screening can be forced into the voids of the coarse
aggregate. Damp and wet screening shall not be used under
any circumstances.
4.4
Sprinkling and Grouting
4.4.1
After spreading the screening and rolling, the surface shall be

copiously sprinkled with water, swept and rolled. Hand brooms
shall be used to sweep the wet screening into the voids and to
distribute them evenly. The sprinkling, sweeping and rolling
operations shall be continued and additional screenings applied
where necessary until the coarse aggregates are well bonded
and firmly set for the entire depth and until a grout has been
formed of screenings and water that will fill all voids and form
a wave of grout ahead of the wheels of the roller. The quantity
of water to be used during the construction shall not be
excessive so as to cause damage to the sub-base or subgrade.
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4.5
Application of Binding Material
4.5.1
After the application of screenings and rolling, a suitable

binding material shall be applied at a uniform and slow rate in
two or more successive thin layers. After each application of
binding material, the surface shall be copiously sprinkled with
water and the resulting slurry swept-in with hand brooms or
mechanical brooms or both so as to fill the voids properly. The
surface shall then be rolled by a 8-10 t roller, water being
applied to the wheels in order to wash down the binding
material that may get stuck to the wheels. The spreading of
binding material, sprinkling of water, sweeping with brooms
and rolling shall continue until the slurry that is formed well,
after filling the voids form a wave ahead of wheels of the
moving roller.
4.6
Setting and Drying
4.6.1
After final compaction of the course, the road shall be allowed

to cure overnight. Next morning defective spots shall be filled
with screenings or binding material, lightly sprinkled with
water, if necessary and rolled. No traffic shall be allowed till
the macadam sets.
4.7
Surface Evenness
4.7.1
The surface evenness of completed WBM sub-base/base in the

longitudinal and transverse directions shall be as specified in
the table given below:
Size
of Longitudinal profile measured with
coarse
a 3 metre straight edge
aggregates
Maximum number of
Maximum
permissible undulations
permitted
in
any
300m
length
exceeding
12mm
10mm
90-45mm
63-45mm
15mm
12mm
30
-
30
Cross profile
Maximum
permissible
undulations
when
measured
with
a
camber
template.
12mm
8mm
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CHAPTER NO. Q6
The longitudinal profile shall be checked
straight edge at the middle of each traffic
parallel to the centre line of the road. The
shall be checked with adjustable template at
VOLUME - V of V
Page 153 of 194
with a 3M long
lane along a line
transverse profile
intervals of 10M.
4.8
Rectification of Defective Construction: Where the surface

irregularity of the WBM sub-base/base course exceeds the
tolerances specified in the table given above or where the
course is otherwise defective due to sub-grade/sub-base soil
mixing with the aggregates, the layer to its full thickness shall
be scarified over the affected area, reshaped with added
material or removed and replaced with fresh material as
applicable, and recompacted. The area treated in the aforesaid
manner shall not be less than 10 sqm. In no case shall
depressions be filled up with screenings and binding material.
5.0
RUBBLE SOLING
5.1
Rubble soling for road work including foot paths, culverts, side
drains etc. shall be carried out as specified here-in before
under chapter-04, para 2.2 for rubble stone soling, as far as
they are applicable, with the following additions.
5.2
Sub-grade for soling shall be prepared by cleaning of all

foreign substances including rank vegetation, if any. Any ruts
or soft yielding places that appear due to improper drainage
conditions, traffic, hauling or from any other cause shall be
corrected by filling/cutting upto 150 mm and compacted and
the Subgrade dressed off parallel to the finished profile and
the same shall be approved by the Consultant, before laying of
soling. Soling shall be laid in regular lines and staggered
joints. The stones shall be laid as closely as possible and
packed well. The stones shall be so laid as to have their bases
and the target area resting on the Subgrade and in contact
with each other.
5.3
Soling shall be laid to proper gradient and camber, which shall

be checked frequently to ensure accuracy. Rolling shall then
be carried out by a 8 to 10 t power roller and soling
consolidated properly shall be lightly sprinkled during rolling, if
ordered by the Consultant.
5.4
The surface thus prepared shall first be passed by the

Consultant, after which 40mm to 50mm thick layer of selected
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CHAPTER NO. Q6
hard murrum available from excavation
the soling as directed by the Consultant,
that the hard murrum gets into the
however, be ensured that a thin layer
remain on the finished surface of soling.
VOLUME - V of V
Page 154 of 194
shall be spread over
and rolled again such
interstices, It shall,
of murrum/grit shall
5.5
The area of soling actually done of specified consolidated

thickness limiting to the dimensions as per drg. Shall be
measured in square metre upto two decimal places.
6.0
WATER BOUND MACADAM
6.1
Metal: Metal required for Water Bound Macadam surfacing

shall be broken from the first sort rubble. The rubble shall be
broken to required size by the Tenderer at his own cost.
However, the metal required for water bound macadam shall
conform to IRC specification in all respects. It shall be hard,
sound; trap stone metal free from decay and weathering and
obtained from approved quarries, and shall be of Grade I & II
nominal size.
6.2
Collection of metal: Metal shall be of first sort black trap stone

and shall be collected in stacks on level ground and stacked on
the sides of the roads as directed. The metal shall be free from
all earth, rubbish and vegetable matter and graded before
stacking and closely packed in stacks. The metal supplied by
the Tenderer shall be arranged in stacks for measurement. No
deductions will be made for voids. The size of stack shall be
1m wide at top, 2.2m wide at bottom and 600mm high. The
length shall be as directed by the Consultant. The Tenderer
shall provide the templates required to ensure, compliance
with size of stack stipulated.
6.3
Supply of Murrum: The Tenderer shall be permitted to

excavate in the selected areas in the place of work, as
approved by the Consultant, for collection of murrum. The
excavation shall be done by the Tenderer to correct line and
level, transport and stack the same at site of work as directed
by the Consultant. Alternately, the Tenderer will be permitted
to bring from outside, approved graded hard murrum 10mm,
down to dust (but not silt) as directed by the Consultant and
shall also be collected in stacks on level ground along side of
the road.
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Page 155 of 194
6.4
SUB-BASE/BASE COURSE
6.4.1
Laying and preparation of Water Bound Macadam surface:
6.4.2
After preparation of the existing surface as specified above,

Grade-I/Grade-II, size metal collected in stacks shall be
spread to uniform thickness over the prepared surface and
each layer consolidated to 100/75mm compacted thickness as
specified here in after.
6.4.3
Templates properly made of full width and gauge or templates

fitted with central plumb to each of edge fixed with it must be
used. The depth of the plank forming the gauge shall be the
thickness of the metal layer in loose state so that when the
metal has been properly spread, the gauges are buried just
flush with the surface. The intermediate work shall be tested
with cord stretched between the gauges. Three templates shall
be provided and used with a distance of about 7.5m between
each but not exceeding 15m. A spirit level shall invariably be
used with the templates to ensure that the edges of metalling
are truly levelled. The metal shall be spread and rolled with 8
to 10t power roller until well compacted and there is no
appreciable movement (in the metal) when walked upon, or no
appreciable wave in front of the advancing roller, Rolling shall
be done by roller perfectly, by a 8 to 10t power roller, till
proper internal packing of adjacent pieces of stones has been
achieved. Excessive dry rolling shall be avoided.
6.4.4
The rolling shall begin from the edges with roller running
forward and backward and adding screenings simultaneously
until the edges have been uniformly compacted. The roller
shall then progress gradually from the edges to the center,
parallel to the center line of the road and uniformly each
preceding rear wheel track by one half width and shall
continue until entire area of the course has been rolled by the
rear wheel. Rolling shall continue until the road metal is
thoroughly keyed with no creeping of metal ahead of roller.
Only slight watering may be done during rolling, if required. In
case of super elevated curve, rolling shall commence from the
inside edge of the centre and progress towards the outside
edge. Where the gradient is steeper than 1 in 60, the roller
shall run up grade, i.e. rolling shall be started from lower level
to upward direction for the 1St rolling.
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6.4.5
While rolling the surface in two or more parts, a strip of about

230mm to 300mm along the predetermined cross section shall
be left unrolled while consolidating the first half. This shall be
properly jointed when the metal is being spread on the second
half and consolidated with it. Care must be taken to avoid the
occurrence of a continuous longitudinal furrow along cross
section of the road. Full width of road will be rolled at a time.
6.4.6
The metalling shall be moderately kept saturated and rolling

continued until consolidation is completed. Just enough
watering shall be done so as to flush the metal slurry into the
interstices. Care shall be taken to avoid excess water softening
the subsoil. The full consolidation stage shall be tested by (a)
putting a piece of metal about the size of wall not on the
surface and roller passed over it. If it is crushed the surface
shall be deemed as well consolidated (b) there shall be no
creeping of stone ahead of the roller.
6.4.7
Until the above conditions are satisfied, no binding or surfacing

materials shall be put on the surface. No rolling shall be done
where signs of metal crushing are noticed or rolling causes
wave like motions in the base course of well compacted.
Before starting rolling, the metal shall be dressed accurately to
camber. No fresh metal shall be added once dry consolidation
has commenced. The part of the road must be fully racked up
so that the metal is thoroughly incorporated into the body of
road.
6.4.8
Binding Course: When the required consolidation has been

completed, the binding material of approved graded
murrum/stone grit and dust (unscreened) as specified shall be
spread over the surface and brushed backwards and forwards
to fill in the surface voids and rolling and watering continued
to such an extent that the binding materials are formed into a
slurry and is grouted into the interstices. After the road has
been fully consolidated, the surface shall be covered with
12mm layer of murrum/stone grit and dust (unscreened) and
road opened to traffic after 4 days. The road shall be kept
watered for 14 days or such other period as specified by the
Consultant. Where tracks are likely to be formed by the traffic
on the road, barriers such as tree branches etc. shall be put to
divert the traffic. After 15 days, light watering and rolling shall
be done. For joints across the road, the end of each layer shall
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be given a flat slope and well consolidated together and hump

formation must be avoided.
6.4.9
Damages to the Owners Property: Any damage to the

departmental property due to negligence of the Tenderer while
executing the work shall be made good to the original
conditions at his own cost.
7.0
Bituminous
macadam
and
surfacing for road (general)
7.1
The work covered under these specifications provides for

bituminous treatment for roads consisting of providing 38 mm
thick bituminous Macadam and 12mm thick seal coat or
bituminous concrete of thickness as specified in item in the
schedule of quantities.
7.2
The Tenderer shall make at his own cost, all the arrangements
for controlling the traffic during the execution of the work. All
arrangements such as proper barricading of road, diversion of
road if necessary, red and green flags during the day and red
lights at nights shall be made by the Tenderer at his own cost
to control and safeguard the traffic.
7.3
Bituminous Macadam over Water Bound Macadam
7.3.1
Preparation of existing Water Bound Macadam surface

a)
bituminous
concrete
The existing Water Bound Macadam surface shall be

brushed, cleaned properly with wire brushes and coir
brooms, so as to free from all loose materials, murrum,
earth, silt and caked mud etc. The surface shall then be
dusted clean with gunny bags etc. if during the process
of cleaning the sub grade (Water Bound Macadam), soft
spots and packets, hollows etc. are found, such
spots/pockets will be filled with approved precoated
bituminous chips, consolidated and finished to proper
level, rolled with power roller if necessary. The potholes
shall be excavated properly in a rectangular or
rhomboidal shape with vertical edges. The bottom and
sides shall be cleaned as stated above. The sides and
bottom shall then be thoroughly painted with heated
30/40-penetration
bitumen.
The
potholes
shall
thereafter be filled with premixed bituminous chips so
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that after thorough tamping and rolling, the surface is

flush with surrounding road surface all as directed by
the Consultant. It shall be the responsibility of the
Tenderer to ensure that the Subgrade is even and is
finished to camber and slope as shown on the drgs. or
as directed by the Consultant.
7.3.2
b)
The surface of the Subgrade shall be checked for its

trenches by means of the scratch template resting on
side forms having scratch points placed at not less than
200mm. apart and set to the exact profile of the base
course. The template shall be drawn along the forms at
right angles to the road.
c)
Unevenness of the surfaces as indicated by the scratch

points shall not exceed 10mm in 30m. The area of
depression shall then be painted or sprayed with 30/40penetration bitumen at the rate of 0.75 kg per sqm and
the levelling course applied by hand or machine to
grade and chamber and rolled. If the depressions are
deeper than 50mm, the levelling course shall be applied
in two or more layers and rolled as directed by the
Consultant.
d)
The prepared surface shall be closed to traffic and

maintained fully clean and no asphalting work shall be
started unless this prepared surface is approved by the
Consultant.
MATERIALS
Representative samples of materials proposed to be used shall
be submitted to the Consultant and got approved. No material
shall be used unless it is approved by the Consultant.
7.3.3
HOT MIXED HOT LAID BITUMINOUS MACADAM

a)
Coarse Aggregate
i)
It shall consist of crushed hard trap stone metal,

free from coatings of clay, silt and any
objectionable material.
Metal brought by
Tenderer for different items of work shall strictly
conform to I R C specifications in all respects.
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The aggregate shall be obtained by crushing
approved stones of specified type in mechanical
crusher and shall be hard, close grained, sound
trap stone metal, free from decay and weathering
and obtained from approved quarries.
ii)
Metal shall be collected in stacks on level ground

and neatly stacked at site of mixing. The metal
shall be free from all earth, rubbish, vegetation
and other foreign matter and graded before
stacking and closely packed in stacks.
iii)
Tests considered necessary shall be carried out in

an approved laboratory when the Consultant
considers the quality to be doubtful or there is
dispute about the quality. The cost of testing
shall be borne by the Tenderer.
iv)
Aggregate grading : The requirements of base

course shall be as under
B.S.Sieve
Designation
32
mm
(about
1.25)
20 mm (about )
12 mm (about )
6 mm (about )
No. 10
No. 200
v)
b)
Equivalent I S Sieves
Passing percentage
40MM (1.5)
100
20 mm
12.5 mm
6.3 mm
1.7 mm
75 micron
50 100
30 60
18 30
10 20
05
The aggregate/chips shall be entirely dry at the

time of mixing.
Bitumen:
Bitumen to be used shall conform to
I.S:73.1992
for
paving
bitumen,
with
30/40
penetrations and shall be from approved manufacturers.
The Tenderer on demand by the Consultant, obtain and
furnish a laboratory test certificate to the effect that the
material conforming to the requirement of the specified
grade, to the satisfaction of the Consultant. Bitumen
(30/40 penetration) content 3.7% to 4.7% by weight of
the total mix, shall be used in the mixture.
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c)
Tack Coat : Bitumen of the same grade as that used for

premix shall be heated to a temperature of 1630 C to
1770C (3250 F to 350 F) in a bitumen boiler and the hot
bitumen shall be applied evenly to the thoroughly
cleaned and prepared road surface (as specified here-inbefore)@ 7.5 kg per 10 sqm leaving no part of the
surface unpainted.
Application shall be done by a
mechanical pressure sprayer or if permitted, by
perforated pouring cans. The tack coat shall be applied
just before the macadam is laid. Application of tack
coat shall be only slightly in advance of laying premixed
chips. In case of surface already asphalted, application
of tack coat is not necessary.
d)
Premixing Chips:
i)
The bitumen shall be heated to 1630 C to 1770 C

(3250 F to 350 F) in boiler The aggregate of the
approved grading or as decided by the
preliminary shall be dried and heated in an
aggregate drier to a temperature of 1490 C to
1770 C (300 F to 350 F) and fed into a twin shaft
peddle type mixer at a temperature not less than
1490 C (about 300 F). The bitumen, the approved
aggregate and the filler shall be measured
separately and accurately to the proportions in
which they are to be mixed and mixed intimately
till all the particles are completely coated with
bitumen.
Asphalt/bituminous
mixing
plant
proposed to be used by the Tenderer for the
preparation of Asphalt/bituminous mixing shall
conform to all of the requirements of the job,
which shall produce uniform mixtures of the
required quality, an got approved by the Owner
before mixing.
ii)
The temperature of the premix bituminous

macadam when leaving the mixer shall not be
less than 130 C (about 280 F) and it shall not be
less than 1210 C (about 250F) at the time of
laying.
iii)
Bituminous macadam shall be transported to site

of work in suitable tipping vehicle
properly
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insulated and covered with canvas or other
suitable materials to protect the mixture from
weather conditions and to retain the heat. The
road surface shall be suitably marked to ensure
correct and uniform application.
Width of
macadam to be laid shall be slightly more (not
exceeding 50 mm on each side) than the required
carriage way as per drawing. Excess on either
side shall be neatly cut after full compaction to
get final width of carriage way as per drawing.
The premixed bituminous macadam shall be laid
by a mechanical self powdered spreader and
compactor and finished to correct line, level, &
final consolidation done by means of power roller
not less than 10 tonne. Any irregularities shall be
corrected during rolling.
e)
Compaction: The base bituminous macadam course

shall be compacted thoroughly and evenly with 10 to 12
tonne power roller immediately after it is laid.
Compacted thickness shall be as specified in schedule of
quantity.
7.3.4
The surface shall be checked for correct grade during and after
rolling.
Any irregularities shall be corrected by adding
precoated chips or removing the surplus.
The disturbed
surface shall be well compacted again. If necessary the roller
wheel shall be coated with oil to prevent the coated chip from
sticking to the wheels. Rolling shall be continued till no wheel
marks are left on the surface. The speed of the roller shall be
sufficiently slow to prevent any pushing under the wheels.
8.0
HOT MIXED HOT LAID BITUMINOUS

WEARING COURSE (SEAL COAT)
8.1
Bituminous concrete:
Shall consist of mixture of mineral
aggregate, sand and filler, graded to fill the voids, mixed with
bitumen binder to obtain the maximum stability. It shall be
spread and compacted on a prepared bituminous macadam
base in conformity with lines, grades and cross section shown
in the drawings.
The aggregate shall be preheated
temperature specified for the bitumen and the mixture shall be
prepared and laid hot.
CONCRETE
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8.2
Coarse Aggregate
8.2.1
The coarse aggregate brought by Tenderer shall be I.R.C. hard

black trap, crushed in mechanical crushers and shall be clean,
strong, tough, dense, close grained, angular but not flaky, and
free from soft, decayed, weathered portion, coating of dust,
dirt or other objectionable matter. Maximum size of the
aggregate shall be suitable for the thickness of the seal coat
(12mm/15mm or as specified).
8.2.2
The aggregate grading composition and characteristics of

surface (wearing course mix) shall conform to standard code
of practice. The mix shall satisfy the following requirements:
a) Fine Aggregate: The fine aggregate shall be clean, natural,
river bank or pit sand or quarry sand produced in a crushing
plant and satisfying the requirement of the grading of
aggregate for the bituminous concrete as stated above or as
determined by the preliminary tests.
b) Filler: The filler shall be dry and clean lime stone powder
hydrated lime having calcium oxide content of not less than
60% both passing BS sieve No.8. It shall be free from lumps
and loosely bonded aggregate. When tested by laboratory
sieves, 100% shall pass through B S sieve No. 14, 80% shall
pass through B S sieve No. 8 . Fillers shall be added to the
aggregate to give the above grading determined by
preliminary tests.
c) Bitumen: Bitumen shall be of 30/40 penetration or such other
grade specified by the Consultant and shall conform to IS: 731961.
8.3
Preparation of Base
Dirt, dust and other foreign materials if accumulated shall be
cleared off leaving the surface entirely clean. The prepared
surface shall be closed to traffic and so maintained fully clean
till the seal coat is applied.
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8.4
Mixing and Laying Wearing Course
8.4.1
Grade 30/40 bitumen shall be heated to a temperature of 1630

C to 1770 C (3250 F to 350 F) in a boiler. The aggregate of the
suitable approved grading or as decided by preliminary tests,
shall be dried and heated in an aggregate drier to a
temperature of 1490 C to 1770 C (300 F to 350 F) and fed into
a twin shaft peddle type mixer at a temperature not less than
1490 C (3000 F). The bitumen, the aggregate and the filler
shall be measured separately and accurately to the proportions
in which they are to be mixed and mixed intimately till all the
particles are completely coated with bitumen. The quantities
of aggregate, bitumen and the filler shall be such as to obtain
the percentage of each as specified above or decided after
tests. Continuous batching and mixing plant shall be used.
Asphalt/bituminous mixing plant proposed to be used by the
Tenderer for the preparation of asphalt/bituminous mixes shall
conform to all of the requirements of the job, which shall
produce uniform mixtures of the required quality.
8.4.2
The temperature of bituminous concrete when leaving the

mixer shall not be less than 1380 C (280F) and it shall not be
less than 1210 C (250 F) at the time of laying.
8.4.3
The bituminous concrete shall be transported to the site of

work in suitable tipping vehicles properly insulated and
covered with canvas or other suitable materials to protect the
mixture from weather conditions and to retain the heat.
8.4.4
The mixture shall be spread with mechanical self powered

spreader.
The bituminous concrete shall be laid to the
specified line, curve, grade camber Any irregularities shall be
corrected immediately before rolling is started. Before laying
the mixture, the faces of the joints shall be painted with a
uniform coating of hot bitumen. The bituminous concrete shall
be laid to such loose depth as to give a compacted layer of
specified thickness as per item in the schedule of quantities.
8.5
Compaction
The bituminous concrete layers shall then be allowed to cool
sufficiently such that it does not spread under wheel load of
10/12 tonne power roller. The compaction shall be done by
the roller till no wheel mark are left on the surface and no
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further compaction is possible. The road shall be opened to

traffic on cooling of the concrete to the atmospheric
temperature or after a lapse of 24 to 40 hr after laying.
9.0
GENERAL REQUIREMENTS FOR BITUMEN MACADAM &

SEAL COAT
9.1
Testing
The Tenderer shall have a well equipped testing laboratory
with a competent laboratory staff. Daily test (not less than
two specimen per day) shall be made by them on the
bituminous mixture produced to ensure compliance with these
specification and copy of the test results duly signed by the
competent authority shall be submitted to Consultant for
record. Tests shall include water absorption, stability, filler
content etc. The Tenderer shall give all facilities at all items to
the Consultant or his representative to inspect the work or
testing done by him.
9.2
Weighing
9.3
Each lorry leaving the plant must be weighed on a weigh

bridge in the presence of the representative of the Owner and
a challan must be issued along with the lorry in duplicate
showing the weight of the material loaded in the lorry. As and
when required, the said lorries shall also be weighed at the
Owners weigh bridge or any other weigh bridge approved by
the Consultant to check the tonnage of the material stated on
the challans. In case of short fall, the same shall be made
good by the Tenderer without extra cost.
Testing Surface
The completed surface when ready for acceptance shall be
thoroughly compacted, smooth, true to line, grade, camber
and free from irregularities when tested by means of a straight
edge of 3m long, laid on the finished surface parallel with the
centre line of the road, the surface shall in no place vary more
than 6mm from the working edge.
9.4
The defects in the bituminous paving which the Tenderer may

be called upon to rectify are of the following type
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a)
b)
c)
d)
9.5
VOLUME - V of V
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Deformation of bituminous pavement resulting in waves

or ruts
Cracking of bituminous pavement resulting in admission
of water to the sub-grade and the deterioration of the
bituminous pavement adjoining the cracks.
Disintegration/Revealing of bitumen pavement resulting
in the formation of potholes.
Polishing of the bitumen pavement under traffic
resulting in a surface on which the vehicles are liable to
skid.
Defects in areas in bitumen pavement under guarantee shall,

when they exceed the limits specified below, be remedied
immediately by the Tenderer. The limiting values of the
defects shall be the following
a)
b)
c)
Deformation: 25mm in 3 m
Cracks: 1500 mm in lengths and 3mm in width
Disintegrated revealed patches: 2.00 sqm and/ or
12mm in depth.
10.0
CEMENT CONCRETE ROADS / PAVEMENTS
10.1
General
The sub-grade/sub-base shall have no soft spots. It shall be
uniformly compacted using mechanical power rollers of 8 to 10
tones capacity (minimum). The subgrade shall be properly
drained and the minimum modulus of sub-grade reaction
obtained with plate bearing test shall be 0.55 N/mm2.
The construction procedure for sub-grade or sub-base should
follow relevant IRC (India Road Congress) specifications and
quality control should be exercised as laid down in IRC: SP.11.
Equivalent British Standards may be followed in lieu of IRC
standards.
The sub-base or hardcore shall be of hard quarry stones of
size 80mm and down graded laid in compact manner to the
required camber and rolled using 8 to 10 tonnes power roller
(both wet and dry rolling). A sand layer shall be placed
between the sub-base and concrete. A layer of waterproof
sheet shall be laid over the sand layer prior to concreting.
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10.2
Joints
10.2.1
Transverse expansion joints
VOLUME - V of V
Page 166 of 194
These joints shall extend over the entire width of the

pavement as shown in relevant drawings. Dowel bars shall be
as per dimensions, locations and spacing stipulated in the
drawing. The pre moulded expansion joints filter, a
compressible material used to fill the gap between adjacent
slab at expansion joint shall conform to IS:1838. The height of
the filler board shall be such that its top is 25mm below the
surface of the pavement. The dowel bars shall be held
accurately in position during the placement, compaction and
finishing of concrete at and near the expansion joints. This and
the protection of the joint grooves during construction may be
achieved by means of sufficiently strong bulkheads with holes
drilled along the centre line to accommodate the dowel bars
and a mild steel section respectively. The later shall be oiled or
greased before placing in position to avoid bonding with
concrete. The top and bottom edges of the bulkheads and mild
steel section shall be shaped to correspond to the camber of
the pavement. Bulkheads shall be used in pairs to hold the
projecting ends of the dowel bars and maintain their
alignment. The bulkheads shall be securely staked in place at
right angle to the centre line and surface of the pavement.
After the concrete has sufficiently hardened, the mild steel
section shall be removed carefully without disturbing the
edges.
Under no circumstance shall any concrete be left at the
expansion joint filler or across the joint at any point.
10.2.2
Transverse Contraction Joints

These shall be the weakened plane or dummy groove type.
They shall be constructed by forming in the surface of the
slab, a slot not less than 6mm wide and having a depth equal
to one third the depth of the pavement at the thinnest part of
its section. This slot shall be formed in a manner approved by
the Engineer-in-charge, such as by pushing into the concrete a
flat bar or web of a T bar using a suitable vibratory device,
removing the bar, and keeping the slot open. It shall be
ensured that no spalling of concrete occurs while removing the
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bars. The edge of the joint shall be rounded with an edging

tool before the concrete hardens.
10.2.3
Transverse Construction Joints

These shall be placed whenever placing of concrete is
suspended for more than 30 minutes. Excepting in case of
emergency, construction shall always be suspended at the
regular site of expansion or construction joints. If the
construction joint is located at the site of an expansion joint,
regular expansion joint shall be provided.
10.2.4
Longitudinal Joints
These shall be of plain butt type and shall be formed by
placing the concrete against the face of the slab concreted
earlier. The face of the slab concreted earlier shall be painted
with bitumen or approved debonding material prior to placing
of fresh concrete.
The dowel bars used in longitudinal joints shall be suitably
supported as not to be displaced during construction
operation.
10.2.5
Reinforcement
Reinforcement steel shall be of grade Fe - 415 and shall be
free of rust, dirt, scale or other deleterious material. The width
of fabric sheet or bar mats shall be such that when properly
placed into the work, the extreme longitudinal bars or wire of
the sheets of mats will be located not less than 50mm and not
more than 100mm from the edges of the slab. Except for
dummy joints, the length of fabric sheets or bar mats shall be
such that when properly placed into the work, the
reinforcement will be clear of the transverse joints by not less
than 50mm and not more than 10mm as measured from the
centre of the joint to the ends of the longitudinal bars or wires
of the sheet or mat.
While overlapping the sheets or bar mats in either direction,
the overlap shall be at least equal to the spacing between the
bars or wires in respective direction or 40 times the diameter
of the bar or wire, whichever is more. The overlap of
reinforcement shall be 50mm below the slab top surface.
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Compaction
The pavement shall be compacted by means of power driven
paver-cum-finisher or by vibrating screen along with internal
vibrators. Compaction with wooden hand tampers may be
adopted only in constricted areas subject to the approval of
the Engineer-in-charge.
10.2.7
Finishing
After the concrete has been compacted and as soon as
practicable, its surface shall be smoothened by means of
longitudinal floats, operated from a footbridge. The
longitudinal float shall be worked with a sawing motion, while
held in a floating position parallel to the carriageways centre
line and passed gradually from one side of the pavement of
the other. Movements ahead along the centre line of the
carriage way shall be in successive advances of not more than
one half the length of the float.
10.2.8
Curing of Concrete
Initial curing: The surface of the pavement shall be covered
with wetted burlaps, cotton or jute mats, as soon as the
concrete has set sufficiently to prevent marring of the surface,
as per the directive of the Engineer-in-Charge. The covering
shall be maintained in fully wetted condition for a period of not
less than 48 hours.
Final curing: Upon removal of the wet covering, the slab shall
be thoroughly cured as follows: Exposed edges of the slab
shall be banked with a berm of earth. Upon the slab shall then
be laid a system of transverse and longitudinal bunds of clay
about 50mm high immediately covered with a blanket of sandy
soil, the rest of the slab shall then be kept covered with a
blanket of sand or sandy soil, at least 30mm deep, and it shall
be kept saturated with water for a minimum period of 14 days.
10.2.9
Sealing of Joints
After the curing period is over, the temporary seal and all
other intruded materials in all expansion and construction
joints, grooves shall be removed completely and then filled
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with approved joint sealing compound as per IRC-57

Recommended practice for Sealing of Joints in Concrete
Pavement or by any equivalent practice as per British Codes.
Joints sealing compound shall be in accordance with IS:1834
(Spec. For hot applied sealing compound) or equivalent.
The joint opening shall be thoroughly cleaned of all foreign
material before the primer is applied followed by placing of the
sealing material.
Typical composition of primer is as follows:
Percentage by weight
1. Bitumen (200 penetration grade)
- 66 (blended hot)
2. Light creosote oil
- 14 (blended hot or cold)
3. Solvent Naptha
- 80 (blended cold)
NB :
(a)
The bitumen shall be melted and fluxed with the oil, and
then cold solvent Naptha shall be added.
(b)
Bituminous emulsion shall not be used as primers.

The sealing compound shall be poured into joint opening
carefully in accordance with the manufacturers
specification. Any excess filler on the surface of the
concrete pavement shall be removed immediately and
the pavement surface cleaned.
In order to prevent tackiness or pick-up of the seal under

traffic, the exposed surface of the sealing compound shall be
dusted with dry hydrated lime or by any other method
approved by the Engineer -in-charge.
The line of separation between adjacent concrete slabs shall
be cleaned and painted with 200-penetration grade bitumen.
Spacing of joints.
The location and spacing of joints shall be decided by the
Engineer-in-charge. However, the following recommendation
regarding spacing of joints may be followed.
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Type of joints Maximum Spacing

1. Transverse expansion joints
2. Transverse contraction joints
3. Longitudinal joints
50m
12m
4m
Opening to traffic
In general, traffic shall be excluded from the newly
constructed pavement for a minimum period of 28 days.
Before the pavement is opened to traffic, it shall be cleaned
and all joints shall be sealed.
10.3
Vacuum Compressed De-watered Concrete Flooring
10.3.1
Technical Assistance/Training of Labour

During the placement of concrete, the Tenderer shall have a
minimum of one person present at all times who has been
adequately trained by a representative of the equipment
manufacturer. This person shall be experienced in the vacuum
dewatering process, and in the operation of all related
equipment and shall direct all concrete dewatering work.
The Tenderer shall provide the services of a representative
from the manufacturer of the vacuum dewatering equipment
on site for a period of time of at least eight (8) hours. The
manufacturers
representative
shall
provide
technical
assistance for the vacuum dewatering process on the initial
day of operation.
10.3.2
Equipment for Compacting, Placing, Vacuum Processing and

Finishing of Slab
All process equipment to be used shall be of a design
representative of the state of the art, and shall be subjected to
the approval of the engineer. Equipment shall be Tremix or
approved equivalent. System shall have a demonstrated five
years history of performing such work. The vacuum pumps
shall be able to generate a minimum vacuum of 69mm (24
inches) of mercury (0.80 atmospheres) in actual operation
using the maximum number and size of suction mats required
for this work.
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The Tenderer shall have at the job site sufficient equipment

(vacuum pumps, mats, filter pads and accessories) to ensure
that the vacuum dewatering process continues uninterrupted
to completion. Stand by equipment is sometimes required.
10.3.3
Mix Design
The Tenderer is responsible for the mix design of the grade as
called for on the Construction Drawings and must submit the
mix proposed for use in the works before any work is started.
The Tenderers shall utilize a knowledgeable and experienced
concrete technician for the design and production of mix
(mixes) meeting all the requirements of the specifications.
10.3.4
Quality Control
The Tenderer has the responsibility for achieving the quality of
concrete specified by controlling the concrete mixes, placing,
vacuum process finishing and curing. The concrete technician
in charge must be present at the site when work is in
progress.
The Tenderer shall be responsible for mix adjustments,
performing necessary tests, correcting deficiencies and trouble
shooting in general.
The Tenderer shall be required to maintain control charts
showing individual test results for aggregate gradation, slump,
air content, cement content and compressive strength.
10.3.5
Planning of Placing
The Tenderer shall submit for review shop drawings for floor
slabs, detailing the location of all construction joints and the
sequence of the slab placement and manufacturers literature
describing the equipment to be used. In addition to the shop
drawings, the Tenderer shall indicate the quantity of each
piece of dewatering equipment that will be located at the
construction site and shall include the dimensions of all suction
mats.
Before concreting is started the work should be planned with a
view to determine areas to be placed daily, the required
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amount of equipment, size of vacuum mats, length of vacuum

houses, arrangement of rails, if any, or screeds etc. Crew
required for the vacuum process is 2 men to handle the mats
and the pump. Note that placing, vibration, vacuum treatment
and floating, follow immediately behind each other.
Check position of vacuum pump in relation to vacuum mat
location to find whether extra vacuum houses are required.
10.3.6
Concrete Materials
All materials such as cement, sand & aggregates etc. shall be
as per relevant specification mentioned for concrete work.
10.3.7
Execution of Work
a)
General
The work shall be planned and executed so that there is no

delay between the placement, screeding, dewatering and
floating of the concrete. Concrete to be vacuum dewatered
shall be handled and placed so as to prevent segregation. The
concrete shall be internally vibrated prior to screeding.
b) Leveling
Immediately following placement, the concrete shall be
levelled with a vibrating screed running on a true surface, set
at the proper elevation required to provide the specified
finished elevation. The concrete surface shall be screeded high
by 2% of the slabs thickness to compensate for the
compaction caused by the vacuum dewatering process. (Slabs
to have an aggregate hardener shall have compensation made
to maintain elevation). The vibrating screed shall be moved
forward as rapidly as proper consolidation allows. The proper
surcharge of concrete must be maintained in front of the
leading edge of the screed.
c) Vacuum
Immediately after levelling, the concrete shall be covered with
filter pads and suction mats in strict accordance with the
recommendation of the manufacturer to have the slab fully
dewatered. The suction mat shall extend 100mm beyond the
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edge of the filter pad on all sides. The pads shall extend to
within 100mm of the edge of concrete slab, and the mats shall
cover entire slab. Before connecting the hose on the suction
mat to the vacuum pump, the edge of the mat shall be
smoothed to enable an airtight seal to be created. A vacuum
shall then be applied to the mat. After a minute the gauge on
the vacuum pump should indicate a minimum vacuum of 0.70
atmospheres (24.0 in Hg) and if not, the mat must be checked
for leakage. For concrete that dewaters readily the vacuum
should then be maintained at 0.70-0.80 atmospheres (24.025.5 in. Hg). For concrete which dewaters less efficiently (e.g.
air entrained concrete) the vacuum shall then be reduced to
0.50-0.60
atmospheres
(15.0-18.0
in.
Hg.).
After
approximately 10 minutes the vacuum can then be increased
to 0.80 atmospheres.
The vacuum shall be maintained for at least 3 minutes per
25mm of concrete thickness at 0.80 atmospheres. (Where
aggregate hardeners are specified, sufficient moisture shall be
maintained to meet manufacturers requirements). The suction
mats and filter pads shall then be removed and moved to the
next section in leapfrog manner.
Stop the vacuum dewatering when light footprints only are left
in the concrete when stepped upon. A suitable suction time
can also be checked with a Proctor apparatus which should
show 1.5-2 kg/cm2.
d) Floating, Hardener Topping & Finishing
The waiting time after the floating operation depends on
concrete temperature and humidity and varies from 10
minutes to 2 hours.
The trowelling operation cannot take place before the concrete
has hardened enough to carry the machine, i.e the trowelling
blades will not leave any marks on the concrete. Repeated
trowelling, with intervals between the passes which are
adapted to the setting of the concrete, greatly improves the
surface characteristics. The surface will be more wear resistant
and less dusty.
At least two passes are recommended for floors, which are not
to be covered. The top surface finish shall be in line and level
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or in gradient as per drawing. The undulation in the finished

surface shall not exceed+3mm per strip.
e)
Curing
Vacuum dewatered concrete should be cured like any other

quality concrete in order to achieve a good final result
11.0
IS / IRC CODES
IRC-19
IRC-37
IRC-73
IS 73
IS 702
IS 1201
Standard specification and code of practice for

water bound macadam
Guidelines for design of flexible pavements
Geometric design of roads
Paving Bitumen
Industrial Bitumen
Methods of testing tar and Bituminous materials
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VOLUME - V of V
Page 175 of 194
C-17: SUPPLY & LAYING RCC PIPES

1.0
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.
2.0
SUPPLY OF PIPES
The Tenderer 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 Tenderer must furnish, on being demanded by
the Consultant, manufacturers certificates and/or test
certificates from recognized authorities.
3.0
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 Consultant.
Contracts shall give all help in supplying instruments,
materials and men to the Consultant 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 Tenderer, at his own cost.
4.0
LAYING OF PIPES
4.1
General
The laying of R.C.C. Pipes shall conform to IS: 783-1985.
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 Consultant shall
be as classified below:
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4.2.1
VOLUME - V of V
Page 176 of 194
Culvert Condition
In this condition the pipe is laid under embankment and may
project wholly or partly above the original ground surface.
4.2.2
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.
4.2.3
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.
4.3
Bedding and Supports
4.3.1
Culvert Condition: In this condition the pipes shall be laid

generally as per sector B9 to B16 of Appendix-B, of IS:7831985.
4.3.2
Trench Condition: In this condition the pipes shall be laid

generally as per Section B1 to B8 of Appendix - B of IS:7831985.
4.3.3
Concrete Cradle Bedding: If specified in the drawing or as

instructed by the Consultant, 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.
4.3.4
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 Consultant. 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.
4.4
Jointing of Pipes: Joints shall be flexible type as per IS: 7831985. 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
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compresses the rubber ring as it rolls into the annular space

formed between the two surfaces of the spigot and socket.
4.5
Hydrostatic Testing of Pipes: The pipeline as laid shall be

subjected to hydrostatic test as per clause 15.5 of IS: 7831985
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Page 178 of 194
C-18 : WATER PROOFING TREATMENT FOR ROOFS

1.0
Water proofing treatment for the flat roof shall be done with
IWL Hyperpplas-F 4kg/sqm or equivalent polymeric water
proofing membrane including preparation of surfaces and
coating the surface and top with blown bitumen 85/25 or
90/15 each at the rate of 1.25 kg/sqm. And sealing of joints
by torch application etc., including sealing the edges around
the rain water pipe locations, including tucking in to the
parapet walls/taking over the coping slab and sealing with
bitumen, complete as per manufactures specification and as
per direction of Consultants.
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PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 179 of 194
SECTION IV NORMS OF CEMENT CONSUMPTION

1.0
GENERAL
1.1
For calculating the requirements of cement in various items of

work the following standards shall be adopted. Over the above
theoretical quantity of cement, additional allowance upto plus
or minus 3% shall also be allowed as certified by the
Consultant.
1.2
For items not covered in this standard, CPWD standards shall

be followed or calculated as per uses/requirement in absence
of standard norms. Cement required for enabling work and
cement required for testing purposes will be taken into
account for consumption purpose. However, in no case such
quantity should exceed 5% of the total cement used in the
work or as certified by the Consultant based on actual
observation whichever is less.
2.0
MASONRY WORK
Sl.
No.
1.
Random Rubble Masonry in
CM (1:4)
1.255 quintals per cum
2.
Random Rubble Masonry in
CM (1:6)
3.
Coursed Rubble Masonry in
CM (1:6)
4.
Brick work in
CM (1:4)
0.95 quintals per cum of BW
5.
Brick work in
CM (1:6)
0.625 quintals per cum of BW
6.
Half brick work in
CM (1:3)
7.
Half brick work in
CM (1:4)
8.
CC block masonry (size of

block 400x200x200) with
20mm thick mortar
CC block masonry (size of
block 400x200x100) with
20mm thick mortar
CM (1:5)
1.43 quintals per 10 sqm of

area
1.06 quintals per 10 sqm of
area
CM (1:5)
9.
Description of Item
Cement requirement
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3.0
Sl.
No.
VOLUME - V of V
Page 180 of 194
PLAIN/REINFORCED CONCRETE
Description of Item
Cement requirement
1.70
1.
2.
3.
4.
4.0
Sl.
No.
PCC of nominal mix (1:4:8)

complete (excluding
finishing with CP)
PCC of nominal mix (1:3:6)
complete (excluding
finishing with CP)
RCC/PCC of nominal mix
(1:2:4) complete
(excluding finishing with
CP)
RCC/PCC of nominal mix
(1:1.5:3) complete
(excluding finishing with
CP)
2.20
quintals per cum of

concrete
quintals per cum of
concrete
3.20
quintals per cum of

concrete
4.00
quintals per cum of

concrete
CONTROLLED CONCRETE PLAIN AND REINFORCED

Description of Item
Cement requirement
1.
Concrete grade
(i) M-7.5B
(ii)M-10B
2.
Concrete grade
(i) M-15C
(ii) M-15D
3.
Concrete grade
(i) M-20C
(ii) M-20D
4.
Concrete grade
(i) M-25C
(ii) M-25D
5.
Concrete grade
(i) M-30C
(ii) M-30D
To be mutually agreed
based on mix design to be
prepared by Tenderer &
approved by the
Consultant plus wastage
and all incidentals as
decided.
To be mutually agreed
based on mix design to be
prepared by Tenderer and
approved by the
Consultant plus wastage
and all incidentals as
decided.
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CHAPTER NO. Q6
5.0
Sl.
No.
VOLUME - V of V
Page 181 of 194
FINISHING
Description of Item
Cement requirement
1.
6 mm thick C.P. 1:4
0.270 quintal per
10 sqm area
2.
12 mm thick C.P. 1:4
0.547 quintal per
10 sqm area
3.
0.450 quintal per
10 sqm area
4.
0.654 quintal per
10 sqm area
5.
0.430 quintal per
10 sqm area
6.0
Sl.
No.
1.
2.
3.
FLOORING
Description of Item
40mm thick IPS cement
concrete flooring (1:2:4) with
20mm and down stone chips
finished with a floating coat of
neat cement
40mm thick (IPS) flooring
with base coat 30mm thick
(1:2:4) using stone chips
10mm nominal size and
10mm topping coat 1:1 (1
cement : 1 stone chips 3 to
6mm size) with a floating coat
of neat cement
Extra for each additional
thickness of 5 mm granolithic
layer of (1:2:4) for flooring
Cement requirement
1.700 quintal per
10 sqm area
2.320 quintal per
10 sqm area
0.016 quintal per
10 sqm area
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7.0
Sl.
No.
1.
2.
VOLUME - V of V
Page 182 of 194
MISCELLANEOUS
Description of Item
Cement requirement
Grouting with
CM (1:2)
6.80 quintal per cum
CM (1:3)
Fixing steel windows with

(1:2:4) concrete blocks
0.40 quintal per
10 sqm of
area
3.
Cement-sand mortar :-
a)
(1:1) (1 cement : 1 sand)
b)
6.8 quintal per cum
c)
5.1 quintal per cum
d)
3.8 quintal per cum
e)
3.1 quintal per cum
f)
2.5 quintal per cum
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PACKAGE NO - II
CHAPTER NO. Q6
SECTION V
VOLUME - V of V
Page 183 of 194
DIMENSONAL TOLERANCES
1.0
GENERAL
1.1
The materials used in construction shall, besides conforming

to the specifications and standards mentioned, be the best of
the existing kinds obtainable. Where a particular Brand or
Make of material is specified such Brand or Make of
material alone shall be used.
1.2
A high standard of workmanship and accuracy shall be

achieved in all sections and parts of the work. The
workmanship shall be in accordance with the latest and the
best civil engineering practice.
1.3
The Tenderer shall ensure that all sections of the work are
carried out with utmost care to achieve the dimensions shown
in drawings or specifications. In the absence of such specific
mention in drawings the following dimensional deviations may
be tolerated, provided they do not impair the appearance or
render the particular section of work unacceptable to the
purpose for which it is intended. Tolerance for materials and
workmanship not covered in this part as mentioned
hereinafter will be in accordance with the relevant IS code.
Description
Building bricks in length, width & height
Laterite stone, in length, width & height
Natural building stones
a) For stones
Length, width
required in
Height
ashlar masonry
Length & width
b)For stones required
Height
other
than
in
ashlar masonry
Concrete
&
Length
Reinforced concrete
pipes
Internal dia upto
300mm
Cast iron spigot &
Length of fittings
socket
pipes
and
Length of pipes
fittings
Thickness
Permissible
tolerance
: As per IS:1077
: 5 mm
:
:
:
:
5 mm
3 mm
+ 5 mm & -10 mm
5 mm
: 1% of standard
length
: + 3 mm, - 1.5 m
: 10 mm
: 20 mm
: - 1 mm
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CHAPTER NO. Q6
VOLUME - V of V
Page 184 of 194
Internal dia of
socket
Depth of socket
External dia upto
75mm
100 mm
150 mm
Stone ware pipes
Upto 75 cm dia
length
Upto 90 cm dia
length
In thickness of
barrel & socket not
exceeding 450 mm
In thickness of
berrel and socket
between 50 to 600
mm
Glazed tiles
Length of all four
sides
Individual
dimensions and
thickness
Metal
Doors, In overall
Windows
& dimensions
Ventilators
Wooden Doors
In overall
Windows &
dimensions
Ventilators
All components Width
of
shutter Thickness
except glazing
bars
Glazing bars
Width & thickness
: 3 mm
: 10 mm
: 3 mm
: 3.5 mm
: 4 mm
10 mm
15 mm
2 mm
3 mm
0.8 %
0.5 %
1.5 mm
3 mm
3 mm
1 mm
1 mm
Mild steel tubes, tubulars and other wrought steel fittings

Thickness
Butt welded light

tubes
Medium and heavy
tubes
Seamless tubes
+ not limited , - 8 %
+ not limited, - 10 %
+ not limited, - 12.5 %
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PACKAGE NO - II
CHAPTER NO. Q6
Weight
VOLUME - V of V
Page 185 of 194
Single tube
(irrespective of the
quality)
For quantity of less
than 150 m of one
size
For quantity of 150
m and over of one
size
+ 10 %, - 8 %
+ 10 %, - 8 %
+ 4 %, - 4%
Earth work
Finished level of site leveling in hard
rock
Finished level of site leveling except
for hard rock
Level of pits, trenches and
foundations
Concrete & reinforced concrete
Footings
Plan dimensions
Eccentricity
Thickness
Foundations
Deviation of plane and

lines of their
intersection from
vertical or inclination
along full height
Deviation of horizontal
plane from horizontal
line
For 1 m of plane in any
direction
For the whole plane
Sizes of cross section
Surface of inserts to
support loads
Length of elements
50 mm
100 mm
50 mm
+ 50 mm, - 12 mm
0.2 times the
dimension of footing in
the direction limited to
50 mm
0.05 times the
specified thickness
20 mm
5 mm
20 mm
8 mm
5 mm
20 mm
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PACKAGE NO - II
CHAPTER NO. Q6
Equipment
foundations
VOLUME - V of V
Page 186 of 194
Top level of bolts
Top level of foundation
before grouting
Axes of anchor bolts in
plan
Axis of foundation in
either direction
Deviation in vertical line
along height
Sizes of pits in plan
Sizes of steps in plan
Levels of steps,
benches and pits
Axes of inserts in plan
Basic
plan
Buildings
dimensions
in
Deviation of horizontal
plane from horizontal
line
For 1 m of plane in any
direction
For whole plane
Local deviation of top
surface when checked
with a 2 m long straight
edge
Surface when checked
with a 2 m long straight
edge
Sizes of cross section
Length of elements
Deviation from
horizontal plane for
whole building
verticality
For columns supporting
floor beams
For frame columns
linked with crane
girders & beams
+ 20 mm
- 20 mm
5 mm
10 mm
5 mm
20 mm
- 20 mm
- 20 mm
10 mm
10 mm
5 mm
20 mm
8 mm
8 mm
+ 8 mm, - 0 mm
20 mm
10 mm
1 in 1000 of height
10 mm
10 mm
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PACKAGE NO - II
CHAPTER NO. Q6
Reinforced
concrete
walls
Placement
of
reinforceme
nt
Anchor bolts
VOLUME - V of V
Page 187 of 194
Length
Flatness of surface
when checked with a 2
m long straight edge
Level of top surface to
support assembled
elements
Deviation in planes and
lines of intersection
from vertical
Size of cross section
Length of bar upto 75
cm long (other that
straight bars)
75 to 150 cm long
150 to 250 cm long
250 cm long and above
Straight bars, all
lengths
Spacing bars
Shift in location in plan
Same when bolts are
located outside of
structural columns
Top level
Threaded length
20 mm
8 mm
5 mm
15 mm
8 mm
+ 3 mm, - 5 mm
+ 5 mm, - 10 mm
+ 6 mm, -15 mm
+ 7 mm, -25 mm
25 mm
+ 5 mm
5 mm
+ 10 mm
20 mm
+ 30 mm
Masonry work
Width
Shift in axes
Deviation from
horizontal line
for every 10 m
length
Flatness of
surface when
checked with a
2 m long
straight edge
Deviation in
lines separating
storyes
For walls
10 mm
10 mm
15 mm
For pillars
10 mm
10 mm
5 mm
15 mm
15 mm
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CHAPTER NO. Q6
VOLUME - V of V
Page 188 of 194
Deviation of
10 mm
10 mm
surface from
vertical and at
angles and
corners for 1
storey
For whole
30 mm
30 mm
building
Dimensions of
+ 15 mm, - 0mm
openings for
doors,
windows, etc.
Flooring, Skirting, Dado and Plastering
In situ flooring
4 mm
Concrete tile and
3 mm
mosaic in any 3 m
length
In large open area
15 mm
Wall tiling
surface should not
1 in 200
vary from general
plane by more than
In any 2 m length
1.5 mm
Marble and
such superior
3 mm
In any row
work
Flatness when
3 mm
Plastered
checked with a 2 m
surfaces
long straight edge
Vertical surfaces
5 mm
upto 1 storey
10 mm
Over full height
Metallic inserts
On assembled
Length & width
3 mm
components
Road work
The levels of subgrade and different pavement courses should not vary
from those calculated with reference to the longitudinal and cross
sections of the road as shown on the drawing beyond the tolerance
given below:
Subgrade
25 mm
Sub base
+ 20 mm
Base
15 mm
Wearing coat
6 mm
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PACKAGE NO - II
CHAPTER NO. Q6
SETION -VI
VOLUME - V of V
Page 189 of 194
METHOD OF MEASUREMENT
1.0
GENERAL
1.1
The works executed shall be measured in stages. Approved

billing schedule for civil works shall form the basis of
identification of stages of construction.
1.2
The tenderer shall submit relevant backup calculations for

the quantum of work considered in each of the stages
considered for approval of billing schedule.
1.3
As a guideline the stages of work shall generally be

considered as Foundation, Lintel level, Floor slab/ roof slab
level. Sanitary & water supply, Finishing, Site clearance &
handing over. For other items of work, such as roads, drains,
stages shall be considered as percentage of the entire work.
1.4
In case of requirement of detailed measurements to be

taken, the method of measurement of work shall be in
accordance with IS: 1200 (Part 1 to 28) 1971 to 1993 /
SP: 27.
1.5
The measurement considered shall be purely for the purpose

of clearance of stage payments and shall not in any way
indicate change of scope. No claims shall be entertained on
this account.
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PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 190 of 194
SECTION VII: SAFETY CODE

1.0
GENERAL
1.1
This specification deals with the subject matter of safety and

protection to be observed in the Civil Construction. This shall
be
followed
along
with
all
related
statutory
requirements/obligation
including
Government
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 Tenderer 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
3764
4014
3696
1991
1992
(P-II) 1967
(P-I & P-II)
1987 to 1991
4138 1977
7293 1974
8989 1978
Demolition of Buildings
Excavation Work
Scaffolding, Steel Tubular
Scaffolds and Ladders
Working in Compressed Air
Working
with
Construction
Machinery
Erection
of
Concrete
Framed
Structures
3.0
EXCAVATIONS
3.1
No excavation or earthwork 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.
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PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 191 of 194
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.
Cutting shall be done from top to bottom. No undercutting of
sides of excavation shall be allowed.
3.4
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 stockpiles, 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 works 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.
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PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 192 of 194
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 formwork 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 Tenderer shall not employ men or women below the age
of 18, on the work of painting with products containing lead in
any form. Whenever men / women 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 Tenderer 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.
5.5
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.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q6
5.6
VOLUME - V of V
Page 193 of 194
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 place in each shift are given adequate training on
first-aid methods to avoid employment of a separate
attendant
6.0
MISCELLANEOUS
6.1
The Tenderer 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
Tenderer 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 pasted 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 Tenderer, 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.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q6
VOLUME - V of V
Page 194 of 194
7.2
Serious Injury
7.2.1
In case of serious injury, the following procedure shall be

adopted by the Tenderer:
a) Provide First Aid at his own First Aid Station.
b) Take the injured person to the Hospital along with the
INJURED ON WORK form duly filled in.
c) Reporting the accident to the Owner/Consultant by the
Tenderer.
7.3
Fatal Accident
Fatal accident must be reported immediately
Consultant/Owner as well as to the Police.
8.0
to
the
PENALTY
Failure to observe the Safety Rules will make the Tenderer
liable to penalty by way of suspension of work, fine and
termination of contract.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 1
of
CHAPTER-Q7
TECHNICAL SPECIFICATION STRUCTURAL
CONTENTS
Description
Section
1
Scope of Work
Design of steel structures
Fabrication of Steel Structures
Erection of Steel Structures
Fabrication and Erection of Miscellaneous structures
LIST OF ANNEXURES:
ANNEXURE - A:
Permissible deviation in pitch and gauge of holes

for bolts of Normal accuracy
ANNEXURE B:
Tolerance of assembled components of steel

structures
ANNEXURE C:
Permissible deviation in assembly of welded

joints
ANNEXURE D:
Tolerance in erected steel structures
ANNEXURE E:
Material of construction
Note: As regards to the various standards mentioned in this

specification, their relevant latest publication as on date
shall be referred to.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 2
of
84
TECHNICAL SPECIFICATION FOR STRUCTURAL WORKS

1.0
SCOPE OF WORK
The scope of work includes Analysis / design, engineering, drawings
supply, preparation of fabrication drawings for structures and sheeting,
fabrication, Handling/ storage/ transportation, erection & painting
including P.A.T. and F.A.T. etc. complete in all respects.
Submissions of layout of buildings, design criteria, design calculations
with design drawings (using AUTOCAD) with bill of quantities for
scrutiny and approval. Submission of assignment/drawings showing
relevant information/civil load data, for foundation of corresponding to
steel structures. Necessary concurrence of all structural design drawings
from the concerned technologist.
The scope of work covers the following units:
a)
Transfer Houses TH-1, TH-2, TH-2A, TH-3, TH-4, TH-5 & TH-6
b)
Structural shed over R.C.C. Silo along with staircase up to top

of silo
c)
Tail / Drive House for Down Hill Conveyor no. 723
d)
Transfer Station at tail end of conveyor no. 727-1 and Parking

stations PS-1 & PS-2 for traveling trolleys
e)
Galleries for Down hill conveyer no. 723 (on R.C.C. pier
supports / Structural Trestles )
f)
Galleries and trestles for conveyor No. 718, 719, 721,

727(Reversible), 727-1 & 727-2
g)
Structural Modification works required for extending the tail

end of the existing tripper conveyor no. 122 and also for
extending travel of tripper on conveyor no. 122 including
gallery for the extended portion of conveyor no.122.
h)
All other necessary structures required for Package-II.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
2.0
VOLUME - V of V
PAGE No. 3
of
DESIGN INCLUDING ANALYSIS AND DRAWINGS FOR

STEEL STRUCTURES
The scope of work includes such that Tenderer shall submit
the design criteria and General Layout of the buildings, layout
of individual buildings, before taking up analysis and design
work. Based on that Actual layout Tenderer shall submit
analysis and design calculations along with basic design
drawings (using AUTOCAD) indicating Bill of quantities also.
During scrutiny changes like design loads/ criteria etc. if any,
inline with technological / serviceability requirements shall be
taken care.
2.1
Specification for Design of steel structures

A)
Design of Building Structures
Design considerations
2.2
General
2.2.1
Structures shall be designed such that they are economical and

safe and meet the functional and service requirement of the
technological process for which they are designed. The
architectural planning of the building shall be inline with
guidelines and requirements given in this specification and
relevant serviceability /technological requirements.
2.2.2
The structures shall be designed conforming to the relevant

safety regulations, Factory Acts, Electricity Rules and
stipulations of Statutory bodies as applicable to the project.
2.2.3
Natural ventilation shall be provided ensuring that it prevents

rainwater entry into the building.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 4
of
2.2.4
Mild steel gutters and down-pipes with gutter outlets and

grating shall be provided to carry rainwater from roofs of
buildings to the drainage system for such building at ground
level. In case access is provided to roof, gutters shall be
designed walk-able with 600-mm sole width.
2.2.5
Adequate facilities in the form of monorails, hoists, platforms

etc. shall be provided to facilitate repair and maintenance of
overhead cranes, equipment, etc. Access to these platforms
shall be provided by stairs from the nearest accessible floor or
platform.
2.2.6
Transverse runway beams for crane maintenance hoist of

suitable capacity shall be provided near the gables. Where the
number of cranes exceeds two, similar beams shall also be
located at intermediate places. The location of hoists shall be
chosen so as not to hamper the operation in the shop.
2.2. 7
Access to all floors, gangways and landings shall be by

staircases. Access to roof and landing of secondary importance
or where such access is used only rarely, shall be by vertical
ladders with safety hoops. Stair together with operating
platforms shall be provided for access to maintenance hoists.
2.2.8
Access to roof shall be generally located at gables and if

required, also at appropriate intermediate locations, so that for
every 150 meters length of the building, at least one access to
roof is available.
2.2.9
Platforms for access to crane cabin shall be provided and shall

preferably located in the crane maintenance bays.
2.2.10
Edges of floors, gangways, stairs and landings shall be

provided with safety hand railings with toe guards.
2.2.11
Roof, along with access shall be provided, with safety handrails

along the periphery of the roof.
Rev. 0
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NMDC LIMITED
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PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 5
of
2.2.12
At gable ends of buildings, platforms shall be provided

connecting the walkways at crane gantry level.
2.2.13
Floors, gangways and landings shall be covered as follows:

a)
Gangways and landings shall have chequered plate with

a minimum thickness of 6mm o/p suitably stiffened to
meet design load requirements.
b)
Repair and operating platforms other than the above

shall have chequered plate (thickness 8mm o/p)
flooring or hot dip galvanised open gratings.
c)
Where there is a possibility of gas or dust collection, hot

dip galvanised open gratings shall be used.
2.2.14
Protective metal heat shields shall be provided for steel

structures exposed to continuous heat radiation of
temperature exceeding 150 C and also where hot metal
splashing on structures is likely to occur.
2.2.15
All buildings and their foundations shall be designed so that it

shall be possible to extend them in the longitudinal direction at
a later date without further strengthening of gable structures.
Provision for transverse extension shall be made where
extension is foreseen at the initial stage.
2.2.16
Sheeting on sides and gables shall generally terminate 3.5 m

above ground level, sides below this level shall be generally
screened by brick walls allowing sufficient air inlet to achieve
natural
ventilation,
unless
otherwise
required
from
technological / ventilation requirements.
2.2.17
Connection by permanent bolts to structural elements subject

to vibration shall be provided with spring washers and lock
nuts.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
2.3
Elements of Structures
2.3.1
Columns
2.3.2
VOLUME - V of V
PAGE No. 6
of
a)
At the location of passage/opening through columns

web shall be suitably strengthened by vierendeel panel
or modified lattice system.
b)
Shear force at the column base shall be resisted either

by shear keys shop-welded to the underside of column
base plates or by welding base plate to inserts
provided in foundation.
c)
The level of underside of column base shall be so

chosen such that the complete anchor table lies below
the finished floor level, thus keeping the shop floor
free from projections of anchor tables.
Crane Girders
a)
Crane girders shall generally be of simply supported

design, unless continuous crane girder are specifically
required.
b)
Top flange plate shall be welded to web plate with full

penetration butt weld with fully automatic submerged
arc welding. Bottom flange plate shall be welded to web
plate
by
continuous
fillet
welds
with
automatic/semi-automatic welding.
c)
All intermediate stiffeners shall be fitted against top

flange and welded to it by fillet welds/partial
penetration butt welds. These stiffeners shall terminate
short of bottom flange with at least 25 mm gap. The
stiffeners shall be fillet welded to web plate and corners
shall be cut suitably to clear thermally affected area of
web to top flange connection.
d)
End bearing stiffener plates of crane girder shall be

capable of transmitting the maximum reactions to the
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 7
of
columns. The bearing surface of the bearing plate shall

be planed/machined to ensure full contact.
2.3.3
2.3.4
e)
Tension flange of crane girders shall be stabilized by

horizontal latticed bracings, where required in order to
limit the slenderness ratio of the flange to 150.
f)
The crane girders (for all spans) shall be checked for

their stability / rigidity in the plane of top and bottom
flange. For girders spans 8 metres and above auxiliary
girder, horizontal latticed bracings in the plane of crane
girder top & bottom flange to be provided.
Surge Girder walkways and auxiliary beams

a)
Continuous maintenance walkways with safety hand

railing shall be provided along each column row
adjacent to each crane gantry girder. These walkways
shall be of non-slip plate construction connected to
crane girder top flange by continuous fillet welds.
Staircase at every 120m shall be provided from floor for
access to this walkway so that stairs are available
within 60m from any location.
b)
Connections between surge girder and the main

columns shall be designed to resist load due to lateral
braking of crane trolley.
c)
On the periphery of the building, full-length handrails

shall be provided along the edge of the maintenance
walkway at crane girder level.
d)
Handrail and its clearance from crane end carriage shall

conform to provisions of relevant safety regulations.
Crane Stops
a)
Crane stops shall be provided at the ends of each crane

girder system or as required to limit the movement of
crane as per technological requirements.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
b)
2.3.5
2.3.6
VOLUME - V of V
PAGE No. 8
of
Crane stops shall be bolted to crane gantry girder.
Roof Structures
a)
The main supporting element shall be roof trusses

provided at uniform spacing to suit shop layout. Roof
shall be provided with adequately sized roof monitor for
natural ventilation, wherever required.
b)
Roof shall have suitable slope to meet technological as

well as rain water drainage requirements.
c)
System of bracings shall be provided in the roof

topchord and bottom chord levels along with
longitudinal ties to ensure stability and rigidity of the
roof
structures. Vertical bracings between trusses shall also
be provided wherever required.
d)
Roof purlins shall be stiffened with sag rods & sag angles.
e)
Wind ties are to be provided on the roof suitably.
Roof drainage system

a)
b)
Roof drainage system shall be designed for maximum

precipitation
for
5
minutes
based
on
local
meteorological data. A factor of safety of 1.3 shall be
kept in the design.
All valley and eaves gutters shall be of pressed plate
construction with a minimum sole width of 600 mm so
as to function as walkways.
c)
Eaves gutter shall be provided for eaves height ranging

between 10 m to 25 m above apron/ground level.
d)
The gutters shall be laid to slope towards down-pipes

with welded outlets and having grills fitted flush with
gutter sole. Slope of gutters and collector pipes shall
not be flatter than the following limits:
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
i)
ii)
2.3.7
PAGE No. 9
of
Longitudinal slope of gutter

1 : 500
Longitudinal slope of collector 1 : 300
pipe
e)
Poking holes with cover shall be provided in the downpipes at suitable intervals as well as at accessible levels,
to clean the down-pipes.
f)
Collector pipes shall be provided with covered manholes

at 6 m interval.
g)
Eaves gutter shall be provided with safety handrails.
h)
When rainwater falls from higher to lower roof, double

layer of sheets shall be provided for the portion of roof
sheeting on which rainwater falls provided the drop of
roof is in the range of 3 m to 6 m. In case the drop is
more than 6 m, independent gutter shall be provided.
i)
Down pipes shall be spaced preferably at 24 m centres.

The down-pipes shall be connected to the gutter with
suitably designed hoppers with gratings at sole level of
gutter, made of 8 mm dia rounds at 50 mm centers.
j)
Joints of gutter and collector pipes shall be by welding

in order to be leak-proof.
Wall Structures
a)
Wall runners with necessary sag rod arrangements shall

be provided to support wall and gable sheeting,
including internal partition wall, wherever required.
b)
Gables of buildings shall have wall post spaced at

intervals to suit bay width.
c)
Walls shall be provided with louvres and glazing at

appropriate levels, to provide natural ventilation and
lighting.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
2.3.8
2.3.9
2.3.10
VOLUME - V of V
PAGE No. 10
of
Floor Frameworks
a)
Floor beams supporting vibrating equipment shall be

designed to avoid resonant frequencies.
b)
Beams along-with framework, shall be provided with

both horizontal and vertical bracing (wherever
permissible) to achieve overall rigidity.
Vertical bracings
a)
Vertical bracings shall be provided for columns /frames

of each expansion block, to ensure the stability of such
columns/frames of the block.
b)
Vertical bracings shall extend from ground level to roof

level and shall be designed to transmit longitudinal
forces i.e wind forces, crane tractive & braking forces,
seismic forces etc. to the foundation.
c)
Below crane girder level, the bracings shall be of twin

system in the plane of each column leg, suitably tied or
laced together.
Access staircase, walkways, platforms and ladders.

a)
Wherever possible, access shall be provided by means

of stairs.
b)
All walkways and stairs leading to working platforms

shall have minimum 1100-mm width of walkways/flight
of stair.
c)
All other walkways and stairs leading to areas for

maintenance purpose, or due to restriction of space,
shall have a minimum width of 800 mm of
walkway/flight of stair, unless required otherwise.
d)
Staircases shall be generally designed with slope of

approximate 37.5 with the horizontal. (in no case the
slope shall exceed 40 with the horizontal).
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 11
of
Intermediate landings shall be provided wherever

required such that vertical rise of each flight does not
exceed 3000 mm. Risers/treads in each flight shall be
equally spaced.
e)
Walkway floors and stair treads shall be designed with

chequered plate (or non-slip type plates). Ribbed
floor/treads (gratings) may be provided wherever the
possibility of accumulation of dust exists, taking care
that such provisions do not create a nuisance to the
operating personnel on the shop floor.
f)
Rise in staircases shall not exceed 200 mm.

Staircase stringer beam shall be minimum ISMC200
and its adequacy shall be checked and verified for case
to case. Treads shall not be less than 250mm.
g)
Minimum headroom of 2200 mm shall be provided over

operating platforms, visitor's galleries, or other areas
with possibility of public gathering. In all other
platforms, walkways and stairs, minimum headroom of
2000 mm shall be provided. Only in special cases, local
headroom of 1800 mm may be allowed (i.e. at
intersection with structural members etc.).
h)
Cat ladders shall be provided for access, wherever

provision of staircase is impracticable due to limitations
of space, or the access is required not very frequently
i)
Wherever the height of cat ladder exceeds 2.5 m,

safety cage shall be provided. Intermediate landing
shall be provided to cat ladders such that vertical height
of single rise does not exceed 8.0 m.
j)
Cat ladders shall be designed with following provisions:
i)
ii)
iii)
Width of rung
=500
Minimum rise of rung
=250
Maximum rise of rung
=300
Minimum clearance from rung of ladder to
back of cage (in case of caged ladders)
=700
mm
mm
mm
mm
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NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
iv)
v)
VOLUME - V of V
PAGE No. 12
of
Minimum clearance from the centre of cage all =350 mm

round
Slope of cat-ladders
:
I. For normal cat-ladders, slope shall be within
the range of 75-90 with the horizontal.
II. For ship-type ladders (i.e cat-ladders with
short side handrails) the slope shall be within
the range of 65-75 with the horizontal.
Ladder leg section shall be minimum ISA L 65x65x6 its
adequacy shall be checked and verified for case to case.
k)
All walkways, platforms and stairs shall be provided

with safety handrails. All handrails shall be constructed
with steel tubes for posts, top and middle rail and
plates for toe guard plates. In case of stairs, the toe
guards need not be provided.
l)
The vertical height of hand-railings on walkways and

stairs shall be minimum 1100 mm above floor level.
m)
Hand-railing along edge of roof and gutters shall have a

minimum height of 600 mm over top edge of
gutters/sheets. In such hand-railings toe guards need
not be provided. (Only top handrail and mid-rail shall be
provided).
2.4
Design
2.4.1
Design of structures
a)
Design of steel structures shall be done in accordance

with IS: 800-2007 and other relevant Indian Standards.
Where there is no Indian Standard in existence, then
only the relevant B.S. or other recognized standards
shall be used, but with prior approval of the
Consultant/Owner.
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
2.4.2
VOLUME - V of V
PAGE No. 13
of
b)
Structures subjected to fluctuating/reversal of stress

(eg. Crane girders) shall be designed in accordance with
IS: 1024-1999.
c)
Resonance in structures - Structures supporting

vibratory/reciprocating equipments shall be designed so
as to obviate occurrence of resonance. The ratio of
applied frequency to natural frequency shall be beyond
the limits of 0.7 to 1.5 (preferably less than 0.7).
Description of design loads

Loads considered in design shall allow fully for all aspects of:
a)
Dead weight of structures, wall, floors, equipment,

wiring, machinery, pipe-work, cabling and any item of a
permanent nature.
b)
Superimposed loads for roofs and floors plus any

temporary machinery not allowed within the general
superimposed loads.
c)
Crane loading.
d)
Temperature loads from process requirements because

of the position of the structure relative to the heat
source or from support of mains, pipes etc. subject to
heat.
e)
Range of temperature variation for climatic conditions

= Maximum: 46C, Minimum : 2C
f)
Dust load.
g)
Dynamic loads from Vibratory Equipments: like

Crushers, screens, apron feeders and any other such
(reciprocating) machinery.
h)
Maintenance hoists on Runway beams.
i)
Wind Loads
Rev. 0
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NMDC LIMITED
MECON
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PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
2.4.3
PAGE No. 14
j)
Seismic loads
k)
From future extensions.
l)
Any special/specific erection requirements.
m)
Blasting effects
of
Loading codes
a)
All live loads shall be considered in accordance with IS:

875(Part-2)-1987.
b)
Wind loads shall be in accordance with IS:

875(Part-3)-1987 and any other consideration specific
to the site.
c)
Seismic loads shall be in accordance with IS: 18932002.
d)
Crane loading to be considered in design shall be as

follows:
i.
As per relevant clause of IS: 800-2007.
ii.
IS: 875(Part-2)-1987 for conditions not covered

in IS: 800-2007. Unless more severe loads have
to be considered for technological/operational
conditions.
e)
Crane stopper shall be designed in accordance with

clause 6.1.4 of IS: 875 (Part-5)-1987.
f)
In absence of any suitable provision for design loads,

any other recognized code of practice may be followed
subject to prior approval of the Consultant/Owner.
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
2.4.4
VOLUME - V of V
PAGE No. 15
of
Additional Design loads

Besides technological loads, all platforms, walkways, stairs
etc. shall be designed for the following live loads:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
2.4.5
Walkways and Platforms

Visitor's galleries
Maintenance
platforms
crane level walkway.
Staircase and treads
Monorail walkways
Handrails
:2
:5
including : 5
KN/m
KN/m
KN/m
: 4 KN/m
: 4 KN/m
: 0.75 KN/m run
(Horizontal)
: 0.9 KN
and : 0.5 KN/m
Ladder at middle of rung

Dust
loads
(for
buildings
structures located in dusty zone)
For design of monorails, hoists an
impact factor of 1.25 be considered.
For design of floor beams directly
supporting drive machineries like
head end/ tail end drive pulley,
motors, gear boxes etc. an impact
factor of 1.5 shall
be considered
unless otherwise specified .
Specific loads if any
Combination of loads
Various design loads considered shall be combined in
accordance with clause 8.0 of IS: 875(Part-5)-1987 to give
the most severe loading condition for design of structures.
2.4.6
Stress Enhancements
Permissible limits of stress may be increased wherever
permissible, in accordance with IS: 800-2007.
Rev. 0
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NMDC LIMITED
MECON
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PACKAGE NO - II
CHAPTER NO. Q7
2.4.7
VOLUME - V of V
PAGE No. 16
of
Limiting deflection
a)
The deflection of various structural members shall not

impair the strength or smooth working of the building
system.
b)
Generally the deflection shall be limited in various

elements of structures in accordance with IS:8002007. In view of serviceability requirements the
following limitations in deflection shall be observed in
design:
Vertical Deflection
i)
ii)
iii)
Monorail track beams

: Span/500
Main roof trusses, Building roof girders, : Span/500
main floor beams directly supporting
drive machineries, motors, gears boxes
etc. on operating platforms
Crane Girders
: Span/750
Horizontal Deflection
i)
ii)
iii)
Crane girders due to surge force (from one : Span/2000

crane only).
Main columns at crane rail level in : H/2500
transverse direction due to action of crane
surge
(for surge force consider one
crane for single bay and one crane on
adjacent aisles for multi-bay buildings)
Open gantry for condition as in (ii)
H/4000
above
Where H = Height of Column from bottom of base plate to

crane rail level.
All deflections shall be calculated without dynamic factor.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
2.4.8
VOLUME - V of V
PAGE No. 17
of
Camber
Wherever excessive deformation is likely to cause operational
problem or is aesthetically not agreeable, camber shall be
provided to neutralize the effect of deformation due to dead
load plus 50 % of imposed loads.
2.4.9
2.4.10
Expansion joints
a)
Longitudinal and transverse expansion joints shall be

provided in buildings and structures in accordance with
IS: 800-2007 (refer relevant clause)
b)
Expansion joints shall be formed by providing double

rows of columns, with interconnecting gantry girders,
secondary roof and wall framing being detailed to allow
the maximum calculated movement for the specified
temperature variation.
c)
The above said expansion block 150 metres long shall

be separated by twin trestles/supports (formed by end
trestles of successive blocks) with a provision
gap/space for free expansion. (See relevant clause).
Miscellaneous design requirements

a)
The minimum thickness of structural steel elements

shall be in accordance with IS: 800-2007 and subject to
the following minimum requirements:
Gusset plate
: 8 mm
Base plate
: 20 mm
Stiffeners plates for Base plates
: 8 mm
Flange plates for plate girders
: 12 mm
Web plates for plate girders
: 10 mm
Stiffeners for webs of plate girders
: 8 mm
Bracing member
: 50 x 50 x 6 angle
Hand Rail toe-guard
: 100 x 4mm thk.
Rev. 0
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NMDC LIMITED
MECON
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PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 18
of
Hand rail: Horizontal rails/Vertical posts Pipe 32 NB

(Medium) dia
maximum spacing of vertical posts
1000 mm and minimum height of handrail shall be
1100mm.
b)
The diameter of structural bolts shall not be less than

16 mm except for those securing roof and wall
sheets, windows, doors and stitching of thin coverings.
For bolted joints, at least two bolts per joint shall be
provided.
c)
The size of fillet welds shall not be less than 6 mm.
d)
Main structural elements shall be welded continuously.

Intermittent welding shall be used only on secondary
members, which are not exposed to weather or other
corrosive influence.
e)
B)
Field connection and splices shall be made as follows:

i)
By welding
ii)
By permanent bolts (for secondary members

such as purlins, wall runners etc.)
Design of Conveyor galleries
Design considerations
2.5
General
2.5.1
The dimensional parameters for conveyor galleries shall be in

line with the dimension indicated in the tender drawings. The
structure shall be designed so as to meet functional
requirements and shall provide space for operation,
maintenance and removal of machinery and give the workers
good and safe environment.
2.5.2
Gallery floors shall be of Chequered plates / Gratings

supported on steel beams as per the requirement
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PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 19
of
2.5.3
Steps shall be provided (rise not exceeding 130 mm) along

the walkways if the gallery slope exceeds 12. In case the
slope of gallery is between 6 to 12, suitable rods 6 dia. shall
be provided on floor (without any sharp edges) at 250 to 300
mm intervals.
2.5.4
Provisions shall be made for i) Emergency exit from Conveyor

gallery to ground with a door (to be latched from inside and
opening outwards), landing & staircase 600mm wide
(minimum). Exit shall be located at every 300 metres
(approximately) length of conv. gallery, such that the gallery
floor shall be as close as possible to the ground.
ii) Crossover above conveyor at 150 m intervals (maximum).
The width of cross over shall not be less than 600 mm.
2.5.5
Roof and sidewalls of conveyor galleries shall be covered with

Precoated Galvalume Corrugated/troughed Steel Sheets With
a provision of gap of 300 mm below roof and 150 mm from
top of floor level on the side wall for ventilation. Wind ties are
to be provided on the roof suitably.
2.5.6
Adequate provision for natural light inside conveyor gallery

shall be made through sidewalls by providing translucent
sheets (FRP sheets). Every sixth sheet on sidewall shall be FRP
sheet and shall be staggered on opposite wall.
2.5.7
Roof slopes of conveyor galleries shall be 1:3 (1 vertical, 3

Horizontal).
2.5.8
The level of underside of the base plate of gallery supporting

trestles shall be 300 mm above the average ground level of
the surrounding area.
2.5.9
Protective hand railing shall be provided along gallery

walkways, open platform, stairways, landings, edges of
walkways and around erection openings, if any, to ensure
safety of operating personnel. Toe guard shall be provided on
sides of conveyor gallery walkway as a safety measure.
Rev. 0
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NMDC LIMITED
MECON
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PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 20
of
2.5.10
Conveyor galleries longer than 150 m shall be provided with

expansion joints with twin trestles/supports. Each expansion
block shall have fixed support/rigid trestle with adequate
arrangement (provision of top chord and bottom chord bracing
to gallery girder etc.) for transferring the transverse and
longitudinal forces to the foundation. The above said
expansion block 150 metres long shall be separated by twin
trestles/supports (formed by end trestles of successive blocks)
with a provision gap/space for free expansion. ( see relevant
clause ).
2.5.11
Gallery girders near transfer house shall be preferably

supported on trestle located as close to the transfer house as
possible, with part of gallery girder between transfer house
and trestle cantilevered from the trestle. Supporting gallery
girders on transfer house shall be generally avoided.
2.5.12
Seal plate of min. 3.15 mm thickness with adequate

stiffeners shall be provided below the gallery at road / rail
crossing, above nallahs, above buildings, in BMM plant area,
near Ranjitpura village and near proposed Pellet Plant to
avoid falling of material.
2.5.13
The effect of inclination of conveyors shall be taken into

account for design of structures. The inclination shall be as
per appropriate conveyor layout.
2.5.14
End portal of gallery (Vertically straight) shall be of ISMB

sections/Built-up I sections, designed to transfer all vertical
and lateral loads to supporting trestles / transfer houses.
2.5.15
Loads due to temperature effect, wind loads, effect of gravity

take up, material loads, conveyor loads along with other load
combinations, with appropriate dynamic coefficient, shall be
considered for the design.
2.5.16
Conveyor galleries (Top & Bottom chord shall be ISMB

sections/Built-up I sections) and trestles shall be designed
considering both the conveyors are working simultaneously in
case of twin conveyor system.
Rev. 0
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NMDC LIMITED
MECON
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PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 21
of
2.5.17
The lattice girders supporting the conveyors shall be suitably

braced at top and bottom chord levels to transfer the wind
load to the end portals connected to trestles. Roof purlins
and walkway runners shall be suitably braced at each end to
take care of effect due to inclination of gallery.
2.5.18
For sliding supports (of pipelines), steel-to-steel contact with

slotted holes are not acceptable. Either Teflon pad bearings
or roller supports shall be adopted.
2.5.19
For design of conveyor galleries, load due to cables, light

fittings, water pipes effect of gravity take-up etc. shall be
considered as appropriate along with other load combination.
2.5.20
Base plates for trestles shall be designed as gusseted bases

considering all axial loads and moments, shear lugs shall be
provided below base plate to take up all horizontal loads.
2.5.21
Anchor bolts shall be designed for maximum uplift for the

worst combination of loads. Live loads and equipment loads
shall be ignored in order to evaluate maximum uplift.
2.5.22
Proposed bracing patterns and locations shall be planned

such that it does not hinder movement of personnel and
maintenance of equipment.
2.5.23
All over ground trestles shall be out of ISMB sections. In case

the channels/angles sections are used, prior information to
be given to Consultant/Owner. Approval to be obtained from
Consultant/Owner, on case-to-case basis.
2.5.24
When conveyor gallery crosses above or below H.T Lines, a

clear distance (as per Indian Electricity Rules) between the
structural elements/cladding and HT cables shall be
maintained.
2.5.25
The clearance between the road surface and the lowest points
of the gallery / any other structure of the conveyor shall not
be less than 8.0 m at road crossings, above railway line
crossing, over BMM plant, over Ranjitpura village and over
proposed Pellet plant. In other locations, a minimum
Rev. 0
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PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 22
of
clearance of 6.0 m shall be ensured from the ground to the

bottom of gallery / any other structure of the conveyor.
2.5.26
The transfer house shall be designed to suit the technological

requirements. Number of floors, height of building etc. shall be
decided accordingly.
2.5.27
In general the transfer house shall be designed as framed

structures on shorter span side and vertically braced on longer
side to achieve stability.
2.5.28
Floor of transfer houses shall be of RCC slab supported on

steel beams, unless required otherwise from technological
consideration.
2.5.29
Roof and side covering of transfer houses shall be Precoated

Galvalume Corrugated/troughed Steel Sheets as specified.
Roof slope shall be 1: 3 (1 Vertical: 3 Horizontal).
2.5.30
Suitable access staircase and safety hand railing shall be

provided to all floors of transfer houses.
2.5.31
When hydro washing of floor of transfer house is envisaged,

the floor beam supporting RCC slab shall be laid to a suitable
slope to achieve the same, wherever the same is not
practicable to achieve through screed concrete. (Minimum
slope of floor shall be 1.5%).
2.5.32
Wall sheeting shall generally start from the lowest working

floor and extend up to roof level with louvers at each floor
level to ensure adequate natural ventilation.
2.5.33
Monorails for maintenance hoists shall be provided for

maintenance and repair of various equipments located on the
floors.
2.5.34
Loads due to Pipelines for Fire Hydrants and Service water

(with loading 150 kg/m per pipe) shall be considered while
designing of the conveyor galleries. However pipes and their
fittings are not included in the scope.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
2.5.35
a)
VOLUME - V of V
PAGE No. 23
of
Gallery for Down Hill Conveyor-723:

Gallery for down hill conveyor no. 723 shall be suitable
for 1050 mm belt width and shall be Open Type
rectangular Gallery with R.C.C. pier supports (up to 12
metres height) and 4 legged steel structural supports
for heights above
12 metres. Roofing and side
sheeting shall not be provided for the above conveyor
gallery. Walkway shall be provided on one side of the
gallery. Gallery shall be designed considering the
movement of self-propelled maintenance trolleys along
the entire length of the conveyor.
However, the following option may also be considered
subject to the Approval of Owner/consultant:
The Structural Gallery Truss may be of Triangular cross
section. Each face of the Triangle shall be formed as a
truss such that their chord/main members (top &
bottom chord) will run longitudinally along the three
vertices of the triangle. i.e. one at ridge and the other
two at the base. The Truss members shall be of Tubular
sections. These Tubular sections will additionally
facilitate the movement of a maintenance trolley
longitudinally. This Gallery truss shall not be provided
with roof or side sheeting.
b)
Also please refer to the other clauses viz: 2.5.2, 3,

4,9,1012,13,15,18,19,22,24,25,34
etc.
mentioned
above.
2.6
Components of structures
2.6.1
Gallery Trusses and Roof

a)
Gallery truss shall be of latticed type construction and

shall support roof (for covered galleries) as well as floor
deck supporting conveyor system.
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MECON
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PACKAGE NO - II
CHAPTER NO. Q7
b)
2.6.2
VOLUME - V of V
PAGE No. 24
of
The trusses shall be adequately braced at top and

bottom chord level to transfer the horizontal wind
forces to end portals.
Stringer beam
These beams shall be suitably spaced to support the conveyor
stringer post and shall deliver load to gallery trusses.
Walkways on either side of the conveyor shall also be
supported on these stringer beams & truss bottom chord
member.
2.6.3
Supporting Trestles
Intermediate trestles shall be two legged and shall deliver
loads from gallery trusses to the foundations. In addition, four
legged trestles shall be provided which will act as fixed
support to transmit all longitudinal forces between expansion
blocks, in addition to other forces.
2.6.4
2.6.4.1
Transfer houses
a)
b)
Floors - Floor beam layout shall be arranged to suit

equipment layout as well as equipment anchoring
system.
Columns - In addition to loads from floor and roof,
columns shall be designed to transmit horizontal load
due to belt tension/snapping of belts to the foundation
2.6.4.2
Transfer houses/Towers shall be designed with structural

steel framing. While peripheral framing will be designed as
braced structure, intermediate framing may be designed as
framed structures.
2.6.4.3
Chute loads on floors shall be evaluated duly considering the

chutes as fully plugged with material for its entire height.
Rev. 0
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MECON
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PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 25
of
2.6.4.4
Handrail shall be provided around all openings and along Gaps

(if any) other than entries in floors. Anchor fastenings shall
not be used for supporting equipment imparting dynamic
loads.
2.6.4.5
Floor beams carrying R.C.C. slabs shall be provided with shear

keys to facilitate connection with slab. However no composite
action of R.C.C slabs with steel beam shall be considered for
the design of floor/roof beams. Alternatively floor
bracings/lateral bracings shall be provided at minimum 75mm
below top of steel beam to transfer horizontal loads to braced
columns. Horizontal load transfer through RC slabs on braced
column shall also take into account stiffness of slab/frame and
bracing system.
2.6.4.6
Incase of chequered plates, the thickness of chequered plate

shall be minimum thickness 8 mm o/p. for operating platforms
and 6 mm o/p for other floors/walkways, staircases etc.
Suitable plan bracings shall be provided 75 mm below top of
floor beam to transfer all horizontal forces to braced columns.
Horizontal load transfer on to braced frames shall also take
into account stiffness of the frame.
2.6.4.7
Incase Brick wall cladding, cladding to be provided for steel

structures shall be such that there is a clear gap of 40mm
between inside face of external brick wall and outside face of
column flange. At each column flange location on RCC mullion
of
230
wide
and
270
mm
deep
shall
be
provided with link reinforcement welded to the steel column.
Structural steel beams supporting brickwork shall be suitably
encased in RCC using concrete of grade not less than M20.
Incase of structural steel of box type section encasement of 50
mm thickness minimum shall be done using wire
netting/reinforcement.
2.6.5
Belt tensioning device
2.6.5.1
Suitable structures shall be provided to accommodate

belt-tensioning device & same are to be located under the
conveyor gallery.
Rev. 0
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PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 26
of
2.6.5.2
Design shall duly consider belt tension at starting condition

with wind/seismic load in combination with other load cases.
2.6.5.3
Designs shall be carried out for the case of one belt at

starting condition and the other belt in running condition
along with wind/ seismic load in combination with other
loads.
2.6.5.4
Supports of gravity take up provided within the building shall

be designed to cater for impact force in the event of belt
failure and release of counter weight.
2.6.6
Wall structures
a)
Wall runners with necessary sag rods and sag angles

shall be provided to support wall sheeting in conveyor
galleries, transfer houses and other buildings.
b)
Wall sheeting and louvers
2.6.7
Access stairs, walkways, platforms, ladders, hand railing etc. These shall be provided in accordance with relevant clause of
this specification.
2.7
Design of Structures.
2.7.1
a)
Design of steel structures shall be done in accordance

with IS: 800-2007.
b)
In absence of specified dynamic factor to be considered

for the load from the belt conveyor, a dynamic factor of
not less than 1.3 shall be considered for the design of
floor beams and gallery girders.
c)
Gallery trusses and stringers as well as floor beams of

transfer house shall be checked for obviating
occurrence of resonance and shall be designed in
accordance with clause 2.4.1(c).
Rev. 0
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MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 27
of
2.7.2
Description of loads and loading codes
2.7.2.1
Unless specified otherwise hereinafter, all the live loads shall

be considered in accordance with IS: 875 (Part-2)-1987.
2.7.2.2
Wind loads shall be considered in accordance with IS: 875

(Part-3)-1987.
2.7.2.3
Seismic loads shall be considered in accordance with IS:

1893-2002.
2.7.2.4
Live loads from conveyor on the gallery floor shall be as per

conveyor suppliers load data.
2.7.2.5
While designing the fixed support/rigid trestles in an

expansion block of conveyor gallery the following loads (in
addition to wind load) shall be considered.
2.7.2.6
a)
Forces due to difference in frictional resistance of top

and return idle rollers of conveyor.
b)
Forces due to inertia of rollers at the time of starting of

conveyor belt.
c)
Break down load caused by snapping of belt (in case of

multiple conveyors, snapping of one belt at a time) shall
be considered.
d)
Loads due to curvature in the conveyor in both planes

horizontal and vertical
e)
Special loads if any
Gallery girders and floor shall be designed for the following

live loads, inclusive of spillage loads on floors.
a)
b)
c)
Walkway/Supporting beams for floor

Under the conveyor belt
Gallery girder, for floor load of
4.0 KN/m
0.75 KN/m
3.0 KN/m
Rev. 0
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NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
2.7.2.7
2.7.2.8
2.7.2.9
2.7.2.10
VOLUME - V of V
PAGE No. 28
of
Dust load on roof of transfer house and conveyor galleries

shall be considered as follows:
a)
For building and structures located at a distance of 300

m from the dust-producing units: 0.5 KN/m
b)
At a distance of 300 m to 800 m from the dustproducing unit: 0.25 KN/m
As per technological requirements, provision of supporting the

following, and load arising thereof shall be considered in the
design of conveyor gallery.
a)
Ventilation duct.
b)
Electrical cables/cable racks.
c)
Fire Fighting equipment.
Transfer house floor shall be designed for the following loads

a)
Live load on floor: 5.0 KN/m
b)
Tension from conveyor belt.
c)
Load due to equipment located on floor.
d)
Load due to jamming of chutes.
e)
Erection loads anywhere on the floor.
f)
Specific loads if any
a)
Dynamic Analysis shall be carried out for beams

supporting vibrating
equipment such as screens,
vibrating feeder, any other rotating equipment etc. to
provide sufficient rigidity inline with serviceability
requirements. Conveyor supporting beams in gallery,
Trestles of height more than 25 metres, for gallery
trusses/beams of span more than 25 metres.
Rev. 0
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NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
b)
PAGE No. 29
In case of beams supporting vibratory equipments:

like screens/vibrating feeders/crushers etc.; it is to be
ensured that the
beams upon which such vibratory
equipment is mounted (or from which it is suspended)
are level and in line. Sufficient rigidity to be provided
to support the weight of the screen, material load and
to absorb the vibrational residue from the live frame.
The following design considerations

structures are to be adopted.
a)
of
for
the
supporting
Supports:
Design of the supporting structures shall be done
ensuring the proper functioning of the unit with no
occurrence of troublesome secondary vibration in the
supporting structures. In the design of the supporting
structures, therefore, consideration must be given to:
i)
ii)
iii)
iv)
Static loads of the screen.

Dynamic loads.
Weight of the material carried by the vibratory
equipment.
Other loads supported by the structures.
Vibratory equipments are to be isolated from the

structure by relatively soft coil springs, which are
designed to absorb approximately 98% of the dynamic
forces generated by the vibrating equipment.
The
following
consideration
b)
design
aspects
need
special
Beams:
i)
ii)
RS Joists or RS Channels placed back-to-back,

and adequately coupled.
The beams should be level and in line; variation
in level should be corrected by inserting shims
under the spring pedestals.
Rev. 0
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NMDC LIMITED
MECON
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PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
iv)
v)
vi)
PAGE No. 30
of
The
natural
frequency
of
the
beams
should not be less than
1.5 times the
operating
frequency
of
the
Vibratory
equipment.
The natural frequency requirement is generally
fulfilled if the length-to-depth ratio of the beam
is not more than 10.
The above in line with clause 2.4.1 to be verified
with
due
consideration
to
technological
requirement s/ serviceability / performance etc.
When calculating the natural frequency of the beams,

do not take into consideration the weight of the
Vibratory Equipment and the material carried on it.
c)
Columns:
i)
ii)
d)
Bracing:
i)
ii)
e)
The slenderness ratio of the columns supporting

the vibrating screen should not be more than
80.
Place the columns as close as possible to the
spring pedestals of the vibrating unit.
The slenderness ratio should not be more

than 80.
All bays should be braced as completely
as possible.
Connections:
i)
ii)
All
connections
of
joists
and
channels
should be rigid.
Use end cleats, either on both flanges, or
on
the
web
and
on
one
flange.
Alternatively,
web
cleats,
and
flange
gussets can be used.
Rev. 0
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NMDC LIMITED
MECON
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PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
f)
of
Walkways, Platforms, etc.:

i)
g)
PAGE No. 31
Provide the necessary platforms, walkways and

adequate room for maintenance operations.
Horizontal Lattice bracings:

Adequate bracings should be provided between the
screen support beams and the beams supporting the
walkways or platforms.
2.7.2.11
The minimum thickness of structural steel elements shall be in

accordance with IS: 800-2007(refer relevant clause).
2.7.2.12
Intermittent welding shall not be permitted.
2.7.2.13
Angle sections shall not be used as flexural members except

for roof trusses, purlins, side runners.
2.7.2.14
For axial loaded members in framework, minimum angle

section to be used shall be ISA 50x50x6
2.7.2.15
End connections for rolled beams, built-up beams

etc. shall be designed for a minimum of 80 % of
their shear capacity inaddition to
any axial load for plate
girders and end
connection for other beams ( i.e. Rolled
sections) can be
designed for minimum of 60% of beam
shear capacity or actual shear forces whichever is more plus
axial force if any.
2.7.2.16
Moments shall be considered for design of columns arising due

to eccentricity of floor beams connections with column.
Minimum eccentricities on column shall be considered as per
IS: 800-2007.
2.7.2.17
For edge protection all round cutouts/openings in floor slabs,

minimum angle section ISA 65x65x6 and in the openings at
staircase supporting edge, a channel section same as depth of
slab shall be used.
2.7.2.18
Minimum thickness of chequered plate refer clause 2.6.4.06
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PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 32
of
2.7.2.19
Where floor beams form part of the vertical bracing system

additional loads from
floor beams transferred to bracing
shall be taken into consideration in the design.
2.7.3
Combination of loads
The various loads specified shall be combined in accordance
with clause 8.0 of IS: 875 (Part-5)-1987 to give the most
severe loading condition for design of structures.
2.7.4
Stress enhancements
Permissible limits of stress may be increased, wherever
permissible, in accordance with IS: 800-2007.
2.7.5
Limiting deflection
a)
The deflection shall be limited in various elements of

structures in accordance with clause 3.13 IS: 800-1984.
b)
In addition following limitation in deflection shall be

observed in design:(refer clause: 2.4.07)
i)
Conveyor Gallery Trusses/

bridge cross beams and beams
directly supporting conveyor
short posts
Top of End portal of gallery
truss
ii)
iii)
Transverse deflection of top of

supporting trestles
iv)
Frame of Transfer house towers
- Span/500
- H/1000
Where H = Height of
portal above beams
- H/1000
Where H = Height of
trestle above foundation
- Height of tower/1000
Rev. 0
84
NMDC LIMITED
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2.8
Submission of design calculations/design drawings for

steel structures
2.8.1
The following guidelines may be followed for submission of

design calculations for steel structures of relevant project:
a)
All design calculations shall be submitted on A4 size

sheets with proper page numbering and indexing. The
design drawings to which the calculations refer and the
assignment drawings on which the design is based must
be mentioned. The name of the project and the build /
sub-unit and the date shall also be mentioned.
b)
The
sheets
shall
be
signed
under
the
Designed/Reviewed/ Approved columns.
The date
and Rev Number shall be mentioned.
A table of
contents shall be included.
c)
The calculation sheets shall include a schedule of loads.

All loads considered in the design shall be listed and the
values indicated with proper units (kg, Tonne, kg/m,
etc.)
d)
The general design assumptions / design philosophy

adopted shall be indicated.
Material specifications,
properties, codes of practice followed, and software
packages used shall be listed.
e)
Where Frame analysis is adopted, a copy of the data file

and the output must be submitted on a floppy diskette
or emailed. Any other data / calculations etc. available
on electronic media may also be submitted on a floppy
diskette or submitted by e-mail.
This shall be in
addition to and not a substitute for printed or
handwritten matter. (Refer clause 2.8.3) Where Frame
analysis of a particular frame results in voluminous
printed output, discretion may be used and selected
relevant extracts of the output may be submitted in
printed form. However the full output shall be included
in electronic media.
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f)
Calculations shall preferably be printed using a

computer or typed. Handwritten calculations may also
be accepted if the handwriting is neat and legible. The
calculations shall be neatly filed or bound. Loose sheets
are not acceptable.
g)
The calculations shall be brief and to the point. No

details of various intermediate steps in routine
calculations are necessary. Summarized calculations in
tabular form are preferable to long, descriptive
calculations. The calculations shall be presented in such
a way that the consultant can easily and conveniently
verify them. The input and output shall be readily
available.
The expected input and output to be
presented in the calculations are mentioned below for
some typical designs.
h)
For members subjected to axial force and/ or Bending

Moment, the input shall consist of BM, Axial Force,
Effective Lengths about major and minor axes.
Unrestrained length of compression flange, section
dimensions. The output shall consist of Slenderness
ratios. Section properties, Bending and axial stresses,
(both allowable and actual) and the final interaction
ratio.
i)
For beam designs, the input shall consist of span, the

loads and the load positions, and the section adopted.
The output shall include the value of the Maximum
Bending Moment. Shear force, and mid span deflection
and the bending and shear stresses (both allowable and
actual) in tabular form.
j)
For crane girder designs, the input shall consist of the

relevant crane wheel load data, the spans, the number
of cranes considered, the trolley weight, the cross
section details of the crane girder, the brake platform,
the crane rail the auxiliary girder if any. The output
shall consist of Bending Moments, Shear forces, and all
relevant section properties and stresses (allowable and
actual) and the deflections.
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k)
All design calculations shall be supplemented by a

sketch / diagram wherever relevant. For frame analysis
a diagram of the frame with the joint and member
numbering is absolutely necessary.
l)
It is recommended that before proceeding with detailed

analysis and calculations, the basic inputs, loads and
assumptions be carefully compared with design criteria
specified, submitted, discussed and got approved.
The following guidelines may be followed for submission of

design drawings for steel structures of relevant project:
a)
Drawings showing layouts with structural systems

showing all equipment loads, cutouts, embedment etc.
based upon the approved mechanical GA drawings shall
be submitted by the Tenderer and these shall
accompany detailed calculations. Drawings and design
calculations submitted without prior approval of
relevant mechanical GA drawings will not be considered
for review.
b)
Design drawings (size not less than A1) (also Design

calculations in A4 size sheets) shall be submitted
sequentially in a phased manner and Tenderer shall
ensure that Design calculations/Drawings for several
structures are not submitted at one time. For this
purpose, Design/ Drawings submission schedule shall
be furnished by the Tenderer for Owner & Consultant s
review and approval. Owner & Consultant will review
and furnish comments/approval to the designs and
drawings. Timely submission of Designs/Drawings to
the Owner & Consultant for review/approval is the sole
responsibility of the Tenderer and postal or other delays
as reasons for late/non-submission will not be
entertained by the owner.
c)
Designs and Drawings submitted by the Tenderer shall

be thoroughly checked and approved by the authorized
Tenderer engineer. The Owner & Consultant will not
review any unchecked/unsigned documents. No claim
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from the Tenderer for extra cost on this account shall

be entertained by the owner under any circumstances.
d)
All the modifications/changes suggested by the Owner

&
Consultant
to
meet
specification
(technological/serviceability) requirements and sound
engineering practices shall be incorporated by the
Tenderer at no extra cost to the Owner. Owner &
Consultant will accord his approval only after the
Tenderer has incorporated in the Designs/Drawings all
modifications required by the Owner & Consultant.
e)
In case any requirement for the preparations of

separate drawings to show enlarged details to facilitate
construction/ erection, then such drawings shall also be
prepared by the Tenderer at no extra cost.
f)
Design Drawings shall indicate Structural arrangements,

member size, member forces, splice locations, details
base plate, anchor bolts, typical connection details etc.
so that the drawings indicate clearly all the necessary
information brought out in the relevant design
calculations. Proposed bracing patterns shall be subject
to approval by Owner & Consultant duly considering
system requirement point of view. Changes in structural
sections on approved drawings shall be got ratified with
necessary supporting calculations and reason for the
change.
g)
The design shall take into account the erection scheme

for various structures envisaged by the Tenderer and
resulting additional loadings, if any, shall be duly
accounted for, while designing. Before taking up actual
erection work. Detailed erection scheme proposed to be
followed by the Tenderer shall be submitted for
Engineers approval.
h)
Approval/Comments
conveyed
by
the
Owner
/consultant neither relieves the Tenderer of his
contractual obligations and his total responsibility for
correctness of dimensions, materials for constructions
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of
loadings, quantities, design details assembly fitments,

performance particulars, safety and stability of the
structures including foundations/appurtenances and
conformity of supplies with the statutory laws as may
be applicable, nor does it limit the Owners right under
this
contract.
No
change
in
the
approved
designs/drawings shall be permitted without prior
written approval of the Owner & Consultant.
2.8.3
Ten copies of drawings and design calculation shall be

submitted for scrutiny and approval. One set of the design
drawing will be returned to the Tenderer with a stamp
signifying Approved or Not approved on the drawing. After
final approval by the Owner & Consultant the Tenderer shall
submit the fabrication drawing (5 no. of sets or as required by
the Owner & Consultant ) for information only.
2.8.4
Soon after the fabrication of steel work pertaining to a

particular drawing is completed, immediate steps shall be
taken by Tenderer to incorporate in the relevant fabrication
drawings, all the authorized corrections, additions and
alterations made during the course of fabrications and 2 sets
or as required by the Owner & Consultant of the same shall be
submitted to Owner & Consultant for his record.
2.8.5
Notes on specifications shown on design drawings shall be

considered as superseding or overriding the specifications
given elsewhere, with which they conflict. On all drawings,
dimensions shown in figures shall be acted upon.
2.8.6
a)
On completion of the work all working drawings (Design

/ Fabrication drawings) shall be updated by
incorporating
the
as
built
corrections,
changes/modifications carried out during execution of
the project along with revised bill of quantities and
summary wise steel etc.
b)
Five hard copies each and two soft copies each of

updated AS BUILT drawings for both DESIGN Drgs.
and FABRICATION Drgs. shall be submitted.
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2.8.7
Supply and distribution of fabrication drawings and other

documents like bolt list, etc. for the Tenderer's own use or for
the use of his Sub-Contractors shall be the responsibility of
the Tenderer
2.8.8
The Tenderer shall ensure that fabrication / erection drawings

are prepared based on approved design drawings. The
fabrication work shall be taken up as per fabrication drawings,
which are made conforming to relevant design drawings.
3.0
3.1
Fabrication of steel structures

Scope of work
The scope of work under fabrication includes, but not limited
to, the following:
a)
Preparation and supply of material indents, bolt lists

bought out items list.
b)
Procurement and collection of all steel materials from

Stockyards/stores, including loading, transportation,
unloading and stacking and storing on skids or
supports.
c)
Procurement and collection of all consumables like bolts

nuts, washers, electrodes, paints, shims, packs, etc.,
including allowance for spares and wastage.
d)
Preparation (using AUTO CAD) of fabrication drawings,

using
relevant
design
drawings,
modification
/rectification sketches, as made drawings, erection
drawings, bill of materials, bolts lists and shipping
documents for Owner & Consultant.
e)
Preparation of design calculations for non-standard

connections, temporary bracings, etc, for approval of
Owner & Consultant.
f)
Cold straightening of section and plates, whenever they

are bent and kinked
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g)
Fabrication of all steel structural components covered

under tender drawings, design drawings and generally
described under the scope of the project.
h)
Making arrangements for and conducting tests, such as

chemical analysis, physical and mechanical tests on raw
materials where specified/as directed by the Owner &
Consultant.
i)
Making arrangements for providing all facilities for

conducting ultrasonic, Radio Graphic (X-ray or gamma
ray) tests of all important butt weld joints; getting the
tests conducted by reputed testing laboratories making
available test films / graphs, reports and interpretation.
j)
Control Assembly of steel structural components at

shop, wherever required.
k)
Preparation of steel structural surfaces for painting as

provided in the specifications / drawings.
l)
Application for one primer coat of painting at shop, as

specified in the design drawing/specifications.
m)
Loading, transportation from fabrication workshop to

site of erection and unloading of all steel structural
components / units / assemblies.
n)
Preparation of "As-built" drawing (Using AUTOCAD).
3.2
Preparation of Fabrication and Erection drawings
3.2.1
Fabrication drawings (using AUTOCAD) shall be prepared

based on design drawings of steel structures.
3.2.2
Drawing shall be prepared in metric system as per IS:

696-1972 and IS: 813-1986. The fabrication drawings shall
specify the following details:
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a)
Type, size and length of welds in case of welded

connections, (specifying clearly shop or site weld).
Length of weld specified shall be effective length
(excluding end crates).
b)
In case of bolted joints, arrangement of bolts and

specification of bolts, nuts etc. (specifying clearly shop
and site bolts).
c)
Specification of electrode/wire flux.
d)
If required special provision to be mentioned in the

drawings for handling of structures during and after
fabrication.
e)
Specification of paint
preparation for painting.
f)
General arrangement / marking plan.
g)
Reference to design drawings.
h)
Layout with all connecting members with blown up joint

details wherever required, in order to specify clearly
various fabrication and erection requirements as per
design drawings.
j)
Appropriate edge preparation in case of butt/groove

welds in accordance with IS: 9595-1996, for all plates
and sections having thickness greater than 8 mm.
k)
Erection clearances in order to facilitate smooth

erection at site (Ref relevant clause .of IS: 800- 2007).
l)
Each erection piece shall be clearly identified by an

erection mark in these drawings. All loose members
shall be given part mark, which shall be 'wired on' the
main erection piece for dispatch.
m)
Material list indicating mark number-wise material

requirement giving size, weight, material specification,
and
corresponding
surface
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identification number of each items, number of pieces

required etc.
n)
Also summary list indicating section-wise requirement

of raw steel as well as requirement of permanent /
erection bolts, nuts including washers shall be indicated
in each of the fabrication drawings.
o)
On completion of the work all working drawings

(Fabrication
drawings)
shall
be
updated
by
incorporating
the
as
built
corrections,
changes/modifications carried out during execution of
the project along with revised bill of quantities and
summary wise steel etc. Preparation of As-built
drawing (Using AUTO CAD) refers relevant clause.
3.2.3
Fabrication drawings shall be prepared in such a manner that

Structures can be dispatched from fabrication shop to erection
site with maximum economic transportable size, so as to
reduce work involved at site to a minimum.
3.2.4
Bracings shall be connected for 50% of the capacity of the

member or the force specified in the design drawing,
whichever is more (for single angle bracing member, consider
full area as effective for this purpose).
3.2.5
Standard simple beam connections, unless otherwise stated in

the drawings, shall be designed and detailed for 60% beam
shear / moment carrying capacity.
3.2.6
Wherever there is risk of nuts becoming loose due to

vibration, spring washers and lock nuts shall be provided, or
nuts shall be welded after alignment and tightening.
3.2.7
For all connections by permanent bolts, two nos. of washers

shall be used. One washer bearing against the head and the
other bearing against the nut.
3.2.8
Detailing of structural steel members subject to dynamic

loading shall be such as to ensure smooth transition of load,
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as well as best behavior under stress due to fatigue. Welding

across tension flange of crane girders is not permitted.
3.2.9
For detailing connection, the allowable stress for materials,

welds, bolts etc, shall be as per IS: 800- 2007 and IS:
816-1969, or as specified in the drawing.
3.2.10
The Tenderer shall be responsible for design and detailing all

connections. The design of connection shall provide adequate
strength for transfer of force in the structural elements, as
indicated on design drawings. Detailing shall be such that
erection shall be convenient and free from all interfaces,
drilling and cutting at site.
3.2.11
Both Precoated Galvalume Corrugated/troughed Steel Sheets

& F.R.P. Sheeting drawings for all buildings/ units indicating
layout/ arrangement of sheets & flashing sizes, numbers,
fixing details & material requirement etc. shall be prepared
and submitted for approval.
3.3
Materials
3.3.1
Structural Steel
3.3.1.1
Structural steel and other related materials for construction

shall conform to Annexure - E.
3.3.1.2
Due to non-availability of specified materials, suitable

substitutions may be provided with the consent of the Owner
& Consultant. Such substitution shall be incorporated in the
"As-built" drawings.
3.3.1.3
All the items are to be cut as per requirements of the drawing.

If joints are to be provided in any item, in order to meet
requirements of size and shape, cutting plan showing locations
of joints shall be prepared for consideration of Owner &
Consultant Joints provided shall be incorporated in "As-built"
drawings.
3.3.1.4
Rolling and cutting tolerances shall be as per IS: 1852:1985.
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Only tested materials shall be used unless use of untested

materials for certain secondary structural members is
permitted by Owner & Consultant. If test certificate for the
material is not available from the main producer, the following
tests shall be carried out at the discretion of the Owner &
Consultant:
a)
b)
c)
3.3.1.6
VOLUME - V of V
Chemical Composition
Mechanical Properties
Weldability test
Where steel castings are to be used the same shall conform to

IS: 1030:1998.
3.3.2
Bolts and Nuts
3.3.2.1
Black hexagonal bolts, nuts and lock-nuts shall conform to IS:

1363:2002.
3.3.2.2
Precision and semi-precision hexagonal bolts, screws, nuts

and lock-nuts shall conform to IS: 1364 (Part-1, 2,3,5,6,):
2002,IS: 1364(Part-4)-2003.
3.3.3
Electrodes
3.3.3.1
Mild steel electrodes and high tensile steel electrodes shall

conform to IS: 814:2004. Electrode to be used for submerged
arc welding shall conform to specification IS: 7280:1974.
3.4
Storing of Materials
3.4.1
Materials shall be stored and stacked properly ensuring that

place is properly drained and is free from dirt. It shall be
ensured that no damage is caused due to improper stacking.
3.5
Material preparation
3.5.1
Cut edges shall be finished smooth by grinding or machining

wherever necessary. Sufficient allowance (3 mm to 5 mm)
should be kept in the items incase machining is necessary.
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3.5.2
Cutting may be affected by gas cutting, shearing, cropping or

sawing. In gas cutting of high tensile steel, special care is to
be taken to leave sufficient metal to be removed by machining
so that all metal that has been hardened by flame is removed.
3.5.3
Sufficient shrinkage allowance (@ 1mm/M) shall be kept

wherever heavy welding is involved.
3.5.4
Straightening and bending shall be done in cold condition as

far as practicable.
3.5.5
If required, straightening and bending may be done by

application of heat between 900C and 1100C. Cooling down
of the heated item shall be done slowly.
3.6
Drilling and Punching of holes
3.6.1
Drilling and punching of holes for bolts shall be done as per

relevant clause of IS: 800:2007, unless otherwise specified by
the Owner & Consultant.
3.6.2
Drilling of holes for bolts during assembly shall not cause

enlargement of holes beyond permissible limit or damage the
metal.
3.6.3
Holes for bolted connection should match well to permit easy

entry of bolts. Gross mismatch of holes shall be avoided.
3.6.4
Permissible deviation in holes for mild steel bolts of normal

accuracy and high strength bolts are given in the
ANNEXURE-A.
3.7
Assembly for fabrication
3.7.1
Fabrication of all structural steelwork shall be in accordance

with IS: 800-2007 and in conformity with various clauses of
this specification, unless otherwise specified in the drawings.
3.7.2
Fabrication of structures shall preferably be taken up as per

the sequence of erection.
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3.7.3
All erection units shall bear erection mark no. and reference
drawing number at a prominent location on the structures for
easy identification at site.
3.7.4
Fabricated structures shall conform to tolerance as specified

in this standard and in IS: 7215-1974. In case of
contradiction, tolerances specified in this standard shall
prevail.
3.7.5
All the components of structures shall be free from twist,

bend, damage etc,
3.7.6
Assembly of structures shall be carried out by using suitable

jigs and fixtures in order to obviate distortion during welding.
3.7.7
Cutting of items especially for truss, bracing, bunker, hopper,

galleries surge girder, portal etc, shall be done only after
checking of sizes as per Layout.
3.7.8
Surface, wherever machining is specified, shall be either

planed or milled or ground to ensure maximum contact.
3.7.9
If end-milling or machining is planned after the assembly is

over, sufficient allowance (5 mm to 15 mm) shall be kept in
the items where milling/machining is to be done.
3.7.10
If pre-bending of the plate is required to avoid welding

distortion, it shall be done in cold condition.
3.7.11
If extra joints are required to be provided in column, crane

girder etc, approval should be obtained from the Owner &
Consultant. However, as general guidance following is
suggested. Splice joints of column and crane girder shall be of
full strength butt weld and wherever possible shall be located
at zones of minimum or substantially lesser stress.
3.7.12
Splice joints
staggered.
of
flange
and
web
should
preferably
be
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3.7.13
Sufficient trial assembly of fabricated components (despatch

elements) shall be carried out in the fabrication works to
control the accuracy of workmanship.
3.7.14
Where necessary, washers shall be tapered or otherwise

suitably shaped to give the heads of nuts and bolts
satisfactory bearing.
3.7.15
The threaded portion of each bolt shall project through the nut
at least by one thread.
3.7.16
Tolerance of assembled components of structures are given in

Annexure-B.
3.7.17
Permissible deviations from designed (true) geometrical form

of the dispatch elements shall be in accordance with IS:
7215-1974.
3.8
Welding
3.8.1
The Tenderer shall work out welding procedure for Owner &
Consultant approval, considering the following factors:
a)
Specification and thickness of steel.
b)
Specification of electrode or/and base wire.
c)
Welding process (manual arc welding, submerged arc

welding).
d)
Type of structures to be welded

components meeting at a joint).
e)
Pre and post heating requirement.
f)
Preparation of fusion faces.
g)
Sequence of welding.
h)
Weather condition.
(thickness
of
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i)
Use of jigs and fixtures etc.
j)
Type of non-destructive testing to be carried out.
k)
Inspection procedure to be followed
l)
Design requirements of the joints.
of
3.8.2
Welding of any load bearing structure shall be carried out only

by the person who has passed welder's qualification as per IS:
7318 (Part-I)-1974.
3.8.3
All metal arc welding shall be carried out as per IS:

9595-1996.
3.8.4
Submerged arc welding of mild steel and low alloy steel shall
be as per IS: 4353-1995.
3.8.5
Electrode shall conform to relevant clause of this structural

specification.
3.8.6
Electrodes shall be stored in a dry place. Electrodes whose

coatings are damaged due to absorption of moisture or due to
any other reason shall not be used.
3.8.7
Low Hydrogen electrodes and flux for submerged welding shall

be dried at 250-300 C for one hour in drying even before
use.
3.8.8
For suitability of wire flux combination, procedure test shall be

carried out as per IS: 3613-1974 if so required.
3.8.9
Welding shall be done by electric arc process. Generally

submerged arc, automatic & Semi-automatic welding shall be
employed. Only where it is not practicable, manual arc welding
may be resorted to. In case of manual arc welding,
recommendations of electrode manufacturer are to be strictly
followed.
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3.8.10
Welding surface shall be smooth, uniform, free from fins, tears

notches or any other defect, which may adversely affect
welding.
3.8.11
For multi-run weld deposit, the next run should be done only
after thorough removal of slag and proper cleaning of surface.
3.8.12
Fillet weld shall have the correct profile with smooth transition
into parent metal. Dressing of welds, if specified, shall be done
by such method, which does not cause grooving and other
surface defects on the weld or on the parent metal.
3.8.13
All butt welds shall start and end with run-on and run- off
plates. All such plates shall be carefully trimmed off by gas
cutting after welding is over.
3.8.14
Fillet welds shall not be stopped at corners but shall be

returned round them.
3.8.15
If butt weld is to be ground flush with the surface of the

member as per drawing adequate reinforcement shall be built
up and then the same shall be chipped off and ground flush.
The grinding is to be done in the direction of stress flow till the
transverse marks are eliminated.
3.8.16
Welding shall not be done under such weather conditions,

which might adversely affect the efficiency of the welding.
3.8.17
Manipulators shall be used wherever necessary and shall be

designed to facilitate welding and ensure that all welds are
easily accessible to the operators.
3.8.18
Stress relieving after welding shall be done if especially called

for in the drawing or specification. Ends of structural members
and portions of gussets receiving welding at site, shall be left
unpainted.
3.8.19
Permissible deviation in assembly of weld joints shall be in

accordance with Annexure-C.
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3.9
Inspection & Testing
3.9.1
The Owner & Consultant shall have free access at all times to
those parts of parts of Tenderer's or his Sub-Contractor's
works which are concerned with the fabrication of steel works
and shall be afforded all reasonable facilities at all stages of
preparation, fabrication and trial assemblies for satisfying
himself that the fabrication is being undertaken in accordance
with the provisions of relevant specification.
3.9.2
All gauges and templates, tools, apparatus, labour and

assistance for checking shall be supplied by the Tenderer free
of charge. The Owner & Consultant may at his discretion,
check the test results obtained at the Tenderer's works, by
independent test at the Government Test House or elsewhere,
and should the material so tested be found to be
unsatisfactory, the cost of such test shall be borne by the
Tenderer.
3.9.3
Tenderer shall make all necessary arrangements for stage

inspection by Owner & Consultant during the fabrication at
shop and incorporate all on-the-spot instructions / changes
conveyed in writing to the Tenderer.
3.9.4
Material improperly detailed or wrongly fabricated shall be

reported to the Owner & Consultant and shall be made good
as directed. Minor misfits which can be remedied by moderate
use of drift pins, and moderate amount of reaming and slight
chipping may be corrected in that manner, if in the opinion of
the Owner & Consultant the strength or appearance of the
structure will not be adversely affected. In the event the
Owner & Consultant directs otherwise, the items will be
rejected and a completely new piece shall be fabricated. The
cost of correcting errors shall be to the account of the
Tenderer.
3.9.5
The Owners/Consultants shall have the power:

a)
To certify, before any structure is submitted for

inspection, that the same is not in accordance with the
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of
contract, owing to the adoption of any unsatisfactory

method of fabrication.
b)
To reject any structure as not being in accordance with

specifications and drawings.
c)
To insist that no structure or parts of the structure once

rejected is resubmitted for inspection/test, except in
cases where the Owner & Consultant authorized
representative considers the defects as rectifiable.
d)
To insist that at any structure or parts of the structure

already
Fabricated
/
Inspected
as
per
drawings/specification, to be changed / re-fabricated to
suit technological/serviceability requirements.
e)
If, on rejection of structure by the Owner & Consultant

the Tenderer fails to make satisfactory progress within
the stipulated period, the Owner & Consultant shall be
at liberty to cancel the contract and fabricate or
authorize the fabrication of the structures at any other
place he chooses, at the risk and cost of the Tenderer,
without prejudice to any action being taken in addition
to terms of General Conditions of Contract.
f)
The Owner & Consultant 's decision regarding rejection

shall be final and binding on the Tenderer.
g)
The specifications prescribe various tests at specified

intervals for ascertaining the quality of the work done.
If the tests prove unsatisfactory, Owner & Consultant
shall have liberty to order the Tenderer to re-do the
work, done in that period and/ or to order such
alterations and strengthening that may be necessary at
the cost of the Tenderer and the Tenderer shall be
bound to carryout such orders failing which the
rectification/redoing will be done by the Owner &
Consultant through other agencies and the cost
recovered from the Tenderer.
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h)
Notwithstanding any inspection at the workshop the

Owner & Consultant shall have the liberty to reject,
without being liable for compensation any fabricated
members or materials brought to site that do not
conform to specifications.
i)
All rejected materials shall be removed from the site of

fabrication by the Tenderer at his own cost and within
the time stipulated by the Owner & Consultant.
3.10
Control in Welding
3.10.1
The extent of quality control in respect of welds for structural

elements for both statically and dynamically loaded structures
shall be as follows and shall be conducted by the Tenderer at
his own cost: -
3.10.1.1
Visual Examination - All welds shall be 100% visually

inspected to check the following:
a)
Presence of undercuts
b)
Visually identifiable surface cracks in both welds and

base metals.
c)
Unfilled craters
d)
Improper weld profile and size
e)
Excessive reinforcement in weld
f)
Surface porosity
Before inspection, the surface of weld metal shall be cleaned

of all slag, spatter matter, scales etc. by using wire brush or
chisel.
3.10.1.2
Dye Penetration Test (DPT) - This shall be carried out for all
important fillet welds and groove welds for both statically and
dynamically loaded structures to check the following:
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a)
Surface cracks
b)
Surface porosities
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of
Dye Penetration Test shall be carried out in accordance with

American National Standard ASTM E165.
3.10.1.3
Ultrasonic testing
Ultrasonic test shall be conducted, unless otherwise
mentioned, for all groove welds and heat affected zone in
dynamically loaded structures and for other important load
bearing butt welds in statically loaded structures as desired by
Owner & Consultant , to detect the following:
a)
Cracks
b)
Lack of fusion
c)
Slag inclusions
d)
Gas porosity
Ultrasonic testing shall be carried out in accordance with

American National Standard ANSI/AWS D1.1-96 Chapter -6:
Part F.
Before ultrasonic test is carried out, any surface irregularity
like undercuts, sharp ridges etc. shall be rectified. Material
surface to be used for scanning by probes must allow free
movement of probes. For this purpose, surface shall be
prepared to make it suitable for carrying out ultrasonic
examination.
3.10.1.4
Radiographic Testing
(X-ray or Gamma-Ray Examination): - This test shall be a
minimum 2% of length of welds covering each element of
each joint (eg: A built up beam consists of three elements) for
welds made by manual or semi- automatic welding and 1 % of
length of weld covering each element of each joint (eg: A built
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of
up beam consists of three elements) if made by automatic

welding machines. The location and extent of weld to be
tested by this method shall be decided by Owner & Consultant
to detect the following defects: a)
b)
c)
d)
e)
Gas porosity
Slag inclusions
Lack of penetration
Lack of fusion
Cracks
Radiographic testing shall be conducted in accordance with

American National Standard ANSI/AWS D1.1-96 Part E.
Any surface irregularity like undercuts, craters, pits etc. shall
be removed before conducting radiographic test. The length of
weld to be tested shall not be more than 0.75 x focal distance.
The width of the radiographic film shall be width of the welded
joint plus 20 mm on either side of the weld.
3.11
Acceptable limits of defects in weld
3.11.1
Limits of Acceptability of welding defects shall be as follows:

a)
Visual inspection & Dye Penetration Test - The limits of

acceptability of defects detected during visual
inspection and Dye Penetration Test shall be in
accordance with clauses 6.9 & clause 6.10 of American
National Standard ANSI/AWS D1.1-96 for statically as
well as dynamically loaded structures respectively.
b)
Ultrasonic Testing
- The limits of acceptability of
defects detected during ultrasonic testing shall be in
accordance with clause 6.13.1
& clause 6.13.2 of
American National Standard ANSI/AWS D1.1-96
Chapter 6: Part C for statically and dynamically loaded
structures respectively.
c)
Radiographic testing - The limits of acceptability of

defects detected during Radiographic testing shall be in
accordance with clauses 6.12.1 & 6.12.2 of American
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National Standard ANSI/AWS D1.1-96 Chapter 6: Part

C for statically and dynamically loaded structures
respectively.
3.12
Rectification of defects in welds
3.12.1
In case of detection of defects in welds, the rectification of the

same shall be done as follows:
a)
All craters in the weld and breaks in the weld run shall
be thoroughly filled with weld.
b)
Undercuts, beyond acceptable limits, shall be repaired

with dressing so as to provide smooth transition of weld
to parent metal.
c)
Welds with cracks and also welds with incomplete

penetration, porosity, slag inclusion etc. exceeding
permissible limits shall be rectified by removing the
length of weld at the location of such defects plus 10
mm from both ends of defective weld, and shall be
re-welded. Defective weld shall be removed by
chipping hammer, gouging torch or grinding wheel.
Care shall be taken not to damage the adjacent
material.
3.13
Acceptance criteria of machining surface
3.13.1
Standard of acceptance for machined surfaces, wherever

specified by designer, (e. g. In column cap plates, base plates
and column shafts etc.) shall be as per clause 3.13.2 &
3.13.3.
3.13.2
Maximum surface unevenness on bearing surface of cap/ base

plate shall not exceed 0.5 mm.
3.13.3
When assembled, there must be physical contact for atleast

75% of the contact surface. (The checking shall be carried out
with 0.2mm gauge. Care should be taken that these
connecting members are fixed with such accuracy that they
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of
are not reduced in thickness during machining by more than

1.0 mm.
3.14
Despatch Instructions
3.14.1
Each despatchable structure shall bear mark no. along with

reference drawing number at two prominent locations (e.g. on
flange and bottom of base plate of a column).
3.14.2
"As built" drawing shall be prepared (using AUTOCAD) after

fabrication is completed to indicate additions / alterations
made during the process of fabrication. Refer relevant clause.
3.14.3
Control assembly of important structures shall be done in the

shop floor before despatch to avoid mismatching. For all such
important structures, match marking shall be given at the
control assembly stage in the shop floor and such match
markings shall be made clearly visible while assembling the
structures at site.
3.14.4
Centre lines of column flanges and both sides of web shall be

punched, preferably at top and bottom to facilitate alignment
after erection.
3.15
Completion documents
On completion of work, the Tenderer shall submit to the
Owner & Consultant the following documents: a)
The technical documents according to which the work

was carried out.
b)
Copies of the "As built" drawings showing thereon all

additions and alterations made during the fabrication.
(Refer relevant clause )
c)
Manufacturer's test certificates
d)
Certificates/documents on control checking
e)
Test of welds
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3.15.2
Inspection certificates shall be issued to the Tenderer for the

structures found acceptable in all respects by the Owner &
Consultant.
3.16
In addition to provision of erection and transport equipments,

the scope of work includes supply of tools and tackles,
consumables, materials, labour and supervision and shall
cover the following:
a)
Storing and stacking of all fabricated structural

components/units/assemblies at site storage yards till
the time of erection.
b)
Transportation of structures from storage yard to site of

erection, including multiple handling, if required.
c)
All minor rectification / modifications not limited to such

as:
i)
Removal of bends, kinks, twists etc. for parts

damaged during transportation and handling.
ii)
Reaming of holes which do not register or which

are damaged, for use of next higher size bolt.
iii)
Plug-welding and re-drilling of holes which do

not register and which cannot be reamed for use
of next higher size bolt.
iv)
Drilling of holes, which are either not, drilled at

all or are drilled in incorrect position during
fabrication.
d)
Fabrication of minor missing items as directed by the

Owner & Consultant.
e)
Verification of the position of embedded anchor bolts

and inserts w.r.t. line find levels, installed by others
based on Geodetic Scheme / Bench mark / Reference
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co -ordinates
Consultant .
to
be
furnished
by
the
Owner
of
&
f)
Assembly at site of steel Structural components

wherever required, including temporary supports and
staging.
g)
Making arrangements for providing all facilities for

i)
Conducting ultrasonic, Radiographic (x-ray or

gamma
ray)
tests
by
reputed
testing
laboratories
ii)
Making available test films / graphs, with reports

/ interpretation.
h)
Rectifying at site-damaged portions of shop primer by

cleaning and application of touch-up paint.
i)
Erection of structures including making connections by

bolts /welding as per drawing.
j)
Alignment of all structures true to line, level plumb and

dimensions within specified limits of tolerance.
k)
Application at site after erection, required number of

coats of primer and finishing paint as per specification
and drawing.
l)
Rectification of structures as per Preliminary acceptance

report and Final acceptance report.
3.17
Storing and Handling
3.17.1
Storage of structures shall be preferably be done in such a

manner that erection sequence is not affected.
3.17.2
While storing, care shall be taken so that structures do not

come in direct contact with the earth surface and accumulated
water. Girders, beams, columns shall be placed and stored in
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of
such a manner that during rain, no accumulation of water on

the structures takes place.
3.17.3
Stacking of the structures shall be done in such a way that,

erection marks are visible easily and handling does not
become difficult. Wherever required, wooden sleepers / grilles
may be used.
3.17.4
Handling and storage of materials shall be as per IS:

7969-1975, to ensure safety.
4.0
ERECTION OF STEEL STRUCTURE
4.1
General
4.1.1
Erection shall be carried out in accordance with IS: 800:2007

and other relevant standards referred to therein.
4.1.2
For safe and accurate erection of structural steelwork, staging,

temporary support, false-work etc. shall be erected as
required.
4.1.3
The fabricated materials received at erection site shall be

verified with respect of marking on the key plan/marking plan
or shipping list.
4.1.4
Any material found damaged or defective shall be stacked

separately and the damaged or defective portions shall be
painted in distinct colour for identification and the same shall
be brought to the notice of the Owner & Consultant .
4.2
Erection drawings
4.2.1
The erection drawings shall be inline with design drawings

corresponding fabrication drawing.
4.3
Erection of structures
4.3.1
Erection work shall be taken up after receipt of clearance from

the Owner & Consultant.
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4.3.2
For safety requirements during erection, provisions in IS:

7205:1974, IS: 7969:1975 and other relevant Indian
standards shall be followed.
4.3.3
Erection shall be carried out with the help of maximum

mechanization possible.
4.3.4
Prior to commencement of erection, all the erection

equipment, tools, tackles, ropes etc. shall be tested for their
load carrying capacity. Such tests may be repeated at
intermediate stages also if considered necessary and frequent
visual inspection shall be done of all vulnerable areas and
components to detect damages or distress in the erection
equipment, if any.
4.3.5
Following shall be taken care of during erection, whenever

necessary: -
4.3.5.1
Temporary bracing, whenever required, shall be provided to

sustain forces due to erection loads and equipment etc.
Erected parts of the structures shall remain stable during all
stages of erection when subjected to the action of wind, dead
weight and erection forces etc. Specified sequence of erection
of vertical and horizontal structural members shall be
followed.
4.3.5.2
Erected members shall be held securely in place by bolts to

take care of dead load, wind load and erection load.
4.3.5.3
All connections shall achieve free expansion and contraction of

structures wherever provided.
4.3.5.4
No final bolting or welding of joints shall be done until the

structure has been properly aligned.
4.3.5.5
For positioning beams, columns and other steel members, the

use of steel sledges is not permitted.
4.3.5.6
Instrumental checking of correctness of initial setting out of

structures and adjustment of alignment shall be carried out in
sequence and at different stages as required. The final leveling
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and alignment shall be carried out
completion of each section of a building.
VOLUME - V of V
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immediately
of
after
4.3.5.7
All structural members shall be erected with erection marks in

the same relative position as shown in the appropriate
erection and shop drawings.
4.3.5.8
After ensuring the correctness of all the requirements with

respect to equipment on verification with relevant structural
and equipment drawings the welding of the beams is to be
completed in all respects.
4.3.5.9
The schemes showing the above arrangements of beams

along with details shall be prepared and furnished for their
acceptance by the equipment personnel.
4.3.5.10
The Tenderer shall design, manufacture, erect and provide

false work, staging temporary support etc. required for safe
and accurate erection of structural steelwork and shall be fully
responsible for the adequacy of the same.
4.3.5.11
The Tenderer shall also provide facilities such as adequate

temporary access ladders, gangways, tools & tackles,
instruments etc., to Owner & Consultant for his inspection at
any stage during erection.
4.3.5.12
Ends of built-up box sections, pipes shall be sealed with plates

welded at ends.
4.3.5.13
Chequered plate platforms exposed to weather shall have 25

mm dia. Holes drilled at about 1000 mm c/c to drain of water.
4.3.5.14
Drain holes are to be provided in traverse plates of column

bases, wherever required to avoid collection of rainwater.
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4.4
Field connections
4.4.1
Assembly by permanent bolts
4.4.1.1
The numbers of washers on permanent bolts shall not be more

than two (and not less than one) for the nuts and one for the
bolt head.
4.4.1.2
Wooden rams or mallet shall be used in forcing members into

position in order to protect the metal from injury or shock.
4.4.1.3
Where bolting is specified on the drawing, the bolts shall be

tightened to the maximum limit. The threaded portion of the
each bolt shall be projected through the nut by at-least one
thread. Tapered washers shall be provided for all heads and
nuts to achieve uniform bearing on sloping surface.
4.4.1.4
To prevent loosening of nuts, spring washers or lock- nuts

shall be provided as specified in the design/fabrication (shop)
drawings.
4.4.1.5
All machine-fitted bolts shall be perfectly tight and the ends

shall be checked to prevent nuts from becoming loose. No
unfilled holes shall be left in any part of the structures.
4.4.1.6
a)
Main
structural
elements
shall
be
welded
continuously. Intermittent welding shall be used only
on secondary members which are not exposed
to
weather or other corrosive influence.
b)
Field connection and splices shall be made
as follows:
i)
By welding
ii)
By permanent bolts (for secondary members such as

purlins, wall runners
etc.)
iii) Shop splices shall not be placed less than 6

metres. Not more than one splice shall be permitted
per member. splices / locations
/their
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schemes, shall be
Owner/Consultant.
subject
to
Approval
of
by
4.4.2
Assembly by welding
4.4.2.1
All field assembly by welding shall be executed in accordance

with the requirements for shop fabrication. Where the steel
has been delivered painted, the paint shall be removed before
field welding for a distance of at least 50 mm on either side of
the joints to be welded.
4.4.2.2
All other requirements in welding shall be in accordance with

clauses specified elsewhere in this specification.
4.5
Acceptance Standard of Welding
4.5.1
Acceptance standard of welding shall be as elsewhere in this

specification.
4.6
Bedding And Grouting
4.6.1
Base plates shall be set to elevations shown on the drawings,

supported aligned and leveled using steel wedges and shims
or by other approved methods. Plates shall be leveled
properly, positioned and the anchor bolts tightened.
4.6.2
Bedding/grouting shall be carried out until sufficient number of

columns have been properly aligned, leveled and plumbed and
sufficient number of girders, beams, trusses and bracings has
been put in position to the satisfaction of Owner & Consultant.
4.7
Painting of Steel Structures
4.7.1
Surface Preparation for Painting
4.7.1.1
General
The steel surface which is to be prepared shall be cleaned of
dirt and grease and the heavier layers of rust shall be
removed by grinding prior to Actual surface preparation to a
specified grade.
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of
Surface preparation to be followed prior to painting shall be

based on the requirement of a particular painting system
specified. One of the following specifications for surface
preparation is to be followed as per requirement.
4.7.2
Mechanical Cleaning
4.7.2.1
Manual/power tool cleaning.

Manual/power tool cleaning shall be done as per grade St-2 or
St-3, of Swedish Standard Institution SIS 055900.
a)
Grade St-2: Thorough scraping and wire brushing,

machine brushing, grinding etc. This grade of
preparation shall remove loose mill scale, rust and
foreign matter. Finally the surface is to be cleaned with
a vacuum cleaner or with clean compressed air or with
clean brush. After preparation, the surface should have
a faint metallic sheen. The appearance shall correspond
to the prints designated St-2.
b)
Grade St-3: very thorough scraping and wire brushing,

machine
brushing,
grinding
etc.
The
surface
preparation is same as for grade St-2 but to be done
much more thoroughly. After preparing the surface, It
should have a pronounced metallic sheen and
correspond to the prints designated St-3.
4.7.3
Blast Cleaning
4.7.3.1
Blast cleaning shall be done by sand blasting or shot blasting

as per following grades according to Swedish Standard SIS
055900.
a)
Grade Sa-2 .This involves light blast cleaning. Almost

all mill scale, rust and foreign matter shall be removed.
Finally the surface is cleaned with a vacuum cleaner,
clean dry compressed air or a clean brush. The surface
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shall look greyish in colour and correspond

appearance to the prints designated as Sa-2.
4.7.3.2
of
in
b)
Grade Sa 2
: This involves very thorough blast
cleaning. Mill scale, rust and foreign matter shall be
removed to the extent that the only traces remain in
the form of slight stains. Finally the surface is cleaned
with a vacuum cleaner, clean dry compressed air or a
clean brush. It shall then correspond in appearance to
the prints designated as Sa 2.
c)
Grade Sa-3: This involves blast cleaning to pure metal

surface. Mill scale, rust and foreign matter shall be
removed completely. Finally the surface is cleaned with
a vacuum cleaner, clean dry compressed air or a clean
brush. Then the surface shall have a uniform metallic
colour and correspond in appearance to the print
designated as Sa-3.
Sand Blasting
a)
The sand used for sand blasting shall contain not less
than 94% SIO2. Dried sand with moisture content not
exceeding 2% shall be used. Sand shall be sharp clean
and free from clay and other deleterious materials.
(Grain size 0.6mm-2mm) After sand blasting the
surfaces shall have appearance as mentioned in the
grade of surface preparation.
b)
Sand blasting shall be done with the help of

compressed air at a gauge pressure of approx 3
kg/cm2. The blasting nozzle shall be held not more than
20 to 30 cm from the surface being cleaned and the
angle between the nozzle and the surface shall be
around 75.
c)
The compressed air to be used for sand blasting shall

be clean of all traces of oil and water by passing it
through an oil and water separator. To check
that the
air blast is free of oil and water, its stream shall be
directed towards a sheet of white filter paper, which
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of
should not develop any spot of oil or water

after a period of minimum 30 seconds. This check on
the satisfactory working of oil and water separator must
be carried out before start of every shift.
4.7.3.3
Shot Blast Cleaning

In this process, abrasive particles are directed at high velocity
against the metal surface through compressed air or highpressure water thrown by centrifugal force from an impeller
wheel. The abrasives used are chilled iron grit, cut steel wire,
copper/iron slag etc. The procedure of shot blasting shall
be as per relevant Indian Standards.
4.7.3.4
Flame cleaning
Flame cleaning shall also be carried out with the help of a
special oxy-acetylene torch and the loosened mill scale shall
be removed with a wire brush. This process is not
recommended for cleaning steel sheet or plates less than 6
mm in thickness as it may lead to buckling .The number of
flame passes on such surface shall be limited to three. The
primer coat of paint shall be applied when the surface is still
warm, after removing the scales with brushing and wiping.
If no grade of surface preparation is specified, Grade St-2 as
specified in clause 4.7.2. shall be followed.
4.7.3.5
Paints and Painting

a)
For use of specific painting system,

manufacturer's specification shall prevail.
b)
General compatibility between primer and finishing

paints shall be established
through the paint
manufacturer supplying the paints.
c)
Before buying the paint in bulk, it is recommended to

obtain sample of paint and establish "Control Area of
the
paint
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of
Painting". On control area surface preparation and

painting shall be carried out in the presence of
manufacturer of paint.
d)
In order to ensure that the supplied paint meets the

stipulation in design drawing/ specification, if required,
samples of paint shall be tested in laboratories to
establish quality of paint with respect to (i) Viscosity (ii)
adhesion/ bond of paint in steel surfaces (iii)
adhesion/simulated salt spray test (iv) chemical
analysis (percentage of solids by weight) (v) normal
wear resistance as encountered during handling &
erection (vi) resistance against exposure to acid fumes
etc.
e)
Whole quantity of paint for a particular system of paint

shall be obtained from the same manufacturer.
f)
Thinners,
wherever
used,
shall
be
recommendation of the paint manufacturer.
g)
Areas, which become inaccessible after assembly of

structures shall be painted before assembly, after
cleaning the surfaces as specified.
h)
Wherever shop primer painting is scratched, abraded or

damaged, the surfaces shall be thoroughly cleaned
using emery paper and power driven wire brush
wherever
warranted,
and
touched
up
with
corresponding primer. Touching up paint shall be
matched and blended to eliminate conspicuous marks.
i)
If more than 50% of the painted surface of an item

requires repair, the entire item shall be mechanically
cleaned and new primer coats shall be applied followed
by finishing coats as per painting specification.
j)
All field welded areas on shop painted item shall be

mechanically cleaned (including the weld area proper,
adjacent areas contaminated by weld spatter or fumes
and areas where existing primer. intermediate /
as
per
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of
finishing paint is burnt). Subsequently, new primer and

finishing coats of paint shall be applied as per painting
specification.
k)
Application of paint shall be by spraying or brushing as

per IS: 487-1997 and in uniform layers of 50%
overlapping strokes. Painting shall not be done when
the temperature is less than 5C or relative humidity
more
than
85%,
unless
manufacturer's
recommendations permit. Also painting shall not be
done in frosty or foggy weather. During application,
paint agitation must be provided wherever such
agitation is recommended by the manufacturer.
l)
Paint shall be applied at manufacturer's recommended

rates. The number of coats shall be such that the
minimum dry film thickness (DFT) specified is achieved.
The dry film thickness of painted surfaces shall be
checked with ELCOMETER or measuring gauges to
ensure application of specified DFT.
m)
All structures shall receive appropriate number of

primer and finishing coats in order to achieve overall
DFT as per design drawings/ specifications. First coat of
primer paint shall be applied not later than 2-3 hours
after preparation of surface, unless specified otherwise.
n)
The finishing paint as specified shall be of approved

colour and quality. The under coat shall have different
tint to distinguish the same from the finishing coat.
o)
Edges, corners, crevices, depressions, joints and welds

shall receive special attention to ensure that they
receive painting coats of the required thickness.
p)
Machine-finished surface shall be coated with white

lead and tallow before shipment or before being put
into the open air.
q)
Parts of surfaces embedded in concrete shall be

thoroughly cleaned of grease, rust, mill scale etc. and
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 68
of
shall be given a protective coat of portland cement

slurry immediately after fabrication. No paint shall be
applied on this part.
4.7.3.6
r)
Zinc-rich primer paints, which have been exposed

several months before finishing coat is applied, shall be
washed down thoroughly to remove soluble zinc salt
deposits. In similar circumstances, the surfaces of paint
based on epoxy resin should be abraded or lightly blast
cleaned to ensure adhesion of next coat.
s)
Surfaces, which cannot be painted, but require

protection shall be given a coat of rust inhibitive grease
according to IS: 958-2000 or equivalent international
standard.
Painting System
The painting scheme inline with general service requirement of
steel structures covering surface preparation, application of
primer coats, intermediate coats and final coats to develop the
required minimum dry film thickness on steel surface is
indicated:
Surface preparation:
SIS55900
ST-3 acc. To Swedish Standard
a)
Primer Paint
Two coats of Zinc Phosphate

in phenolic alkyd medium
(DFT=40 microns/coat)
b)
Intermediate Paint
One coat of Synthetic MIO

( ie: micaceous iron oxide)
(DFT=75 microns/coat)
c)
Finishing paint
Two
coats
of
Synthetic
enamel
(DFT=25
microns/coat)
conforming to IS: 2932-2003
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
4.8
PAGE No. 69
of
Erection Tolerances
Maximum permissible tolerances in erected steel structures
shall be as given in ANNEXURE-D.
4.9
Acceptance of work
4.9.1
Acceptance of erected steel structures shall be either after

completion of erection of the whole building or in blocks.
4.9.2
Preliminary acceptance certificates will be given in the

following cases:
a)
Any steelwork or part thereof embedded in concrete.
b)
Steel structures, which are to be covered in the process

of carrying out further work.
4.10
Documentation
4.10.1
The following documents shall be prepared at the time of

acceptance of erected structures.
4.10.2
a)
Documents showing actual deviations made during

execution of erection work and approval of competent
authority.
b)
Documents
structures.
c)
Certificate/documents on control checking and test of

materials (if any) and weld.
d)
Data and result of geodetic measurements obtained

while checking the erection of the structures.
showing
acceptance
of
embedded
Copies of "As-Built" drawing showing thereon all additions and

alterations, which took place between fabrication and erection
of structures. (Refer relevant clause)
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 70
AND
ERECTION
5.0
FABRICATION
STRUCTURES
5.1
Crane rails & Crane rail joints
5.1.1
Only tested materials shall be used. Manufacturer's test

certificate, including chemical analysis shall be supplied.
5.1.2
Rails shall be free from twist, bends, pittings, laminations and

other internal or external defects. The rail shall be straight and
the deviation from straightness shall not exceed +1.5 mm. If
necessary, the rails shall be cold straightened.
5.1.3
Unless otherwise specified, the crane rail joints shall be

butt-jointed (either by termite or fusion welding) or by fish
plates as per specification/ drawings.
5.1.4
For butt-welding, the Tenderer shall take prior approval of the

Owner & Consultant regarding method of edge preparation,
welding procedure and sequence of welding to be done. Edge
preparation shall be done by oxy- acetylene flame and shall be
neatly finished by chipping and grinding.
5.1.5
All position low hydrogen electrode conforming to

IS:814-2004 shall be used for welding. The rail ends shall be
preheated to 250`C before welding .The electrode shall be
preheated as per manufacturer's instructions. The welded joint
shall be allowed to cool slowly. It is recommended that the
initial and intermediate layers of deposits may be built by
using Ferron V, super chord or equivalent. Top 3 mm layer
shall be deposited with Duroid 2A or equivalent, to obtain
good wearing surface.
5.1.6
The joints shall be free from kinks, twists etc. and shall be
ground properly after welding to ensure smooth running of the
crane.
5.1.7
Method of securing the crane rail to the crane gantry,

alignment and expansion joints, if any, shall be subject to
Owner & Consultant approval. The crane rail clips shall be
preferably forged or pressed from steel plates.
OF
of
MISCELLANEOUS
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
5.2
Roof and side cladding with

Corrugated/troughed Steel Sheets
5.2.1
The scope of work shall cover:
VOLUME - V of V
PAGE No. 71
Precoated
of
Galvalume
a)
Preparation of drawings showing layout and size of

sheets used, details of connections and flashings, bill
materials.
b)
Procurement and supply sheets of all gauges and sizes,

flashings and fittings like corner pieces, apron pieces,
ridges, cutting and bending of sheets wherever
required; drilling of holes all as per specification and
drawings.
c)
Procurement and supply of Galvanized Hex self drilling

tapping screws and EPDM/neoprene washers.
d)
Loading, transportation, unloading and delivery of

sheeting material from place of procurement to erection
site.
e)
Provision of all tools, tackles, equipment, labour

supervision and services required for the satisfactory
completion of the work specified herein and on the
drawings.
f)
Erection in position sheets for roofing, walling,

louveres, erection of all flashings, fittings like ridges,
valleys, gutters, corners, apron etc. at all locations all
work as per drawings and specifications.
g)
Erection of FRP translucent sheets along roof and sides

at specified locations with corrugations matching with
corrugations of roof and side sheeting, along with
suitable / proper safety mesh frame (capable of
sustaining live load of 120 kg/sq.m) underneath the
FRP sheets at roof.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 72
of
5.2.2
All necessary sheeting flashings, ridging, capping, gable and

corner trimming shall be made from precoated galvalume
plain steel sheets in line with the gauge of roof/side covering
where it is used. Where connection between two different
gauge sheetings is involved thickness corresponding to lower
gauge may be used.
5.2.3
Fixing of sheets
5.2.3.1
All fixing of the roof and side sheeting to purlins/walling shall

be by means of
self drilling tapping screws. Fixing
accessories conforming to IS: 730-1978.
5.2.3.2
All screws/bolts shall pass through the crown of the

corrugations for roof sheets and through trough corrugations
for side sheets. Fixing to the purlins shall be provided through
atleast every third or fourth corrugations of sheets. Sheets are
to be provided with NPDM/neoprene washers. For Fixing of the
sheets with the purlins the specification of the respective
suppliers also to be referred.
5.2.4
Holing
In general all holes for sheetings and flashings are to be
drilled at site from the bottom side of the crown. The method
of drilling shall be such that the material fits snugly together
at laps to allow washers to have good seating.
5.2.5
Laps
5.2.5.1
All normal roofing shall be provided not less than 150 mm end
lap for roof slopes between 15 to 18 . For roof slopes below
15 end laps shall be increased by at least 50mm for every 2
decrease in slope from 15. However, manufacturers
instructions, also to be followed
5.2.5.2
All side/gable end sheets shall be as per manufacturers

instructions.
5.2.5.3
Overhang of sheets on the roof and side cladding shall not

exceed 150 mm.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 73
of
5.2.6
Erection
5.2.6.1
Erection is to be carried out with the lay of the side laps such
that under the prevailing wind, rain is not driven into the lap.
The sheets shall be laid so that side laps in any two
consecutive rows are staggered.
5.2.6.2
Broken or otherwise damaged sheeting shall not be erected.
5.2.6.3
Cutting, framing and trimming of all openings required shall

be carried out at site.
5.3
Grated Walkways/Grilled Flooring (Grating) :
5.3.1
Unless otherwise stated all grill flooring shall be designed for

in addition to its self weight, for a superimposed load of 500
kg/m2 or the alternative minimum load specified in IS:875 or
the incidental load, due to erection, operation or
maintenance or as specified in the drawing whichever is more
critical. The maximum deflection due to dead load and live
load should not be more than 1/200 span.
5.3.2
Material used for fabrication shall conform to IS:20622006.
5.3.3
Grill flooring shall be fabricated from flats of size 25x6 for

main bars & 25x3 for secondary bent rib plates. Located of
main bars at a spacing of not more than 40 mm and shall be
provided with suitable transverse bent rib members to
provide rigidity. Fabrication shall make provision to connect
the flooring panels by bolts or by bolts and clips or welding to
supporting members as per drawings. Provision shall also be
made to interconnect the adjacent panels by bolts or by bolts
and clips to prevent movement of floor panels. Top surface of
all bars/members shall be flush giving a neat appearance.
Welding of different members shall be by electroforge,
electric resistance or similar type of welding so that there are
no crude weld deposits or lumps.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
VOLUME - V of V
PAGE No. 74
of
5.3.4
If permitted, grated walkways may be fabricated by manual

arc welding. However, the welding shall be finished smoothly
by proper grinding/filing.
5.3.5
The fabricated floor panels shall be cleaned of all rust, dust,

grease, oil, mill scale, weld flux etc., by sand blasting to
Swedish standard Sa 2 and made ready for painting.
Painting shall be by cold dip process. First dip shall be in antisaline metallic primer. After the primer paint has completely
dried, the grill flooring shall be dipped for the second time in
heavy-duty anti-corrosive and wear resistant bituminous
black paint. Minimum DFT of antisaline primer shall be 25
microns and minimum DFT of finishing paint shall be 75
microns.
5.3.6
For cold dip painting a thinner recommended by the

manufacturer in suitable quantities shall be added. During
cold dip painting care shall be taken to guard against sagging
or flow-down of paint.
5.3.7
The gratings when erected around openings, shall have

circular bands.
5.3.8
Sample grating shall be got approved before taking up full

scale manufacture.
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 75
of
ANNEXURE-A
Permissible deviations in pitch and gauge of holes for bolts of normal
accuracy (high strength bolts included)
Description
Hole
diameter
(mm)
1
Deviation in the
hole diameter
2
Upto
17.0
Above
17.0
Ovality
(difference
between
the
biggest and the
smallest
diameter)
Curves,
exceeding 1mm
and cracks on
the hole edges
Non-coincidence
of
holes in
separate
details of
the
assem-bled unit,
upto 1mm
Non-coincidence
of
holes in
separate
details of
the
assem-bled unit,
above 1 mm
upto 1.5 mm
Slope of axis
Permissible
deviations
In spacing
(mm)
3
Permissible deviations
in each group of holes
Carbon Steel
4
+1
+1.5
No limits
Upto
17.0;
Above
17.0;
+1
+1.5
No limits
Not permissible
Upto 50%
Upto 10%
Upto 30%
of the
thickness of
unit
No Limits
Low Alloyed
5
Upto 50%
Upto 10%
No Limits
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 76
of
ANNEXURE -B
TOLERANCE OF ASSEMBLED COMPONENTS OF STRUCTURES
Description of Deviation () in mm for the Elements of Structures
Components of Length in Metres
Structures
1
I.
i)
Deviations
from
the
dimensions
assembled.
Length & width of the Details
Cut :
a) Manual gas Cutting as
per marking
b) With shears or with a saw
as per marking
c) With shears or with a saw
with a stop
d) Machine Gas Cutting
ii)Length and width of planed
ends processed on Edge
Planing Machine
II i) Distance between the
Centres of the End holes.
a)
Drilled
according
to
marking
b) Drilled according to a
gauge with bushing
ii)Distance
between
the
centres of adjacent holes
a)
Drilled
according
to
marking or to a gauge
b) Drilled according to a
gauge with bushings
Up
to
1
2
1
to
5
3
5
to
10
4
10
to
15
5
15
to
20
6
20
to
25
7
3.5
4.5
2.5
3.5
1.5
2.5
3.5
2.5
3.5
1.5
2.5
2.5
3.5
1.5
2.5
1.5
0.5
Over
25
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
Structures
1
III.
Deviation
in
the
dimensions
of despatch
elements after
completion
of fabrication, Assembled in
positioners
or
in
other
Devices with clamps in fixed
positioners and also
a) According to guide blocks
with pins.
b) Assembled with bolts
c) Size (length & width)
between Milled surface (for
all cases of assembly)
d) The same made in
separate
details during
machining & fixed during the
assembling work with clamps
e)
The
same
drilled
according to
positioners in
finished structures
PAGE No. 77
of
Up
to
1
2
1
to
5
3
5
to
10
4
10
to
15
5
15
to
20
6
20
to
25
7
10
11
12
14
15
1.5
2.5
3.5
10
1.5
2.5
3.5
Over
25
8
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 78
ANNEXURE C
Extent of permissible deviation in assembly of welded joints:

Description
A.
a)
b)
B.
a)
b)
Square-butt
Joints:
Gap between
the ends of
plates (d)
Stepping of
one plate
over the
other (s)
Single Veegroove Joints
(without
backing
strip):
Bevel angle
(A)
Gap between
two Plates
(d)
Permissible
deviation
Sketch
1 mm
1 mm
5
1 mm
c)
Stepping of
one plate
over the
other (s)
2 mm
d)
Root
thickness (t)
1 mm
Rev. 0
of
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
Description
C.
PAGE No. 79
Permissible
deviation
Sketch
Double Vgroove Joint:
a)
b)
c)
d)
D.
Stepping of one
plate over the
others (s)
2 mm
Deviation in the
value of Root
thickness (t)
1 mm
Deviation in
Bevel angle (A)
Deviation in
value of Gap (d)
Lap Joints:
1 mm
a)
Overlap (B)
5 mm
b)
Gap between
the surfaces (e)
1 mm
E.
Tee fillet Joints:

a)
Gap between
the edge of the
web and the
surface of the
flange (e)
2 mm
Rev. 0
of
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 80
of
ANNEXURE D
TOLERANCES IN ERECTED STEEL STRUCTURES
Sl No
A.
1.
2.
3.
Description
COLUMNS
Deviation of column axes at foundation top
level with respect to true axes.
i) In Longitudinal direction
Ii) In Lateral direction
Deviation in the level of bearing surface of
columns at foundation top with respect to
true level
Out of plumbness (vert.) of column axis
from true vertical axis and measured at
column top:
a) For columns without any special
requirements:
i) Upto and including 30m
Ii) Over 30 m height
b) For column with special requirements
like cranes or such similar requirements:
i)
Upto and including 30m
ii)
4.
5.
6.
Over 30 m height
Deviation in straightness in longitudinal &

transverse planes of columns, at any point
along the height
Difference in the erected position of
adjacent pairs of columns along length or
across width of building, prior to connecting
trusses / beams,
With respect to true distance.
Deviation in any bearing or seating level
with respect to true level.
Tolerance (mm)
5
5
5
H/1000 or 25mm
height whichever is less
H/1200 or 35mm
maximum
H/1000 or 20mm
height whichever is less
H/1500 or 25mm
maximum
H/1000or 10mm
whichever is less
5
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
7.
Difference in bearing levels of a member on

adjacent pair of columns both across and
along the building, from the true difference
NOTE:
i)
Tolerance specified under 3(a) and
conjunction with 4 and 5.
ii)
"H" above is the column height in mm.
B.
1.
2.
3.
4.
5.
C.
1.
2.
3.
PAGE No. 81
3(b)
TRUSSES
Shift, at the center of height span of top chord
member of truss or with respect to the centre of
Span or vertical plane passing whichever
through the centre of bottom chord.
Lateral shift of top chord span of truss at the
centre of truss span from the vertical whichever
plane passing through the centre of supports of
the truss.
Lateral shift in location of truss from its true
vertical position
Lateral shift in location of purlins from true
position.
Deviation in difference of bearing levels of
trusses or beam from the true (L = span)
difference.
of
should
be
read
in
Tolerance (mm)
1/250 of height span
in mm 15 mm is less
1/1500 of in mm or
10 mm is less
10
5
L/1200 or 20 mm
whichever is less
CRANE GIRDERS & RAILS

Tolerance (mm)
Shift in the centre line of crane rail with respect
(web thickness in
To centre line of web of crane girder
mm + 2) / 2
Shift in plan of alignment of crane rail with
5
respect to true axis of crane rail at any point.
Deviation in crane track gauge with respect to
5
true gauge:
i) For track gauge upto and including 15 m.
5
ii) For track gauge more than 15 m.
(5+0.25(S-15)
subject to minimum of
+10 mm, where S is
the true track gauge
(In metre)
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q7
4.
5.
6.
7.
Deviation in the crane rail level at any point from

true level.
Difference in levels between crane track rails
(across the bay) at
i) Supports of crane girders
ii) Mid span of crane girders
6. Relative shift of crane subject to rail surface
at a joint grinding of surface both in plan and
elevation for smooth transition
Relative shift in the track location of crane stops
(end buffers) along the crane tracks, along track
VOLUME - V of V
PAGE No. 82
of
10
15
20
2 mm
1/1000 of gauge S in
mm
subject
to
maximum of 20 mm
gauge.
NOTES: 1.
The tolerances specified

do not apply to steel structures where
deviations from true positions are intimately linked with or directly
influence the technological process. In such cases, the tolerances on
erected steel structures shall be as per recommendations of process
technologists / equipment suppliers.
2.
The observed or calculated values of deviations of steel structures

from their true positions shall be rounded off in accordance with IS:
2-1960 for comparison with permissible tolerances specified in this
table. The number of significant places retained in the rounded-off
value should be same as that specified in this table.
Rev. 0
84
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 83
of
ANNEXURE-E
MATERIAL OF CONSTRUCTION (AS APPLICABLE)
1.
Unless otherwise specified in the drawing:

a)
All rolled sections and plates (Thickness 20 MM and less) shall

conform to Grade-A (Fe 410 WA) as per IS: 2062-2006.
(SAIL, RINL and TATA STEEL)
b)
Plated structures above 20 MM and subjected to dynamic

loading shall conform to Grade-B (Fe 410 WB) as per IS:
2062-2006. (SAIL, RINL and TATA STEEL)
c)
High strength micro-alloyed steel shall conform to SAIL-MA

350 HYA/HYB (SAIL product).
2.
Steel sheets shall conform to IS: 1079-1994.
3.
Steel tubes for structural purposes shall conform to IS:1161-1998.

(Grade YST-240).
4.
a)
Colour coated corrugated/troughed steel sheet for roof shall

be made of cold rolled steel of 300 MPA minimum yield
strength conforming to ASTM A 366 or AS 1595 with hot dip
metallic coating of minimum 150 gm/sq.m zinc-aluminium
alloy coating mass (55% Aluminium, 43% zinc and 1.5%
silicon), total of both sides as per ASTM A 792 or AS 1397.
Base metal thickness shall be 0.6 mm. Total thickness of
colour coated profiled sheet shall be 0.68 mm. The colour
shall have a total coating thickness of 40 microns of paint
system as per AS/NZS-2728:1997 of approved colour
comprising of 20 microns exterior coat on top surface and 10
microns reverse coat on back surface over 5 microns primer
coat on both surfaces.
b)
Translucent sheets (FRP) of thickness 2 mm at specified

locations to match with the corrugations shall conform to
IS:12866-1989(FRP)
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
VOLUME - V of V
CHAPTER NO. Q7
PAGE No. 84
shall
be
of
copper
bearing
of
5.
Gutters and down comers

conforming to IS:2062-2006.
steel
6.
Crane rails shall conform to IS:3443-1980.
7.
All black hexagonal bolts, nuts and lock nuts shall conform to
IS:1363-2002 and IS:1364-2002 (for precision and semi- precision
hexagonal bolts). Washers shall conform to IS:1148-1982.
8.
Covered Electrodes for welding shall conform to IS:814-1991. coding

of electrodes shall be as follows:
a)
ER 421 C x for mild steel of Grade-A & Grade-B as per

IS:2062 (Latest)
b)
EB 542 C x H3X for

i)
Mild steel of Grade-B as per Is:2062(Latest) for

dynamically loaded structures( pertaining to Crane,
Vibratory screen, equipment etc.)
ii)
For SAIL-MA micro alloyed steel 350 HYA / HYB
Rev. 0
84
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q8
VOLUME - V of
PAGE No. 1 of
CHAPTER Q-8
TECHNICAL SPECIFICATION
- HYDRO ENGINEERING
WATER SUPPLY FACILITIES
1.0
Scope of Work and Battery Limit:

The scope of work covers manufacture/ fabrication, shop testing,
packing, loading, transportation to site, comprehensive insurance,
unloading, unpacking and storage at site, site handling, fabrication of
fittings, erection and laying of above ground / underground pipes along
with accessories as per drawings issued by consultant, painting,
wrapping and coating as the case may be, commissioning and
Performance Guarantee testing and handing over of the system,
including fulfillment of guarantee of all the systems and integrated
systems, envisaged for meeting the water requirement of
Kumaraswamy Iron Ore mines of NMDC Limited as specified in the
technical specification.
The Water available at the hill top reservoir of Kumaraswamy mine is
of potable quality. Water requirement for drinking purpose and for the
Dust Suppression system will be made available by the purchaser at
the outlet flange of hill top reservoir. Galvanized pipes to IS: 1239
Part-I (Heavy) shall be used for the drinking water pipelines. The flow
diagram for water supply facilities for the down hill conveyor package
is indicated in the enclosed drg. no. MEC/01/Q6DH/KIOP/II/216/TS.
Filtered/potable water is required for drinking purposes at field office,
electrical room and various transfer houses.
The tentative total quantity of water required for dust suppression and
other units is indicated in the drg. no. MEC/01/Q6DH/KIOP/II/216/TS.
The water requirement of Kumaraswamy Iron Ore mines will be met by
drawing water by gravity from 727 Cu.M capacity reservoir of
NMDC KIOP (Pkg VA) located at FGL 1042M (Abs.). The reservoir
will be receiving the water by pumping from the Donimalai pump
house (The reservoirs and pumping of water are not under the scope
of package-II). An MS pipeline of adequate diameter shall be laid from
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7
NMDC LIMITED
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PACKAGE NO - II
CHAPTER NO. Q8
VOLUME - V of
PAGE No. 2 of
the outlet flange of the hill top reservoir to the various units for
drinking water purpose and dust suppression system.
The battery limit shall start from
(potable) hill top water reservoir.
above reservoir shall be drawn by
shops/ units areas in Kumaraswamy
i)
ii)
iii)
iv)
v)
vi)
the outlet flanges of the filtered

The filtered water stored in the
gravity and supplied to following
Iron Ore project site.
Drinking water for TH1, TH2, TH2A, PS1, Silo building at belt
feeder platform & Tail end/ drive house of down hill conveyor.
Drinking water for Electrical cum office room at tail end of down
hill conveyor and near TH-5.
Drinking water for PS2, TH3, TH4, TH5 & TH6.
Water for shop cleaning at tail / drive house of down hill
conveyor.
Water for sanitary purpose at Electrical cum office room at tail
end of down hill conveyor & near TH-5
Water for Dry fog dust suppression system.
In addition to the above hill top reservoir, a reservoir of approx. 400

cu.m is also planned (by the side of hill top reservoir) to meet the
water requirement of fire detection and suppression system (FDSS).
The battery limit for FDSS shall start from the outlet flange of the
above reservoir. Refer chapter no. Q9 for details of the fire detection
and suppression system.
1.1
Pipelines & Valves:

The pipelines and valves be used in this package shall be as per the
data sheet. Pipe work shall be complete in all respects including all
accessories essential for proper installation, operation and
maintenance even though such items might not have been specifically
mentioned in the specifications.
Piping system shall be designed with high degree of reliability so that
the systems perform the duty of fluid handling without any failure
under all conditions of plant operation.
Piping layout must follow good engineering practice. Proper attention
shall be paid to obtain full functional requirement of the piping system
with a layout, which provides sufficient clearance for other equipment
and operating personnel, convenient supporting points and neat
appearance.
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PACKAGE NO - II
CHAPTER NO. Q8
VOLUME - V of
PAGE No. 3 of
Complete design of piping system shall be subject to approval by the

Owner/ Consultant.
The design shall take into account the effect of internal/ external
pressures, self weight of piping, support reactions, wind effects at site,
corrosion, erosion, etc., and any other effects dictated by good
engineering practices.
Piping systems shall not impose undue forces on equipment terminals
to which they are connected.
Frictional pressure drop in water lines shall be calculated using Hazen
& Williams formula considering value of C = 100 for pipelines.
The following flow velocities shall be maintained in the pipe network for
various categories of water:
Nominal pipe size (mm)

Up to 150
200 to 450
500 to 1200
Above 1200
Recommended flow
velocities (m/s)
1.2 to 1 .5
1.5 to 1.8
1.8 to 2.2
2.2 to 2.5
Note: The above table sets the maximum limits of the flow velocity.
Lower velocities may be selected if found necessary due to hydraulic
considerations in specific cases.
All the pipe network shall be provided with manually operated butterfly
valves for isolation /controlling purposes. Valves of size 250 mm and
above shall be gear operated.
The pipe network shall be provided with air release valves at high
points and drain valves at the lower points with isolation valve.
Each of the branch connection taken from the main network shall be
provided with an isolation valve.
Pipes passing under or through equipment foundations or walls of
buildings or any other inaccessible structure, roads etc., shall be taken
through encasing pipe for easy insertion and removal.
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PACKAGE NO - II
CHAPTER NO. Q8
VOLUME - V of
PAGE No. 4 of
RCC encasing pipes shall be of Class NP-3 as per IS:458, with collars
jointed by cement mortar in the ratio of (1:4). The ID of the encasing
pipe shall be atleast three sizes higher than the size of crossing pipe
but in no case less than 300 mm dia.
All the pressure pipes shall be laid with a nominal slope and the gravity
network with slopes for self-cleaning velocities.
For drinking water, screwed and socketed Gl pipelines shall be used.
Provisions shall be made for branches for cleaning and flushing of
pipelines wherever necessary.
Provision shall be made for support of piping, which may be
disconnected during maintenance work. All large pipes and long pipes
shall have at least two supports each arranged in such a way that any
length of piping or valve may be removed without any additional
supports being required.
Pipe supports shall be capable of supporting the pipelines under all
conditions of operation.
G.I. pipes up to 150 mm dia shall conform to lS: 1239 Part I (heavy)2000.
Pipefittings of dia up to 150 mm shall conform to IS: 1239 Part II. The
supporting span for the pipeline shall be generally as follows:
Nominal pipe size (mm)
15 to 32
40 to 65
80 to100
150 to 300
Maximum unsupported
span (m)
2.0
3.0
4.0
6.0
All GI pipelines laid underground shall be provided with external

coating and as per IS: 10221-2000. The total thickness of coating and
wrapping shall not be less than 4.0 mm.
In general BIS standard No.IS: 5822-1994 (Code of practice for the
laying of ERW steel pipes for water supply) shall be followed for laying
of the pipelines.
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PACKAGE NO - II
CHAPTER NO. Q8
2.0
VOLUME - V of
PAGE No. 5 of
V
7
DATA SHEETS FOR PUMPS, PIPES & BUTTERFLY VALVES

2.1 SPECIFICATION FOR PIPES (NORMALLY CHARGED WITH POTABLE
WATER)
2.2.1 DESIGN PARTICULARS
a)
b)
Material
Standard
i) For pipes DN 150mm
c)
Fittings
Mild Steel Galvanised (G.I. Pipe)
:
& below
IS: 1239 Part-I, heavy quality

IS: 1239 Part-II, heavy quality
Flanges
d)
e)
i) For sizes DN 80 mm
& above
Galvanised MS Plate flanges of steel

as per IS: 2062 with dimensions as
per IS: 6392,Table-17
Connections between pipe and fittings

i) For sizes DN 40 mm & below
:
Threaded
ii) For sizes DN 50 mm & above
Threaded
f)
g)
Special requirements
Nuts & Bolts
:
:
h)
i)
Gaskets
Painting
:
:
2.1.2
a)
b)
c)
d)
GI Pipes for drinking water

IS 1387 (Galvanised for drinking
water)
Rubber as per IS: 638
As per manufacturers standard
ERECTION REQUIREMENT
Segmental test pressure during erection
13.20 Kg/cm2 (g)
System test pressure after completion of

8.8 Kg/cm2 (g)
erection and flushing with valves in position but :
prior to commissioning
Hydro/ Leak test duration (No pressure drop and
no sign of leakage shall be observed during the
:
4 hrs minimum.
test)
Line flanges to be provided for maintenance and end flanges with blank
flanges to be provided for flushing.
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LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q8
2.2 SPECIFICATION FOR CAST IRON
(sizes: DN 50 to DN 300mm)
2.2.1
DESIGN PARTICULARS
a)
Fluid to be handled
b)
Working pressure
Type
c)
VOLUME - V of
PAGE No. 6 of
V
7
BUTTERFLY VALVE
Rating
Drinking Water
Max. 6 Kg/cm
Wafer type conforming IS: 13095-1991
/ BS: 5155
Size up to 200mm NB lever operated,
size 250mm NB and above gear
operated
10 Kg/cm (125 class)
2.2.2
a)
b)
c)
d)
CONSTRUCTION MODE
Body
Disc
Seat
Hand leaver/gear
Cast
Cast
Soft
To be provided
2.2.3
a)
b)
c)
MATERIAL OF CONSTRUCTION
Body
Cast iron IS: 210-1978, FG 200(Min)
Disc
SG Iron
Shaft
Stainless steel IS: 6603-1972, 12 Cr 13
Seating ring / seal retaining
Stainless steel / IS: 6603-1972, 04 Cr
ring
18 Ni 10
Seat
Elastomers, Grade: Nitrile
Type of operation
d)
e)
d)
e)
2.2.4
a)
2.2.5
a)
b)
c)
TEST TO BE WITNESSED BY OWNER / CONSULTANT

Hydro test
Body
Disc
As per IS: 13095/BS: 5155

Disc Strength Test
WORKMANSHIP FINISH & PAINT

Workmanship
Good
Finish
All burrs and sharp edges shall be
removed and the inside surface should
have smooth finish
Paint
2 coats of primer followed by 2 coats of
enamel paint of approved colour
scheme and quality.
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NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q8
VOLUME - V of
PAGE No. 7 of
V
7
2.3 SPECIFICATION FOR CAST IRON DUAL PLATE CHECK VALVE

2.3.1 DESIGN PARTICULARS
Fluid to be handled
a)
Drinking water
b)
c)
d)
e)
f)
2.3.2
Working pressure
Type
Manufacturing std
Type of operation
Rating
CONSTRUCTION MODE
Max. 5 Kg/cm
Wafer type Dual plate check valve
API 594
Automatic
ASME Class 150
a)
b)
c)
d)
2.3.3
Body
Cast
a)
b)
c)
d)
e)
f)
2.3.4
a)
Disc
With renewable liner
Seal / liner
Metallic
Cover
Bolted
MATERIAL OF CONSTRUCTION
Body
CI BS 1452 Gr. 220/ IS: 210-1999 Gr.FG 260
Plates
ASTM A 217 Gr. CA 15
Seal
SS 316
Spring
ASME SS 316
Body bearing
ASME SS 316
Plate bearing
ASME SS 316
TEST TO BE WITNESSED BY OWNER / CONSULTANT
a)
Hydro test
Body
As per API 6D
Seat
Disc Strength Test
WORKMANSHIP FINISH & PAINT
Good
Workmanship
b)
Finish
2.3.5
c)
Paint
All burrs and sharp edges shall be

removed and the inside surface should
have smooth finish
2 coats of primer followed by 2 coats of
enamel paint of approved colour scheme and
quality.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 1 of 64
CHAPTER-Q9
TECHNICAL SPECIFICATION
FIRE DETECTION & SUPRESSION SYSTEM

CONTENTS
Description
SL. No
1.0
General Project Information
2.0
Scope of Work
3.0
Special Instructions to the Tenderer
4.0
Technical Specification for Mechanical &

Electrical Items
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MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
1.
GENERAL PROJECT INFORMATION
1.0
General
VOLUME - V of V
PAGE No. 2 of 64
M/s NMDC Ltd. has proposed to install fire detection and

suppression systems for the conveyors # 723 of Down Hill
Conveyor System for KIOM, at Bellary district, in Karnataka State.
1.1
Intent of Specification
The intent of this technical specification is to provide fire detection
and suppression system, for conveyor # 723, located at Down Hill
Conveyor System for KIOM, in order to effectively control the
occurrence of fire in its incipient stage. The specification covers
design, manufacture, supply, erection, testing, commissioning and
handing over of the complete Fire Detection and Suppression
System.
1.2
Meteorological data of site

The Fire Detection and Suppression Systems shall be designed
taking into account the meteorological data of the project site as
provided in chapter C of vol. III of V.
2.0
SCOPE OF WORK AND SERVICES
2.1
The scope of work covers design, engineering, manufacture/

fabrication, shop testing, packing, supply, transportation to site,
comprehensive insurance, unloading, unpacking, storage at site,
site handling, preparation of erection drawings, fabrication, erection
as per approved drawings, painting, Performance Guarantee
testing, commissioning, and handing over of complete Fire
Detection and Suppression System, on turnkey basis including
fulfillment of guarantee of all the systems and integrated systems,
envisaged for conveyor # 723 of Down Hill Conveyor System of
NMDC Limited as specified hereinafter and also mentioned in
various chapters.
For the conveyance of water the Tenderer should plan the
alignment of incoming water pipeline from reservoir for fire fighting
system (at FGL of approx. +1042m (Abs.)) leading to conveyor
# 723.
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PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 3 of 64
The Fire Detection and Suppression System shall comprise:

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Medium velocity water spray (MVWS) systems,

Microprocessor based automatic fire detection and alarm
system (AFDA- Intelligent type) for various conveyor
galleries. The system shown also includes linear heat sensing
cables and infrared detectors along with purging unit for the
conveyor gallery,
Piping, valves, fittings, orifice plates etc.,
All civil works including RCC supports for pipes,
All electrics-required for power supply and distribution for
FDA system and operation of deluge valves.
Controls and instrumentation,
Shop and site painting for all equipment, pipes etc.,
Erection, testing, commissioning, PG test and Warranty for
the complete Fire Detection and Suppression System,
Supply of mandatory spares including commissioning spares,
Supply of tools & tackles,
All the requirements of statutory authorities for complete Fire
detection and suppression system shall be incorporated by
the Tenderer in their scope of work irrespective of whether
the details are described in specification and/or shown in the
drawings or not.
Detailed scope of work wherever necessary has been described in

respective chapters also.
2.2
Scope of work of the Tenderer shall also include all the following
materials and services but not limited to the following:
a)
All piping integral to and/or between any equipment

furnished under this specification, except as otherwise
specified.
b)
Thrust blocks, matching flanges and supporting materials.
c)
All necessary instruments, power and control wiring integral

to any equipment furnished under this specification. This
shall include terminal blocks and integral wiring to these
terminal blocks for equipment requiring external connection.
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PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 4 of 64
d)
Earthing strips of all panels and other fire fighting equipment

supplied by the Tenderer shall be connected to the nearest
earthing ring available at site.
e)
Digging of under ground trenches, laying of cables, laying of

protection slab/ bricks over the cable routes, back filling of
trench and levelling of earth.
f)
GI pipes/ conduits and other accessories wherever required

for laying of cables.
g)
Other erection materials like cable supporting structures,

channels, brackets, clamps and other hardware, as required,
for laying of cables.
h)
All erection accessories, consumables and miscellaneous

materials, though not specifically indicated in this
specification, but actually required for completing the job in
all respects.
i)
Erection, testing and commissioning materials.
j)
Valve chambers for all isolation valves.
k)
Miscellaneous items required to complete the Fire Detection

and Suppression System.
l)
Furnishing the size / dimension and other details including

G.A of equipment.
m)
Supply of all the engineering

documents, manuals etc.
n)
All piping supports/ structures, making holes and putting

sleeves in wall/ floor/roof for crossing pipes / cables, putting
inserts for piping and other equipment supports, cutting of
road for pipe / cable crossing and rebuilding of the road and
other work in good condition, closing of openings in wall,
floor etc.
o)
and
erection
drawings,
Civil works pertaining to underground buried pipelines such

as excavation, laying, back-filling, compacting, construction
of valve chambers, manholes etc. Laying of encasing pipes
below roads shall also be in the scope of work of the
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PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 5 of 64
Tenderer as a part of pipe laying. In case a group of pipes is

crossing the road, RCC culvert shall be provided below the
roads and the same shall be included in the scope of work of
the Tenderer.
p)
Providing necessary equipment and laying of cables for

repeating the fire signals for MVWS systems (cable
cellars/galleries) from fire alarm panels to control valves
near new reservoirs.
3.
SPECIAL INSTRUCTIONS TO THE TENDERER
3.0
General
3.1
Standards and Regulations

a)
The design and engineering, manufacture, installation and

performance testing (including safety, earthing and other
essential provisions) of equipment and accessories covered
under this specification shall, in general, comply with the
latest issue of:
Applicable Standards and Codes of Practice published by the

Bureau of Indian Standards.
N.F.P.A. codes and regulations in the absence of BIS standard

/ codes of practice.
b)
Equipment complying with other recognised Standards such

as IEC, BS, VDE, DIN etc. will also be considered if they
ensure performance equivalent to or superior to Indian
Standards.
c)
Equipment and accessories for which Indian Standards are

not available, shall be designed, manufactured and tested in
accordance with the latest issues of recognised standards
such as IEC, BS, VDE, DIN, UL etc.
d)
In case of conflict between applicable Standards referred to

in this part and the Technical Specifications given in various
volumes of this specification, the more stringent shall govern
to the extent of such difference.
Rev. 0
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
3.2
VOLUME - V of V
PAGE No. 6 of 64
Safety
a)
All equipment shall be complete with approved safety devices

wherever a potential hazard exists and with provision for
safe access of personnel to and around equipment for
operational and maintenance functions. The design shall
include not only those usually furnished with elements of
machinery but also the additional covers, stairways, ladders,
steel structural platforms, control panel handrail, partitions
etc. which are necessary for safe operation of the plant.
b)
All danger and caution notice boards shall be both in English

and Kannada languages.
c)
When the work is carried out at night or in obscure daylight,

adequate arrangements for flood lighting in the working area
shall be made by the Tenderer at his own cost and got
approved by the Owner.
d)
The safety posters/regulation for prevention of accidents shall

be displayed by the Tenderer at appropriate places. Notices
and warning signs shall be displayed for all sources of dangers.
The Tenderer shall place posters indicating operating
instructions in Kannada and English, wherever portable fire
extinguishers are installed.
e)
All electrical drives and equipment must be equipped with

safety devices. The safety provisions shall conform to the
recognised standards, safety codes and statutory regulations.
f)
All safety measures as required to be adopted as per the

statutory regulations and the safety rules of the plant shall be
strictly followed by the Tenderer during the execution of the
Contract.
g)
Adequate number of first aid boxes as defined in the State

Factory Rules shall be provided and maintained at all work
sites.
h)
In main plant control room, following information shall be

displayed on a separate notice board legible from a distance.
Area wise /floor wise location

extinguishers
plan
of
portable/fire
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PACKAGE NO - II
CHAPTER NO. Q9
3.3
VOLUME - V of V
PAGE No. 7 of 64
Route layout of cable gallery with entry/exit points

Key board having duplicate keys to all doors of elect
rooms/cable gallery
Coding/Numbering Scheme
A coding scheme for identifying the drawings, plant and equipment,
structures, spares and shipping documents shall be adopted by the
Tenderer in a sequential manner. The objective shall be to provide
the following:
a)
b)
c)
Streamlined archives management

Effective control with respect to identification of equipment
and drawings to be supplied by different Tenderers/subContractor.
Identification of the spare parts for easier inventory control.
The scheme will be finalised with the Tenderer during engineering

stage.
3.4
License
The Tenderer shall possess a valid and competent license issued by
the Licensing authorities of the Govt. of Karnataka or other States for
carrying out the type, nature and magnitude of work covered in this
specification, in the state Karnataka. Copy of the license shall be
made available to the Owner/Consultant for verification during
execution of contract if required.
All linemen, wiremen, electricians, welders, supervisors and
engineers engaged by the Tenderer or his sub- Contractor shall
possess necessary valid license/ passes issued by the statutory
authority and the same shall be submitted for verification, if called
for.
3.5
Instruction Manuals
a)
Instruction manual shall give step-by-step procedure for:

-
Erection, testing and commissioning
Operation
Maintenance and Repair.
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PACKAGE NO - II
CHAPTER NO. Q9
b)
Maintenance instruction shall include:

-
3.6
VOLUME - V of V
PAGE No. 8 of 64
Diagnostic trouble shooting/fault location charts.

Tests for checking of proper functioning.
Instruction manual shall also contain:
Manufacturer's catalogues with ordering specification for all
items.
List of consumables with specifications, brand names and
annual consumption figures.
Drawings relevant for erection, operation, maintenance and
repair of the Fire Detection and Suppression System.
Procedure for ordering spares.
The Tenderer shall possess the latest test tools/equipment for

testing of Fire Detection and Suppression System equipment viz.:
-
Walkie-Talkie sets of adequate range for testing FDA system.
Small test laboratory with all gadgets for testing electronic

components of the system.
Computerised facilities including software for calculating head

losses in pipes etc.
Pump sets with necessary instrument and control valves for

conducting hydraulic tests for pipelines.
3.7
Testing of equipment
a)
General
Testing of all equipment shall be conducted as per latest IS. Tests
shall also conform to International Standards IEC/VDE/DIN/BS.
All routine tests shall be carried out at manufacturer's works in
presence of Owner or his representative.
The Tenderer shall submit type test certificates for similar
equipment supplied by him elsewhere. In case type test certificates
for similar equipment are not available, the same shall be conducted
in presence of Owner or his representative if Owner so desires,
without any financial implications to Owner.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 9 of 64
To prove the fire retardant low smoke characteristics, the following

additional tests shall be conducted at works any size of each type of
cable namely, LT Power, control and instrumentation cables:Flammability tests on finished cable as per the requirements of IEEE383 & IEC-332-1.
Smoke generation by inner/outer sheath fire as per ASTMD 2843.
The cable shall meet the requirement of light transmission of
minimum 40% after the test.
The site tests and acceptance tests to be performed by the Tenderer
are indicated below but not limited to these tests.
The Tenderer shall be responsible for satisfactory working of
complete integrated system and its guaranteed performance.
Following tests shall be carried out in addition to other tests:
b)
Determination of characteristic curves of electrical drives.

Response characteristics of heat detectors.
Temperature rating test of heat detectors.
Operation test of alarm valves.
Calibration test on instruments and tests on control panels
Site Tests and Checks

All the equipment shall be tested at site to know their condition and
to prove suitability for required performance.
The tests indicated in the following pages shall be conducted after
installation. All tools, accessories and required instruments shall have
to be arranged by Tenderer.
Any other test which is considered
necessary by the manufacturer of the equipment or mentioned in
commissioning manual also has to be conducted at site.
In addition to tests on individual equipment some tests/ checks
are to be conducted/ observed from overall
system point of
view. Such tests shall be finalised in consultation with the Owner
before charging of the system.
The Tenderer shall be responsible for satisfactory working of

complete integrated system and guaranteed performance.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 10 of 64
All checks and tests shall be conducted in the presence of Owner's

representative and test results shall be submitted in six copies to the
Owner and one copy to statutory/approving authorities for various
equipments.
c)
Site tests
Testing including site tests to be carried out during precommissioning check ups and commissioning by the Tenderer on
individual equipment/system are also enlisted in various Chapters.
Tenderer shall have to fully abide by all the clauses indicated in
these chapters.
Site tests on equipment/systems shall be as indicated below, but not
limited to these tests.
i)
Fire Detection & Alarm System
ii)
Auto/manual operation of all control valves.

Simulated operation of all detectors and actuation of
automatic
Fire Detection and Suppression System (viz. spray
system)
Functional test of all components including charger.
AH capacity test for battery.
Simulation of all annunciation points.
Other tests on detectors at site as per NFPA 72E.
Valves
The tests to be conducted at shop for various subassemblies/
assemblies of equipment shall include, but not limited to the
following:
Material test
Testing during manufacture/fabrication
Dimensional checking
Hydrostatic testing of body and seat.
Demonstration of guaranteed opening and closing time.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
iii)
VOLUME - V of V
PAGE No. 11 of 64
Site and shop inspection and testing for the deluge

valves will be as per the applicable codes / regulations
or as agreed during detailed engineering.
Electrical equipment
CONTROL PANEL
IR value test by megger

Checking of control cable connection.
Operational test of all components mounted on control
panel.
Testing and calibration of indicating meters
Testing of all schemes for their functions as per
approved drawings
Check operation of annunciation facias, operation of
hooter etc. and system sequence
Check dressing of cables, sealing of openings in gland
plate and for provision of double compression glands
Check earthing connection of panels, fixing of panels
and openings from side/bottom
MCC
HV test with 2.5 kV megger

IR test before and after HV test.
Functional test for all feeders
Testing and calibration of all meters
Checking and calibration of overload relays and
protective relays as per supplier's commissioning
manuals.
Check operation of contactors from local and remote
points
Checking of inter locking between in-comers/ bus
coupler and other feeders.
Test to prove interchangeability of similar parts
Tests to prove correct operation of breakers at
minimum and maximum specified control voltages
Checking of earthing connection for neutral-earth bus,
cable armour, etc. as per the scheme.
Check test, service and draw out position of all the
breakers and operations of mechanical flag indicator
and electrical indication lamps.
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MECON
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PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 12 of 64
Breaker: IR value checking with breaker ON. Phase to

phase & phase to earth and between phases in off
position
CURRENT TRANSFORMER
Testing of CT polarity and CT ratio by primary injection

test and CT characteristics.
IR test on each winding, winding to earth and between
windings.
Continuity check for all windings.
Check for connections to correct taps.
Checking of continuity and IR values for cables from CT
Checking tightness of earthing connections.
Check output after loading of the main circuit.
CABLES & CABLE SUPPORTING STRUCTURES
IR test for all the cables

Checking of earth continuity for armor.
Check for mechanical protection of cables.
Check for identification (tag number system), placement
of cable marker, cable joint etc. as per the cable layout
drawing.
Check earthing of cable structures.
Check proper fixing of cable structures.
EARTHING SYSTEM
Check tightness of all earth connections

Check earthing of all metallic equipment, cable trays, all
elect. equipment, etc. as per the requirement of IE rules
and IS 3043
Measurement of total earth resistance.
MISCELLANEOUS
Checking of continuity of the system

Checking safe accessibility of all operating points
Check proper covering of all channels/trenches
Rev. 0
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
4.0
TECHNICAL
SPECIFICATION
ELECTRICAL ITEMS
4.0
FIRE FIGHTING SYSTEM
4.1
General
VOLUME - V of V
PAGE No. 13 of 64
FOR
MECHANICAL
&
A fire fighting system comprising pipeline from Reservoir for fire

fighting for water storage, isolation valves, deluge valves, pressure
reducing valves, pipe network, nozzles, couplings, related electrics
& instrumentation and all other equipments and pipe fittings
required for the completion of the system shall be provided.
The detailed specification for pipes & valves have been given in
chapter no. 4.6 to 4.11.
The Tenderer shall design the system for 90 minutes operation &
also tenderer shall ensure sufficient head / pressure required for
the system to operate.
4.2
Electrical System Design Criteria

The detailed specification for Electrical system design have been
given in chapter no. 4.28 to 4.47.
4.3
MEDIUM VELOCITY WATER SPRAY SYSTEMS (MVWS)

Introduction
The Downhill Conveyor system will have one conveyor gallery for
down hill conveyor # 723 meant for transportation of iron ore which
are prone to fire due to various reasons viz. forest fire, accumulated
rubber dust, sabotage etc.
In order to protect the equipments of the above-mentioned facilities
from fire, it is proposed to provide Medium Velocity Water Spray
system. Details of such equipments and facilities protected by Water
Spray System are as follows:
Sl.
No
1.
Name of units/premises
Conveyor gallery # 723
Rev. 0
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
4.4
VOLUME - V of V
PAGE No. 14 of 64
Location of units / conveyor

Conveyor mentioned above viz. Down Hill Conveyor System for KIOM
is located at Bellary District, in Karnataka State
4.5
Description of the System
I)
Medium Velocity Water Spray System (MVWS)

Medium velocity water spray system envisaged is a special fixed pipe
system connected to a reliable water supply in adequate quantity and
equipped with Medium Velocity water spray nozzles, capable of
creating spray, designed for specific water discharge and
impingement over the surface or area to be protected. Further the
MVWS system shall be of auto type. The main header-piping network
shall be connected to the branch header of the MVWS system
through a gate valve. The branch header piping system is to be
connected to the water supply main header through an automatically
actuated valve (deluge valve), which can initiate flow of water.
Deluge valves for the spray system are to be operated by an
automatic detection system which in the case of conveyor area
consists of LHS detectors mounted along the area to be protected. In
case of fire, the heat sensing LHS cables (detector) shatters at about
65oC temperature, thereby actuating the solenoid valve with the help
of a switch. It results in opening the deluge valve and allowing water
to rush into the system with always-open (locked condition) gate
valve. Pressurized water starts flowing through the piping network
and gets sprayed along the conveyor belt through the spray nozzles.
The MVWS System shall be provided with the following major
components:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
Water Supply from proposed firewater storage tanks (GLR)

Arrangement of Medium velocity Spray Nozzles
Arrangement of LHS Detectors
Valve-pneumatic diaphragm/ motor actuated
Deluge Valves
Basket / Y-type Strainers (upstream of deluge valve)
Pipes, fittings and fixtures
Basket strainers in MVWS system header.
Gate valves
PRVs and Orifice Plates.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
II)
VOLUME - V of V
PAGE No. 15 of 64
Water Supply from proposed firewater storage tanks

Assured and uninterrupted water supply at all times is the heart and
soul of the system. Therefore firewater storage tanks are proposed
for the water network of suitable diameter header for fire fighting
system of conveyor # 723. Water shall be tapped for the proposed
MVWS System from the water network having a common main
header from the firewater storage tanks. Pressure to be made
available from existing / proposed firewater tanks in the network is
approximately 3.0 kg / cm2 at the remotest point. However, the
Tenderer should ensure the header pressure shall not exceed 7.0
kg/cm2 by providing suitable pressure reducing device / orifice plates
at intervals (Approx. 45 mtrs or at locations depending on the
pressure drop calculations).
II)
Arrangement of Medium Velocity Spray nozzles.

Medium Velocity Water Spray nozzles shall be installed all along the
conveyor galleries in such a manner that their full length and crosssection is adequately covered and water is sprayed uniformly as per
segments planned to cater for fire suppression requirement. The
number, spacing and discharge angles of these nozzles shall be
designed to give effective coverage with an economical discharge of
water to minimize the extent of damage on the equipment. The
branch header for water sprays shall be provided with integral
strainer to arrest any oversize foreign matters being carried alongwith water.
III)
Arrangements of LHS cable Detectors

LHS cable Detectors shall be provided as heat sensing element for
the MVWS System for conveyors. Detectors shall be placed at the
both sides of the conveyor idlers where maximum temperature rise is
expected due to friction / overheating of jammers bearing of the
idlers leading to fire condition. The detectors are to be mounted on
independent supporting arrangement. The heat sensing detector
cables should shatter at about 65oC in case of fire, actuating the
solenoid valve with the help of a switch. It results in opening the
deluge valve.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
IV)
VOLUME - V of V
PAGE No. 16 of 64
Automatic Deluge Valve (DV)

This shall be basically a hydraulically operated valve. Normally the
clack shall be in closed condition owing to equal pressure in the upper
and lower chamber of the deluge valve. The DVs actuation shall be
by solenoid valve operations. In case of fire, on actuation of solenoid
valve, clack shall open due to hydraulic thrust by the pressurised
water from below the clack. Once the clack opens, the pressurised
water shall be sprayed onto the conveyor flowing through the Deluge
Valve and spray nozzles.
Isolating valves shall be provided before and after deluge valves to
facilitate the testing and maintenance of the system.
V)
Strainer for Deluge Valve Assembly

`Y' type strainers are to be provided on the inlet side of the deluge
valve assembly. This strainer shall be provided to remove foreign
matter deemed to be harmful for effective operation of the MVWS
System. These strainers shall be so designed that prolonged use up
to one year without cleaning will not hamper effective operation of
the system.
VI)
Pipe, fittings etc.

These have been described in chapter 4.6 to 4.11.
VII) Basket Strainers

Basket strainers shall be provided in the main header.
VIII) Ball and Gate valves
MVWS System is an automatically actuated system. To control the
flow of water ball valves up to DN 80mm and Gate valves for sizes
more than DN 80mm
shall be provided inside the conveyor
galleries.
IX)
PRVs and Orifice Plates
Pressure Reducing Valves (PRV) shall be provided in the system to

restrict the header pressure to 7.0 Kg/cm2 and Orifice plates of
suitable diameter/ thickness to reduce the pressure to 3.0 Kg/cm2 in
the MVWS nozzle header.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
c)
VOLUME - V of V
PAGE No. 17 of 64
Operation of the systems

Water header pressure shall be 7.0 Kg/cm2 up to deluge valves.
Deluge valve clack shall be kept in horizontal position during normal
condition, when there is no fire and system is kept in automatic
mode, due to balanced hydraulic pressure on both sides of the clack.
In case of fire, temperature will rise any where along the conveyor
gallery. On reaching a predetermined temperature (generally 30oC
above ambient temperature) LHS detectors, which are installed
along the conveyor gallery will shatter. As the cable shatters,
pressure switch installed on the detection line actuates and sends
signal to the main fire alarm panel (MFAP). This in turn actuates the
solenoid valve of the deluge valve and water starts flowing through
the deluge valve assembly and finally gets sprayed on the conveyor
gallery through the spray nozzles.
Generally
ball/gate
valve
located in the branch header of spray system is in open condition.
d)
Design Criteria
MVWS Systems shall be designed as per the stipulations of the
statutory authority on the subject as well as NFPA guidelines.
Following salient parameters shall be followed for the design of the
system.
i)
Water application rate shall be considered as 10.2 lpm/m2 of

the surface area of the entire conveyor gallery including
bottom return conveyor surface etc. as per TAC norm.
ii)
In case of MVWS system, pressure at the hydraulically

remotest spray nozzle in the network shall be 3.0 bars.
iii)
Max. permissible pressure in any spray nozzle shall be not

more than 3.0 bars.
iv)
Velocity in the feed pipe shall not be more than 3.0 m/s.
v)
There shall be common header for proposed MVWS systems,

which shall be designed to take each of 40m segments.
vi)
LHS detectors shall be installed along the conveyors.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
vii)
e)
VOLUME - V of V
PAGE No. 18 of 64
The distance between adjoining sprayers loops shall not

exceed 4m anywhere.
Equipment Specification
i)
Deluge Valve Assembly

Deluge valve assembly functions on differential pressure
operation allowing quick opening of the valve and thereby rush
of water to the protection system. The valve consists of inlet,
outlet and priming chamber. The inlet and outlet chambers are
separated from the priming chamber by the valve chamber
and a diaphragm. In the `Set' position, pressure is applied to
the priming chamber through a restricted prime line. The
pressure is trapped in the priming chamber and holds the
clapper on the seat due to the differential design. In the `Set'
position the clapper separates the inlet from the outlet keeping
the system piping dry. When the pressure is released from
priming chamber, the clapper moves and allows the inlet water
supply to flow through the outlet and to the fire extinguishing
system.
The deluge valve under reference shall be a control valve
assembly, which will operate on receipt of fire signal from the
fire alarm control panel. It will consist of solenoid operated
discharge valve capable of operating at the voltage that of the
FDA system. Emergency Manual override facility at local and
at MFAP shall be provided for actuating the valve in case the
automatic operation fails.
The deluge valve assembly shall consist mainly of the
following:
-
Isolation valves
Ball valves
Inline strainer
Deluge valve proper
Actuator/pilot assembly
Drain valve
Pressure gauges
Solenoid valve
Pressure switches
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 19 of 64
The deluge valve shall be of resetting type, taking minimum

time for resetting. The deluge valve shall be UL/FM approved
make.
ii)
MVWS System nozzles (Sprayers)

Water spray nozzles for the MVWS system shall be of suitable
orifice size and varying discharge angles to cover fully all the
area to be protected. The nozzles (Sprayers) shall be of
stainless steel (SS-304) material.
The nozzles shall be
normally open type, Spray nozzles (projectors) shall bear IS
approvals.
iii)
Strainers
Basket type strainers shall be provided on the main header, at
the outlet of the GLRs and Y- type strainer shall be provided
on the inlet side of each deluge valve assembly. The strainer
shall prevent deposition of foreign particles in the valves and
thereby malfunctioning of control valves. The material of
construction of the strainer shall be stainless steel and it shall
bear statutory authority / IS approval.
iv)
Solenoid operated valve

The solenoid-operated valve shall be a 24V D.C. operated
valve, which will get energized on receipt of fire signal from
the respective zone of the main fire alarm panel. The status of
its function (open/close) shall be indicated in the main fire
alarm control panel. In case the solenoid valve fails to open
within a stipulated time period, the corresponding signal shall
appear in the main control panel.
There shall be a pressure switch on the outlet side of the
deluge valve to indicate opening of the deluge valve in the
main control panel.
v)
LHS detectors
The LHS detectors shall bear UL/FM approval and shall have a
temperature rating of minimum 65 degree centigrade.
However the Tenderer shall take into account the
temperature at which they shall operate, considering ambient
temp. of 40 deg C.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
vi)
VOLUME - V of V
PAGE No. 20 of 64
Pipes & fittings

Pipes and pipefittings in general shall comply with the
requirements of IS codes as mentioned under Chapter No. 4.8
to 4.9.
The complete piping layout required for the MVWS system
shall be designed in accordance with various requirements of
NFPA/ TAC fire protection manuals and relevant IS codes.
Piping layout must follow good engineering practice. Proper
attention shall be given to obtain full functional requirement of
piping system with a layout, which provides sufficient
clearance for other equipment and easy access for operation
and maintenance.
All piping shall be complete in all respects and shall consist of
necessary valves, fittings, supports, air release and drain
valves and other accessories. The air release and drain valves
shall be provided at high and low points respectively. Each of
the branch connections taken from the network shall be
provided with an isolation valve.
Wherever over-ground pipelines are crossing roads, they shall
be laid under ground or on pipe bridges to provide the
necessary clearance for the traffic movement.
A minimum clear depth of 1.2 m for under ground or a height
of 6.0 m above road top level shall be maintained.
Valves provided on the over-ground pipe network shall be
provided with steel structural platforms and access ladders.
All pipe-work shall be designed to provide complete flexibility
to prevent development of undesirable forces or moments at
points of connection to equipment, at anchorages or at guide
points, due to thermal expansion. Flexibility shall be provided
by changes of direction or by use of bends, loops, offsets etc.
Rev. 0
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
vii)
VOLUME - V of V
PAGE No. 21 of 64
Valves
Valves shall be provided on pipe-work for stopping and
starting of flow, controlling flow rate, diverting flow, preventing
back flow, controlling pressure, relieving pressure and for
venting and draining of pipelines etc.
Valve selection shall be made based on the following
considerations:
-
Suitability of valve materials with regard to properties of

fluids, temperature, pressure, erosion and shock.
Valve size.
Main function of the valve (viz. throttling, stop,

permitting flow in one direction, diverting flow, relieving
/reducing pressure etc.)
Friction head losses.
Ease of operation, i.e. method of actuation-closing time.
Maintenance considerations.
The valves to be provided shall include but not be limited to

the following:
-
Isolation valves on the main header at various locations.
Ball valves upto DN 80 mm in the branch pipes from

header to Deluge valve (DV) and Gate valves from DV
to the served area for sizes more than DN 80 mm.
NRV on all pipelines requiring unidirection flow only.
Quick opening safety shut off valves.
Manual drain valves.
Pressure reducing valves.- These shall be installed in

the pipeline in order to restrict the pressure at spray
nozzles.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
viii)
VOLUME - V of V
PAGE No. 22 of 64
Pipe supports and fixtures

Necessary pipe supports & fixture, pipe thrust block or pipe
bridge to run the pipes overhead/underground or in the pipe
trench as the case may be, shall be included in the scope of
the Tenderer. The successful Tenderer shall study the location
of protected premises and their auxiliary equipment and
accordingly plan the pipe routing and the location of spray
nozzles, deluge valves and auto/manually operated valves.
The fire protection equipment and the fixtures located in the
vicinity of the conveyor galleries should not pose any
operational problem. At places, where no supports/trenches
are available the Tenderer shall consider dedicated supports
required for the pipe lines/spray nozzles etc. for the MVWS
systems.
4.6
TECHNICAL SPECIFICATION FOR PIPES, VALVES & FITTINGS
4.7
Detailed Scope of Work

a)
All piping and valves required for completeness of the MVWS

complete with all fittings etc.
b)
All bends, reducers, tees, distance pieces, etc. of all sizes and
shape required to complete the system.
c)
All piping and fittings for vents, drains, instruments tapping

points and valves etc.
d)
All counter flanges, blank flanges, caps etc. necessary for the
piping. All necessary bolts, nuts, and gaskets required for
installation of the system.
e)
All flanges, Valve Chambers, manhole and manhole covers,

flanged tees with blank flanges, automatic air-vent valves
required on above piping are included in the successful
Tenderers scope of supply.
f)
The term 'pipe work' referred herein generally covers pipes,

fittings (such as bends, tees, reducers, plugs, nipples, sockets,
unions, flanges, crosses, etc) valves, thrust blocks, auxiliary
pipe supports, throttling pieces, stubs for primary sensing
instruments etc. Each of the branch connections taken from
the network shall be provided with an isolation valve.
Rev. 0
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
4.8
VOLUME - V of V
PAGE No. 23 of 64
Technical Specification (T.S.) for Pipes for Spray (MVWS)

system
The material of construction and manufacturing standard of pipes,
fittings, fasteners, gaskets, etc. shall be as described below: a)
T.S. for Pipes upstream of deluge valve/ control valve
i)
Up to 150 mm nominal size -
ii)
200 mm to 300 mm size - MS ERW black pipes conforming to

IS 3589 - thickness as specified below:
Nominal Dia O.D
DN 200 mm
DN 250 mm
DN 300 mm
b)
X
:
:
:
MS
ERW
black
pipes
conforming to IS
1239
(Part-1) heavy grade with
plain ends
Thickness in mm
219.1 x 6.35
273.0 x 7.14
323.9 x 7.14
The Material of construction and manufacturing standard of

pipes, fittings, fasteners, gaskets, etc. shall be as described in
table indicated bellow.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 24 of 64
Material of Construction of Pipes, fittings, fasteners, gaskets etc.:
Sl. No.
1.
Items
Pipe
Nominal dia.
(mm)
65 and below
80
100 to 150
200 to 300
2.
2.1
2.2
Pipe fittings
Screwed fittings
Fabricated
fittings
Bends
65 & below
Above 150
Tees/Crosses
Reducers
Above 150
Above 150
3.
4.
Bolting
Gaskets
All sizes
All sizes
5.
Flanges
All sizes for

pipes
Specification
IS-1239 (Part-1) - 2004 heavy,
MS
IS-1239 (Part-1) - 2004 heavy,
MS
IS-1239 (Part-1) -2004 heavy,
MS
IS-3589
Gr.410
ERW
pipe
commercial quality or equivalent.
Thickness same as in clause 4.8
(ii) above.
IS-1239 (part 2)/3589
IS-1239 (Part-2) - 2004
Mitre bends with radius 1.5 DN

from black pipe.
Fabricated from black pipes.
Fabricated from black pipes by
taper cutting and welding.
IS 1367
Sheet rubber to IS-635-82, typeA, 3 mm thick compressed
Asbestos to IS-2712-`98
Slip on flanges to IS-6392 - `71
(Table-17)
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
4.9
VOLUME - V of V
PAGE No. 25 of 64
Pipe fittings
Fittings shall be supplied as per IS: 1239-1992 Part II for pipes up to
150 mm dia and shall be fabricated from pipes for dia 200 mm and
above.
4.10
T.S. for Valves
4.11
General
a)
b)
The valves shall be designed, manufactured and tested as per

relevant Indian Standards, BS as applicable or as per other
International standards acceptable to the Owner and shall be
suitable for the duty conditions as specified in TS.
Direction of flow shall be clearly indicated on the valve by
embossing an arrow on the valve body.
c)
All the valves shall have a permanent stainless steel name

plate and stainless steel tag fixed on the valve body indicating
the tag number, diameter, pressure rating and manufacturing
standard code of the valve.
d)
The valves shall be designed for 100% water tight shut off.
e)
All the valves shall be provided with hand wheel/lever. The

face of the wheel/lever shall be clearly marked with the words
OPEN and CLOSE and an
arrow to indicate the direction for
opening/closing.
f)
All the valves shall be supplied with companion flanges,

gaskets, nuts, washers and bolts.
g)
All underground valves shall be provided with valve chambers

with RCC covers. The size of chambers shall be suitable for
easy maintenance of the valve. Complete civil work for this is
in the Tenderers scope.
The Technical Specification of valves, etc. shall be as described
in table indicated below at 4.27 (c).
Rev. 0
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
4.12
ERECTION
4.13
General Requirements
system- Equipment
VOLUME - V of V
PAGE No. 26 of 64
of
erection
of
Fire
fighting
a)
The erection of all fire fighting system equipment shall be

carried out according to the latest engineering practices and
according to the working drawings, specification, instructions
etc. duly approved by the Owner. The Tenderer shall carry
out the work in the presence and/or as per the instructions
of site engineer/supervisory personnel deputed by the
Owner. The erection shall be carried out by highly skilled
workmen.
b)
The Tenderer shall take care of positioning, levelling and

plumbing of all pipelines and equipment as well as
supporting structures within the required accuracy and
tolerance limits.
It shall be deemed as a contractual
obligation that the pipelines are not thrown out of alignment
or lifted off during commissioning and subsequent operation.
c)
There may be more than one Tenderer working in the area at

the same time. As such, the work has to be carried out in
proper co-ordination and consultation with the Owner and all
other parties concerned with the work. The Tenderer shall
take due notice of the working conditions, practices and
agreements in vogue, in the area of the plant site and shall
satisfy himself before quoting.
d)
The Tenderer shall be responsible for paying strict attention

to statutory regulations for prevention of accidents and to
other safety rules. The regulations for prevention of accidents
shall be displayed at appropriate places and should be
distinctly visible to all personnel working in the area.
e)
The Tenderer shall supply all required consumables,

construction and erection materials, solvents, sealing
compound, tapes, brazing and soldering materials, welding
and brazing gases, erection bolts, nuts and packing
sheets/compounds, temporary supports, wooden blocks,
spacers, templates, jute and cotton wastes, sand and emery
paper etc. as required for the satisfactory completion of work.
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 27 of 64
f)
The Tenderer shall make his own arrangement for handling

the equipment and pipelines at the stores and transporting
them to the site of installation. In addition to the above, the
Tenderer
shall
follow
all
the
relevant
erection
clauses/conditions stated under various chapters in the
tendering specification.
g)
The Tenderer shall provide all tools, labour including

necessary subsistence, erection supervision, equipment,
materials, accessories, to erect/install and make ready for
operation, functionally complete the total Fire Detection and
Suppression System for conveyor # 723 as described and
specified in this specification.
4.14
Erection of Mechanical Equipment
4.15
Pipe Work
i)
Erection of piping covers erection (both underground and

overground), cleaning, testing, purging/ flushing, cleaning,
painting and commissioning of pipe work and associated
structures including hangers, support assemblies, and other
miscellaneous items. Pipes are to be laid along the approved
route as per site condition.
ii)
All fittings and accessories like air release valves, orifice

plates, T-pieces, Y-pieces, flanges, reducers, etc. shall be
suitably matched with pipes for welding.
4.16
Underground piping
i)
Excavation of trenches
Trench excavation shall include the removal of all materials

including the haul of excess material to disposal area and
usable material to a stockpile within plant areas as directed
by the Site In-charge. Excavation in both common and rock
material shall be carried out to the lines and grades shown
on the drawings, unless otherwise specified. In the event
that trench is constructed to a width or depth greater than
that permitted above, through Tenderer's error, the
Tenderer shall furnish the necessary material, labour and
equipment to correct such error as decided by the Owner/
Consultant. Shoring and bracing shall be used to support the
sides of trenches wherever necessary to protect life and
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 28 of 64
limbs of workers. When closed sheeting is required, it shall

be so driven as to prevent adjacent soil from entering
trenches either below or through sheeting and bracing shall
be removed after they have served their purpose.
ii)
Disposal
by
the
Excavated
materials
deemed
suitable
Owner/Consultant for any purpose shall be stockpiled in
required quantities in the vicinity of the excavation sites, as
per the approval/ directions of the Owner/ Consultant.
Unsuitable or excess excavation material and debris shall be
transported to spoil areas as directed and approved by the
Owner/ Consultant. Material shall be end dumped, leveled
and graded at these areas.
iii)
Backfill
Backfill shall contain no excavated rocks, ashes, rubbish,
combustible or decomposable material, nor any other
material which the Owner/Consultant deems unsuitable for
this purpose. If the excavated material is deemed unsuitable
by the Owner/Consultant for use as backfill, the Tenderer
shall
backfill
with
material
approved
by
the
Owner/Consultant which shall be obtained from locations
specified by Owner / Consultants and do the backfilling at no
extra cost. Prior to the lowering and laying of pipe in any
trench or excavation, the Tenderer shall backfill and
compact the bottom of the trench or excavation to provide
an acceptable bed for placing the pipe.
a)
Back filling shall be conducted at all times in such a

manner as to prevent damage and abrasion to coaltar
protection if any, on pipe.
b)
Placing of backfill above the protected pipe shall be

done after conducting necessary tests in the presence of
the Owner/ Consultant / statutory authority and after
their final inspection and acceptance.
c)
Immediately after placing and aligning the pipe in the

trench and before completing the joint, loose back fill
shall be placed above the pipe to a thickness of about
150 mm above the pipe, except at field joints.
This
Rev. 0
NMDC LIMITED
MECON
LIMITED

PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 29 of 64
back fill shall consist only of fine soil, sand or other

selected backfill.
d)
If rocks or other hard objects occur in the back fill along

any section of the pipeline, such back fill shall be
screened before being placed about the pipe or at the
option of the Tenderer, suitable back fill from other
places may be transported to and placed around the
pipe in such section.
e)
Settlement of back fill in the trench shall be by means

of flooding, puddling, tamping or jetting; poking with
metal rods will not be permitted.
f)
Back filling shall not be

completion of hydrostatic
requested by the Owner.
g)
However temporary or intermittent backfilling of road

crossing and other places wherever necessary will be
done by the Tenderer as directed by the Owner to
enable unhindered progress of other Contractors
works at the site.
carried out before the

test unless specifically
The depth of the pipe (top) from ground level shall be

1200 mm, wherever applicable.
iv)
Road Crossing
a)
All underground pipelines/ cables, crossing roads

where the depth of cover from the bottom of the
tracks or road bed to the top of the pipe is less than
1200 mm, shall be protected by providing RCC
culverts/RCC encasing pipe/steel encasing pipes or
sleeves (hume pipes).
b)
Hume pipes to be provided under road crossing shall be

of NP-3 rating. Tenderer shall make good the cut
road , drain
and other civil work to the
satisfaction of the site incharge.
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PACKAGE NO - II
CHAPTER NO. Q9
v)
VOLUME - V of V
PAGE No. 30 of 64
Protective Coating for Under Ground Pipes

a)
Underground mild steel pipes shall be wrapped and

coated generally as per IS: 10221-latest (Code of
practice for coating and wrapping of underground mild
steel pipelines)/AWWA-C203 and as per the following
procedure.
Alternatively Pipe coat (minimum
thickness 4mm) tape is acceptable in the place of
coating and wrapping provided it complies with IS:
10221.
-
Application of one coat of coal tar primer

Application of first coat of coal tar enamel
Wrapping of first layer of fibreglass tissue
impregnated with coal tar enamel.
Application of second coat of coal tar enamel
Wrapping of second layer of fibreglass tissue
impregnated with coal tar enamel.
Application of final coat of coal tar enamel.
Application of outer wrap of Kraft Paper.
b)
The outer surface coating shall be applied at the

fabrication yard before laying the pipes in position
leaving about 200 mm on both ends uncoated for
welding. Outer coating shall be visually inspected just
before lowering pipe in the pipe trench. The portion of
pipe at the joints shall be given protective coating as
specified above after welding and testing.
c)
Total thickness of coating shall be minimum 4.0 mm.
d)
Alternatively, the Tenderer shall quote for ready

made wrapped and coated pipes, subject
to
Owners/Consultant's / statutory authoritys approval.
e)
All coated and wrapped pipes shall be tested with an

approved high voltage holiday detector equipped with
a positive signaling device to indicate any faults,
holes, breaks or conductive particles in the protective
coating.
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PACKAGE NO - II
CHAPTER NO. Q9
vi)
VOLUME - V of V
PAGE No. 31 of 64
Above ground piping

a) The Tenderer shall supply / fabricate and install piping and
fittings in strict compliance with the detailed engineering
drawings. Deviations if considered necessary to suit site
conditions could however, be permitted in consultation with
and with prior approval of the Owner/Consultant.
b) All openings in the piping shall be kept effectively closed
until assembled in the system to avoid foreign matter
entering into the system.
c) All piping shall be installed with adequate clearance from
light fittings, and other openings.
d) Piping shall be arranged in the straightest possible runs
with minimum amount of fittings.
Flanges of
the
pipelines, fittings, etc. must be so mounted that top
boltholes are symmetrical about the vertical axis of the
flange. When several pipelines are laid parallel, flanged
joints must be staggered.
e) Joints shall be as far as possible located at one-third span
from supports and must be avoided in the middle of the
span.
f) All supports for overhead yard pipe works shall conform to
the approved working drawings. These shall include pipe
trestles, bridges, saddles, as well as other types of
supports.
Supports to pipe work within the gallery /
buildings may be taken from gallery / building structures
such as columns, trusses, etc. Any additional members
such as struts, purlins, etc. as required, shall be provided
by the Tenderer.
The
Tenderer shall provide all
required supports, anchors, saddles, hangers, rollers,
clamps, U-bolts, spring supports, etc. for aligning and
controlling the pipe work.
vii)
Instruction for laying of GI Pipeline

a)
Screwed end socket jointing shall be performed for

joining the GI pipelines. Welding of GI pipelines shall
not
be
done
without
prior
permission
of
Owner/Consultant. GI screwed unions shall be provided
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PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 32 of 64
at suitable intervals on a straight length and other joints

as necessary.
viii)
b)
All joining and branching shall be done with screwed

fittings conforming to IS 1239, Part-II-1992. Before
joining two pipes, the matching surfaces shall be
thoroughly cleaned of dust, rust and other foreign
materials.
c)
Matching surfaces shall be coated with white lead.
d)
All the joints must be watertight.
Laying and jointing of pipelines

Pipe shall be laid to lines and levels as shown in the
drawings. Jointing of pipes shall be made as given below:
a)
Welding of joints
Laying and jointing of welded MS pipes shall be as per IS:
5822-latest. For making welded joints, the welding shall be
performed by the manual shielded metallic arc process. All
welding and inspection of welding shall be done according to
IS 5822 and IS 7307 respectively. Pipes for butt-welded run
shall be supplied with ends beveled by machining or grinding.
The ends of the pipe during welding should be covered with
asbestos or by other means to eliminate the possibility of fast
cooling of metal. In case of interruptions, before starting the
welding again, it is necessary to heat the butt up to the
required temperature and maintain this temperature till the
butt is completed.
Besides systematic inter operational control, the quality of
welded joints shall be controlled by visual inspection and
mechanical tests in conformity with the provisions of
applicable standard codes including percent of radiography
required as per codes.
b)
Pipe Welding
The Tenderer shall arrange at his cost all tools, plant,

welding transformers, instruments
and
consumables
including welding electrodes for electric arc welding at site.
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PACKAGE NO - II
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VOLUME - V of V
PAGE No. 33 of 64
Welding shall be carried out as per relevant IS / International

code
The Tenderer shall indicate the procedure he is going to
follow for fabrication/erection/hydraulic testing of M.S. pipes
along with the tender.
c)
Requirement of welded joints

The Tenderer shall ensure the following requirements while
welding the plates/ pipe joints etc: Strength-quality with parent metal
Absence of defects
Corrosion resistance of the weld shall not be less than
that of the parent metal in aggressive environment.
d)
Preparation of joints
The Tenderer shall prepare the edge correctly to the shape,
size and dimensions of the vee-grooves as per ANSI B-16.25
unless otherwise specified in drawings/documents. The
welding surfaces shall be smooth, uniform and free from fins,
tiers, notches or any other defect which may adversely affect
welding and shall be free from loose scale, slag, rust,
grease, paint, moisture or any other foreign material. The
clean surface shall extend to about 10 mm beyond the welding
faces to avoid contamination of the weld metal with foreign
material and to avoid unsound weld deposit.
e)
Method of Quality Control in Welded Joints

Following steps shall be taken by the Tenderer, besides
controlling quality in general, to make effective control in
carrying out welded joints.
i)
Welding procedures shall be prepared in line with IS:

7307 (Part-I)-1974, reaffirmed in 1991 and tests shall
be carried out to qualify procedures.
Number of
procedures will depend on variables like positions of
welding, thickness range etc. Once a welding procedure
is qualified, strict adherence to it shall be made during
actual welding.
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PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 34 of 64
ii)
Welders employed shall be qualified as per IS: 7310

(Part-I)-1974, reaffirmed in 1987 after passing
necessary tests. Only qualified welders as per IS 7310
and suitable for the job shall be employed. The
Owner/Consultants at his discretion can order periodic
tests in accordance with IS 817 of the welders and/or of
the welds produced by them at no extra cost.
iii)
Welding consumables shall be of approved type. Such

consumables are, however, subject to qualifying initial
check tests as per IS: 814-1991.
iv)
The Tenderer shall strictly follow

approved welding
procedures during actual welding.
Besides, the
following stages of inspection shall also be carried out:
Weld edge preparation before welding, proper fit up,

position of welding, cleaning of slag between the
passes, proper weld profile etc., shall be checked
visually, amongst others.
Non-destructive tests of welded joints shall be carried

out as per approved procedures/ drawings.
f)
Tests on welded joints
i)
Visual examination
The Tenderer shall examine the following during the visual
examination:
Check the correctness of shape and size of the welded

joints
Cracks in welded spots and heat affected zones.
The Tenderer shall carryout any or all tests as specified

hereinafter to satisfy the Owner about the acceptability of the
welded joints, as directed by the Owner.
ii)
Radiography test
At least 10% of all joints shall be radiographically tested and
half of the joints radiographed shall be field joints.
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PACKAGE NO - II
CHAPTER NO. Q9
g)
VOLUME - V of V
PAGE No. 35 of 64
Bending of pipe works

Hand operated pipe bending machines shall be used for pipes
of up to 20 mm dia.
Hydraulic bending machines shall be used to bend pipe work
beyond 20 mm dia.
Smooth bends may be fabricated by bending pipes. Cold
bending may be adopted for DN 50mm and lower.
Pipe bends shall be true to angle and have a smooth surface
free of flat spots and corrugations. Actual inside diameter at
any portion of the pipe shall not deviate by more than + 3%.
Smooth bends shall have a radius three times the nominal
diameter, unless otherwise mentioned in the drawings.
Standard bends and elbows shall have dimensions as per
relevant IS or equivalent code for the service. Bends and
elbows shall have butt-welding ends unless otherwise
specified.
4.17
Pipeline testing
a)
Hydraulic tests
Pipelines for liquid services after erection generally shall be
hydraulically tested by water at a pressure of 1.5 times of
maximum working pressure. For carrying out hydraulic tests,
the Tenderer shall arrange all testing equipment like tanks,
pumps, temporary pipes ,blank flanges, instruments, valves
and fittings etc. at his cost.
The hydrostatic test pressure for Fire Fighting System shall be
1.5 times of maximum working pressure. Pipelines shall be
kept pressurised until the entire section under test has
been examined for leakage. However, minimum duration for
keeping pipes under hydrostatic pressure shall not be less than
2 hours. Defects revealed by the tests shall be repaired or
defective parts replaced and the system shall be re-tested.
Welded joints shall be subjected to hand hammer test while
under test pressure.
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PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 36 of 64
Spark testing (holiday testing) to identify defects in the

coating /wrapping done on the buried pipelines shall be carried
out as per applicable codes.
b)
Flushing procedure
i)
Initial flushing
The following shall be planned and done before initial flushing:
ii)
Various types of control valves, cocks, orifice plates,

filters etc. shall be removed and fitted with distance
pieces. The above fittings will be flushed and cleaned
manually.
All the pumps and equipment in the cleaning circuit

shall be isolated by blanking and by-passing through
temporary connections on the pipeline. If filters and
strainers are kept in the main circuit during flushing
operation, these will be removed, cleaned and refitted
after flushing is completed.
Valves
Before erection of valves, it shall be ensured that:
All grit and foreign matter are removed from

inside of the valves before connecting the pipes.
the
All the faces are thoroughly cleaned and coated with

a thin layer of mineral grease.
The valves should be tightly closed when being

installed, to prevent any foreign matter from getting in
between the working parts of valves.
It shall be ensured that the joining material sits
squarely between the flanges of valves and pipelines
without obstructing the waterway.
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PACKAGE NO - II
CHAPTER NO. Q9
4.18
VOLUME - V of V
PAGE No. 37 of 64
Testing of Valves
The tests to be conducted at shop for various subassemblies/assemblies of equipment shall include, but not
limited to the following:
1.
2.
3.
4.
5.
4.19
Material test ( Mechanical / Chemical test certificates )

Testing during manufacture/fabrication
Dimensional checking
Hydrostatic testing of body and seat.
Site and shop inspection and testing for the deluge
valves shall be as per the applicable codes / regulations
or as agreed during detailed engineering.
Erection of Electrical Equipment

Tenderer shall include erection of all the electrical equipment under
his scope of work as described in chapter 4.28 to 4.48.
4.20
TESTING, COMMISSIONING & PERFORMANCE GUARANTEE

Tenderer shall do testing, commissioning and performance
guarantee for all the Fire Detection and Suppression Systems as per
technical specification and relevant norms.
4.21
Testing
a)
All tests and inspection of the installation shall be done in

conformity with the functional and statutory requirement of
the system. Tests shall also be done in conformity with the
requirement of the following norms viz., BIS, NFPA norms in
the presence of Owners representative. The Tenderer shall
furnish a detailed testing, commissioning and performance
procedure for all the systems for approval of the Owner. As
soon as a given facility or a portion thereof is completed and
ready to be energized and start-up, the Owner may test run
and operate it without relieving the Tenderer of his
responsibility or guarantee.
b)
All tests of the FDA (Fire Detection and Alarm) installation

shall be done in conformity with the functional requirement
of the system as per IS: 2189 and NFPA norms.
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PACKAGE NO - II
CHAPTER NO. Q9
4.22
VOLUME - V of V
PAGE No. 38 of 64
Start-up and commissioning

a)
Tenderer shall provide the services of all technicians, erection

and start-up engineers necessary to bring the complete
installation of Fire Detection and Suppression System into
operation.
b)
The Tenderer shall be responsible for the integrated

commissioning of the plant and equipment supplied by him
including trials, commissioning and demonstration of
performance guarantee test.
c)
The Tenderer shall render the following services:

1.
2.
3.
Prepare equipment for trial runs and start-up

Start-up and commissioning of equipment.
Preliminary operation, initial operation, trial operation
and Final acceptance test.
d)
The Tenderer shall be required to clean up the equipment and

surrounding area and prepare it for trial runs and operation.
e)
The Tenderer shall clean up dirt, remove any protective

coating applied by the manufacturer, clean ventilating
openings and remove all visible foreign bodies from the
equipment erected.
Priming connections, cooling water supply to bearings,
lubrication piping to bearings, stuffing box jackets and sealing
glands of all rotating equipment shall be checked by the
Tenderer.
f)
g)
Sequence checking of all control systems, Cable connections,

checking operation of all interlocks and protective devices shall
be done by the Tenderer.
h)
Blow down of all piping systems, installations and removing

strainers in piping and equipment, for cleaning as required
shall be done by the Tenderer.
i)
Calibration and adjustment of relay settings, instruments etc.,

disconnecting and reconnecting the driven and driving parts of
any equipment and drives, as required, during the trial runs
and rectification, if any, shall be done by the Tenderer.
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CHAPTER NO. Q9
j)
VOLUME - V of V
PAGE No. 39 of 64
The Tenderer shall provide personnel as required for assisting

starting up and commissioning of equipment as well as
adjustments, repairs and rectifications of defects in erection of
the equipment during commissioning of the equipment and
upto final acceptance.
Trial runs
4.23
Trial runs shall be carried out after completion of erection and

shall determine functionability and the readiness of the system
and equipment to operate. The system shall be tested in all its
functions and checked for proper performance.
Any
irregularities found shall be remedied by the Tenderer.
4.24
Commissioning
On completion of the trial operation, all the segmental
systems shall be under observation in operative condition.
The Tenderer shall provide skilled personnel including
necessary tools and consumables wherever necessary to
rectify the deficiencies observed.
4.25
Performance guarantee test

a.)
The Tenderer shall conduct the operation of the system during

the performance tests as per approved methodology and shall
take full responsibility of the operations.
b.)
The performance guarantee tests shall be completed within 3

months after the successful commissioning of the system by
the Tenderer. Details of the performance tests, test procedures
and test schedules for the demonstration of the performance
guarantee as per NFPA Codes and BIS norm shall be submitted
to the Owner / Consultant for approval.
c.)
The Tenderer shall demonstrate the automatic actuation

/ operation of the system within 20 seconds after
simulating an occurrence of fire. If the Tenderer is unable
to achieve the guaranteed performance as a whole or in part
during the performance tests, the Tenderer shall repeat the
tests for demonstrating the performance. Before repeating the
tests the Tenderer shall take any and all measures as may be
needed, at his own cost in order that the performance can be
achieved.
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VOLUME - V of V
PAGE No. 40 of 64
d.)
The observations of each performance test shall be recorded

and signed by the Owner and the Tenderer. If such data
conform to the performance test values, the Tenderer shall
be entitled for the "Final Acceptance Certificate" from the
Owner.
e.)
If even with two repetitive tests and if necessary, by using

additional operating personnel from the Tenderer's crew and
at his own expenses, the performance values are not reached,
the Tenderer shall undertake at his own cost such
modification or replacement as are considered necessary to
obtain the performance guarantee values and the
responsibility to demonstrate performance guarantee shall
continue to remain with the Tenderer till so established.
4.26
PENALTY
VALUES
FOR
NON-FULLFILMENT
OF
GUARANTEE
a)
In case of non-fulfillment of the performance values, penalty

shall be levied on the Tenderer. The penalty to be levied for
the various guarantee parameters shall be as follows:
b)
PENALTY FOR NON-PERFORMANCE

In the event of performance not meeting the guaranteed
parameters, (Clause 4.25 (c) above) the OWNER shall levy
penalty at the rate of 1.0% of the total contract price for every
5 Secs shortfall in the performance or part thereof subject to a
maximum of 5.0% (20 Secs) of the total contract price. The
system having shortfall in performance beyond 5% shall be
rejected.
4.27
WARRANTY
a)
The system shall be guaranteed for a period of 12 months

from the date of successful commissioning during which the
Tenderer shall repair / replace any defective parts of the
works performed by him.
b)
In case of non-availability, the Owner shall have the right to

encash the performance bank guarantee submitted by the
Tenderer.
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PACKAGE NO - II
CHAPTER NO. Q9
c)
VOLUME - V of V
PAGE No. 41 of 64
Technical specification for valves:

Sl.
No.
Items
1.
Isolation
Valve
Nominal
dia.(mm)
Below 80
80 to 400
Specification
Cast iron ball valve flanged, as per
BS: 5351, standard, class 150#,
flange drilled to IS: 6392 Table-17,
Gasket SPW S.S. 304 with CAF Hand
Lever - Cast steel. Bolts/Nuts
B7/2H.
Cast iron gate valve flanged as per
standard BS 1414-1975 / 106111983, API-600, class 150 #, Body &
bonnet material CI, Trim 13% Cr S.S,
Spindle & Gland bush A1S1 410.
Hand wheel C.S, Gasket SW S.S-304
+ CAF, flange drilled to IS: 6392
Table-17, along with companion slip
on welded flange (without hub) drilled
as per IS: 6392 Table-17 and gasket,
Nuts & bolts etc. Hand Wheel-CS
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PACKAGE NO - II
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VOLUME - V of V
PAGE No. 42 of 64
4.28 FIRE DETECTION AND ALARM SYSTEM

4.29 GENERAL:
The specification shall be read in conjunction with general conditions
of tender and other project requirements provided in other volumes.
The Tenderer has to strictly agree to all the terms and conditions
mentioned in the tender documents. Detailed scope of work is given
in the following chapter. Items not specifically mentioned but
required for completion of the job shall be treated as included.
Tenderer to carry out all work as per IS 2189, erstwhile TAC and
NFPA guidelines. In case of conflict the more stringent shall govern.
General layout drawing indicating location of each area is enclosed in
the tender specification. The Tenderer shall cover in his scope all
interconnecting cables as per the requirement.
This system envisaged under this specification shall work in
conjunction with MVWS System and shall ensure the automatic
actuation of the water spray system at the location of fire occurring
anywhere along the length of Conveyor # 723 of Down hill conveyor
system of NMDC.
Two Nos. of Fire Alarm Panels are envisaged one each in Down hill
conveyor
# 723 tail end control room and at TH3 at head end
of the Conveyor # 723. The FAPs shall extend detector loops from
both ends of the conveyor the panels shall be networked preferably
using SMF Fibre Optic cable link. The system shall have a common
HMI located at the Central Control Room of Crusher Plant for
fault/fire alarms and engineering.
Fire protection of the Conveyor will be achieved through dedicated
system as indicated below
LHS cable detectors will be provided all-along the conveyor, both on

the take off and return side to detect fire on conveyors.
One length of 110 m (approx.) LHS cable shall cover one segment of
the conveyor.
One junction box shall be provided in the middle of two adjacent
segments for termination of the LHS Cables.
The JB shall also house addressable input and output modules for
interfacing with the FAP. Provision also shall be made in the JB for
termination of detector loop, control and power cables for operation
of DV, Hooter etc.
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Deluge valves will be activated on occurrence of fire to operate the

spray system.
Following signal/facilities are required on the main fire- alarm control
panel.
1. Fire alarm signal from the conveyor segment location actuated

through the of LHS cable sensor.
2. ON/OFF command to solenoid operated deluge valve at water line.
24 V DC power shall be provided for solenoid valves from the FDA
system detector loops.
3. Feedback from DV to know that it is operated
4. Provision of Hooters at every 120 metres along the conveyor to
annunciate the fire locally.
4.30 SCOPE OF WORK
The scope of work includes design, engineering, supply, erection,
testing, commissioning, performance tests and handing over of
analogue addressable type Fire Detection and Alarm system and
successful integration of the system with the Water Spray system
envisaged under this specification.
The Tenderer as per approved drawings shall supply all items
indicated against fire detection cum alarm system. The system shall
be supplied as per specification / as per approved drawings with bill
of quantities meeting the NFPA, IS 2189-1999 and TAC norms
Manufacturers certified persons shall carry out site supervision work.
Bill of materials shall be indicated by the Tenderer considering the
following:
Detection and alarm equipment offered shall be complete in all
respects and any equipment / accessories not explicitly indicated in
the bill of materials, but considered essential for proper functioning of
equipment and system shall be treated as included in the
Tenderers scope of supply and work.
The quantities shown as lot in the BOQ shall be assessed by the
Tender before making the offer. At detail engineering stage it will be
finalized based on the actual requirement and Tenderer shall
undertake to supply and execute the jobs as per the finalised
quantity during detailed engineering without any financial
implications.
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VOLUME - V of V
PAGE No. 44 of 64
Tenderer shall include 30 man-days training for customers

personnel at site.
4.31 TECHNICAL
a.
Fire Detection system

The Fire Detection and Alarm system shall be State of-the-art
microprocessor based, intelligent and addressable, software
controlled automatic system with necessary programming functions,
annunciation and controls. The system will consist of Microprocessor
based Fire Alarm Panels, junction boxes, Addressable Manual Call
Points with necessary enclosures, Electronic sounders/ hooters,
Repeater panel, Control modules and Other units/accessories as
required.
In the Downhill conveyor # 723, LHS cable shall detect the presence
of fire and transmit the signal to the Main Control Panel. Audio-visual
alarms shall be initiated simultaneously on main control panel. The
system also shall activate hooters connected to the local loop so as to
attract attention of the nearby people.
Main panel shall show the address of the physical location as to
where the fire has occurred. The panel shall be provided with a block
type mimic display/ backlit LCD display for indicating fire zones,
detector address and LEDs for fire and fault conditions.
Fire protection of the conveyor will be achieved through dedicated
system as indicated below:
LHS cable will be provided all along the conveyor, both on the take
off and return side to detect fire on conveyors.
One length of 110m(approx.) LHS cable shall cover one segment of
the conveyor.
One junction box shall be provided in the middle of two adjacent
segments for termination of the LHS cables.
The junction boxes shall also house addressable input and output
modules for interfacing with the FAP. Provision also shall be made
in the junction box for termination of detector loop, control and
power cables for operation of DV, Hooter etc.
Deluge valve will be activated on occurrence of fire to operate the
spray system.
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PAGE No. 45 of 64
The total area under surveillance shall be divided into several

zones/segments (detector loops). Provision shall be kept for
automatic activation of deluge valve for 4 segments from the place
of occurrence of fire.
Main Fire Alarm Panel shall be placed in the Transfer House 2 and Transfer House 3. The Repeater Panel shall be
placed at Crushing plant control room.
Suitable backup, adequate to supply backup power to the system
for a period not less than four hours in case of normal power failure
shall also be provided. Battery used for back up power shall be
Sealed maintenance free type and shall be preferably
accommodated inside the panel.
b.
ENVIRONMENTAL CLASSIFICATION
The equipment shall be suitable for continuous duty under the
following conditions:
Temperature while operating:
lower limit
: 0 degree C
Upper limit
: 60 degree C
Temperature while not operating (storage)
lower limit
: 20 degree C
Upper limit
: 75 degree C
Relative humidity
-
c.
Daily average 80 to 90% (10 h) and 65 to 90% (16 h)

Maximum 98%, not occurring simultaneously with maximum
temperature.
FIRE DETECTION SYSTEM
It is proposed to include Linear Heat Sensing cable (LHS) with SS

braiding for the main material carrying belt and also for the return
belt to detect heat from the conveyor belts. The total length of the
conveyor shall be divided into equal segments. Each segment will run
approx. 110 m length of LHS cable separately for material carrying
conveyor (upside) and return conveyor (downside). For each
conveyor segment separate addressable module should be
considered. Consecutive address should be given to segments/loops.
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PACKAGE NO - II
CHAPTER NO. Q9
VOLUME - V of V
PAGE No. 46 of 64
Addressing shall be used for identifying the exact fire hit zone and
necessary protection system should be activated in that zone through
Fire Alarm Panel. In each segment LHS cable should be laid under the
belts (separate for upside and downside) in zigzag fashion to get the
maximum exposure of heat. One Junction Boxes with required
number of terminals shall be considered for each segment. The
same JB shall be used for termination of LHS cables for one segment
as well as generation of LHS cables for the next segment. On each JB
test Push Button shall be provided to check the healthiness of the
system. From all the JBs, connections shall be taken to respective
Addressable module/Field Interface unit (the last JB is for termination
only) through control cables. Each Field Interface unit shall
accommodate sufficient DI, DO, communication interface cards, relay
and power supply modules etc. as per requirement. 20% spare
terminals shall be left in the JB.
The Field Interface units/Addressable modules shall be connected to
Fire Alarm Panels through detector loop/ communication bus with
supporting protocols. The proposed Engineering Station/Operating
Station for Fire Alarm Panel should be given at Central Control Room
of the Crushing Plant or at a suitable location finalized during the
detail engineering in consultation with the client. Outdoor
hooter/siren should be considered at prescribed intervals along the
conveyor belt to satisfy the requirement. Indoor hooter should be
given at the control rooms only.
Apart from this, infra red detectors should be given above the main
belt at specific locations (head end, tail end and at belt turn over
areas) to detect flames.
The main fire alarm panel shall be wired to the control circuit of the
conveyors to stop the conveyor in case of fire.
Once fire is detected (flame or heat), signal wired to the respective
conveyor control panels should stop the conveyors and generate
audio-visual alarm to alert the operators.
d.
WATER BASED FIRE DETECTION AND SUPPRESSION SYSTEM
Each segment/loop will have one solenoid operated deluge valve

that will be activated through either Local Control Panel (LCP/FAP).
Emergency stop button and local/remote selection should be
present in the LCP. When the conveyor is running and a particular
segment is affected by fire, the system shall send a signal to the
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deluge valve to release water on the affected conveyor segment

and one preceding and two succeeding segments respectively or vice
versa, when head end or tail end segment is not affected. If head
end/tail end segment is affected then system shall activate the
deluge valves of affected and its succeeding/preceding segments
accordingly or vice versa. In case the conveyor is not moving and is
in static position, then the deluge valves of the segments one
preceding and two succeeding along with the affected segment
shall operate. Also, the deluge valves to be operated on number of
preceding and succeeding segments shall be programmable as per
the requirement. For this purpose, the required control wiring and
interface with the conveyor control circuits shall be carried out by
the tenderer. The water spray can be stopped only manually. The
elevations at which the water tanks will be installed shall be such
that the static pressure of water will be able to operate the water
spray system. The requirement of water for fire fighting will be
drawn from the existing reservoir. For that pump house and water
tanks should be constructed at suitable locations.
4.32 SYSTEM FEATURES
a.
The total area under surveillance shall be divided into several

segment / zones (detector loops) Each segment consists of
approx.110 m of LHS cable as detector, one deluge valve and a set
of water spray nozzles and junction boxes (JB). Deluge valve shall
be preferably solenoid operated and shall be directly connected to
the Detector loop using addressable output modules. The junction
boxes shall be used for termination of detector cables, signal
cables/ detector loop cables to interface units (addressable input
and output modules) / Fire alarm panel. A hooter shall also be
provided every 120 meters and connected to the detector loop
through the local junction box for giving a local alarm
b.
In the event of fire, alarm shall be generated in the local and main
fire panel and the fire signal shall be communicated to the conveyor
control rooms where action shall be taken to stop the conveyors
and generate audio visual alarm to alert the operating/security
personnel. The system also shall send a signal to the deluge valves
to release water to the spray system. Main Control room shall be
provided with display for the address of the detector where the fire
has been sensed.
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c.
Various detector loops used with the system shall continuously

report about the general condition of the area being monitored.
d.
The complete system shall be fail-safe type. All the external cable
connected to the individual fire stations shall be fully supervised for
short circuits or open circuits. Electronic display board and indoor
hooters shall be given to all the control rooms. Outdoor hooters
should be given at proper interval along the conveyor length. The
audio signal can be silenced but the visual fault indication will
however continue to glow till the fault in a particular zone is
removed.
e.
The system fault audio alarm shall be differentiated from the fire
audio alarm.
f.
A test switch shall be provided at each LCP to check the proper

functioning and healthiness of the system.
g.
There shall be provision for automatic operation / actuation of fire

fighting system e.g. Water spray systems etc. The water spray
system of each of the conveyors will be divided into segments of 40
m. Each of these segments will be provided with a deluge valve. In
case fire is detected in any segment, the movement of the belt will
be stopped and water will be sprayed on the affected conveyor
segment and on the succeeding segments. The water spray can be
stopped only manually.
h.
In all fire prone areas or loops (below conveyor belt including

return belt), Linear Heat Sensor cable digital type with SS braiding
shall be laid in zigzag way to ensure fire detection on upside and
downside of conveyors. Those shall be connected to addressable
interface unit (AIU)/RIOs through local junction boxes.
From
RIOs/AIUs it shall go to control room Fire Alarm Panel. Wherever
there is a bend or change of alignment of conveyor, separate
Infrared Detectors should be used with the similar automatic fire
detection and prevention philosophy.
i.
The fire detection and alarm system shall have following functions/
provisions:
Detection of fire in the incipient stage.

Facility of interchange photoelectric and heat detectors.
Battery back up and automatic uninterrupted change-over in
the FCBC mode of operation.
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Supervision of all fault conditions.

Electronic hooters for fire and fault audible alarms.
Pinpoint indication of location of fire.
Complete programming with GUI/HMI software
Provision to get backup history of occurrence of fire.
Fire Alarm system to be interfaced with the ventilation
system operation.
4.33 SYSTEM COMPONENTS
The Fire detection & alarm system shall broadly consist of the
following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Fire Alarm control panel(s) including sealed maintenance free

battery and Battery chargers.
PC Base Graphic Display/HMI/Engineering unit.
Personal Computer with visual unit, Key Board, Mouse,
Printer with required HMI/Engineering Software for
programming and display.
Addressable I/O modules.
Electronic Hooters
Addressable Linear Heat Sensing Cable (S/S braided and
digital type with supports)
Infrared Red Detectors
Control and Power Cable
Area panels for Deluge valves
Sealed Maintenance free battery and battery chargers
Electronic Display Board
Local control panel with provision for L/R selection and
testing operation for Deluge valves.
4.34 COMPONENT DESCRIPTION

a.
MAIN CONTROL PANEL.
Fire alarm control panel shall be intelligent, with its own

Microprocessor and memory. It shall be enclosed, wall / floor
mounting type of modular design. Entire panel shall be designed
with solid-state circuitry and provision to house required printed
circuit cards. It shall operate on 240 V AC mains with a provision
for operation through battery backed-up power source during main
failure. Back up power shall be provided by using suitable capacity
SMF battery set to give a backup of at least 4 hours in full alarm
condition.
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The control panel as a built in feature shall have one/ two loop
modules with 2 loops per module. Each loop shall be able to take at
least 90 detectors and 90 devices. Control panel shall have
provision for future expansion so that additional loops can be
created by addition of loop cards/ modules.
The control panel shall have necessary hardware and software
modules for the following:
4.34.1 Alarm output and control output for various control functions.
4.34.2 Facility to process the input data received from addressable
analogue type detectors /addressable interface unit.
4.34.3 Electronic filters to ignore false alarm and increase sensitivity to
real fires from sensors. The electronic filters shall recognize the
unwanted alarm from detectors due to electrical spikes.
4.34.4 Separate back-lit display area to indicate the address of each
device and clear text about the location of alarm / trouble.
4.35
The facility to support a graphic workstation comprising PC, Printer,

Keypad, Mouse, peripherals etc.
4.35.1Printer facility to print out the alarm / trouble occurrences

Control panel shall have the following features:
Logging and storage of alarms and faults.
Status check of disabled alarm addresses before they are

restored.
Programming facility to create, add, delete, modify the loops

and detector addresses. For this purpose an alpha-numeric
keyboard shall be preferably integrated with the Control
panel.
Programmable activation of control output relays for tripping

ventilation system, AC system and closing of fire doors in the
event of fire.
The possibility of connecting to non - addressable detectors,

manual call points, alarm initiating devices etc.
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The fire alarm control panel display shall have facilities of

brief user guide menu to enable the operator or proper use
of various menu functions.
The sensitivity of each addressable analogue detector shall

be changeable and readable at the control panel.
Each addressable detector, interface units can be disabled

from panel for maintenance purpose and restore the same
whenever required.
The status check of each detector, interface units for alarm,

prior warning, trouble, disabling shall be possible from
control panel.
The fire alarm control panel shall be able to provide the following
test and operator interface features:
Acknowledge
To acknowledge the alarm
Automatic day / Night
To have higher sensitivity
sensitivity Adjust
during unoccupied period.
Device Blink Control
For flashing LEDs on the
detector.
Drift Compensation
For compensating the detector
response due to environmental
changes.
Pre-alarm control panel
For early indication of fire in
indication
the incipient stage.
System Status Report
Documentation
of
various
system parameters.
Alarm Verification, by
To eliminate generation of
device
false alarm due to dust /
cigarette smoke.
Printer Interface
For printer interface which is
used
for
system
documentation.
Periodic Detector Test
For detector testing
from the panel which
eliminates the need for
testing the detectors in
the field every now and
then.
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Trouble Reminder
Upload /download to PC
Walk Test
VOLUME - V of V
PAGE No. 52 of 64
To remind the operator
of
the
maintenance
required
at
the
individual detectors.
For programming the
panel in the first power
up.
The entire loop can be
tested by a single
person with the print
out at the printer.
The system display shall provide a backlit alphanumeric Liquid

Crystal Display (LCD) for at least 400 characters and an
alphanumeric keyboard for entry of any alphanumeric information
and field programming. All system functions shall be controlled
from the panel through the keyboard and display unit. It shall also
provide five Light-Emitting-Diodes (LEDs) that shall indicate the
status of the following system parameters: AC POWER, SYSTEM
ALARM, DISPLAY TROUBLE and SIGNAL SILENCE.
Two different password levels shall be accessible through the
display interface assembly to prevent unauthorized system control
or programming.
The system display shall include the following operator control
switches: SIGNAL SILENCE, LAMP TEST, RESET, SYSTEM and
ACKNOWLEDGE.
The following indications shall be provided in the main control
panel:
1.)
2.)
3.)
4.)
5.)
6.)
7.)
8.)
9.)
Fire condition.
Pre-alarm indication.
System test.
System fault.
System isolation.
Alphanumeric display for fire address, function menu etc.
Stand by Battery Low.
AC failure.
Others as required.
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The panel shall be dust and vermin proof and shall be fabricated of
CRCA sheet of not less than 2 mm thickness and conform to IP 42
protection class.
Paint shade of the panel shall match with that of the walls of the
room and other equipment in the room.
The front door of the panel shall be provided with transparent glass
for easy monitoring to the status of the system. There shall be
provision for locking up of the panel. All the controls and indication
shall be mounted on the front side of the panel and all circuitry and
equipment for the working of the system shall be housed within the
unit.
Suitable terminal blocks shall be provided for termination of
external cables and provision shall be made for mounting of cable
glands or conduits whichever is applicable.
Facility shall be provided for connection of external hooters which
shall be energised in case of fire within any of the area under
surveillance.
4.36 INFRARED FLAME DETECTORS:
The infrared flame detectors shall be capable of detecting infrared
radiation produced by flaming fires involving carbonaceous materials.
The infrared flame detectors shall be approved and listed by the Loss
Prevention Council Board (LPCB)/UL.
All circuitry must be protected against usual electrical transient and
electromagnetic interference.
The detector shall have no moving parts or components subject to
wear and tear and shall have serial number and seal of the
approving laboratory/body.
The response (activation) of a detector shall be clearly visible from
the outside by a flashing light of sufficient brightness.
The detector shall be inserted into or removed from the base by a
simple push-twist mechanism to facilitate exchange for cleaning
and maintenance.
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The manufacturer shall produce and provide test equipment

allowing to test and exchange the detectors, situated up to 7
metres (23 ft.) above floor level.
It shall be possible to test the detector in the field.
It shall be possible to test the sensitivity of detectors in the field.
Specifications:
Normal operating temperature
Operating voltage
Quiescent current
Alarm current
Approval by
Operating temp
Operating Time
: 45 Deg. C
: 24VDC nominal (18V-30V)
: 150 micro amps. (Max)
: 100 milliamps. (Max)
: LPCB/ FM / UL
:Fixed: 75-80 deg. C , for rate of
temperature rise of 2 deg. C /
min. and air
velocity of 1Mtr /
Sec.
: 70-90 sec. For rate of rise of 22
deg. C / min. & air velocity of
1Mtr / Sec. 180 -320 second for
rate of rise of 15 deg. C/min. and
air velocity of 5 cm per second.
The infrared shall be able to detect a fire of 0.1 square metre area
from a distance of 30 metres.
The infrared detectors shall employ narrow band optical filters that
block unwanted radiation such as that emanating from the sun or
tungsten filament lamps.
The infrared detectors shall be designed to be sensitive to
modulation of the received radiation in a small range of frequencies
corresponding to the flicker of flames.
The infrared flame detectors shall be designed to have high
resistance to contamination and corrosion.
The electronic assembly of the infrared flame detectors shall be
encapsulated in high resistivity epoxy resin.
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The infrared flame/smoke detectors shall include RFI screening and

feed-through connecting components to minimize the effect of
radiated and conducted electrical interferences.
Tenderer shall have available the following versions of infra-red
flame detectors to meet different applications:Analogue addressable - intrinsically safe
Conventional - intrinsically safe
The intrinsically safe versions of the infrared flame detectors shall
be suitable for use with safe area circuits.
The infrared flame detector shall incorporate an LED, clearly visible
from the outside, to provide indication of alarm actuation.
4.37 LINEAR HEAT SENSING (LHS) CABLE
LHS cable shall also be provided along the length of down hill
conveyor as per TAC norm. LHS cables shall be digital type and
necessary braiding for mechanical strength shall be provided in LHS
cables with SS braiding. The Tenderer to suit site conditions shall
provide support arrangement. All interface devices required to hook
up to fire alarm Panel shall be included in the system.
4.38 SIREN /HOOTER
Siren shall be mounted on suitable support located strategically to
make a loud annunciation of the fire occurance (capacity 1 Km
range to operate in case of confirmed fire is registered in the main
fire alarm panel). Siren shall also be suitable for manual operation.
Siren shall have three types of sound; first alarm (or alert), second
fire (or emergency) and third clear. Tenderer has to furnish details
for above. Siren shall be connected to UPS power supply and the
Tenderer for this shall provide all necessary arrangement. Outdoor
type hooters shall have IP 65 protection class.
Hooter shall be connected in each control and security rooms
internally as well as externally along the conveyor length. External
hooters may be clubbed together w.r.t. common entry/exit point of
view for cable areas.
Electronic hooters shall be used for audio alarm to alert people in
case of fire and shall be fully solid state with audio output sufficient
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to be heard at a distance not less than 50 m. Normally the hooters

shall be loop powered using suitable addressable modules. The
hooters shall have facility for adjustment of volume as per
requirement at site.
4.39 DELUGE VALVE CONTROL PANEL
Cast aluminium (LM6) construction
Enclosure conforming to IP 65
Suitable knockouts with glands on bottom & top cover.
Internal wiring shall be carried out with HR PVC extra flexible
wires of 2.5 mm sq. copper.
Terminals to be suitable for 2.5 mm2 conductors with 20%
spare terminals.
Control switches, Local / Remote, Test push buttons, lamps
etc. mounted on front door.
All push buttons shall have 2 NO + 2 NC contacts rated for 5
A at 230VAC. Switches shall have spare contacts.
All indicating lamps shall be LED clustered type mounted on
front with Inscription in English on corrosion resistant metal
strips.
Stop push button to be stay put type with mushroom head
and twist to unlock type.
4.40 MANUAL CALL STATION
Manual call station shall be wall/ structure mounting break-theglass/ pull-down-cover type and shall be located near the Transfer
houses , so that in case of fire being spotted by the personnel in
the premise, they can actuate the alarm. The unit shall be
addressable and communicate with the FAP like other detectors. In
case of break glass type, the unit shall be supplied along with a
hammer chained with the unit for breaking the glass marked, In
case of fire break glass. The outdoor units shall conform to
protection class of IP 65
4.41 JUNCTION BOXES
Besides the LCPs, it may be required to use Jn. Boxes for
termination of cables of different types. All junction boxes including
terminal blocks wherever required and outlet boxes should be fixed
to walls/ceiling/structures using MS bracket and bolt and nuts.
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PAGE No. 57 of 64
The location of these boxes shall be selected in such a way that

easy accessibility is available for maintenance. All these boxes
shall be of MS minimum 1.6mm thick duly painted as specified
elsewhere in this document.
The junction boxes if used separately for LHS cables shall have a
minimum of 6 terminals.
4.42 ELECTRONIC DISPLAY BOARD
The tenderer shall provide electronic display boards as per the
specification mentioned below at a suitable location near control
room where the FAP is located. These display boards shall be
connected to the FAP in the control room through a RS 485 Serial
link.
Make
As per approved Vendor

list
Type of Display Board
Weather Proof IP65,

Electromagnetic Display
with LED
Visibility
Day & Night
Size of mosaic
15 mm square / equivalent
Matrix of mosaics
Min.100 x 7 arranged
along length x width.
Total 700 dots. /
Equivalent
Colour of mosaic
One side fluorescent

yellow and another side
black / equivalent
No. Of display lines
Character height
50 mm or equivalent
No. of characters per

line
16
Display area/line
Vendor to specify
Power supply
230 V +/- 10%, 50 Hz +/5%, single phase A/C

mains
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Power requirement
To be indented by vendor
Visibility
Upto 55 mtrs. excellent

visibility reqd. during day
& light, low ambient light
and night.
Angle view
Upto 150
Communicating link
between PC and
Display Board
RS 485 interface
Communication
protocol
Tenderer to specify
Dimensions of the
Board
Tenderer to specify
Enclosure
CRCA powder coated

enclosure to be housed
inside control room
Mounting
Wall mounting
Mounting options for

Display
Suitable for wall mounting

or hang mounting or frame
mounting.
Duty
Indoor duty.
0`
4.43 OPERATOR STATION (HMI)

The Operator workstation shall be connected to the Fire Alarm
Panel. The workstation shall operate as a node and offer all the
functions, alarms and annunciations available in the Fire Panels.
The work station shall be of latest Pentium processor based PC with
following configuration
Processor Latest Pentium processor with min Core Duo 3 GHz
configuration.
FSB 800 MHz
Memory 1 GB RAM
Graphics Integrated Intel Graphics 2
Secondary drives 1.44 MB FDD, 52 X CD Read- Write Combo
drive, 160 GB HDD
I/O Ports 1 Serial, 1 Parallel, 4 USB, 2 PS/2, 1 VGA, 1 RJ 45 NIC
Pointing device PS/2 Optical scroll mouse
Keyboard PS/2 Windows
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Op System Win XP Professional

Monitor 17 LCD Flat panel
Power supply 240 V, 1 Ph. AC, 50 Hz
A Desk-jet printer shall be provided with the above to print the
Alarms and logs.
4.44 PROGRAMME SOFTWARE:
The system shall be supplied/loaded with the necessary software
for operation of the panel as per the desired sequence/scheme of
operation/ specification/ system configuration, smoke detector
environmental compensation, detector pre-alarm, history logging,
output control by event, check & change time based control,
detectors sensitivity, alarm verification by device or zone etc. The
software shall also include complete programming functions for
Detectors and HMI .
The system operation shall be secured
by use of passwords at
different levels i.e.
for
normal operation and programming/
administration.
4.45 PAINTING
Metal parts of all equipment shall be protected against corrosion.
The sheet steel parts shall be cleaned by sand blasting (wherever
required) and shall undergo rust removal by seven-tank process
consisting of alkaline, degreasing, de-scaling, pickling and
phosphating.
Two final coats of epoxy spray painting shall be applied over two
coats of primer. The colour of finished painting shall be as per the
approved.
4.46 EARTHING PITS
Vendor shall provide a separate electronic earthing system.
Electronic components of workstations, cabinets, consoles etc. of
FAP and drain wires of the instrumentation signal cables shall be
connected to this earthing system.
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The body earth of the FAP cabinets and workstations / consoles

shall be connected to the Electrical Earth grid in the plant, which
shall be separate from the Electronic Earth. The electronic earth
pit(s) shall be at least 3 m away from the nearest electrical earth
pit.
The design of the electronic earth pit shall be as per IS:3043, 1991
or based on the manufacturers recommendation.
4.47 POWER SUPPLY
Power supply to the FDA Systems and all related components shall
be from UPS systems. One. no. of UPS shall be provided for each
FAP. The UPS systems shall be standardized to min. 5 kVA models
each with 2 units in parallel redundant configuration having
automatic changeover facility.
The UPS systems will cater to one Fire Alarm panel and nearby
equipment and provide 4 hour battery backup and with following
specifications.
Lightning & surge protection
Facilitate fast battery replacement
Warnings for low battery / hi voltage / low voltage
Should consist of voltmeters and voltmeters at inlet / outlet
User-friendly LEDs for information
Adjustable output voltage between 230 and 240V
Response time less than 4 milliseconds
Modular
Maintenance-free dry batteries
With min. IP 52 class of protection for protection from dust
and water
Common relay output for annunciation of fault at the HMI
Station
The UPS output shall be connected to a Power Distribution Board,
which is in scope of Tenderer. All incoming and outgoing power
distribution shall be done by the tenderer.
The design criteria for the UPS will be:
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Type
and
on
100%
: On-line
parallel redundant mode
Rating
: 5KVA
model
&
15
KVA
model
Input voltage
: 415 V+10%, -15%, 3Phase,

50Hz 5%
Inverter type
: High frequency switching

sinusoidal with pulse width
modulation
Output voltage
: 230 V, single Phase
Output
: Free running 50 Hz, 0.1

% tracking bypass 2 % (
1to 4 %)(selectable)
Frequency
regulation
than
1%
for
: Better
simultaneous variation from
no load to full load & input
voltage to any extreme.
Output
: Sinusoidal
Output
voltage
voltage
waveform
Total
Harmonic
distortion
Transient
: Less than 3 % for linear

load, less than 5 % for
non-linear load.
: For 100 % step load
response
Dip
: Typical 5 %, Max 8 %
Peak
: Typical 5 %, Max 8 %
Recovery
normal
Over
capacity
to
load
Audible noise
: Up to 60 m secs i.e. 3 cycles

: 125 % for 10 min
: Less than 50 dB at 1 mtr
distance
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LCD/
indications
LED
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PAGE No. 62 of 64
: Mains OK, Inverter OK,
Overload
On Battery, Low Battery,
Inverter trip, Bypass ON,
Load on Inverter, Load on
Bypass, Bypass frequency
out of range
Auto
bidirectional static
switch
: Shall be provided
Environment
: 0 50 deg. C
Relative
humidity
: 95 % RH non condensing
Switch gear
: Input MCB, Bypass MCB,

Battery isolator, inverter
ON/OFF switch, manual
bypass switch, Surge
Suppressor.
Remote
Indication
: Provision for all the available

LCD/ LED for remote
indication and potential free
contact (1 NO and 1 NC) for
fault indication should be
provided
Bi-directional
static
switch
with SCVS
: Shall be provided
Batteries
: Sealed maintenance free

batteries
Battery Backup
: Battery back-up for 4 hours
Capacity
: Min. 120 % of the actual

load requirement for the
system to be calculated by
vendor.
Enclosure
: IP 42
Isolation
transformer
: Shall be provided with class

H insulation
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Configuration
: Diagram to be submitted
UPS distribution
board
: With MCCB incomer and

MCB outgoings of suitable
ratings
Make
: As per approved vendor list
4.48 CABLES & CABLE LAYING

Cables used for interconnecting hooters shall be limited to one
premise only. All incoming-outgoing power supply cables & inter
connecting cables used for the system shall be fire retardant low
smoke (FRLS) type 1100 V grade PVC insulated, PVC inner and outer
sheathed having 1.5 mm 2 copper conductor conforming to IS: 1554
(Pt.-1). Three core cables (keeping one core as spare) shall be used
for the detector/ device connection.
Fire cable routing shall be separated from other cables to the extent
possible. All switches, cable ending junction boxes, multi-way
junction boxes, FRLS connecting cables, panels etc. shall be included
to make the system complete in all respects. This shall include
wiring/cabling up to Area Annunciation panels. Cable shall be laid as
per approved cable routing and cable layout drawings and as per
normal plant practice and manufacturers guideline. Route markers
for fire cables shall be separate and distinct from other markers.
All Outdoor cables shall be armoured type. The cables shall be laid in
encasing pipes while crossing road, drain etc.
Cables armoured TP type shall be laid on existing cable trays, if
available, otherwise Tenderer has to arrange suitable supports,
structures, under ground trenches etc.
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4.49 APPLICABLE CODES AND STANDARDS

SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
DESCRIPTION
CODE NUMBER
IS-2189-1988
Reaffirmed in -1998
IS-5-1994,
2000
Code of practice for selection, installation

: and maintenance of automatic fire
detection and alarm system (second
revision Amendment-II)
Reaffirmed
IS-9537PART-II-1981
IS-1554 PART-I-1998
Color for ready mixed paints and enamels
Specification for conduits for electrical

: wiring.
PVC insulated (heavy duty electric cables
: part-I for working voltages up to &
including
1100V
(Third
EditionAmendment-I).
IS-10810
PART-53Method of test for cables part-53:
1984
flammability test.
Reaffirmed in 2001
Code of practice for installation and
: maintenance of power cables up to and
IS-1255-1983
Reaffirmed in 2001
including 33kV rating. (Second revisionAmendment-I).
IS-3043-1987
Code of practice for Earthing.
Reaffirmed in 2001
:
Code for design and installation of
: Automatic Fire Detection and Alarm
NFPA 72
System
Rev. 0
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q10
VOLUME - V of
PAGE No. 1 of
CHAPTER-Q10
GENERAL LAYOUT, ROADS AND FIRE FIGHTING
1.0
General Layout
Considering the material flow, various facilities are proposed at
different elevations and the same are shown in the enclosed tender
drawings. It is necessary to carryout detailed survey work along the
alignment of down hill conveyor no. 723 and reversible conveyor
no. 727 for a width of 15m on either side of conveyor for planning
and designing of conveyor gallery structures including construction
works. Also, survey shall be carried out at the tail end area of down
hill conveyor, TH-3, TH-4, TH-5, TH-6 and Transfer station at tail
end of conveyor 727-1 where various facilities are planned.
2.0
Roads
Following are
package-II:
a.
b.
c.
d.
e.
the
various
approach
roads
planned
under
Approach road to TH1, Silo area, Tail / drive house of Down

Hill Conveyor, TH-2, TH-2A, PS-1 and Electrical, control cum
office building from the approach road proposed for
Secondary Crushing Plant.
Approach road to PS-2 and take-up area of down hill
conveyor
Approach road to TH-3 from the kachcha road already
developed by NMDC
Approach road to TH-4, TH-5, TH-6 & electrical room near
TH-5 from the roads available already.
Approach road to belt lay down area at two locations
The approach roads shall be provided with 4.0m wide black topping
with 1.5m wide shoulders to suit single lane traffic. The corridor
width of road shall be 10m. The necessary approach roads required
for various units shall be planned considering the connectivity to
the existing roads. It also includes road side and cross drainage
system.
Rev. 0
V
2
MECON
LIMITED
NMDC LIMITED

PACKAGE NO - II
CHAPTER NO. Q10
VOLUME - V of
PAGE No. 2 of
Super elevation, widening and transitions at curves shall be

adequate for the movement of fully laden truck / tipper with axle
load of 10 t traveling at 30km/hr.
Following are the allowable gradients to be considered for the roads
under this package:
a.
b.
c.
d.
e.
3.0
Ruling gradient
Limiting gradient
Exceptional gradient
Gradient in hairpin bends
Super elevation
:
:
:
:
:
1
1
1
1
1
in
in
in
in
in
20
14.98
12
40
10
Fire fighting:
In order to combat the fire at initial stage it self, it is necessary to
plan and provide first aid fire fighting extinguishers of suitable type
and capacity as per TAC norms & IS: 2190 in various premises.
Rev. 0
V
2

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NMDC LIMITED

KUMARASWAMY IRON ORE PROJECT

KUMARASWAMY IRON ORE PROJECT

DOWN HILL CONVEYOR SYSTEM

Preamble, Summary of Prices, Price for exemptions / variations

KUMARASWAMY IRON ORE PROJECT

DOWN HILL CONVEYOR SYSTEM

Documents /drawings to be submitted by successful Tenderer

Spares, Special tools & Tackles

List of Preferred makes of equipment

Technical specification Mechanical

Technical specification Environmental

Tender drawings as per the list under chapter-L

Technical specification Automation and Control

Technical specification Plant Communication System

Technical specification Fire Detection and Suppression

Soft copy of Questionnaire and design data sheet Chapter-M (Part-2 of 2)

KUMARASWAMY IRON ORE PROJECT

KUMARASWAMY IRON ORE PROJECT

SECTION I : GENERAL & SCOPE OF WORK

The scope of this tender includes analysis, design, detailed

The following / Buildings facilities are envisaged:

RCC trestle foundations / foundation for See clause

KUMARASWAMY IRON ORE PROJECT

Down hill Conveyor No: 723 with RCC,

KUMARASWAMY IRON ORE PROJECT

The following Service Roads including

KUMARASWAMY IRON ORE PROJECT

construction work is taken-up. Work shall be executed in

The civil construction drawings, in AutoCAD, shall take care of

Design criteria, civil analysis and design, architectural

Contractor shall submit ten sets of design calculations

Only latest revisions of the drawings shall be followed and

The tenderer shall acquaint himself of the site related data,

Provision for building drains, apron, sanitary & water supply

KUMARASWAMY IRON ORE PROJECT

GENERAL DESCRIPTION OF BUILDINGS AND FACILITIES

Foundations for trestle supports for conveyors:

RCC Storage Silo (1000t (effective storage) Capacity):

KUMARASWAMY IRON ORE PROJECT

considering the dynamic forces as per manufacturers load

Open Excavation for single flight down hill conveyor:

Office Building / Electrical Room / MCC Room / Control

KUMARASWAMY IRON ORE PROJECT

barrier, Cat-eyes kilometer stones, informatory and warning

The tenderer shall consider the following finishes/ fixtures for

Plastering and White / colour

6mm thk. In CM (1:3) + 3

KUMARASWAMY IRON ORE PROJECT

Flooring and skirting

White glazed tile for 1500mm

Roof water proofing treatment.

Schedule of plumbing sanitary fitting / fixtures

Closet: Indian type vitreous water closet of 580x440mm size

Urinal: White vitreous china urinal of size 430x260x350mm

Wash basin: white vitreous chaina wash basin of size

Min. 1000 lit. Capacity HDPE overhead water tank with

KUMARASWAMY IRON ORE PROJECT

Schedule of Doors, Windows & Ventilators.

1000X2100 35 mm commercial ply flush door

900X2100 35 mm commercial ply flush door

800X2100 35 mm commercial ply flush door

1500X1200 Glazed wooden window in 2nd class

600 X450 wooden ventilator in 2nd class teak